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Yamaha ROADLINER XV19MW Service Manual

Other manuals for ROADLINER XV19MW: Owner's Manual

Summary of ROADLINER XV19MW

  • Page 1

    Yamaha service manual arranged by cyclehippie www,cyclehippie.Com the best service manuals have been cyclehippied! Over 30 years of powersports industy experience goes into the arrangement of the official yamaha factory service data. If you obtained this manual from a source other than cyclehippie, ...

  • Page 2: Service Manual

    Service manual xv19sw(c) xv19w(c) xv19mw(c) xv19ctsw(c) xv19ctw(c) xv19ctmw(c) lit-11616-20-40 1d7-28197-11.

  • Page 3

    Eas20050 xv19sw(c)/xv19w(c)/xv19mw(c)/ xv19ctsw(c)/xv19ctw(c)/xv19ctmw(c) service manual ©2006 by yamaha motor corporation, u.S.A. First edition, july 2006 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohib...

  • Page 4

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

  • Page 5

    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 6

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

  • Page 8: Table of Contents

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

  • Page 10: General Information

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

  • Page 11: Identification

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

  • Page 12: Features

    Features 1-2 eas20170 features et1d71017 outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor sy...

  • Page 13: Features

    Features 1-3 et1d71018 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 392 kpa (3.92 kg/cm², 55.7 psi). Accordingly, when the energizing signal from the ecu energizes the f...

  • Page 14: Features

    Features 1-4 et1d71036 instrument functions multi-function meter unit warning ew1d71008 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. The multi-function meter unit is equipped with the following: • a speedometer (which shows the riding speed) • a tac...

  • Page 15: Features

    Features 1-5 tachometer the electric tachometer allows the rider to mon- itor the engine speed and keep it within the ideal power range. When the key is turned to “on”, the tachometer needle will sweep once across the r/min range and then return to zero r/min in order to test the electrical circuit....

  • Page 16: Features

    Features 1-6 to set the clock: 1. Push the “select” switch to change the dis- play to the clock mode. 2. Push the “select” and “reset” switches together for at least two seconds. 3. When the hour digits start flashing, push the “reset” switch to set the hours. 4. Push the “select” switch, and the mi...

  • Page 17: Features

    Features 1-7 7. Push the “select” switch. The odometer/tripmeter/clock display will re- turn to the prior mode. 1. Speedometer needle 2. Tachometer needle 3. Fuel gauge needle 4. Item number 5. Brightness level 4 2 3 1 5.

  • Page 18: 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 19: Important Information

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

  • Page 20: 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 21: 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 22: Special Tools

    Special tools 1-12 timing light 90890-03141 inductive clamp timing light yu-03141 3-10 oil filter wrench 90890-01426 yu-38411 3-12 belt tension gauge 90890-03170 rear drive belt tension gauge ym-03170 3-24 steering nut wrench 90890-01403 spanner wrench yu-33975 3-26, 4-71 damper rod holder 90890-014...

  • Page 23: Special Tools

    Special tools 1-13 valve guide remover (ø6) 90890-04064 valve guide remover (6.0 mm) ym-04064-a 5-40 valve guide installer (ø6) 90890-04065 valve guide installer (6.0 mm) ym-04065-a 5-40 valve guide reamer (ø6) 90890-04066 valve guide reamer (6.0 mm) ym-04066 5-40 piston pin puller set 90890-01304 p...

  • Page 24: Special Tools

    Special tools 1-14 rotor puller 90890-01080 stator rotor puller ym-01080-a 5-74 vacuum/pressure pump gauge set 90890-06756 6-12 pressure gauge 90890-03153 6-12 fuel pressure adapter 90890-03176 ym-03176 6-12 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 6-12 ignitio...

  • Page 25: Special Tools

    Special tools 1-15.

  • Page 26: Specifications

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

  • Page 27: General Specifications

    General specifications 2-1 eas20280 general specifications model model xv19sw 1d74 (usa) xv19sw 1d76 (cdn) xv19swc 1d75 (california) xv19w 4d45 (usa) xv19w 4d47 (cdn) xv19wc 4d46 (california) xv19mw 4d54 (usa) xv19mw 4d56 (cdn) xv19mwc 4d55 (california) xv19ctsw 2c54 (usa) xv19ctsw 2c56 (cdn) xv19ct...

  • Page 28: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type air cooled 4-stroke, ohv displacement 1854.0 cm³ cylinder arrangement v-type 2-cylinder bore × stroke 100.0 × 118.0 mm (3.94 × 4.65 in) compression ratio 9.48 :1 starting system electric starter fuel recommended fuel premium...

  • Page 29: Engine Specifications

    Engine specifications 2-3 inner-rotor-to-outer-rotor-tip clearance less than 0.12 mm (0.0047 in) limit 0.20 mm (0.0079 in) outer-rotor-to-oil-pump-housing clearance 0.10–0.15 mm (0.0039–0.0059 in) limit 0.22 mm (0.0087 in) oil-pump-housing-to-inner-and-outer-rotor clearance 0.04–0.09 mm (0.0016–0.00...

  • Page 30: Engine Specifications

    Engine specifications 2-4 rocker arm/rocker arm shaft rocker arm inside diameter 18.000–18.018 mm (0.7087–0.7094 in) limit 18.036 mm (0.7101 in) rocker arm shaft outside diameter 17.976–17.991 mm (0.7077–0.7083 in) rocker-arm-to-rocker-arm-shaft clearance 0.009–0.042 mm (0.0004–0.0017 in) limit 0.08...

  • Page 31: Engine Specifications

    Engine specifications 2-5 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) limit 0.080 mm (0.0032 in) valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–...

  • Page 32: Engine Specifications

    Engine specifications 2-6 valve push rod runout 0.3 mm (0.012 in) cylinder bore 100.000–100.010 mm (3.9370–3.9374 in) taper limit 0.050 mm (0.0020 in) out of round limit 0.050 mm (0.0020 in) piston piston-to-cylinder clearance 0.025–0.050 mm (0.0010–0.0020 in) limit 0.15 mm (0.0059 in) diameter d 99...

  • Page 33: Engine Specifications

    Engine specifications 2-7 oil ring dimensions (b × t) 2.50 × 3.40 mm (0.10 × 0.13 in) end gap (installed) 0.20–0.70 mm (0.0079–0.0276 in) connecting rod oil clearance (using plastigauge ® ) 0.050–0.074 mm (0.0020–0.0029 in) bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow crankshaft width ...

  • Page 34: Engine Specifications

    Engine specifications 2-8 primary reduction system spur gear primary reduction ratio 72/51 (1.412) secondary reduction system belt drive secondary reduction ratio 70/31 (2.258) operation left foot operation gear ratio 1st 38/16 (2.375) 2nd 33/21 (1.571) 3rd 29/25 (1.160) 4th 26/28 (0.929) 5th 24/30 ...

  • Page 35: Engine Specifications

    Engine specifications 2-9 idling condition engine idling speed 850–950 r/min intake vacuum 31.3–35.3 kpa (9.3–10.4 inhg) (235–265 mmhg) oil temperature 80.0–90.0 °c (176.00–194.00 °f) throttle cable free play 4.0–6.0 mm (0.16–0.24 in).

  • Page 36: Chassis Specifications

    Chassis specifications 2-10 eas20300 chassis specifications chassis frame type double cradle caster angle 31.20 ° trail 152.0 mm (5.98 in) front wheel wheel type cast wheel rim size 18m/c × mt4.00 rim material aluminum wheel travel 130.0 mm (5.12 in) radial wheel runout limit 1.0 mm (0.04 in) latera...

  • Page 37: Chassis Specifications

    Chassis specifications 2-11 front brake type dual disc brake operation right hand operation front disc brake disc outside diameter × thickness 298.0 × 5.0 mm (11.73 × 0.20 in) brake disc thickness limit 4.5 mm (0.18 in) brake disc deflection limit 0.10 mm (0.0039 in) brake pad lining thickness (inne...

  • Page 38: Chassis Specifications

    Chassis specifications 2-12 recommended oil fork oil 10wt quantity 571.0 cm³ (19.31 us oz) (20.10 imp.Oz) level 124.0 mm (4.88 in) rear suspension type swingarm (link suspension) spring/shock absorber type coil spring/gas-oil damper rear shock absorber assembly travel 50.0 mm (1.97 in) spring free l...

  • Page 39: Electrical Specifications

    Electrical specifications 2-13 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system transistorized coil ignition (digital) advancer type electrical ignition timing (b.T.D.C.) 10.0 °/900 r/min engine control unit model/manufacturer f008t83271/mitsubishi ignit...

  • Page 40: Electrical Specifications

    Electrical specifications 2-14 indicator light neutral indicator light led turn signal indicator light led high beam indicator light led fuel level warning light led engine trouble warning light led electric starting system system type constant mesh starter motor model/manufacturer 1d7/moric power o...

  • Page 41: Electrical Specifications

    Electrical specifications 2-15 fuel pump relay model/manufacturer g8r-30y-v3/omron coil resistance 162–198 Ω thermo unit model/manufacturer 5px/denso resistance at 100°c 898.4–1098.0 Ω fuses main fuse 50.0 a headlight fuse 20.0 a taillight fuse 10.0 a signaling system fuse 10.0 a ignition fuse 25.0 ...

  • Page 42: Tightening Torques

    Tightening torques 2-16 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 2-17 eas20340 engine tightening torques item thread size q’ty tightening torque remarks cylinder head nut m12 8 60 nm (6.0 m·kg, 43 ft·lb) cylinder head stud bolt (exhaust pipe) m8 4 15 nm (1.5 m·kg, 11 ft·lb) spark plug m12 4 18 nm (1.8 m·kg, 13 ft·lb) engine temperature sensor —...

  • Page 44: Tightening Torques

    Tightening torques 2-18 oil pipe 2 bolt m6 3 10 nm (1.0 m·kg, 7.2 ft·lb) oil pipe 4 bolt m6 3 10 nm (1.0 m·kg, 7.2 ft·lb) oil pump housing cover 1 screw (crankcase) m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) oil pump housing cover 2 screw (crankcase) m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) throttle body joint clamp sc...

  • Page 45: Tightening Torques

    Tightening torques 2-19 clutch cover damper plate screw m6 4 10 nm (1.0 m·kg, 7.2 ft·lb) camshaft cover bolt m6 8 10 nm (1.0 m·kg, 7.2 ft·lb) generator damper cover bolt m5 3 5 nm (0.5 m·kg, 3.6 ft·lb) engine oil filler plug m20 1 10 nm (1.0 m·kg, 7.2 ft·lb) camshaft sprocket cover plate bolt m6 2 1...

  • Page 46: Tightening Torques

    Tightening torques 2-20 note: • tighten the connecting rod bolts to 15 nm (1.5 m·kg, 11 ft·lb), and then tighten them further to reach the specified angle 125–135°. • install the crankcase stud bolts (m12) so that their installed length is 141.5 mm (5.57 in). • install the crankcase stud bolts (m10)...

  • Page 47: Tightening Torques

    Tightening torques 2-21 cylinder head tightening sequence: 3 1 2 4 a b 3 1 2 4 a. Front cylinder b. Rear cylinder.

  • Page 48: Tightening Torques

    Tightening torques 2-22 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine mounting bolt (left upper side) m12 2 66 nm (6.6 m·kg, 48 ft·lb) engine mounting bolt (right upper side) m12 2 59 nm (5.9 m·kg, 43 ft·lb) engine mounting nut (rear upper side) m12 1 98 ...

  • Page 49: Tightening Torques

    Tightening torques 2-23 relay arm nut (relay arm and connecting arm) m12 1 59 nm (5.9 m·kg, 43 ft·lb) rear shock absorber assembly nut (rear side) m10 1 40 nm (4.0 m·kg, 29 ft·lb) rear shock absorber assembly nut (front side) m12 1 59 nm (5.9 m·kg, 43 ft·lb) upper drive belt cover bolt m6 2 7 nm (0....

  • Page 50: Tightening Torques

    Tightening torques 2-24 fuel tank bracket bolt (front side) m8 2 16 nm (1.6 m·kg, 11 ft·lb) fuel tank bracket nut (rear side) m6 2 10 nm (1.0 m·kg, 7.2 ft·lb) sub-fuel tank bolt m6 3 10 nm (1.0 m·kg, 7.2 ft·lb) rider seat bracket bolt m8 2 23 nm (2.3 m·kg, 17 ft·lb) fuel tank and fuel tank bracket b...

  • Page 51: Tightening Torques

    Tightening torques 2-25 rear fender bracket and frame bolt m10 2 40 nm (4.0 m·kg, 29 ft·lb) rear fender bracket and rear fender bolt m8 4 23 nm (2.3 m·kg, 17 ft·lb) passenger seat bolt m8 2 16 nm (1.6 m·kg, 11 ft·lb) rider seat bracket assembly and seat lock assembly bolt m6 2 7 nm (0.7 m·kg, 5.1 ft...

  • Page 52: Tightening Torques

    Tightening torques 2-26 * for xv19cts(c), xv19ct(c) and xv19ctm(c) note: 1. First, tighten the lower ring nut to approximately 52 nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 18 nm (1.8 m·kg, 13 ft·lb) with a torque wrenc...

  • Page 53

    Lubrication points and lubricant types 2-27 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings cylinder head nuts and washers connecting rod small end and big end crankshaft journals piston surfaces piston pins connecting rod bo...

  • Page 54

    Lubrication points and lubricant types 2-28 primary driven gear inner surface clutch push rods and ball clutch boss nut and washer transmission gears (wheel and pinion) and collar drive pulley nut and washer shift forks and shift fork guide bars shift drum shift shaft and shift shaft oil seal shift ...

  • Page 55

    Lubrication points and lubricant types 2-29 eas20380 chassis lubrication point lubricant steering bearings and upper bearing dust cover lip lower bearing dust seal lip front wheel oil seal lips (left and right) rear wheel oil seal lips rear wheel drive hub oil seal lip rear wheel drive hub mating su...

  • Page 56

    Lubrication points and lubricant types 2-30

  • Page 57

    Lubrication system chart and diagrams 2-31 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart 22 21 19 18 20 23 17 16 15 11 10 14 13 9 8 12 14 7 6 5 4 2 3 1 9 8.

  • Page 58

    Lubrication system chart and diagrams 2-32 1. Oil strainer (transfer gear case) 2. Oil pump 3. Oil tank 4. Drive axle 5. Main axle 6. Oil strainer (crankcase) 7. Balancer 8. Front cylinder head cover 9. Rear cylinder head cover 10. Rear cylinder camshaft 11. Front cylinder camshaft 12. Rear valve li...

  • Page 59

    Lubrication system chart and diagrams 2-33 eas20410 lubrication diagrams e a-a b-b e-e d-d c c a a b e d d b 2 9 3 8 1 10 4 5 6 7 8 11 4 5.

  • Page 60

    Lubrication system chart and diagrams 2-34 1. Oil tank 2. Dipstick 3. Oil pipe 2 4. Oil delivery pipe 1 5. Oil filter cartridge 6. Oil delivery pipe 2 7. Oil pipe 3 8. Oil pipe 4 9. Oil pipe 5 10. Oil strainer (oil tank) 11. Oil delivery pipe 3.

