FZS10V FZS10VC SERVICE MANUAL LIT-11616-19-79 3C3-28197-10
EAS20050 FZS10V/FZS10VC SERVICE MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. First edition, January 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A.
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 manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
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 divided into chapters and each chapter is divided into sections. The current section title is shown at the top of each page “1”. • Sub-section titles appear in smaller print than the section title “2”.
EAS20100 16.Replace the part SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 2 3 4 5 6 7 8 T. 1 R. 9 10 E 12 11 13 B 15 M G 14 M LS 16 LT New 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6. Wear limit, clearance 7. Engine speed 8. Electrical data 9. Engine oil 10.Gear oil 11.Molybdenum-disulfide oil 12.Wheel-bearing grease 13.
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9
CHAPTER 1 GENERAL INFORMATION IDENTIFICATION.......................................................................................... 1-1 VEHICLE IDENTIFICATION NUMBER................................................... 1-1 MODEL LABEL....................................................................................... 1-1 FEATURES ................................................................................................... 1-2 FI SYSTEM ..............................................................
CHASSIS .............................................................................................. 2-21 LUBRICATION SYSTEM CHART AND DIAGRAMS ................................. 2-23 ENGINE OIL LUBRICATION CHART ................................................... 2-23 LUBRICATION DIAGRAMS .................................................................. 2-25 COOLING SYSTEM DIAGRAMS ............................................................... 2-35 CABLE ROUTING .........................................
BLEEDING THE HYDRAULIC BRAKE SYSTEM................................. 3-24 ADJUSTING THE SHIFT PEDAL ......................................................... 3-25 ADJUSTING THE DRIVE CHAIN SLACK ............................................ 3-25 LUBRICATING THE DRIVE CHAIN...................................................... 3-26 CHECKING AND ADJUSTING THE STEERING HEAD ...................... 3-26 CHECKING THE FRONT FORK ..........................................................
REMOVING THE FRONT BRAKE CALIPERS ..................................... 4-25 DISASSEMBLING THE FRONT BRAKE CALIPERS ........................... 4-25 CHECKING THE FRONT BRAKE CALIPERS ..................................... 4-26 ASSEMBLING THE FRONT BRAKE CALIPERS ................................. 4-26 INSTALLING THE FRONT BRAKE CALIPERS.................................... 4-26 REMOVING THE FRONT BRAKE MASTER CYLINDER..................... 4-27 CHECKING THE FRONT BRAKE MASTER CYLINDER .....................
SWINGARM ................................................................................................ 4-63 REMOVING THE SWINGARM ............................................................. 4-65 CHECKING THE SWINGARM ............................................................. 4-65 INSTALLING THE SWINGARM ............................................................ 4-66 CHAIN DRIVE .............................................................................................
CHECKING THE STARTER CLUTCH.................................................. 5-35 INSTALLING THE STARTER CLUTCH ................................................ 5-36 CRANKSHAFT POSITION SENSOR ......................................................... 5-37 REMOVING THE CRANKSHAFT POSITION SENSOR ...................... 5-38 INSTALLING THE CRANKSHAFT POSITION SENSOR ..................... 5-38 ELECTRIC STARTER.................................................................................
REMOVING THE CRANKSHAFT ASSEMBLY ..................................... 5-71 CHECKING THE CYLINDER AND PISTON......................................... 5-72 CHECKING THE PISTON RINGS ........................................................ 5-72 CHECKING THE PISTON PINS ........................................................... 5-73 CHECKING THE BIG END BEARINGS ............................................... 5-74 INSTALLING THE CONNECTING ROD AND PISTON ........................ 5-77 CHECKING THE CRANKSHAFT .
CHECKING THE FUEL PUMP BODY .................................................... 7-2 CHECKING THE FUEL PUMP OPERATION ......................................... 7-2 INSTALLING THE FUEL PUMP ............................................................. 7-2 INSTALLING THE FUEL TANK............................................................... 7-3 THROTTLE BODIES..................................................................................... 7-4 CHECKING THE INJECTORS .....................................
FUEL INJECTION SYSTEM ....................................................................... 8-29 CIRCUIT DIAGRAM.............................................................................. 8-29 TROUBLESHOOTING.......................................................................... 8-31 ECU SELF-DIAGNOSTIC FUNCTION ................................................. 8-35 SELF-DIAGNOSTIC FUNCTION TABLE.............................................. 8-36 TROUBLESHOOTING METHOD ..............................
SHIFT PEDAL DOES NOT MOVE.......................................................... 9-2 JUMPS OUT OF GEAR.......................................................................... 9-2 FAULTY CLUTCH ................................................................................... 9-2 OVERHEATING ...................................................................................... 9-2 OVERCOOLING .....................................................................................
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
FEATURES EAS20170 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
FI SYSTEM ET2D1001 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm2, 46.1 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remain open.
INSTRUMENT FUNCTIONS miles, press the “SELECT” button for at least one second. ET2D1002 INSTRUMENT FUNCTIONS Multi-function meter unit Tachometer 1. Coolant temperature display/air intake temperature display 2. Speedometer 3. Tachometer 4. Odometer/tripmeter/fuel reserve tripmeter 5. “SELECT” button 6. “RESET” button 7. Clock 8. Fuel meter 1. Tachometer 2. Tachometer red zone The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range.
INSTRUMENT FUNCTIONS 3. When the hour digits start flashing, push the “RESET” button to set the hours. 4. Push the “SELECT” button, and the minute digits will start flashing. 5. Push the “RESET” button to set the minutes. 6. Push the “SELECT” button and then release it to start the clock. Odometer and tripmeter modes 1. Fuel meter The fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter disappear towards “E” (Empty) as the fuel level decreases.
INSTRUMENT FUNCTIONS If any of those circuits are defective, the engine trouble warning light will come on, and then the display will indicate a two-digit error code (e.g., 11, 12, 13). EC2D1011 CAUTION: Do not operate the engine if it is overheated. LCD and tachometer brightness control mode Air intake temperature mode 1. Air intake temperature display 1. 2. 3. 4. The air intake temperature display indicates the temperature of the air drawn into the air filter case.
IMPORTANT INFORMATION EAS20180 IMPORTANT INFORMATION EAS20190 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. EAS20210 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease. 2.
IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. ECA13300 CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfaces.
CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Analog Pocket tester YU-03112-C 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 several times. NOTE: • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (3).
SPECIAL TOOLS 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 or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. NOTE: • For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
SPECIAL TOOLS Tool name/Tool No.
SPECIAL TOOLS Tool name/Tool No.
SPECIAL TOOLS Tool name/Tool No. Illustration Valve guide remover (E) 90890-04111 Valve guide remover (4.0 mm) YM-04111 Reference pages 5-25 Valve guide remover (E.5) 90890-04116 Valve guide remover (4.5 mm) YM-04116 5-25 Valve guide installer (E) 90890-04112 Valve guide installer (4.0 mm) YM-04112 5-25 Valve guide installer (E.5) 90890-04117 Valve guide installer (4.5 mm) YM-04117 5-25 Valve guide reamer (E) 90890-04113 Valve guide reamer (4.0 mm) YM-04113 5-25 Valve guide reamer (E.
SPECIAL TOOLS Tool name/Tool No. Illustration Yamaha bond No.1215 (Three Bond No.
SPECIAL TOOLS Tool name/Tool No.
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 3C34 (U.S.A.) 3C35 (California) Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius 2140 mm (84.3 in) 770 mm (30.3 in) 1205 mm (47.4 in) 815 mm (32.1 in) 1460 mm (57.5 in) 135 mm (5.31 in) 3000 mm (118.1 in) Weight With oil and fuel 220.0 kg (485 lb) (U.S.A.) 221.0 kg (487 lb) (California) 190 kg (419 lb) (U.S.A.) 189.
ENGINE SPECIFICATIONS Limit Bypass valve opening pressure 0.20 mm (0.0079 in) 80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20 kgf/cm²) 600.0–680.0 kPa (87.0–98.6 psi) (6.00–6.80 kgf/cm²) Relief valve operating pressure Cooling system Radiator capacity (including all routes) Coolant reservoir capacity (up to the maximum level mark) Radiator cap opening pressure Radiator core Width Height Depth Water pump Water pump type Reduction ratio Max impeller shaft tilt limit 2.25 L (2.38 US qt) (1.98 Imp.qt) 0.25 L (0.