  • Page 61

    Lubrication system chart and diagrams 2-35 d d b-b d-d c-c a a b c c b 3 2 1 3 4 6 7 6 7 5.

  • Page 62

    Lubrication system chart and diagrams 2-36 1. Valve lifter 2. Push rod 3. Rocker arm shaft 4. Oil pipe 1 5. Crankshaft 6. Oil pipe (“f” mark) 7. Oil pipe (“r” mark).

  • Page 63

    Lubrication system chart and diagrams 2-37 a-a a a 1 3 2 4.

  • Page 64

    Lubrication system chart and diagrams 2-38 1. Oil pipe 1 2. Oil pump 3. Oil strainer (crankcase) 4. Joint pipe.

  • Page 65

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

  • Page 66

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

  • Page 67

    Lubrication system chart and diagrams 2-41 a a a 1 5 5 1 3 2 4 b b b-b.

  • Page 68

    Lubrication system chart and diagrams 2-42 1. Oil pipe 5 2. Transfer gear oil pump 3. Oil strainer (transfer gear case) 4. Middle drive shaft 5. Oil strainer (oil tank) a. From the oil pump.

  • Page 69

    Lubrication system chart and diagrams 2-43 1 2.

  • Page 70

    Lubrication system chart and diagrams 2-44 1. Transfer gear oil pump 2. Middle driven shaft.

  • Page 71: Cable Routing

    Cable routing 2-45 eas20430 cable routing c d f f c d b-b c-c d-d f-f a e a e b b 1 1 1 1 2 3 4 5 5 5 5 5 6 6 6 6 7 7 7 7 8 9 10 11 a b c e f g d.

  • Page 72: Cable Routing

    Cable routing 2-46 1. Clutch hose 2. Right handlebar switch lead 3. Main switch 4. Left handlebar switch lead 5. Front brake hose 6. Throttle cable (decelerator cable) 7. Throttle cable (accelerator cable) 8. Horn 1 lead 9. Horn 1 10. Rear brake light switch 11. Rear brake light switch lead a. Cross...

  • Page 73: Cable Routing

    Cable routing 2-47 b b c d d e e b-b g-g f-f e-e d-d a a c f f 1 1 1 1 2 2 2 2 2 3 3 4 4 5 6 6 7 8 8 9 12 g g 3 b g j h i a c d e f k l 10 11.

  • Page 74: Cable Routing

    Cable routing 2-48 1. Main switch lead 2. Right handlebar switch lead 3. Wire harness 4. Left handlebar switch lead 5. Air temperature sensor lead 6. Front left turn signal/position light lead 7. Headlight lead 8. Front right turn signal/position light lead 9. Headlight coupler (high beam) 10. Headl...

  • Page 75: Cable Routing

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

  • Page 76: Cable Routing

    Cable routing 2-50 1. Exup servo motor 2. Fuse box 3. Wire harness 4. Fuel outlet hose 5. Cylinder-#1 right spark plug cap 6. Cylinder-#1 right ignition coil 7. Cylinder-#2 intake air pressure sensor coupler 8. Fuel sender (fuel tank) coupler 9. Meter assembly coupler 10. Throttle cable 11. Front br...

  • Page 77: Cable Routing

    Cable routing 2-51 e d d d d a a c b b c a-a b-b c-c d-d e g-g f h h f a b c d e f g h i j k l m n n o q r u s t o q r s v y z 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 15 16 17 18 15 16 18 34 18 35 19 20 21 22 23 24 24 25 26 27 28 29 30 31 32 33 36 g g x w p ad ac ab aa aa 1 2 3.

  • Page 78: Cable Routing

    Cable routing 2-52 1. Clutch hose 2. Throttle cable (decelerator cable) 3. Throttle cable (accelerator cable) 4. Cylinder-#2 left spark plug cap 5. Cylinder-#1 left spark plug cap 6. Sub-wire harness 1 7. Rectifier/regulator 8. Crankshaft position sensor lead 9. Stator coil lead 10. Rectifier/regula...

  • Page 79: Cable Routing

    Cable routing 2-53.

  • Page 80: Cable Routing

    Cable routing 2-54 1. Meter assembly coupler 2. Cylinder-#2 intake air pressure sensor coupler 3. Cylinder-#1 right spark plug cap 4. Wire harness 5. Negative battery lead 6. Exup servo motor 7. Fuse box 8. Starter motor lead 9. Positive battery lead 10. Sub-wire harness 1 11. Ecu (electronic contro...

  • Page 81: Cable Routing

    Cable routing 2-55 c-c b c c a a b d e c l n 1 2 3 4 4 5 5 6 6 7 7 4 5 6 7 8 8 8 9 10 11 11 11 12 14 13 15 16 17 18 19 20 21 22 26 27 a b f g h i j k l m o p q r s t u v w x 21 23 24 25 28 h f 24 g.

  • Page 82: Cable Routing

    Cable routing 2-56 1. Fuel tank breather hose 2. Fuel sender (fuel tank) 3. Fuel tank 4. Fuel hose (fuel tank to fuel hose joint) 5. Fuel return hose (fuel return pipe to sub-fuel tank) 6. Air vent hose (fuel hose joint to fuel tank) 7. Fuel hose joint 8. Fuel outlet hose 9. Fuel pump 10. Sub-fuel t...

  • Page 83: Cable Routing

    Cable routing 2-57 c-c b a b a c c a b d c e f h g i j 1 2 3 4 5 4 5 6 7 8 9 10 11 12 13 11 13 14 15 16 17 18 19 20 22 7 11 11 13 13 11 21 k.

  • Page 84: Cable Routing

    Cable routing 2-58 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#1 intake air pressure sensor hose 3. Air filter case breather hose 1 4. Fuel hose (intake manifold assembly to pressure regulator) 5. Pressure regulator 6. Air filter case breather hose 2 7. Canister purge hose (for california...

  • Page 85: Cable Routing

    Cable routing 2-59 a b b a a b b c d e f g h i j 1 2 3 4 4 5 6 7 8 8 8 9 9 9 10 10 10 11 9 10 12 13 14 15 16 17 18 19 b.

  • Page 86: Cable Routing

    Cable routing 2-60 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#2 intake air pressure sensor hose 3. Cylinder-#2 intake air pressure sensor 4. Isc (idle speed control) unit coupler 5. Isc (idle speed control) unit 6. Rollover valve 1 7. Rollover valve 2 8. Isc (idle speed control) unit inl...

  • Page 87: Cable Routing

    Cable routing 2-61.

  • Page 88

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

  • Page 89

    Electrical system ................................................................................ 3-31 checking and charging the battery....................................... 3-31 checking the fuses ........................................................................ 3-31 replacing the headlig...

  • Page 91: 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 92: Periodic Maintenance

    Periodic maintenance 3-2 * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. 6 * wheels • check runout and for dam- age. • replace if necessary. √ √ √ √ √ 7 * tires • check tread depth and for damage. • replace if necessary. • check air pre...

  • Page 93: Periodic Maintenance

    Periodic maintenance 3-3 note: from 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. Eau38440 note: • air filter • this model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compresse...

  • Page 94: Engine

    Engine 3-4 eas20470 engine eas20530 adjusting the valve clearance the following procedure applies to all of the valves. Note: • the valve clearance is automatically adjusted by the hydraulic valve lifter. However, there are times when the valve clearance needs to be adjusted manually. If this is the...

  • Page 95: Engine

    Engine 3-5 8. Remove: • fuel tank damper “1” • cylinder head breather hose “2” 9. Disconnect: • oil tank breather hose “3” • fuel outlet hose “4” 10.Remove: • front cylinder head cover “1” • rear cylinder head cover “2” note: due to the small clearance between the frame and the rear cylinder head co...

  • Page 96: Engine

    Engine 3-6 d. Measure the valve clearance with a thickness gauge. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ piston #2 tdc (front cylinder) a. Turn the crankshaft counterclockwise from the piston #1 tdc by 408 degrees. B. When piston #2 is at ...

  • Page 97: Engine

    Engine 3-7 d. Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica- tion. E. Measure the valve clearance again. F. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ment steps until the specified clearance is obtained...

  • Page 98: Engine

    Engine 3-8 6. Install: • fuel tank refer to “fuel tank” on page 6-1. 7. Adjust: • throttle body synchronization ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Start the engine and let it warm up for several minutes, and then let it run at specified en- gine idling speed. B. With throttle body ...

  • Page 99: Engine

    Engine 3-9 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the locknut “1”. B. Turn the adjusting nut “2” in direction “a” or “b” until the specified throttle cable free play is obtained. C. Tighten the locknut “1”. Warning ewa12910 after adjusting the throttle cable free play, start the...

  • Page 100: Engine

    Engine 3-10 10.Install: • air filter case refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 6-1. • rider seat bracket assembly • rider seat refer to “general chassis” on page 4-1. Eas20700 checking the ignition timing note: prior to checking the ignition timing, check ...

  • Page 101: Engine

    Engine 3-11 note: align the mark “a” on the shift pedal shaft with the slot in the shift pedal. Eas20750 checking the engine oil level 1. Stand the vehicle on a level surface. Note: • place the vehicle on a suitable stand. • make sure the vehicle is upright. 2. Start the engine, warm it up for appro...

  • Page 102: Engine

    Engine 3-12 5. Remove: • engine oil drain bolts (crankcase) “1” (along with the gaskets) 6. Drain: • engine oil (completely from the oil tank and crankcase) 7. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Re...

  • Page 103: Engine

    Engine 3-13 caution: ec1d71008 when starting the engine make sure the dip- stick is securely fitted into the oil tank. 12.Fill: (when engine is disassembled) • crankcase and oil tank (with the specified amount of the recom- mended engine oil) 13.Install: • engine oil filler cap 14.Start the engine, ...

  • Page 104: Engine

    Engine 3-14 eas20850 changing the transfer gear oil 1. Remove: • muffler • exhaust pipes refer to “engine removal” on page 5-1. 2. Place a container under the transfer gear oil drain bolt. 3. Remove: • straight plug “1” • transfer gear oil drain bolt “2” 4. Drain: • transfer gear oil (completely fro...

  • Page 105: Engine

    Engine 3-15 • refill with the same type of clutch fluid that is already in the system. Mixing clutch flu- ids may result in a harmful chemical reac- tion, leading to poor clutch performance. • when refilling, be careful that water does not enter the clutch fluid reservoir. Water will significantly l...

  • Page 106: Engine

    Engine 3-16 4. Remove: • air filter element “1” 5. Check: • air filter element damage → replace. Note: the air filter needs more frequent service if you are riding in unusually wet or dusty areas. 6. Install: • air filter case cover caution: ec1d71002 never operate the engine without the air filter ...

  • Page 107: Engine

    Engine 3-17 3. Install: • fuel tank refer to “fuel tank” on page 6-1. • rider seat bracket assembly • rider seat refer to “general chassis” on page 4-1. Eas21050 checking the cylinder head breather hose 1. Remove: • rider seat • rider seat bracket assembly refer to “general chassis” on page 4-1. • f...

  • Page 108: Engine

    Engine 3-18 • muffler “3” • muffler bracket “4” cracks/damage → replace. • gaskets “5” exhaust gas leaks → replace. 2. Check: tightening torque • front exhaust pipe nuts “6” • front exhaust pipe and rear exhaust pipe bolt “7” • rear exhaust pipe nuts “8” • rear exhaust pipe and muffler bolt “9” • mu...

  • Page 109: Engine

    Engine 3-19 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Check: • exup cable free play (at the exup valve pul- ley) “a” and “b” 4. Adjust: • exup cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen both locknuts “1”. B. Turn both adjusting bolts “2” in or out until th...

  • Page 110: Chassis

    Chassis 3-20 eas21140 chassis eas21190 adjusting the rear disc brake 1. Check: • brake pedal position (distance “a” from the top of the rider footrest to the top of the brake pedal) out of specification → adjust. 2. Adjust: • brake pedal position ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. ...

  • Page 111: Chassis

    Chassis 3-21 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 112: Chassis

    Chassis 3-22 2. Check: • brake hose clamps loose → tighten the clamp bolt. 3. Hold the vehicle upright and apply the brake several times. 4. Check: • brake hoses brake fluid leakage → replace the damaged hose. Refer to “front brake” on page 4-31. Eas21290 checking the rear brake hoses 1. Remove: • r...

  • Page 113: Chassis

    Chassis 3-23 note: • be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. • when bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this pre- caution could allow a...

  • Page 114: Chassis

    Chassis 3-24 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen both locknuts “1”. B. Turn the shift rod “2” in direction “a” or “b” until the specified installed shift rod length is ob- tained. Note: make sure that the exposed thread length “c” be- tween the locknut and joint on both ends ...

  • Page 115: Chassis

    Chassis 3-25 3. Remove: • muffler refer to “engine removal” on page 5-1. 4. Adjust: • drive belt slack ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ note: place the vehicle on a suitable stand so that the rear wheel is elevated. A. Loosen the wheel axle nut “1”. B. Loosen both locknuts “2”. C. T...

  • Page 116: Chassis

    Chassis 3-26 3. Remove: • upper bracket refer to “front fork” on page 4-60. 4. Adjust: • steering head ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the lock washer “1”, the upper ring nut “2”, and the rubber washer “3”. B. Loosen the lower ring nut “4”, and then tight- en it to the sp...

  • Page 117: Chassis

    Chassis 3-27 3. Hold the vehicle upright and apply the front brake. 4. Check: • front fork operation push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → repair. Refer to “front fork” on page 4-60. Eas21590 adjusting the rear shock absorber as...

  • Page 118: Chassis

    Chassis 3-28 warning ewa13180 • the tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • the tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories) and the ant...

  • Page 119: Chassis

    Chassis 3-29 warning ewa14090 after extensive tests, the tires listed below have been approved by yamaha motor co., ltd. For this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee con- cerning handling characteristics can be giv- en if a t...

  • Page 120: Chassis

    Chassis 3-30 note: hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device. Eas21700 lubricating the levers lubricate the pivoting point and metal-to-metal moving parts of the levers. Eas21710 lubricating the pedal lubricate the pivot...

  • Page 121: Electrical System

    Electrical system 3-31 eas21750 electrical system eas21760 checking and charging the battery refer to “electrical components” on page 7-67. Eas21770 checking the fuses refer to “electrical components” on page 7-67. Eas21790 replacing the headlight bulbs 1. Remove: • windshield (for xv19cts(c)/ xv19c...

  • Page 122: Electrical System

    Electrical system 3-32 b. Disconnect: • headlight coupler “1” c. Detach: • headlight bulb holder “2” d. Remove: • headlight bulb warning ewa13320 since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. E. Install: • headlight b...

  • Page 123: Electrical System

    Electrical system 3-33 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ a b 1.

  • Page 124: Chassis

    4 chassis general chassis ...................................................................................... 4-1 removing the windshield ............................................................... 4-2 assembling the windshield ........................................................... 4-2 i...

  • Page 125

    Rear brake............................................................................................... 4-43 introduction..................................................................................... 4-49 checking the rear brake disc ................................................... 4-49 ...