ENGINE SPECIFICATIONS Timing chain Model/number of links Tensioning system RH2020/122 Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake Exhaust Valve dimensions Valve head diameter A (intake) Valve head diameter A (exhaust) 0.11–0.20 mm (0.0043–0.0079 in) 0.21–0.25 mm (0.0083–0.0098 in) 23.40–23.60 mm (0.9213–0.9291 in) 24.90–25.10 mm (0.9803–0.9882 in) Valve face width B (intake) Valve face width B (exhaust) 1.760–2.900 mm (0.0693–0.1142 in) 1.760–2.900 mm (0.0693–0.
ENGINE SPECIFICATIONS Cylinder head valve seat width (intake) Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) 0.90–1.10 mm (0.0354–0.0433 in) Valve spring Inner spring Free length (intake) Free length (exhaust) Installed length (intake) Installed length (exhaust) Spring rate K1 (intake) Spring rate K2 (intake) Spring rate K1 (exhaust) Spring rate K2 (exhaust) Installed compression spring force (intake) Spring tilt (intake)* Spring tilt (exhaust)* 40.47 mm (1.59 in) 40.53 mm (1.
ENGINE SPECIFICATIONS Piston pin bore inside diameter Piston pin outside diameter 17.002–17.013 mm (0.6694–0.6698 in) 16.991–17.000 mm (0.6689–0.6693 in) Piston ring Top ring Ring type Dimensions (B × T) Barrel 0.90 × 2.75 mm (0.04 × 0.11 in) End gap (installed) Ring side clearance 2nd ring Ring type Dimensions (B × T) 0.15–0.25 mm (0.0059–0.0098 in) 0.030–0.065 mm (0.0012–0.0026 in) Taper 0.80 × 2.75 mm (0.03 × 0.11 in) End gap (installed) Ring side clearance Oil ring Dimensions (B × T) 0.30–0.
ENGINE SPECIFICATIONS Clutch plate thickness Plate quantity Warpage limit Clutch spring free length Spring quantity 1.90–2.10 mm (0.075–0.083 in) 8 pcs 0.10 mm (0.0039 in) 52.50 mm (2.07 in) 6 pcs Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratio 1st 2nd 3rd 4th 5th 6th Main axle runout limit Drive axle runout limit Constant mesh 6-speed Spur gear 65/43 (1.512) Chain drive 45/17 (2.
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Caster angle Trail Diamond 25.00 ° 109.0 mm (4.29 in) Front wheel Wheel type Rim size Rim material Wheel travel Radial wheel runout limit Lateral wheel runout limit Cast wheel 17M/C x MT3.50 Aluminum 130.0 mm (5.12 in) 1.0 mm (0.04 in) 0.5 mm (0.02 in) Rear wheel Wheel type Rim size Rim material Wheel travel Radial wheel runout limit Lateral wheel runout limit Cast wheel 17M/C x MT6.00 Aluminum 130.0 mm (5.12 in) 1.0 mm (0.
CHASSIS SPECIFICATIONS Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Recommended fluid 16.00 mm (0.63 in) 30.20 mm (1.19 in) 27.00 mm (1.
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) Transistorized coil ignition (digital) 5.0 °/1200 r/min Engine control unit Model/manufacturer TBDF29/DENSO Transistorized coil ignition Crankshaft position sensor resistance 336–504 Ω at 20°C (68°F) Ignition coil Model/manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance F6T558/MITSUBISHI 6.0 mm (0.24 in) 1.19–1.
ELECTRICAL SPECIFICATIONS Electric starting system System type Constant mesh Starter motor Model/manufacturer Power output Armature coil resistance Brush overall length Limit Brush spring force Commutator diameter Limit Mica undercut (depth) SM13/MITSUBA 0.80 kW 0.0250–0.0350 Ω 12.5 mm (0.49 in) 5.00 mm (0.20 in) 7.65–10.01 N (27.54–36.03 oz) (780–1021 gf) 28.0 mm (1.10 in) 27.0 mm (1.06 in) 0.70 mm (0.03 in) Starter relay Model/manufacturer Amperage Coil resistance 2768109-A/JIDECO 180.0 A 4.18–4.
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Item Spark plug Cylinder head nut Thread Q’ty size M10 4 M10 10 Tightening torque 13 Nm (1.3 m·kg, 9.4 ft·lb) See NOTE Cylinder head bolt Camshaft caps bolt M6 M6 2 28 12 Nm (1.2 m·kg, 8.7 ft·lb) 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head cover bolt Cylinder head stud bolt (exhaust pipe) Air indication system cap bolt M6 M8 6 8 12 Nm (1.2 m·kg, 8.7 ft·lb) 15 Nm (1.5 m·kg, 11 ft·lb) M6 4 10 Nm (1.0 m·kg, 7.