  • Page 127: General Chassis

    General chassis 4-1 eas21830 general chassis removing the windshield (for xv19cts(c)/xv19ct(c)/xv19ctm(c)) order job/parts to remove q’ty remarks 1 windshield 1 2 windshield bracket brace 1 3 windshield bracket (left and right) 2 4 windshield brace (left and right) 2 5 windshield screen 1 6 windshie...

  • Page 128: General Chassis

    General chassis 4-2 et1d71039 removing the windshield 1. Remove: • windshield ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Insert the key “1” into the windshield lock, turn it clockwise and then remove the key. B. Remove the windshield by pushing it forward, and then pulling it upward as sho...

  • Page 129: General Chassis

    General chassis 4-3 c. Insert the key into the windshield lock, turn it counterclockwise until it stops to lock the fas- tener, and then remove the key. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 1. Lock 2. Fastener 2 1 1.

  • Page 130: General Chassis

    General chassis 4-4 removing the sidebags and backrest (for xv19cts(c)/xv19ct(c)/xv19ctm(c)) order job/parts to remove q’ty remarks 1 sidebag (left and right) 2 note: water can be harmful to untreated leather. Use yamaha saddle soap or another quality brand according to the manufacturer’s direc- tio...

  • Page 131: General Chassis

    General chassis 4-5 et1d71041 removing the backrest 1. Remove: • backrest ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Open the sidebag lids. B. Insert the key “1” into the backrest lock, turn it counterclockwise, and then remove the key. C. Pull the lever “1” on each side of the backrest up...

  • Page 132: General Chassis

    General chassis 4-6 b. Push the rear of the backrest down smoothly but forcefully to lock it in place and make sure that the lever hook “1” on each side is secure- ly fit over its holder “2”. Warning ew1d71017 both lever hooks must be securely fitted over their holder. If the backrest is loose, a pa...

  • Page 133: General Chassis

    General chassis 4-7 removing the sidebag brackets (for xv19cts(c)/xv19ct(c)/xv19ctm(c)) order job/parts to remove q’ty remarks sidebag/backrest refer to “general chassis” on page 4-1. 1 passenger footrest (left and right) 2 2 sidebag bracket brace 1 3 sidebag bracket (left and right) 2 note: remove ...

  • Page 134: General Chassis

    General chassis 4-8 et1d71047 checking the sidebag bracket spring nuts 1. Check: • sidebag bracket spring nut height “a” out of specification → adjust. 2. Check: • sidebag bracket spring nuts damage → replace. Sidebag bracket spring nut height 12.0 mm (0.47 in) a.

  • Page 135: General Chassis

    General chassis 4-9 removing the seats and side covers order job/parts to remove q’ty remarks 1 rider seat 1 2 passenger seat 1 3 tool kit 1 4 tool kit tray 1 5 rider seat bracket assembly 1 6 right side cover 1 7 left side cover 1 8 seat lock cable assembly 1 for installation, reverse the removal p...

  • Page 136: General Chassis

    General chassis 4-10 removing the headlight order job/parts to remove q’ty remarks 1 headlight cover 1 2 air temperature sensor coupler 1 disconnect. 3 air temperature sensor 1 4 headlight (low beam) coupler 1 disconnect. 5 headlight (high beam) coupler 1 disconnect. 6 headlight lens unit 1 7 front ...

  • Page 137: General Chassis

    General chassis 4-11 removing the battery order job/parts to remove q’ty remarks tool kit tray/seat bracket refer to “general chassis” on page 4-1. 1 ecu band 1 2 ecu (electronic control unit) 1 3 coupler tray 1 4 negative terminal cover 1 5 negative battery lead 1 disconnect. 6 positive battery lea...

  • Page 138: General Chassis

    General chassis 4-12 17 headlight relay 1 18 turn signal relay 1 19 plastic locking tie 2 20 battery box 1 for installation, reverse the removal proce- dure. Removing the battery order job/parts to remove q’ty remarks 13 18 17 16 15 19 14 12 19 20 8 5 6 7 2 1 3 9 10 (3) 11 4.

  • Page 139: General Chassis

    General chassis 4-13 removing the air filter case order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 6-1. Pressure regulator cover refer to “throttle bodies” on page 6-6. 1 air filter case cover 1 2 air filter element 1 3 ...

  • Page 140: General Chassis

    General chassis 4-14 15 air filter case bracket 1 16 air filter case joint clamp screw 2 loosen. 17 air filter case 1 for installation, reverse the removal proce- dure. Removing the air filter case order job/parts to remove q’ty remarks 15 9 7 8 14 16 11 4 3 12 13 16 5 6 1 17 2 10 t r 10 nm (1.0 m •...

  • Page 141: Front Wheel

    Front wheel 4-15 eas21870 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks note: place the vehicle on a suitable stand so that the front wheel is elevated. 1 right front fender stay 1 2 left front fender stay 1 3 front fender stay rod 1 4 front brake hose g...

  • Page 142: Front Wheel

    Front wheel 4-16 14 collar 2 15 front brake disc cover 1 16 front brake disc 2 for installation, reverse the removal proce- dure. Removing the front wheel and brake discs order job/parts to remove q’ty remarks t r 7 nm (0.7 m • kg, 5.1 ft • ib) t r 7 nm (0.7 m • kg, 5.1 ft • ib) t r 7 nm (0.7 m • kg...

  • Page 143: Front Wheel

    Front wheel 4-17 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal 2 2 wheel bearing 2 3 spacer 1 for assembly, reverse the disassembly pro- cedure. 2 1 2 1 3 ls ls new new.

  • Page 144: Front Wheel

    Front wheel 4-18 eas21900 removing the front wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • right front fender stay “1” • left front fender stay “2” • front fender stay rod “3” note: • remove th...

  • Page 145: Front Wheel

    Front wheel 4-19 2. Check: • tire • front wheel damage/wear → replace. Refer to “checking the tires” on page 3-27 and “checking the wheels” on page 3-29. 3. Measure: • radial wheel runout “1” • lateral wheel runout “2” over the specified limits → replace. 4. Check: • wheel bearings front wheel turns...

  • Page 146: Front Wheel

    Front wheel 4-20 c. Turn the front wheel 90 ° so that the “x 1 ” mark is positioned as shown. D. Release the front wheel. E. When the wheel stops, put an “x 2 ” mark at the bottom of the wheel. F. Repeat steps (d) through (f) several times un- til all the marks come to rest at the same spot. G. The ...

  • Page 147: Front Wheel

    Front wheel 4-21 2. Check: • front brake discs refer to “checking the front brake discs” on page 4-36. 3. Lubricate: • oil seal lips 4. Install: • front wheel axle note: install the tire and wheel with the mark “1” point- ing in the direction of wheel rotation. 5. Tighten: • front wheel axle • front...

  • Page 148: Front Wheel

    Front wheel 4-22.

  • Page 149: Rear Wheel

    Rear wheel 4-23 eas22020 rear wheel removing the rear fender order job/parts to remove q’ty remarks rider seat/passenger seat/tool kit tray refer to “general chassis” on page 4-1. 1 sub-wire harness 1 coupler 1 disconnect. 2 rear fender bracket 2 3 dowel pin 4 4 rear fender assembly 1 for installati...

  • Page 150: Rear Wheel

    Rear wheel 4-24 removing the rear wheel order job/parts to remove q’ty remarks note: place the vehicle on a suitable stand so that the rear wheel is elevated. Muffler refer to “engine removal” on page 5-1. 1 upper drive belt cover 1 2 rear brake caliper 1 3 rear brake pad 2 4 brake pad spring 2 5 dr...

  • Page 151: Rear Wheel

    Rear wheel 4-25 14 collar 1 silver 15 rear wheel 1 for installation, reverse the removal proce- dure. Removing the rear wheel order job/parts to remove q’ty remarks t r 7 nm (0.7 m • kg, 5.1 ft • ib) t r 27 nm (2.7 m • kg, 19 ft • ib) t r 150 nm (15.0 m • kg, 110 ft • lb) 12 9 4 2 4 3 13 15 7 8 6 5 ...

  • Page 152: Rear Wheel

    Rear wheel 4-26 removing the rear brake disc and rear wheel drive hub order job/parts to remove q’ty remarks 1 rear brake disc cover 1 2 rear brake disc 1 3 rear wheel pulley 1 4 oil seal 1 5 circlip 1 6 rear wheel drive hub 1 7 circlip 1 8 bearing 1 9 collar 1 10 bearing 1 11 rear wheel drive hub d...

  • Page 153: Rear Wheel

    Rear wheel 4-27 disassembling the rear wheel order job/parts to remove q’ty remarks 1 collar 1 2 bearing 1 3 spacer 1 4 oil seal 1 5 circlip 1 6 bearing 1 for assembly, reverse the disassembly pro- cedure. 6 4 3 2 1 new ls 5.

  • Page 154: Rear Wheel

    Rear wheel 4-28 eas28760 removing the rear wheel (disc) 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • rear brake calipe...

  • Page 155: Rear Wheel

    Rear wheel 4-29 eas22110 checking the rear wheel drive hub 1. Check: • rear wheel drive hub cracks/damage → replace. • rear wheel drive hub dampers damage/wear → replace. Eas22130 checking and replacing the rear wheel pulley 1. Check: • rear wheel pulley surface plating has come off → replace the re...

  • Page 156: Rear Wheel

    Rear wheel 4-30 note: temporarily tighten the wheel axle nut. 5. Adjust: • drive belt slack refer to “adjusting the drive belt slack” on page 3-24. 6. Tighten: • rear wheel axle nut 7. Install: • rear brake caliper warning ewa13500 make sure the brake hose is routed properly. T r . Rear wheel axle n...

  • Page 157: Front Brake

    Front brake 4-31 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake hose holder 1 2 reflector 1 3 reflector bracket 1 4 front brake caliper 1 5 brake pad clip 2 6 brake pad pin 1 7 bra...

  • Page 158: Front Brake

    Front brake 4-32 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-22. 1 right rearview mirror 1 2 brake master cylinder reservoir cap 1 3 brake master cylinder reservoir diaphragm hold- er 1 4 ...

  • Page 159: Front Brake

    Front brake 4-33 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. New 1 3 2 4 ls new.

  • Page 160: Front Brake

    Front brake 4-34 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-22. 1 brake hose holder 1 2 front brake hose union bolt 1 3 coppe...

  • Page 161: Front Brake

    Front brake 4-35 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad clip 2 2 brake pad pin 1 3 brake pad spring 1 4 brake pad 2 5 brake pad shim 2 6 brake caliper piston 4 7 brake caliper pist...

  • Page 162: Front Brake

    Front brake 4-36 eas22220 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the...

  • Page 163: Front Brake

    Front brake 4-37 d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 164: Front Brake

    Front brake 4-38 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • brake pad pin • brake pad clips • front brake caliper 4. Check: • brake fluid level below the minimum level mark “a” → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” on pa...

  • Page 165: Front Brake

    Front brake 4-39 b. Remove the brake caliper piston seals. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas22390 checking the front brake calipers 1. Check: • brake caliper pistons “1” rust/scratches/wear → replace the brake caliper pistons. • brake caliper cylinders “2” scratches/wear → replac...

  • Page 166: Front Brake

    Front brake 4-40 2. Remove: • front brake caliper 3. Install: • brake pads • brake pad spring • brake pad pin • brake pad clips • front brake caliper • brake hose guide refer to “replacing the front brake pads” on page 4-37. 4. Fill: • brake master cylinder reservoir (with the specified amount of th...

  • Page 167: Front Brake

    Front brake 4-41 • brake fluid delivery passages (brake master cylinder body) obstruction → blow out with compressed air. 2. Check: • brake master cylinder kit damage/scratches/wear → replace. 3. Check: • brake master cylinder reservoir cracks/damage → replace. • brake master cylinder reservoir diap...

  • Page 168: Front Brake

    Front brake 4-42 warning ewa13540 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful che...

  • Page 169: Rear Brake

    Rear brake 4-43 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 rear brake caliper bolt 2 2 rear brake caliper 1 3 rear brake pad 2 4 brake pad spring 2 for installation, reverse the removal proce- dure. 1 2 4 4 3 1 t r 6 nm (0.6 m • kg, 4.3 ft • ib) r 27 nm...

  • Page 170: Rear Brake

    Rear brake 4-44 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-22. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm holder 1 3 brake fluid reservoir diaphragm 1 4 brake fluid re...

  • Page 171: Rear Brake

    Rear brake 4-45 15 brake master cylinder 1 for installation, reverse the removal proce- dure. Removing the rear brake master cylinder order job/parts to remove q’ty remarks 1 10 12 15 9 6 8 13 14 11 5 2 3 4 7 r 7 nm (0.7 m • kg, 5.1 ft • ib) r 16 nm (1.6 m • kg, 11 ft • ib) t r 23 nm (2.3 m • kg, 17...

  • Page 172: Rear Brake

    Rear brake 4-46 disassembling the rear 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 circlip 1 5 brake hose joint 1 6 o-ring 1 7 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. 1 2 3 4 5 6 7 new ...

  • Page 173: Rear Brake

    Rear brake 4-47 removing the rear brake caliper order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-22. 1 rear brake hose union bolt 1 2 copper washer 2 3 rear brake hose 1 4 rear brake caliper bolt 2 5 rear brake caliper 1 for installat...

  • Page 174: Rear Brake

    Rear brake 4-48 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 brake caliper piston 1 2 brake caliper piston seal 2 3 bleed screw 1 for assembly, reverse the disassembly pro- cedure. 2 1 3 t r 6 nm (0.6 m • kg, 4.3 ft • ib) new.

  • Page 175: Rear Brake

    Rear brake 4-49 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 176: Rear Brake

    Rear brake 4-50 note: always install new brake pads and brake pad springs as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. B. Loosen the bleed screw and push the brake...

  • Page 177: Rear Brake

    Rear brake 4-51 b. Remove the brake caliper piston seals. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas22640 checking the rear brake caliper 1. Check: • brake caliper piston “1” rust/scratches/wear → replace the brake caliper piston. • brake caliper cylinder “2” scratches/wear → replace the ...

  • Page 178: Rear Brake

    Rear brake 4-52 • brake pad springs • rear brake caliper bolts • rear brake caliper refer to “replacing the rear brake pads” on page 4-49. 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13090 • use only the designated brake fluid. Other brake...

  • Page 179: Rear Brake

    Rear brake 4-53 2. Check: • brake master cylinder kit damage/scratches/wear → replace. 3. Check: • brake fluid reservoir cracks/damage → replace. • brake fluid reservoir diaphragm cracks/damage → replace. 4. Check: • brake hoses cracks/damage/wear → replace. Eas22730 assembling the rear brake master...

  • Page 180: Rear Brake

    Rear brake 4-54 5. Check: • brake pedal operation soft or spongy feeling → bleed the brake sys- tem. Refer to “bleeding the hydraulic brake system” on page 3-22. 6. Adjust: • brake pedal position refer to “adjusting the rear disc brake” on page 3-20. 7. Adjust: • rear brake light operation timing re...

  • Page 181: Handlebar

    Handlebar 4-55 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks headlight body refer to “general chassis” on page 4-1. 1 rearview mirror 2 2 plastic clamp 2 3 front brake light switch connector 2 disconnect. 4 front brake master cylinder holder 1 5 front brake master ...

  • Page 182: Handlebar

    Handlebar 4-56 15 handlebar grip 1 16 upper handlebar holder 1 17 handlebar 1 18 hose guide 1 19 lower handlebar holder 1 for installation, reverse the removal proce- dure. Removing the handlebar order job/parts to remove q’ty remarks 1 5 13 18 14 17 15 12 14 11 7 9 4 7 8 19 2 2 3 16 9 1 6 10 lt t r...

  • Page 183: Handlebar

    Handlebar 4-57 eas22860 removing the handlebar 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • handlebar grip “1” note: blow compressed air between the handlebar and the left handlebar grip, and gradua...

  • Page 184: Handlebar

    Handlebar 4-58 warning ewa13700 do not touch the handlebar grip until the rub- ber adhesive has fully dried. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Install: • left handlebar switch “1” note: align the projection “a” on the left handlebar switch with the hole “b” in the handlebar. 7. In...

  • Page 185: Handlebar

    Handlebar 4-59 throttle cable free play 4.0–6.0 mm (0.16–0.24 in).

  • Page 186: Front Fork

    Front fork 4-60 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. Windshield bracket (left and right) for xv19cts(c)/xv19ct(c)/ xv19ctm(c) only lower handlebar holder refer to “handlebar” on page 4-...

  • Page 187: Front Fork

    Front fork 4-61 12 front fork leg 1 for installation, reverse the removal proce- dure. Removing the front fork legs order job/parts to remove q’ty remarks 1 5 6 7 8 11 3 12 9 2 10 r 10 nm (1.0 m • kg, 7.2 ft • ib) r 7 nm (0.7 m • kg, 5.1 ft • ib) t r 115 nm (11.5 m • kg, 85 ft • lb) r 16 nm (1.6 m •...

  • Page 188: Front Fork

    Front fork 4-62 disassembling the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. 1 cap bolt 1 2 o-ring 1 3 spacer 1 4 spring seat 1 5 fork spring 1 6 dust seal 1 7 oil seal clip 1 8 damper rod bolt 1 9 copper washer 1 10 damper ...

  • Page 189: Front Fork

    Front fork 4-63 17 spring 1 18 oil flow stopper 1 19 outer tube 1 for assembly, reverse the disassembly pro- cedure. Disassembling the front fork legs order job/parts to remove q’ty remarks 6 7 13 14 12 16 17 18 9 8 19 15 5 10 11 1 2 3 4 t r 23 nm (2.3 m • kg, 17 ft • ib) r 40 nm (4.0 m • kg, 29 ft ...

  • Page 190: Front Fork

    Front fork 4-64 eas22960 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so t...

  • Page 191: Front Fork

    Front fork 4-65 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas23010 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: • inner tube • outer tube bends/damage/scratches → replace. Warning ewa13650 do not attempt to straighten a bent inner tub...

  • Page 192: Front Fork

    Front fork 4-66 2. Lubricate: • inner tube’s outer surface 3. Install: • inner tube (in the outer tube) 4. Install: • copper washer • damper rod bolt 5. Tighten: • damper rod bolt “1” note: while holding the damper rod assembly with the damper rod holder “2” and t-handle “3”, tighten the damper rod ...

  • Page 193: Front Fork

    Front fork 4-67 8. Install: • oil seal clip “1” note: adjust the oil seal clip so that it fits into the outer tube’s groove. 9. Install: • dust seal “1” (with the fork seal driver weight “2”) 10.Fill: • front fork leg (with the specified amount of the recom- mended fork oil) 11.Measure: • front fork...

  • Page 194: Front Fork

    Front fork 4-68 eas23050 installing the front fork legs the following procedure applies to both of the front fork legs. 1. Install: • lower front fork cover “1” • front fork leg “2” • upper bracket “3” temporarily tighten the lower bracket pinch bolts and steering stem nut. Note: make sure the inner...

  • Page 195: Steering Head

    Steering head 4-69 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks lower handlebar holder refer to “handlebar” on page 4-55. Upper bracket/front fork legs refer to “front fork” on page 4-60. 1 headlight bracket and throttle cable guide 1 2 front brake hose gu...

  • Page 196: Steering Head

    Steering head 4-70 13 bearing outer race 2 for installation, reverse the removal proce- dure. Removing the lower bracket order job/parts to remove q’ty remarks 8 1 3 2 12 11 13 13 10 9 7 6 5 4 ls ls ls t r 1st 52 nm (5.2 m • kg, 37 ft • lb) 2nd 18 nm (1.8 m • kg, 13 ft • ib) t r 10 nm (1.0 m • kg, 7...

  • Page 197: Steering Head

    Steering head 4-71 eas23110 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • upper ring nut • rubber washer • lower ring nut “1” • lower bracket warning ewa13730 securely supp...

  • Page 198: Steering Head

    Steering head 4-72 2. Install: • lower ring nut “1” • rubber washer “2” • upper ring nut “3” • lock washer “4” refer to “checking and adjusting the steering head” on page 3-25. 3. Install: • front brake hose joint “1” • front brake hose guide “2” note: • make sure that the projection “a” on the lowe...

  • Page 199

    Rear shock absorber assembly and swingarm 4-73 et1d71001 rear shock absorber assembly and swingarm removing the rear shock absorber assembly and swingarm order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-23. Exhaust pipes refer to “engine removal” on page 5-1. Brake m...

  • Page 200

    Rear shock absorber assembly and swingarm 4-74 10 lower drive belt cover 1 for installation, reverse the removal proce- dure. Removing the rear shock absorber assembly and swingarm order job/parts to remove q’ty remarks 6 2 7 10 9 8 6 t r 59 nm (5.9 m • kg, 43 ft • ib) t r 125 nm (12.5 m • kg, 90 ft...

  • Page 201

    Rear shock absorber assembly and swingarm 4-75 removing the rear shock absorber and swingarm order job/parts to remove q’ty remarks 1 self-locking nut/washer/bolt 1/2/1 2 oil seal/collar/bushing/bearing 2/2/1/2 3 swingarm 1 4 self-locking nut/washer/bolt 1/1/1 5 connecting arm 2 6 o-ring 4 7 spacer ...

  • Page 202

    Rear shock absorber assembly and swingarm 4-76 eas23180 handling the rear shock absorber warning ewa13740 this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be...

  • Page 203

    Rear shock absorber assembly and swingarm 4-77 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas23240 checking the rear shock absorber assembly 1. Check: • rear shock absorber rod bends/damage → replace the rear shock absorber assembly. • rear shock absorber gas leaks/oil leaks → replace the rea...

  • Page 204

    Rear shock absorber assembly and swingarm 4-78 2. Install: • bearings “1”, “2”, “3” (to the relay arm) • oil seals “4”, “5” (to the relay arm) 3. Lubricate: • bushings • oil seals • o-rings • collar note: apply grease only to the collar between the con- necting arms and rear shock absorber. 4. Insta...

  • Page 205

    Rear shock absorber assembly and swingarm 4-79 6. Tighten: • connecting-arm-to-relay-arm nut • rear-shock-absorber-assembly-to-relay-arm nut • relay-arm-to-swingarm nut eas28780 installing the swingarm 1. Lubricate: • bearings • collars • oil seals • pivot shaft 2. Install: • bearings “1” (to swinga...

  • Page 206: Belt Drive

    Belt drive 4-80 eas23510 belt drive removing the drive belt and drive pulley order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-23. Rear shock absorber assembly and swingarm refer to “rear shock absorber as- sembly and swingarm” on page 4-73. 1 rectifier/regulator cove...

  • Page 207: Belt Drive

    Belt drive 4-81 13 drive pulley 1 for installation, reverse the removal proce- dure. Removing the drive belt and drive pulley order job/parts to remove q’ty remarks lt 7 8 13 12 11 10 9 6 1 2 4 t r 10 nm (1.0 m • kg, 7.2 ft • ib) t r 63 nm (6.3 m • kg, 45 ft • ib) r 53 nm (5.3 m • kg, 38 ft • ib) t ...

  • Page 208: Belt Drive

    Belt drive 4-82 eas23520 removing the drive belt and drive pulley note: loosen the drive pulley nut before removing the rear wheel. 1. Loosen: • drive pulley nut “1” note: when loosening the drive pulley nut, press down on the brake pedal so the drive pulley does not move. Eas23530 checking the driv...

  • Page 209: Belt Drive

    Belt drive 4-83 3. Install: • swingarm • rear shock absorber refer to “rear shock absorber as- sembly and swingarm” on page 4-73. • rear wheel refer to “rear wheel” on page 4-23. 4. Tighten: • drive pulley nut note: • when tightening the drive pulley nut, press down on the brake pedal so the drive p...

  • Page 210: Engine

    5 engine engine removal ........................................................................................ 5-1 installing the shift pedal assembly......................................... 5-5 checking the oil cooler ................................................................ 5-7 removing ...

  • Page 211

    Clutch ........................................................................................................ 5-50 removing the clutch ..................................................................... 5-60 removing the primary drive gear ............................................ 5-60 removi...

  • Page 212

    Crankcase................................................................................................ 5-89 disassembling the crankcase ................................................... 5-92 checking the crankcase.............................................................. 5-92 checking the b...

  • Page 213: Engine Removal

    Engine removal 5-1 eas23710 engine removal removing the muffler and exhaust pipes order job/parts to remove q’ty remarks 1 rear brake light switch 1 2 right rider footrest assembly 1 3 exup valve pulley cover 1 4 exup cable 2 disconnect. 5 o 2 sensor coupler holder 1 6 o 2 sensor coupler 1 disconnec...

  • Page 214: Engine Removal

    Engine removal 5-2 15 gasket 1 for installation, reverse the removal proce- dure. Removing the muffler and exhaust pipes order job/parts to remove q’ty remarks 5 8 9 10 3 11 12 14 15 1 2 12 13 6 7 4 r 10 nm (1.0 m • kg, 7.2 ft • ib) r 7 nm (0.7 m • kg, 5.1 ft • ib) t r 7 nm (0.7 m • kg, 5.1 ft • ib)...

  • Page 215: Engine Removal

    Engine removal 5-3 removing the cylinder-#1 ignition coils and sidestand order job/parts to remove q’ty remarks rider seat/left side cover/battery box/air filter case refer to “general chassis” on page 4-1. Fuel tank/sub-fuel tank refer to “fuel tank” on page 6-1. Throttle body/intake manifold/press...

  • Page 216: Engine Removal

    Engine removal 5-4 6 cylinder-#1 ignition coil bracket 1 7 horn 1 connector 2 except for california disconnect. 8 horn 1 1 except for california 9 horn 2 coupler 1 10 horn 2 1 11 shift rod 1 12 rear brake light switch coupler 1 13 left rider footrest assembly 1 14 shift pedal shaft bracket 1 15 shif...

  • Page 217: Engine Removal

    Engine removal 5-5 et1d71029 installing the shift pedal assembly 1. Assemble: • shift pedal (heel side) “1” • shift pedal (toe side) “2” note: align the mark “a” on the pin on the toe side with the mark “b” on the heel side. 2. Install: • shift pedal assembly “1” note: align the mark “a” on the shif...

  • Page 218: Engine Removal

    Engine removal 5-6 removing the oil cooler and oil filter bracket order job/parts to remove q’ty remarks 1 oil filter cartridge 1 2 oil cooler outlet hose 1 3 oil cooler inlet hose 1 4 oil cooler 1 5 oil cooler bracket 1 6 oil filter bolt 1 7 oil filter bracket 1 for installation, reverse the remova...

  • Page 219: Engine Removal

    Engine removal 5-7 et1d71028 checking the oil cooler 1. Check: • oil cooler fins obstruction → clean. Apply compressed air to the rear of the oil cooler. Damage → repair or replace. Note: straighten any flattened fins with a thin, flathead screwdriver. 2. Check: • oil cooler inlet hose • oil cooler ...

  • Page 220: Engine Removal

    Engine removal 5-8 disconnecting the leads order job/parts to remove q’ty remarks drive pulley case refer to “transfer gear case” on page 5-81. 1 spark plug cap 2 2 stator coil lead 1 3 neutral switch coupler 1 disconnect. 4 neutral switch lead 1 5 lead holder bracket 1 6 wire harness guide 1 7 thro...

  • Page 221: Engine Removal

    Engine removal 5-9 15 speed sensor lead 1 for installation, reverse the removal proce- dure. Disconnecting the leads order job/parts to remove q’ty remarks 3 2 7 1 10 8 9 5 11 6 lt lt r 10 nm (1.0 m • kg, 7.2 ft • ib) r 10 nm (1.0 m • kg, 7.2 ft • ib) r 7 nm (0.7 m • kg, 5.1 ft • ib) t r 7 nm (0.7 m...

  • Page 222: Engine Removal

    Engine removal 5-10 removing the engine order job/parts to remove q’ty remarks note: place a suitable stand under the frame and engine. Transfer gear case refer to “transfer gear case” on page 5-81. 1 engine mounting bolt (right upper side) 2 2 engine mounting bolt (left upper side) 2 3 engine brack...

  • Page 223: Engine Removal

    Engine removal 5-11 14 engine mounting nut (rear upper side) 1 15 engine mounting bolt (rear upper side) 1 16 engine bracket nut (rear upper side) 2 17 engine bracket bolt (rear upper side) 2 18 engine bracket (rear upper side) 2 19 engine mounting nut (front lower side) 1 20 spacer bolt 1 loosen. 2...

  • Page 224: Engine Removal

    Engine removal 5-12 et1d71019 removing the engine 1. Loosen: • spacer bolt note: loosen the spacer bolt with the pivot shaft wrench “1”. Eas23720 installing the engine 1. Install: • spacer bolt “1” • engine “2” • washer “3” • engine mounting bolt (rear lower side) “4” • engine mounting nut (rear low...

  • Page 225: Engine Removal

    Engine removal 5-13 5. Install: • engine brackets (front upper side) “1” • engine bracket bolts (front upper side) “2” • engine bracket nuts (front upper side) “3” • engine cross-member bracket “4” • engine cross-member bracket bolts “5” • engine mounting bolt (front upper side) “6” • engine mountin...

  • Page 226: Camshafts

    Camshafts 5-14 eas23750 camshafts removing the camshaft sprocket cover order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 6-1. Air filter case refer to “general chassis” on page 4-1. Muffler/exhaust pipes refer to “engine removal” on page 5-1. 1 spark plug cap 4 disconnect...

  • Page 227: Camshafts

    Camshafts 5-15 removing the cylinder head covers order job/parts to remove q’ty remarks 1 cylinder head breather hose 1 2 oil tank breather hose 1 disconnect. 3 wire harness guide 1 4 fuel tank damper 1 5 fuel outlet hose 1 disconnect. 6 cylinder head cover bolt 8 l = 40 mm (1.57 in) 7 cylinder head...