TIGHTENING TORQUES Item Cylinder head and exhaust pipe nut Exhaust pipe and muffler bolt EXUP pulley and shaft arm nut EXUP valve pulley cover bolt EXUP cable nut Exhaust pipe and exhaust pipe bracket bolt EXUP servo motor cover bolt EXUP servo motor nut Crankcase stud bolt Thread Q’ty size M8 8 Tightening torque 20 Nm (2.0 m·kg, 14 ft·lb) M8 M6 M6 M6 M8 1 1 2 2 2 20 Nm (2.0 m·kg, 14 ft·lb) 7 Nm (0.7 m·kg, 5.1 ft·lb) 14 Nm (1.4 m·kg, 10 ft·lb) 7 Nm (0.7 m·kg, 5.1 ft·lb) 20 Nm (2.
TIGHTENING TORQUES Item Clutch spring bolt Thread Q’ty size M6 6 Tightening torque Remarks 10 Nm (1.0 m·kg, 7.2 ft·lb) Use a lock washer Drive sprocket nut Bearing plate bolt Shift fork stopper plate bolt M22 M6 M6 1 3 2 85 Nm (8.5 m·kg, 61 ft·lb) 12 Nm (1.2 m·kg, 8.7 ft·lb) 10 Nm (1.0 m·kg, 7.2 ft·lb) Stopper screw M8 1 22 Nm (2.2 m·kg, 16 ft·lb) Shift rod locknut (front) Shift rod locknut (rear) M6 M6 1 1 7 Nm (0.7 m·kg, 5.1 ft·lb) 7 Nm (0.7 m·kg, 5.
TIGHTENING TORQUES 2-15
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Item Upper bracket pinch bolt Steering stem nut Upper handlebar holder bolt Lower handlebar holder nut Lower bracket pinch bolt Lower ring nut Cap bolt Damper rod assembly bolt Brake master cylinder bracket bolt Brake master cylinder reservoir cap screw Front brake hose union bolt Front brake hose holder bolt Cowling stay bolt Cowling bracket bolt Front fender bolt Clutch lever holder pinch bolt Right front engine mounting bolt 1 Right front engine mou
TIGHTENING TORQUES Item Rear brake hose holder screw Fuel tank bolt (front) Fuel tank bolt (rear) Fuel tank bracket screw Fuel tank cap bolt Fuel pump bolt Seat lock assembly nut Mud guard assembly bolt License plate light screw Rear reflector nut Mud guard assembly bracket screw Tail/brake light bracket bolt Rear fender bracket bolt Seat bracket bolt Exhaust pipe assembly bracket bolt Side cover screw Lean angle sensor bolt Coolant reserver tank bolt Front wheel axle shaft Front wheel axle pinch bolt Front
TIGHTENING TORQUES NOTE: 1 First, tighten the ring nut to approximately 52 Nm (5.2 m•kg, 38 ft•lb) with a torque wrench, then loosen the lower ring nut completely. 2 Retighten the lower ring nut 18 Nm (1.8 m•kg, 13 ft•lb).
LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Crankshaft journals Camshaft lobes Camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Water pump impeller shaft Oil pump rotors (inner and outer) Oil pump housing Oil strainer Clutch (pull rod) Oil/water pump drive sprocket and washer Clutch (thrust plate) Starter
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Pickup rotor cover 2-20 Lubricant Yamaha bond No.
LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Steering bearings and bearing races (upper and lower) Throttle grip inner surface Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Engine mount bolts (rear upper and lower) Engine mount bolts (front left and right) Relay arm, connecting rod and rear shock absorber collar Pivot shaft Swingarm pivot bearing Swingarm head pipe end, oil seal and bush Oil seal (relay ar
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-23
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter 6. Main gallery 7. AC magneto drive gear shower 8. Shift fork (upper) 9. Main axle 10.Mission shower 11.Drive axle 12.AC magneto axle 13.Piston cooler 14.Chain tensioner 15.Intake camshaft 16.
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-25
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. 2. 3. 4.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. 2. 3. 4. 5. 6. 7. 8.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. 2. 3. 4. 5. 6.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil delivery pipe 3.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2.
COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-35
COOLING SYSTEM DIAGRAMS 1. Water pump 2. Radiator 3.