  • Page 228: Camshafts

    Camshafts 5-16 removing the push rods and rocker arms order job/parts to remove q’ty remarks 1 rear rocker arm base assembly 1 2 front rocker arm base assembly 1 3 rocker arm base gasket 2 4 dowel pin 4 5 pull rod 1 3 l = 286.5 mm (11.280 in) pink painting 6 pull rod 2 1 l = 288.5 mm (11.358 in) sky...

  • Page 229: Camshafts

    Camshafts 5-17 removing the valve lifters order job/parts to remove q’ty remarks front cylinder refer to “cylinders and pistons” on page 5-45. 1 push rod cover 2 2 o-ring 2 3 o-ring 2 4 seal 2 5 rear valve lifter case 1 6 front valve lifter case 1 7 valve lifter 4 for installation, reverse the remov...

  • Page 230: Camshafts

    Camshafts 5-18 removing the camshafts and right balancer order job/parts to remove q’ty remarks 1 camshaft driven gear 1 2 straight key 1 3 circlip 1 4 washer 1 5 conical spring washer 1 6 washer 1 7 rear cylinder camshaft gear 1 8 front cylinder camshaft gear 1 9 straight key 1 10 right balancer dr...

  • Page 231: Camshafts

    Camshafts 5-19 18 dowel pin 2 19 rear cylinder camshaft 1 20 front cylinder camshaft 1 21 right balancer 1 for installation, reverse the removal proce- dure. Removing the camshafts and right balancer order job/parts to remove q’ty remarks new r 10 nm (1.0 m • kg, 7.2 ft • ib) r 40 nm (4.0 m • kg, 29...

  • Page 232: Camshafts

    Camshafts 5-20 disassembling the camshafts order job/parts to remove q’ty remarks 1 circlip 2 2 washer 2 3 decompression cam spring 2 4 decompression cam 2 5 decompression pin 2 6 front cylinder camshaft 1 7 rear cylinder camshaft 1 for assembly, reverse the disassembly pro- cedure. 4 4 7 6 5 5 3 2 ...

  • Page 233: Camshafts

    Camshafts 5-21 et1d71030 removing the cylinder head covers 1. Remove: • front cylinder • rear cylinder “1” note: due to the small clearance between the frame and the rear cylinder head cover, the three bolts “2” cannot be removed when the cover is in place. Loosen the bolts, and then remove the cove...

  • Page 234: Camshafts

    Camshafts 5-22 2. Remove: • camshaft driven gear • straight key note: cover the crankcase hole with a clean rag to prevent the straight key from falling into the crankcase. 3. Loosen: • front cylinder camshaft gear bolt “1” note: • place a folded copper washer “2” between the teeth of the front cyli...

  • Page 235: Camshafts

    Camshafts 5-23 eas23860 checking the camshafts 1. Check: • cam blue discoloration/pitting/scratches → re- place the camshaft. 2. Measure: • cam dimensions a “a” and b “b” out of specification → replace the camshaft. 3. Measure: • camshaft journal diameter (crankcase side) “a” out of specification → ...

  • Page 236: Camshafts

    Camshafts 5-24 5. Measure: • crankcase hole inside diameter “a” out of specification → replace the crank- case. 6. Measure: • camshaft cover hole inside diameter “a” out of specification → replace the camshaft cover. 7. Calculate: • camshaft-to-crankcase clearance out of specification → replace the ...

  • Page 237: Camshafts

    Camshafts 5-25 4. Measure: • rocker arm shaft outside diameter “a” out of specification → replace. 5. Calculate: • rocker arm to rocker arm shaft clearance note: calculate the clearance by subtracting the rock- er arm shaft outside diameter from the rocker arm inside diameter. Above 0.08 mm (0.003 i...

  • Page 238: Camshafts

    Camshafts 5-26 4. Measure: • valve lifter case inside diameter “a” out of specification → replace. 5. Calculate: • valve lifter-to-valve lifter case clearance note: calculate the clearance by subtracting the valve lifter outside diameter from the valve lifter case inside diameter. Above 0.072 mm (0....

  • Page 239: Camshafts

    Camshafts 5-27 2. Measure: • compressed decompression cam spring force “a” out of specification → replace the decom- pression cam spring. Eas23990 checking the oil delivery pipe 1. Check: • oil delivery pipe 1 damage → replace. Obstruction → wash and blow out with com- pressed air. • o-rings damage/...

  • Page 240: Camshafts

    Camshafts 5-28 note: • lubricate the camshaft drive gear bolt and right balancer driven gear bolt threads with engine oil. • place a folded copper washer “3” between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them. • place a folded copper washer “4” be...

  • Page 241: Camshafts

    Camshafts 5-29 7. Install: • straight key • camshaft driven gear “1” note: • cover the crankcase hole with a clean rag to prevent the straight key from falling into the crankcase. • align the punch mark “a” on the camshaft driv- en gear “1” with the punch mark “b” on the camshaft drive gear “2”. • i...

  • Page 242: Camshafts

    Camshafts 5-30 caution: eca14650 be sure to install the valve lifter in its appro- priate position. C. Start the engine and warm it up. D. Stop the engine. E. Remove the camshaft sprocket cover. F. Rotate the camshaft until the punch mark “1” on the camshaft driven gear aligns with the punch mark on...

  • Page 243: Camshafts

    Camshafts 5-31 2. Install: • push rod covers “1” note: install the push rod covers so that their paint marks “a” are facing towards the cylinder heads. Eas24070 installing the rocker arms and push rods the following procedure applies to both cylin- ders. 1. Install: • rocker arms “1” • rocker arm sh...

  • Page 244: Camshafts

    Camshafts 5-32 bolts “2”: l = 45 mm (1.77 in) bolts “3”: l = 70 mm (2.76 in) ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas24080 installing the cylinder head covers 1. Install: • rear cylinder head cover “1” • front cylinder head cover “2” note: due to the small clearance between the frame an...

  • Page 245: Cylinder Heads

    Cylinder heads 5-33 eas24110 cylinder heads removing the cylinder heads order job/parts to remove q’ty remarks cylinder-#1 ignition coil bracket refer to “engine removal” on page 5-1. Throttle bodies/intake manifolds refer to “throttle bodies” on page 6-6. Cylinder head covers/rocker arms refer to “...

  • Page 246: Cylinder Heads

    Cylinder heads 5-34 13 rear exhaust pipe gasket 1 for installation, reverse the removal proce- dure. Removing the cylinder heads order job/parts to remove q’ty remarks 4 13 3 8 9 10 1 11 5 2 12 7 9 5 6 10 r 18 nm (1.8 m • kg, 13 ft • ib) t r 20 nm (2.0 m • kg, 14 ft • ib) t r 59 nm (5.9 m • kg, 43 f...

  • Page 247: Cylinder Heads

    Cylinder heads 5-35 eas24140 removing the cylinder heads 1. Remove: • cylinder head nuts note: • loosen the nuts in the proper sequence as shown. • loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. Eas24170 checking the cylinder heads the following proce...

  • Page 248: Cylinder Heads

    Cylinder heads 5-36 eas24250 installing the cylinder heads 1. Install: • cylinder head gasket “1” • dowel pins “2” note: the “1d7” mark on the cylinder head gasket must face up and towards the left side of the cyl- inder. 2. Install: • cylinder heads • washers • cylinder head nuts note: lubricate th...

  • Page 249: Cylinder Heads

    Cylinder heads 5-37 t r . Engine mounting bolt (right up- per side) 59 nm (5.9 m·kg, 43 ft·lb) engine mounting bolt (left upper side) 66 nm (6.6 m·kg, 48 ft·lb) loctite ® engine bracket bolt (right upper side) 53 nm (5.3 m·kg, 38 ft·lb) engine bracket bolt (left upper side) 53 nm (5.3 m·kg, 38 ft·lb...

  • Page 250: Valves and Valve Springs

    Valves and valve springs 5-38 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks the following procedure applies to both cyl- inders. Cylinder heads refer to “cylinder heads” on page 5-33. 1 valve cotter 8 2 upper spring seat 4 3 valve spri...

  • Page 251: Valves and Valve Springs

    Valves and valve springs 5-39 eas24280 removing the valves the following procedure applies to all of the valves and related components. Note: before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • valve seal...

  • Page 252: Valves and Valve Springs

    Valves and valve springs 5-40 2. Replace: • valve guide note: to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve guide with the valve guide remover ...

  • Page 253: Valves and Valve Springs

    Valves and valve springs 5-41 • valve stem end mushroom shape or diameter larger than the body of the valve stem → replace the valve. 5. Measure: • valve margin thickness d “a” out of specification → replace the valve. 6. Measure: • valve stem runout out of specification → replace the valve. Note: •...

  • Page 254: Valves and Valve Springs

    Valves and valve springs 5-42 4. Lap: • valve face • valve seat note: after replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. ...

  • Page 255: Valves and Valve Springs

    Valves and valve springs 5-43 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 256: Valves and Valve Springs

    Valves and valve springs 5-44 • lower spring seat “2” • valve stem seal “3” • valve “4” • valve spring “5” • upper spring seat “6” (into the cylinder head) note: • make sure each valve is installed in its original place. • install the valve springs with the larger pitch “a” facing up. 4. Install: • ...

  • Page 257: Cylinders and Pistons

    Cylinders and pistons 5-45 eas24360 cylinders and pistons removing the cylinders and pistons order job/parts to remove q’ty remarks cylinder heads refer to “cylinder heads” on page 5-33. 1 front cylinder 1 2 rear cylinder 1 3 cylinder gasket 2 4 dowel pin 4 5 circlip 4 6 piston pin 2 7 piston 2 8 to...

  • Page 258: Cylinders and Pistons

    Cylinders and pistons 5-46 eas24380 removing the piston 1. Remove: • piston pin clips “1” • piston pin “2” • piston “3” caution: eca13810 do not use a hammer to drive the piston pin out. Note: • before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston p...

  • Page 259: Cylinders and Pistons

    Cylinders and pistons 5-47 b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. C. Measure piston skirt diameter d “a” with the micrometer. D. If out of specification, replace the piston and piston rings as a set. E. Calculate the piston-to-cy...

  • Page 260: Cylinders and Pistons

    Cylinders and pistons 5-48 3. Measure: • piston ring end gap out of specification → replace the piston ring. Note: the oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Eas24440 checking the piston pins the following pro...

  • Page 261: Cylinders and Pistons

    Cylinders and pistons 5-49 • oil ring expander “5” note: be sure to install the piston rings so that the manufacturer’s marks or numbers face up. 2. Install: • piston “1” • piston pin “2” • piston pin clips “3” note: • apply engine oil onto the piston pin. • make sure the arrow mark “a” on the pisto...

  • Page 262: Clutch

    Clutch 5-50 eas25060 clutch removing the clutch cover order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-11. Left side cover refer to “general chassis” on page 4-1. Horn 1/canister refer to “throttle bodies” on page 6-6. For california only fuel tan...

  • Page 263: Clutch

    Clutch 5-51 5 dowel pin 2 for installation, reverse the removal proce- dure. Removing the clutch cover order job/parts to remove q’ty remarks t r 12 nm (1.2 m • kg, 8.7 ft • ib) 5 3 4 5 2 1 r 10 nm (1.0 m • kg, 7.2 ft • ib) r 10 nm (1.0 m • kg, 7.2 ft • ib) new (11) (5).

  • Page 264: Clutch

    Clutch 5-52 removing the crankshaft position sensor order job/parts to remove q’ty remarks 1 oil seal 1 2 bearing 1 3 clutch cover damper plate 1 4 clutch cover damper 1 5 crankshaft position sensor lead holder 3 6 crankshaft position sensor 1 for installation, reverse the removal proce- dure. 5 6 5...

  • Page 265: Clutch

    Clutch 5-53 removing the clutch order job/parts to remove q’ty remarks 1 clutch spring plate retainer 1 2 clutch spring plate 1 3 clutch spring plate seat 1 4 pressure plate 1 5 short clutch push rod 1 6 friction plate 1 1 inside diameter: 124 mm (4.88 in) 7 clutch plate 9 8 friction plate 2 9 9 clu...

  • Page 266: Clutch

    Clutch 5-54 18 thrust washer 1 1 19 clutch housing 1 20 circlip 1 21 washer 1 22 oil pump drive gear 1 23 dowel pin 2 24 bearing 1 25 collar 1 26 thrust washer 2 1 27 ball 1 28 long push rod 1 29 spacer 1 30 crankshaft position sensor rotor 1 31 primary drive gear 1 32 straight key 1 33 washer 1 for...

  • Page 267: Clutch

    Clutch 5-55 removing the left balancer order job/parts to remove q’ty remarks 1 left balancer idle gear shaft holder 1 2 dowel pin 2 3 o-ring 2 4 left balancer idle gear 1 5 left balancer idle gear shaft 1 6 left balancer drive gear 1 7 straight key 1 8 left balancer driven gear 1 9 left balancer we...

  • Page 268: Clutch

    Clutch 5-56 removing the clutch master cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-15. 1 left rearview mirror 1 2 clutch master cylinder reservoir cap 1 3 clutch master cylinder reservoir diaphragm holder 1 4 clutch ma...

  • Page 269: Clutch

    Clutch 5-57 disassembling the clutch master cylinder order job/parts to remove q’ty remarks 1 clutch master cylinder push rod 1 2 dust boot 1 3 circlip 1 4 washer 1 5 clutch master cylinder kit 1 6 clutch master cylinder body 1 for assembly, reverse the disassembly pro- cedure. 3 4 5 6 2 1 new new l...

  • Page 270: Clutch

    Clutch 5-58 removing the clutch release cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-15. Muffler/exhaust pipes refer to “engine removal” on page 5-1. 1 clutch pipe union bolt cap 1 2 clutch pipe union bolt 1 3 copper wa...

  • Page 271: Clutch

    Clutch 5-59 disassembling the clutch release cylinder order job/parts to remove q’ty remarks 1 boots 1 2 clutch release cylinder piston 1 3 clutch release cylinder spring 1 4 clutch release cylinder piston seal 1 5 bleed screw 1 6 clutch release cylinder body 1 for assembly, reverse the disassembly ...

  • Page 272: Clutch

    Clutch 5-60 eas25080 removing the clutch 1. Loosen: • clutch boss nut “1” note: while holding the clutch boss “2” with the univer- sal clutch holder “3”, loosen the clutch boss nut. 2. Remove: • clutch boss nut “1” • conical spring washer “2” • washer “3” • clutch boss assembly “4” note: there is a ...

  • Page 273: Clutch

    Clutch 5-61 eas25100 checking the friction plates the following procedure applies to all of the fric- tion plates. 1. Check: • friction plate damage/wear → replace the friction plates as a set. 2. Measure: • friction plate thickness out of specification → replace the friction plates as a set. Note: ...

  • Page 274: Clutch

    Clutch 5-62 2. Check: • clutch spring plate seat damage → replace. Eas25150 checking the clutch housing 1. Check: • clutch housing dogs damage/pitting/wear → deburr the clutch housing dogs or replace the clutch housing. Note: pitting on the clutch housing dogs will cause er- ratic clutch operation. ...

  • Page 275: Clutch

    Clutch 5-63 • left balancer driven gear • left balancer idle gear burrs/chips/roughness/wear → replace the defective part(s). 2. Measure: • left balancer driven gear inside diameter “a” out of specification → replace. 3. Measure: • left balancer driven gear housing outside di- ameter “a” out of spec...

  • Page 276: Clutch

    Clutch 5-64 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • generator rotor refer to “installing the generator” on page 5-75. 5. Install: • left balancer drive gear “1” • left balancer idle gear “2” • left balancer driven gear “3” note: • align the punch mark “a” on the left balancer...

  • Page 277: Clutch

    Clutch 5-65 eas25260 installing the clutch 1. Install: • clutch housing • thrust washer note: • lubricate the clutch housing bearings with en- gine oil. • make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly. • make sure that the primary driven gear teeth and oil ...

  • Page 278: Clutch

    Clutch 5-66 6. Install: • clutch spring plate • clutch spring plate retainer note: tighten the clutch spring plate retainer bolts in stages and in a crisscross pattern. 7. Apply: • sealant (onto the crankshaft position sensor lead grommet) 8. Install: • shift arm “1” note: install the shift arm “1” ...

  • Page 279: Clutch

    Clutch 5-67 • clutch master cylinder reservoir diaphragm damage/wear → replace. 4. Check: • clutch hose cracks/damage/wear → replace. Eas25300 assembling the clutch master cylinder warning ew1d71010 • before installation, all internal clutch com- ponents must be cleaned and lubricated with clean or ...

  • Page 280: Clutch

    Clutch 5-68 note: in order to ensure a correct reading of the clutch fluid level, make sure the top of the reservoir is horizontal. 4. Bleed: • clutch system refer to “bleeding the hydraulic clutch system” on page 3-15. 5. Check: • clutch fluid level below the minimum level mark “a” → add the recomm...

  • Page 281: Clutch

    Clutch 5-69 eas25350 installing the clutch release cylinder 1. Install: • copper washers • clutch pipe “1” • clutch pipe union bolt “2” warning ew1d71003 proper clutch pipe routing is essential to in- sure safe vehicle operation. Refer to “cable routing” on page 2-45. Caution: ec1d71005 when install...

  • Page 282: Shift Shaft

    Shift shaft 5-70 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 5-50. 1 washer 3 2 circlip 2 3 shift shaft 1 4 shift shaft spring 1 5 stopper lever 1 6 collar 1 7 stopper lever spring 1 8 shift shaft spr...

  • Page 283: Shift Shaft

    Shift shaft 5-71 eas25420 checking the shift shaft 1. Check: • shift shaft bends/damage/wear → replace. • shift shaft spring damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever bends/damage → replace. Roller turns roughly → replace the stopper lever. • stopper lever ...

  • Page 284: Generator and Starter Clutch

    Generator and starter clutch 5-72 eas24480 generator and starter clutch removing the stator coil order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-11. Muffler/exhaust pipes refer to “engine removal” on page 5-1. Lead cover refer to “belt drive” on ...

  • Page 285: Generator and Starter Clutch

    Generator and starter clutch 5-73 removing the generator rotor order job/parts to remove q’ty remarks 1 torque limiter 1 2 starter clutch idle gear shaft 1 3 starter clutch idle gear 1 4 generator rotor 1 5 starter clutch 1 6 woodruff key 1 7 starter clutch gear 1 8 bearing 1 9 bearing housing 1 for...

  • Page 286: Generator and Starter Clutch

    Generator and starter clutch 5-74 eas24490 removing the generator 1. Remove: • generator rotor bolt “1” • washer note: while holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. 2. Remove: • generator rotor “1” (with the rotor puller “2”) • woodruff key eas245...

  • Page 287: Generator and Starter Clutch

    Generator and starter clutch 5-75 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et1d71020 checking the torque limiter 1. Check: • torque limiter damage/wear → replace. Note: do not disassemble the torque limiter. Eas24600 installing the starter clutch 1. Install: • starter clutch note: while hol...

  • Page 288: Generator and Starter Clutch

    Generator and starter clutch 5-76 yamaha bond no. 1215 90890-85505 (three bond no.1215 ® ).

  • Page 289: Electric Starter

    Electric starter 5-77 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks 1 starter motor lead 1 disconnect. 2 starter motor 1 for installation, reverse the removal proce- dure. 2 1 t r 10 nm (1.0 m • kg, 7.2 ft • ib).

  • Page 290: Electric Starter

    Electric starter 5-78 disassembling the starter motor order job/parts to remove q’ty remarks 1 starter motor front cover 1 2 bearing 1 3 oil seal 1 4 circlip 1 5 starter motor rear cover 1 6 brush 2 7 brush holder (along with the brushes) 1 8 brush seat (along with the brushes) 1 9 bearing 1 10 gask...

  • Page 291: Electric Starter

    Electric starter 5-79 eas24790 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter “a” out of specification → replace the starter motor. 3. Measure: • mica undercut “a” out of specification → scrape the mica to the proper measurem...

  • Page 292: Electric Starter

    Electric starter 5-80 7. Check: • gear teeth damage/wear → replace the gear. 8. Check: • bearings • oil seal damage/wear → replace the defective part(s). Eas24800 assembling the starter motor 1. Install: • starter motor yoke “1” note: align the projection “a” on the brush holder with the slot “b” in...

  • Page 293: Transfer Gear Case

    Transfer gear case 5-81 eas25460 transfer gear case removing the middle driven shaft order job/parts to remove q’ty remarks rider seat/right side cover refer to “general chassis” on page 4-1. Engine oil drain. Refer to “changing the engine oil” on page 3-11. Transfer gear oil drain. Refer to “changi...

  • Page 294: Transfer Gear Case

    Transfer gear case 5-82 8 oil strainer 1 9 gasket 1 10 conical spring washer 1 11 primary chain 1 12 middle drive gear 1 13 middle driven shaft 1 for installation, reverse the removal proce- dure. Removing the middle driven shaft order job/parts to remove q’ty remarks 8 6 7 1 2 3 12 10 5 5 4 9 (7) (...

  • Page 295: Transfer Gear Case

    Transfer gear case 5-83 disassembling the transfer gear oil pump order job/parts to remove q’ty remarks 1 transfer gear oil pump cover 1 2 transfer gear oil pump outer rotor 1 3 transfer gear oil pump inner rotor 1 4 pin 1 5 washer 1 6 transfer gear oil pump shaft 1 7 transfer gear oil pump housing ...

  • Page 296: Transfer Gear Case

    Transfer gear case 5-84 removing the transfer gear case order job/parts to remove q’ty remarks horn 2 connector disconnect. Refer to “engine removal” on page 5-1. Battery box refer to “general chassis” on page 4-1. Sub-fuel tank refer to “fuel tank” on page 6-1. 1 oil tank breather hose 1 disconnect...

  • Page 297: Transfer Gear Case

    Transfer gear case 5-85 disassembling the oil tank order job/parts to remove q’ty remarks 1 sub-fuel tank bracket 1 2 oil tank cover 1 3 oil tank cover gasket 1 4 dowel pin 2 5 oil strainer 1 6 oil pipe 5 1 7 oil tank 1 for assembly, reverse the disassembly pro- cedure. 3 2 (15) 4 5 6 1 7 new r 10 n...

  • Page 298: Transfer Gear Case

    Transfer gear case 5-86 eas25470 removing the middle driven shaft note: loosen the middle drive gear nut before remove the drive pulley. 1. Install: • right rider footrest assembly refer to “engine removal” on page 5-1. 2. Loosen: • middle drive gear nut “1” note: when loosening the middle drive gea...

  • Page 299: Transfer Gear Case

    Transfer gear case 5-87 3. Check: • transfer gear oil pump operation rough movement → repeat steps (1) and (2) or replace the defective part(s). Eas25510 checking the oil pipes 1. Check: • oil pipes damage → replace. Eas25520 assembling the transfer gear oil pump 1. Lubricate: • transfer gear oil pu...

  • Page 300: Transfer Gear Case

    Transfer gear case 5-88 • install the middle drive gear “2” with its cham- fered side facing “b” the transfer gear case. • install the middle driven shaft, middle drive gear and primary chain at the same time. • align the splines on the middle drive gear with the splines on the drive axle. • tempora...

  • Page 301: Crankcase

    Crankcase 5-89 eas25540 crankcase separating the crankcase order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Camshafts refer to “camshafts” on page 5-14. Pistons refer to “cylinders and pistons” on page 5-45. Left balancer driven gear housing refer to “clutch” on p...

  • Page 302: Crankcase

    Crankcase 5-90 10 joint pipe 1 11 oil pipe 1 “r” mark 12 oil pipe 1 “f” mark 13 right crankcase 1 for installation, reverse the removal proce- dure. Separating the crankcase order job/parts to remove q’ty remarks new 1 11 9 4 5 6 2 (5) 7 3 13 8 9 10 12 t r 10 nm (1.0 m • kg, 7.2 ft • ib) 24 nm (2.4 ...

  • Page 303: Crankcase

    Crankcase 5-91 removing the oil seals and bearings order job/parts to remove q’ty remarks oil pump refer to “oil pump” on page 5-95. Crankshaft refer to “crankshaft” on page 5-101. Transmission refer to “transmission” on page 5-107. 1 oil baffle plate (right crankcase) 1 2 bearing retainer 2 3 beari...

  • Page 304: Crankcase

    Crankcase 5-92 eas25570 disassembling the crankcase 1. Remove: • crankcase bolts note: • 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. • loosen the bolts in decreasing numerical order (refer to the numbers i...

  • Page 305: Crankcase

    Crankcase 5-93 eas25610 checking the engine oil pump driven gear 1. Check: • engine oil pump driven gear chips/pitting/roughness/wear → replace. Et1d71034 installing the bearing retainers 1. Install: • bearing retainers “1” note: • apply locking agent (loctite ® ) to the threads of the bearing retai...

  • Page 306: Crankcase

    Crankcase 5-94 5. Apply: • engine oil (onto the crankshaft pin bearings and oil de- livery holes) 6. Check: • crankshaft and transmission operation rough movement → repair. A. Right crankcase b. Left crankcase 4 1 5 3 6 7 2 8 a 21 20 16 15 14 19 17 18 12 10 9 22 23 13 11 24 b.

  • Page 307: Oil Pump

    Oil pump 5-95 eas24910 oil pump removing the oil pump order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-89. 1 oil pump assembly 1 for installation, reverse the removal proce- dure. 1 t r 24 nm (2.4 m • kg, 17 ft • ib).

  • Page 308: Oil Pump

    Oil pump 5-96 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump housing cover 1 1 2 oil scavenging pump outer rotor 1 1 3 oil scavenging pump inner rotor 1 1 4 pin 1 5 oil pump housing 1 1 6 oil strainer 1 7 pin 2 8 ball spring 1 9 oil scavenging pump outer rotor 2 1 10 oi...

  • Page 309: Oil Pump

    Oil pump 5-97 18 oil pump shaft 1 19 oil seal 1 20 circlip 1 21 oil seal 1 22 ball 1 23 ball guide 1 24 oil pump housing 2 1 for assembly, reverse the disassembly pro- cedure. Disassembling the oil pump order job/parts to remove q’ty remarks e e t r 7 nm (0.7 m • kg, 5.1 ft • ib) t r 7 nm (0.7 m • k...

  • Page 310: Oil Pump

    Oil pump 5-98 eas24960 checking the oil pump 1. Check: • oil pump housing • oil pump housing cover cracks/damage/wear → replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance “a” • outer-rotor-to-oil-pump-housing clearance “b” • oil-pump-housing-to-inner-rotor-and-ou...

  • Page 311: Oil Pump

    Oil pump 5-99 2. Measure: • ball spring force • relief valve spring force out of specification → replace the defective part(s). Eas24990 checking the oil strainer 1. Check: • oil strainer “1” damage → replace. Contaminants → clean with solvent. Eas25000 assembling the oil pump 1. Lubricate: • inner ...

  • Page 312: Oil Pump

    Oil pump 5-100 3. Check: • oil pump operation refer to “checking the oil pump” on page 5-98. Eas25020 installing the oil pump 1. Install: • oil pump assembly “1” caution: eca13890 after tightening the bolts, make sure the oil pump turns smoothly. T r . Oil pump assembly bolt 24 nm (2.4 m·kg, 17 ft·l...

  • Page 313: Crankshaft

    Crankshaft 5-101 eas25960 crankshaft removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-89. 1 crankshaft 1 2 generator shaft 1 3 connecting rod cap 2 4 big end lower bearing 2 5 connecting rod 2 6 big end upper bearing 2 for installation...

  • Page 314: Crankshaft

    Crankshaft 5-102 eas26010 removing the connecting rods 1. Remove: • connecting rod caps “1” • connecting rods • big end bearings note: identify the position of each big end bearing so that it can be reinstalled in its original place. Eas26090 checking the crankshaft and connecting rods 1. Measure: •...

  • Page 315: Crankshaft

    Crankshaft 5-103 d. Assemble the connecting rod halves. Note: • do not move the connecting rod or crankshaft until the clearance measurement has been completed. • lubricate the bolts threads with molybdenum disulfide grease. • make sure the projection “c” on the connecting rod faces towards the left...

  • Page 316: Crankshaft

    Crankshaft 5-104 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Select: • big end bearings (“p 1 ”–“p 2 ”) note: • the numbers “a” stamped into the crankshaft web and the numbers “b” on the connecting rods are used to determine the replacement big end bearing sizes. • “p 1 ”–“p 2 ” refer to th...

  • Page 317: Crankshaft

    Crankshaft 5-105 7. Calculate: • crankshaft journal-to-crankshaft journal bearing clearance out of specification → replace the crank- shaft and crankshaft journal bearings as a set. Note: calculate the clearance by subtracting the crankshaft journal diameter from the crankshaft journal bearing insid...

  • Page 318: Crankshaft

    Crankshaft 5-106 a. Tighten the connecting rod bolts with a torque wrench. B. Put a mark “1” on the corner of the connecting rod bolts “2” and the connecting rod “3”. C. Tighten the connecting rod bolts further to reach the specified angle 125–135°. Warning ew1d71011 when a bolt is tightened more th...

  • Page 319: Transmission

    Transmission 5-107 eas26240 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-89. 1 shift fork guide bar 2 2 shift drum assembly 1 3 shift fork 1 2 4 shift fork 2 1 5 drive axle assem...

  • Page 320: Transmission

    Transmission 5-108 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 2nd pinion gear 1 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 5th pinion gear 1 5 collar 1 6 toothed washer 1 7 circlip 1 8 3rd pinion gear 1 9 circlip 1 10 toothed washer 1 11 4th pinion ...

  • Page 321: Transmission

    Transmission 5-109 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 circlip 1 2 washer 1 3 1st wheel gear 1 4 collar 1 5 4th wheel gear 1 6 circlip 1 7 toothed washer 1 8 3rd wheel gear 1 9 collar 1 10 toothed lock washer 1 11 toothed lock washer retainer 1 12 5th wheel...