COOLING SYSTEM DIAGRAMS 2-37
COOLING SYSTEM DIAGRAMS 1. 2. 3. 4.
CABLE ROUTING EAS20430 CABLE ROUTING 2-39
CABLE ROUTING 1. 2. 3. 4. 5. 6. 7. 8. 9. A. B. C. D. E. F. Clutch cable Left handlebar switch lead Main switch lead Horn lead Throttle cable (pull side) Throttle cable (return side) Brake hose Throttle cables Right handlebar switch lead Secure the brake hose to the front fork. Secure the horn lead to the front fork. Cut the tip of the clamp head leaving 2 to 4mm (0.08 to 0.16in) toward the outside of the vehicle. The center position of the clamp shall be within this numeric range.
CABLE ROUTING 2-41
CABLE ROUTING N. Pass the coolant reservoir hose to the vehicle inner side of the radiator inlet hose and route it to the lower outside of the vehicle of the thermostat assembly. O. Route in the concavity section of the radiator stay. P. Route the wire guide of the radiator stay as shown in the illustration. (Twisting not allowed) Q. The outside of the vehicle. R. The inside of the vehicle. S. The front side of the vehicle. T.
CABLE ROUTING 2-43
CABLE ROUTING J. Route the sidestand switch lead by the vehicle front side where the hose assembly 1 and water pump inlet pipe are routed. K. Pass the oil level switch lead to the vehicle front side of the water pump breather hose and water pipe. L. Route the AC magneto lead by the inside of the frame. M. There should be no exposure of bare conductors due to the misalignment of tubes. N. Route the AC magneto lead by the inside of vehicle away from the water hose. O.
CABLE ROUTING 2-45
CABLE ROUTING AG.Route and clamp the O2 sensor lead between clamps as shown in the illustration so that there is no slack.
CABLE ROUTING 2-47
CABLE ROUTING 53.Lean angle sensor lead 54.Battery box 55.Turn signal light relay lead 56.Rear frame 57.Battery 58.Sidestand switch lead 59.Oil level switch lead 60.O2 sensor lead 61.Mad guard 62.Fender 63.Fuel hose A. Check that it is secured with the guide of the radiator stay. B. To the direct ignition coil lead C. Make sure to install the air filter after checking that the leads are positioned outside of the vehicle from the throttle body side cover. D. To the engine E.
CABLE ROUTING 2-49
CABLE ROUTING AJ.Route the lean angle sensor lead at the uppermost side of the vehicle. Also, it must not be protruded from the battery box ribs toward the upper side. AK.Routing can be in random order. AL.Push the wire harness securely in as far as it will go. AM.Secure the leads with a clamp. The cut position of the tip of the clamp shall be on the upper side of the vehicle. (Cut it leaving 2 to 4mm (0.08 to 0.16in) of the tip).
CABLE ROUTING 2-51
CABLE ROUTING M. Route the crankshaft position sensor under the fuel hose. N. Route the fuel tank breather hose over the fuel hose. O. Route the air filter drain hose under the fuel hose. P. The oil level switch lead coupler, sidestand switch lead coupler and radiator fan motor lead coupler (left) can be positioned at the front side of the vehicle. Q. The coupler position of the O2 sensor lead shall be at the rear side of the vehicle behind the clamp position. R. Clamps shall fix the leads to the stay.
CABLE ROUTING 2-53
CABLE ROUTING 1. Fuel tank 2. Fuel tank drain hose 3. Fuel tank breather hose 4. Clip 5. Air filter bracket 6. 3 way connector 7. Hose 8. Fuel hose 9. Damper 10.Collar 11.Fuel tank bracket 12.O-ring 13.Fuel pump A. Hook the cover pawl to the fuel tank bracket. B. The knob of the clip can be positioned in any direction. C. Assemble the two folding sections of the collar flange as shown in the illustration. D. Fit the knob of the clip as shown in the illustration. E.
CABLE ROUTING For California 2-55
CABLE ROUTING 1. Frame 2. Stay 3. Clip 4. Pipe 3 5. Rivet 6. Clamp 7. Roll over valve assembly 8. Balance pipe 9. Pipe 4 10.Hose 11.Canister assembly A. Point the clip grip to the lower side of the vehicle. B. Install the part pointing the yellow paint mark to the front side of the vehicle. C. Insert the hose untill reaches the R-bottom of the pipe. D. Install the part pointing the white paint mark to the front side of the vehicle. E. Point the clip grip to the upper side of the vehicle. F.