  • Page 322: Transmission

    Transmission 5-110 17 drive axle 1 for assembly, reverse the disassembly pro- cedure. Disassembling the drive axle assembly order job/parts to remove q’ty remarks.

  • Page 323: Transmission

    Transmission 5-111 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 s...

  • Page 324: Transmission

    Transmission 5-112 3. Check: • transmission gears blue discoloration/pitting/wear → replace the defective gear(s). • transmission gear dogs cracks/damage/rounded edges → replace the defective gear(s). 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) incorrect ...

  • Page 325: Transmission

    Transmission 5-113 • shift fork guide bars “4” note: the embossed marks “1d7” on the shift forks should face towards the left side of the engine. 2. Check: • transmission rough movement → repair. Note: • apply engine oil to each gear and bearing thor- oughly. • before assembling the crankcase, make ...

  • Page 326: Fuel System

    6 fuel system fuel tank .................................................................................................... 6-1 removing the fuel tank.................................................................. 6-3 removing the fuel pump ..........................................................

  • Page 327: Fuel Tank

    Fuel tank 6-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks rider seat/rider seat bracket refer to “general chassis” on page 4-1. 1 meter assembly coupler 3 disconnect. 2 meter cover 1 3 fuel sender coupler 1 disconnect. 4 fuel tank breather hose 1 disconnect. 5 ai...

  • Page 328: Fuel Tank

    Fuel tank 6-2 removing the fuel pump and sub-fuel tank order job/parts to remove q’ty remarks rider seat/rider seat bracket refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 6-1. 1 fuel pump coupler 1 disconnect. 2 fuel hose connector cover 1 3 fuel outlet hose 1 disconn...

  • Page 329: Fuel Tank

    Fuel tank 6-3 eas26630 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel tank caution: ec1d71021 although the fuel has been removed from the fuel tank, be careful when removing the fuel hoses, since there may be fuel remain- ing in t...

  • Page 330: Fuel Tank

    Fuel tank 6-4 caution: ec1d71022 • be sure to disconnect the fuel outlet hose by hand. Do not forcefully disconnect the hose with tools. • although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remain- ing in them. Note: • remove the fu...

  • Page 331: Fuel Tank

    Fuel tank 6-5 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the fuel tank. B. Remove the fuel hose joint caps. C. Connect the fuel hose (fuel hose joint to fuel pump) and air vent hose (fuel pump to fuel hose joint). D. Turn the screws “1” counterclockwise. Note: turn the screws until...

  • Page 332: Throttle Bodies

    Throttle bodies 6-6 eas26970 throttle bodies removing the rollover valves order job/parts to remove q’ty remarks 1 horn 1 connector 2 for california only disconnect. 2 horn 1 1 for california only 3 fuel tank breather hose 1 4 canister purge hose 1 for california only 5 rollover valve 1 1 6 rollover...

  • Page 333: Throttle Bodies

    Throttle bodies 6-7 removing the pressure regulator order job/parts to remove q’ty remarks 1 pressure regulator cover 1 2 fuel hose (intake manifold assembly to pres- sure regulator) 1 3 air filter case breather hose 1 1 4 air filter case breather hose 2 1 5 hose clamp 1 6 pressure regulator 1 7 fue...

  • Page 334: Throttle Bodies

    Throttle bodies 6-8 removing the throttle bodies order job/parts to remove q’ty remarks rider seat/rider seat bracket refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 6-1. Air filter case refer to “general chassis” on page 4-1. Cylinder-#1 ignition coil cover refer to “...

  • Page 335: Throttle Bodies

    Throttle bodies 6-9 removing the intake manifolds order job/parts to remove q’ty remarks 1 engine temperature sensor coupler 1 disconnect. 2 sub-wire harness 2 coupler 2 disconnect. 3 fuel outlet hose 1 disconnect. 4 fuel hose (intake manifold assembly to pres- sure regulator) 1 5 cylinder-#2 isc (i...

  • Page 336: Throttle Bodies

    Throttle bodies 6-10 disassembling the intake manifolds order job/parts to remove q’ty remarks 1 cylinder-#1 injector coupler 1 disconnect. 2 cylinder-#2 injector coupler 1 disconnect. 3 sub-wire harness 2 1 4 fuel pipe 1 5 injector joint 1 1 6 injector joint 2 1 7 injector 2 for assembly, reverse t...

  • Page 337: Throttle Bodies

    Throttle bodies 6-11 et1d71026 removing the fuel hose 1. Disconnect: • fuel hose (intake manifold assembly to pres- sure regulator) caution: ec1d71014 although the fuel has been removed from the fuel tank be careful when removing the fuel hose, since there may be fuel remaining in it. Note: • to rem...

  • Page 338: Throttle Bodies

    Throttle bodies 6-12 f. Start the engine. G. Measure the fuel pressure. H. Use the vacuum/pressure pump gauge set to adjust the fuel pressure in relation to the vac- uum pressure as described below. Note: the vacuum pressure should not exceed 100 kpa (760 mmhg). Faulty → replace the pressure regulat...

  • Page 339: Throttle Bodies

    Throttle bodies 6-13 note: install the fuel pipe “1” so that it contacts the pro- jections “a” on the injector joints. Et1d71027 installing the fuel hose 1. Connect: • fuel hose (intake manifold assembly to pres- sure regulator) caution: ec1d71015 when installing the fuel hose, make sure that it is ...

  • Page 340

    Isc (idle speed control) unit 6-14 et1d71009 isc (idle speed control) unit removing the isc (idle speed control) unit order job/parts to remove q’ty remarks front cylinder head refer to “cylinder heads” on page 5-33. 1 sub-wire harness 4 1 2 sub-wire harness 3 1 3 cylinder-#2 isc (idle speed control...

  • Page 341

    Isc (idle speed control) unit 6-15 et1d71010 checking the isc (idle speed control) system 1. Check: • hoses loose connections → connect properly. Cracks/damage → replace..

  • Page 342: Electrical System

    7 electrical system ignition system ......................................................................................... 7-1 circuit diagram .................................................................................. 7-1 engine stopping due to sidestand operation....................... 7...

  • Page 343

    Electrical components ..................................................................... 7-67 checking the switches ................................................................. 7-71 checking the bulbs and bulb sockets ................................... 7-74 checking the fuses .................

  • Page 345: Ignition System

    Ignition system 7-1 eas27090 ignition system eas27110 circuit diagram w w w r r /g b (gra y) on off r br r b /l r l /y br l l /b r r r r r b b b r r r b r /y l b r wr /w r /y r /y r /w r /w r /l r l y l r r y l w sb w sb l l b /y r r /l l gs b /w l l w r /w l r /y l rb /y l /ys b l g b (blue) l /g b...

  • Page 346: Ignition System

    Ignition system 7-2 3. Main switch 4. Main fuse 6. Battery 11.Relay unit 14.Neutral switch 16.Sidestand switch 19.Crankshaft position sensor 23.Lean angle sensor 27.Ecu (electronic control unit) 28.Cylinder-#1 left ignition coil 29.Cylinder-#1 right ignition coil 30.Cylinder-#2 left ignition coil 31...

  • Page 347: Ignition System

    Ignition system 7-3 et1d71043 engine stopping due to sidestand operation when the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ecu when both the neutral switch...

  • Page 348: Ignition System

    Ignition system 7-4 eas27140 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Rider seat bracket assembly 4. Fuel tank 5. Air filter case 6. Headlight assembly 7. Exh...

  • Page 349: Ignition System

    Ignition system 7-5 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 7-71. Replace the main switch. 9. Check the engine stop switch. Refer to “checking the switches” on page 7-71. The engine stop switch is faulty...

  • Page 350: Ignition System

    Ignition system 7-6.

  • Page 351: Electric Starting System

    Electric starting system 7-7 eas27160 electric starting system eas27170 circuit diagram w w w r r /g b (gra y) on off r br r b /l r l /y br l l /b r r r r r b b b r r r b r /y l b r wr /w r /y r /y r /w r /w r l r l /y l r r y l w sb w sb l l b /y r r /l l gs b /w l l w r /w l r /y l rb /y l /ys b l...

  • Page 352: Electric Starting System

    Electric starting system 7-8 3. Main switch 4. Main fuse 6. Battery 8. Starter relay 9. Starter motor 10.Diode 1 11.Relay unit 12.Starting circuit cut-off relay 14.Neutral switch 15.Diode 2 16.Sidestand switch 27.Ecu (electronic control unit) 54.Clutch switch 68.Engine stop switch 69.Start switch 77...

  • Page 353: Electric Starting System

    Electric starting system 7-9 eas27180 starting circuit cut-off system operation if the engine stop switch is set to “ ” and the main switch is turned “on” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: • the transmission is i...

  • Page 354: Electric Starting System

    Electric starting system 7-10 a. When the transmission is in neutral b. When the sidestand is up and the clutch lever is pulled to the handlebar 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Diode 2 7. Relay unit (starting circuit cut-off relay) 8. Relay unit (diod...

  • Page 355: Electric Starting System

    Electric starting system 7-11 eas27190 troubleshooting the starter motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Headlight assembly ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse...

  • Page 356: Electric Starting System

    Electric starting system 7-12 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 9. Check the starter relay. Refer to “checking the re- lays” on page 7-79. Replace the starter relay. 10.Check the main switch. Refer to “checking the switches” on page 7-71. Replace the mai...

  • Page 357: Charging System

    Charging system 7-13 eas27200 charging system eas27210 circuit diagram w w w r r /g b on off r br r br /l r l /y br /l l /b r r r r r b b b r r r b r /y l b r /wr /w r /y r /y r /w r /w r /l l /y l /r r /y l /w sb /w sb l l b /y r r /l l /gs b /w l l /w r /w l r /y l /rb /y l /ys b l /g b (blue) l /...

  • Page 358: Charging System

    Charging system 7-14 1. Ac magneto 2. Rectifier/regulator 4. Main fuse 6. Battery.

  • Page 359: Charging System

    Charging system 7-15 eas27220 troubleshooting the battery is not being charged. Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Rectifier/regulator cover 3. Lead cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fu...

  • Page 360: Charging System

    Charging system 7-16.

  • Page 361: Lighting System

    Lighting system 7-17 eas27240 lighting system eas27250 circuit diagram w w w r r g b (gra y) on off r br r b /l r l /y br l l /b r r r r r b b b r r r b r /y l b r wr /w r /y r /y r /w r /w r l r l /y l r r y l w sb w sb l l b /y r r /l l gs b /w l l w r /w l r /y l rb /y l /ys b l g b (blue) l /g b...

  • Page 362: Lighting System

    Lighting system 7-18 3. Main switch 4. Main fuse 6. Battery 27.Ecu (electronic control unit) 44.Meter light 47.High beam indicator light 52.Headlight relay 55.Dimmer switch 59.Front right turn signal/position light 60.Front left turn signal/position light 64.Headlight (high beam) 65.Headlight (low b...

  • Page 363: Lighting System

    Lighting system 7-19 eas27260 troubleshooting any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light, taillight, license light, position light, meter light or accessory light (option). Note: • before troubleshooting, remove the following part(s): 1...

  • Page 364: Lighting System

    Lighting system 7-20 ng → ok ↓ 8. Check the entire lighting system wiring. Refer to “circuit diagram” on page 7-17. Properly connect or repair the lighting sys- tem wiring. The lighting system circuit is ok..

  • Page 365: Signaling System

    Signaling system 7-21 eas27270 signaling system eas27280 circuit diagram w w w r r g b (gra y) on off r br r br l r l y br /l l b r r r r r b b b r r r b r y l b r /wr w r y r y r /w r w r /l r l /y l /r r /y l /w sb /w sb l l b /y r r /l l /g b w l l /w r w l r /y l /rb y l ys b l /g b (blue) l /g ...

  • Page 366: Signaling System

    Signaling system 7-22 3. Main switch 4. Main fuse 5. Backup fuse (odometer and clock) 6. Battery 11.Relay unit 14.Neutral switch 18.Fuel sender (fuel pump) 24.Speed sensor 27.Ecu (electronic control unit) 39.Neutral indicator light 40.Multi-function meter 43.Fuel level warning light 45.Left turn sig...

  • Page 367: Signaling System

    Signaling system 7-23 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or an indicator light. • the horn fails to sound. • the fuel level gauge fails to operate. • the speedometer fails to operate. Note: • before troubleshooting, remove the following part...

  • Page 368: Signaling System

    Signaling system 7-24 ng → ok ↓ ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ ng → ok ↓ 2. Check the horns. Refer to “checking the horns” on page 7-86. Replace the horn(s). ...

  • Page 369: Signaling System

    Signaling system 7-25 ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the fuel level gauge fails to operate. Ng → ok ↓ ng → ok ↓ the fuel level warning light fails to come on. Ng → ok ↓ 4. Check the entire signaling system wiring. Refer to “circuit diagram” on p...

  • Page 370: Signaling System

    Signaling system 7-26 ng → ok ↓ ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ 2. Check the fuel sender (fuel pump). Refer to “checking the fuel sender (fuel pump)” on page 7-88. Replace the fuel pump assembly. 3. Check the entire signaling system wiring. Refer to “circuit diagram” ...

  • Page 371: Fuel Injection System

    Fuel injection system 7-27 eas27330 fuel injection system eas27340 circuit diagram w w w r r /g b (gra y) on off r br r br l r l /y br l l /b r r r r r b b b r r r b r /y l b r /wr /w r /y r /y r /w r /w r /l r l /y l r r y l /w sb w sb l l b y r r /l l gs b w l l w r /w l r /y l /rb /y l /ys b l g ...

  • Page 372: Fuel Injection System

    Fuel injection system 7-28 3. Main switch 4. Main fuse 6. Battery 7. Fuel injection system fuse 11.Relay unit 12.Starting circuit cut-off relay 13.Fuel pump relay 14.Neutral switch 15.Diode 2 16.Sidestand switch 17.Fuel pump 19.Crankshaft position sensor 20.Throttle position sensor 21.Cylinder-#1 in...

  • Page 373: Fuel Injection System

    Fuel injection system 7-29 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 374: Fuel Injection System

    Fuel injection system 7-30 eas27380 self-diagnostic function table if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the ...

  • Page 375: Fuel Injection System

    Fuel injection system 7-31 33 cylinder-#1 left or right ignition coil (faulty ignition) malfunction detected in the prima- ry wire of the cylinder-#1 left or right ignition coil. Able (depending on the number of faulty cylin- ders) able (depending on the number of faulty cylin- ders) 34 cylinder-#2 ...

  • Page 376: Fuel Injection System

    Fuel injection system 7-32 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 377: Fuel Injection System

    Fuel injection system 7-33 5. Erase the malfunction history in the diagnos- tic mode. Refer to “sensor operation table (diagnostic code no. 62)”. Note: turning the main switch to “off” will not erase the malfunction history. The engine operation is not normal but the engine trouble warning light doe...

  • Page 378: Fuel Injection System

    Fuel injection system 7-34 7. Verify the operation of the sensor or actuator. • sensor operation the data representing the operating conditions of the sensor appears on the odometer/trip meter/fu- el reserve trip meter/clock lcd. • actuator operation set the engine stop switch to “ ” to operate the ...

  • Page 379: Fuel Injection System

    Fuel injection system 7-35 19 a break or disconnection of the blue/black lead of the ecu is detected. • open circuit in wire harness (ecu coupler). • malfunction in ecu. 20 22 air temperature sensor: open or short circuit detect- ed. • open or short circuit in wire harness. • defective air temperatu...

  • Page 380: Fuel Injection System

    Fuel injection system 7-36 36 malfunction detected in the primary wire of the cylin- der-#2 left or right ignition coil. • open or short circuit in wire sub lead. • open or short circuit in wire harness. • malfunction in cylinder-#2 left or right igni- tion coil. • malfunction in ecu. • malfunction ...

  • Page 381: Fuel Injection System

    Fuel injection system 7-37 sensor operation table er-2 no signals are received from the ecu within the specified duration. • improper connection in wire harness. • malfunction in meter. • malfunction in ecu. — er-3 data from the ecu cannot be received correctly. • improper connection in wire harness...

  • Page 382: Fuel Injection System

    Fuel injection system 7-38 09 fuel system voltage (battery voltage) approximately 12.0 set the engine stop switch to “ ”, and then compare with the actually measured battery voltage. (if the bat- tery voltage is lower, per- form recharging.) 11 engine temperature displays the engine tempera- ture. C...

  • Page 383: Fuel Injection System

    Fuel injection system 7-39 actuator operation table 70 control number 0–255 — diag- nostic code no. Item actuation checking method 30 cylinder-#1 left or right ig- nition coil actuates the cylinder-#1 left or right ignition coil five times at one-second intervals. Illuminates the engine trou- ble wa...

  • Page 384: Fuel Injection System

    Fuel injection system 7-40 eas27460 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunc...

  • Page 385: Fuel Injection System

    Fuel injection system 7-41 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 l...

  • Page 386: Fuel Injection System

    Fuel injection system 7-42 fault code no. 13 symptom cylinder-#1 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code no. 03 cylinder-#1 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder...

  • Page 387: Fuel Injection System

    Fuel injection system 7-43 fault code no. 14 symptom cylinder-#1 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code no. 03 cylinder-#1 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 cy...

  • Page 388: Fuel Injection System

    Fuel injection system 7-44 fault code no. 15 symptom throttle position sensor: open or short circuit detected. Diagnostic code no. 01 throttle position sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of throttle position sensor. • c...

  • Page 389: Fuel Injection System

    Fuel injection system 7-45 fault code no. 17 symptom exup servo motor circuit: open or short circuit detected. Diagnostic code no. 53 exup servo motor order item/components and probable cause check or maintenance job reinstatement method 1 connections • exup servo motor coupler • main wire harness e...

  • Page 390: Fuel Injection System

    Fuel injection system 7-46 fault code no. 19 symptom a break or disconnection of the blue/black lead of the ecu is detected. Diagnostic code no. 20 sidestand switch order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • ...

  • Page 391: Fuel Injection System

    Fuel injection system 7-47 fault code no. 24 symptom no normal signal is received from the o 2 sensor. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 installed state of o 2 sensor. Check for looseness or pinching. Starting the en- gin...

  • Page 392: Fuel Injection System

    Fuel injection system 7-48 fault code no. 25 symptom cylinder-#2 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code no. 04 cylinder-#2 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder...

  • Page 393: Fuel Injection System

    Fuel injection system 7-49 fault code no. 26 symptom cylinder-#2 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code no. 04 cylinder-#2 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 cy...

  • Page 394: Fuel Injection System

    Fuel injection system 7-50 fault code no. 28 symptom engine temperature sensor: open or short circuit detect- ed. Diagnostic code no. 11 engine temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed state of engine temperature sensor. Ch...

  • Page 395: Fuel Injection System

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

  • Page 396: Fuel Injection System

    Fuel injection system 7-52 fault code no. 34 symptom malfunction detected in the primary wire of the cylinder-#2 left or right ignition coil. Diagnostic code no. 31, 33 cylinder-#2 left or right ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 co...

  • Page 397: Fuel Injection System

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

  • Page 398: Fuel Injection System

    Fuel injection system 7-54 fault code no. 36 symptom malfunction detected in the primary wire of the cylinder-#2 left or right ignition coil. Diagnostic code no. 31, 33 cylinder-#2 left or right ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 co...

  • Page 399: Fuel Injection System

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

  • Page 400: Fuel Injection System

    Fuel injection system 7-56 fault code no. 41 symptom lean angle sensor: open or short circuit detected. Diagnostic code no. 08 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 co...

  • Page 401: Fuel Injection System

    Fuel injection system 7-57 fault code no. 42 symptom a. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code no. A 07 speed sensor b 21 neutral switch order item/components and probable cause check or maintenance job reinstatement m...

  • Page 402: Fuel Injection System

    Fuel injection system 7-58 b-1 connections • neutral switch coupler • main wire harness ecu coupler • check the coupler for any pins that may be pulled out. • check the locking condition of the coupler. • if there is a malfunction, repair it and connect the coupler se- curely. Starting the en- gine,...

  • Page 403: Fuel Injection System

    Fuel injection system 7-59 fault code no. 43 symptom the ecu is unable to monitor the battery voltage (an open or short circuit in the line to the ecu). Diagnostic code no. 09 fuel system voltage order item/components and probable cause check or maintenance job reinstatement method 1 connections • r...

  • Page 404: Fuel Injection System

    Fuel injection system 7-60 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 405: Fuel Injection System

    Fuel injection system 7-61 fault code no. Er-1 symptom no signals are received from the ecu. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • main wire harness meter assembly coupler • check...

  • Page 406: Fuel Injection System

    Fuel injection system 7-62 fault code no. Er-3 symptom data from the ecu cannot be received correctly. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • main wire harness meter assembly coupl...

  • Page 407: Fuel Pump System

    Fuel pump system 7-63 eas27550 fuel pump system eas27560 circuit diagram w w w r r /g b (gra y) on off r br r br l r l /y br l l /b r r r r r b b b r r r b r /y l b r /wr /w r /y r y r /w r /w r /l r l /y l r r y l /w sb w sb l l b y r r /l l gs b w l l w r /w l r /y l /rb /y l /ys b l g b (blue) l ...

  • Page 408: Fuel Pump System

    Fuel pump system 7-64 3. Main switch 4. Main fuse 6. Battery 7. Fuel injection system fuse 11.Relay unit 13.Fuel pump relay 15.Diode 2 17.Fuel pump 27.Ecu (electronic control unit) 68.Engine stop switch 77.Ignition fuse 81.Ecu fuse.

  • Page 409: Fuel Pump System

    Fuel pump system 7-65 eas27570 troubleshooting if the fuel pump fails to operate. Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Rider seat bracket assembly 4. Left side cover 5. Headlight assembly ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng ...

  • Page 410: Fuel Pump System

    Fuel pump system 7-66 ng → ok ↓ 8. Check the entire fuel pump system wiring. Refer to “circuit diagram” on page 7-63. Properly connect or repair the fuel pump system wiring. Replace the ecu..

  • Page 411: Electrical Components

    Electrical components 7-67 eas27970 electrical components 11 3 6 7 8 10 4 9 12 13 5 2 1 14.

  • Page 412: Electrical Components

    Electrical components 7-68 1. Cylinder-#2 right ignition coil 2. Cylinder-#2 left ignition coil 3. Fuel sender 4. Engine temperature sensor 5. Cylinder-#1 left ignition coil 6. Cylinder-#1 right ignition coil 7. Ecu (electronic control unit) 8. Exup servo motor 9. Speed sensor 10. Rectifier/regulato...

  • Page 413: Electrical Components

    Electrical components 7-69 16 18 2 11 13 9 8 10 12 14 15 17 1 3 4 5 6 7.

  • Page 414: Electrical Components

    Electrical components 7-70 1. Air temperature sensor 2. Main switch 3. Cylinder-#2 intake air pressure sensor 4. Throttle position sensor 5. Cylinder-#1 intake air pressure sensor 6. Fuse box 7. Starter relay 8. Fuel injection system fuse 9. Battery 10. Diode 2 11. Turn signal relay 12. Headlight re...

  • Page 415: Electrical Components

    Electrical components 7-71 eas27980 checking the switches b b b 11 13 10 6 12 9 y g/l g b p br y r/w b/r l/w w/b r br r br l/y l/b on off g/y g/b push ch br/w dg b y/r (l) (r) (gray) dg ch (gray) b b g/y g/b (blue) y g g/l (gray) b p y/r br/w l/y b/y b b (black) b b (black) 8 7 (blue) b b r/w b/r g/...

  • Page 416: Electrical Components

    Electrical components 7-72 1. Main switch 2. Engine stop switch 3. Start switch 4. Accessory light switch 5. Front brake light switch 6. Neutral switch 7. Sidestand switch 8. Rear brake light switch 9. Clutch switch 10. Horn switch 11. Dimmer switch 12. Select switch 13. Turn signal switch.

  • Page 417: Electrical Components

    Electrical components 7-73 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Caution: eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probe...

  • Page 418: Electrical Components

    Electrical components 7-74 eas27990 checking the bulbs and bulb sockets note: do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or ...

  • Page 419: Electrical Components

    Electrical components 7-75 checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Note: check each bulb socket for continuity in the same manner as described in ...

  • Page 420: Electrical Components

    Electrical components 7-76 cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • rider seat refer to “general chassis” on page 4-1. Eas28030 checking and charging the battery warning ewa1329...

  • Page 421: Electrical Components

    Electrical components 7-77 5. Remove: • battery 6. Check: • battery charge ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a pocket tester to the battery termi- nals. Note: • the charge state of an mf battery can be checked by measuring its open-circuit voltage (i.E., the voltage when t...

  • Page 422: Electrical Components

    Electrical components 7-78 • if the battery becomes hot to the touch at any time during the charging process, dis- connect the battery charger and let the bat- tery cool before reconnecting it. Hot batteries can explode! • as shown in the following illustration, the open-circuit voltage of an mf bat...

  • Page 423: Electrical Components

    Electrical components 7-79 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 8. Install: • battery 9. Connect: • battery leads (to the battery terminals) caution: eca13630 first, connect the positive battery lead “1”, and then the negative battery lead “2”. Note: be sure to route the negative batter...

  • Page 424: Electrical Components

    Electrical components 7-80 relay unit (fuel pump relay) headlight relay et1d71011 checking the turn signal relay 1. Check: • turn signal relay input voltage out of specification → the wiring circuit from the main switch to the turn signal relay cou- pler is faulty and must be repaired. ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 425: Electrical Components

    Electrical components 7-81 b. Turn the main switch to “on”. C. Measure the turn signal relay output voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28050 checking the diodes relay unit (diode) 1. Check: • relay unit (diode) out of specification → replace. Note: the pocket tester or the...

  • Page 426: Electrical Components

    Electrical components 7-82 c. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no continuity. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ diode 1 1. Check: • diode 1 out of specification → replace. Note: the pocket tester and the analog pocket tester readings ar...

  • Page 427: Electrical Components

    Electrical components 7-83 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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 428: Electrical Components

    Electrical components 7-84 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the spark plug cap from the igni- tion coil. B. Connect the pocket tester ( Ω × 1k) to the ig- nition coil as shown. C. Measure the secondary coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ...

  • Page 429: Electrical Components

    Electrical components 7-85 c. Turn the lean angle sensor to 65°. D. Measure the lean angle sensor output volt- age. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et1d71013 checking the starter motor operation 1. Check: • starter motor operation does not operate → perform the electric starting sy...

  • Page 430: Electrical Components

    Electrical components 7-86 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the engine tachometer to the cylinder-#1 left spark plug lead or right spark plug lead. B. Connect the pocket tester (dc 20 v) to the rectifier/regulator coupler as shown. C. Start the engine and let it run at approx...

  • Page 431: Electrical Components

    Electrical components 7-87 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28210 checking the engine temperature sensor 1. Remove: • engine temperature sensor (from the front cylinder head) warning ewa14140 • handle the engine temperature sensor with special care. • never subject the engine tem...

  • Page 432: Electrical Components

    Electrical components 7-88 b. Move the fuel sender float to maximum “3”/minimum “4” level position. C. Measure the fuel sender resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et1d71015 checking the fuel sender (fuel pump) 1. Drain the fuel. 2. Disconnect: • fuel pump coupler (from the ...

  • Page 433: Electrical Components

    Electrical components 7-89 b. Turn the main switch to “on”. C. Elevate the rear wheel and slowly rotate it. D. Measure the voltage of white and black. With each full rotation of the rear wheel, the volt- age reading should cycle from 0.6 v to 4.8 v to 0.6 v to 4.8 v. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ...

  • Page 434: Electrical Components

    Electrical components 7-90 d. Check the fuel pump operation. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28360 checking the exup servo motor 1. Check: • exup servo motor operation out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the exup cables...

  • Page 435: Electrical Components

    Electrical components 7-91 warning ew1d71004 • handle the air temperature sensor with special care. • never subject the air temperature sensor to strong shocks. If the air temperature sen- sor is dropped, replace it. 2. Check: • air temperature sensor resistance out of specification → replace. ▼▼▼ ▼...

  • Page 436: Troubleshooting

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

  • Page 437: Troubleshooting

    Troubleshooting 8-1 eas28450 troubleshooting eas28460 general information note: the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic trouble- shooting. Refer to the relative procedure in this manual for checks, ...

  • Page 438: Troubleshooting

    Troubleshooting 8-2 • improper throttle cable free play • flooded throttle body electrical system 1. Battery • discharged battery • faulty battery 2. Spark plug(s) • incorrect spark plug gap • incorrect spark plug heat range • fouled spark plug • worn or damaged electrode • worn or damaged insulator...

  • Page 439: Troubleshooting

    Troubleshooting 8-3 2. Engine oil • incorrect oil level • incorrect oil viscosity (high) • deteriorated oil eas28590 overheating engine 1. Cylinder head(s) and piston(s) • heavy carbon buildup 2. Engine oil • incorrect oil level • incorrect oil viscosity • inferior oil quality fuel system 1. Throttl...

  • Page 440: Troubleshooting

    Troubleshooting 8-4 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 switch) • burnt-out headlight bulb headlight bulb burnt out ...

  • Page 441

    Xv19sw(c)/xv19w(c)/xv19mw(c)/xv19ctsw(c)/xv19ctw(c)/xv19ctmw(c) 2007 wiring diagram (gray) (blue) (blue) (black) (black) (black) (black) (black) (gray) (gray) (gray) (gray) (gray) (blue) (blue) (gray) (black) (black) (black) (black) (black) (black) (black) (gray) (dark gray) (black) (black) (black) ...

  • Page 442

    Eas28740 wiring diagram xv19sw(c)/xv19w(c)/ xv19mw(c)/xv19ctsw(c)/ xv19ctw(c)/xv19ctmw(c) 2007 1. Ac magneto 2. Rectifier/regulator 3. Main switch 4. Main fuse 5. Backup fuse (odometer and clock) 6. Battery 7. Fuel injection system fuse 8. Starter relay 9. Starter motor 10. Diode 1 11. Relay unit 12...

  • Page 444

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