PERIODIC MAINTENANCE EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
PERIODIC MAINTENANCE INITIAL NO. ITEM ROUTINE • Check for cracks or damage. 5 * Brake hoses ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) or or or or or or 1 month 6 months 12 months 18 months 24 months 30 months ✓ ✓ • Replace. ✓ ✓ ✓ ✓ Every 4 years 6 * Wheels • Check runout and for damage. • Replace if necessary. ✓ ✓ ✓ ✓ ✓ 7 * Tires • Check tread depth and for damage. • Replace if necessary.
PERIODIC MAINTENANCE INITIAL NO. ITEM ROUTINE 23 * Front and rear brake switches • Check operation. 24 * Control cables • Apply Yamaha chain and cable lube or engine oil SAE 10W-30 thoroughly. ✓ • Check operation and free play. • Adjust the throttle cable free Throttle grip housplay if necessary. 25 * ing and cable • Lubricate the throttle grip housing and cable. Lights, signals and • Check operation. 26 * switches • Adjust headlight beam.
ENGINE • Valve clearance Out of specification → Adjust. EAS20470 ENGINE Valve clearance (cold) Intake valve 0.11–0.20 mm (0.0043–0.0079 in) Exhaust valve 0.21–0.25 mm (0.0083–0.0098 in) EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
ENGINE 6. Adjust: • Valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve lifter “1” and the valve pad “2” with a valve lapper “3”. Valve lapper 90890-04101 NOTE: • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. • Make a note of the position of each valve lifter “1” and valve pad “2” so that they can be installed in the correct place. A. Front d.
ENGINE If the valve pad is marked “158”, the pad thickness is 1.58 mm (0.062in) g. Install the exhaust and intake camshafts, timing chain and camshaft caps. d. Calculate the sum of the values obtained in steps (b) and (c) to determine the required valve pad thickness and the valve pad number. Example: 1.58 mm (0.062 in) + 0.05 mm (0.002 in) = 1.63 mm (0.064 in) The valve pad number is 163. e. Round off the valve pad number according to the following table, and then select the suitable valve pad.
ENGINE Refer to "GENERAL CHASSIS" on page 41. • Fuel tank Refer to "FUEL TANK" on page 7-1. 3. Remove: • Synchronizing hoses “1” • Throttle body synchronization ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. With throttle body #3 as standard, adjust throttle bodies #1, #2, and #4 using the air screw “1”. NOTE: • After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.
ENGINE Make sure that the vacuum pressure is within specification. 10. Stop the engine and remove the measuring equipment. 11. Adjust: • Throttle cable free play Refer to "ADJUSTING THE THROTTLE CABLE FREE PLAY" on page 3-8. Throttle cable free play (at the flange of the throttle grip) 3.0–5.0 mm (0.12–0.20 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Adjust: • Throttle cable free play Refer to "ADJUSTING THE THROTTLE CABLE FREE PLAY" on page 3-8. 12.
ENGINE b. Turn the adjusting nut “2” in direction “a” or “b” until the specified throttle cable free play is obtained. • Electrode “1” Damage/wear → Replace the spark plug. • Insulator “2” Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • Spark plug (with a spark plug cleaner or wire brush) 6. Measure: • Spark plug gap “a” (with a wire thickness gauge) Out of specification → Regap. Direction “a” Throttle cable free play is increased.
ENGINE 2. 3. • • b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. Refer to "ADJUSTING THE VALVE CLEARANCE" on page 3-4. Start the engine, warm it up for several minutes, and then turn it off. Remove: Ignition coils Spark plugs EW2D1002 WARNING To prevent sparking, ground all speak plug leads before cranking the engine.
ENGINE The engine oil level should be between the minimum level mark “a” and maximum level mark “b”. Below the minimum level mark → Add the recommended engine oil to the proper level. EAS20790 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3.
ENGINE Quantity Total amount 3.8 L (3.34 lmp qt, 4.02 US qt) Without oil filter cartridge replacement 2.9 L (2.55 lmp qt, 3.07 US qt) With oil filter cartridge replacement 3.1 L (2.73 lmp qt, 3.28 US qt) 9. Install: • Engine oil filler cap 10. Start the engine, warm it up for several minutes, and then turn it off. 11. Check: • Engine (for engine oil leaks) 12. Check: • Engine oil level Refer to "CHECKING THE ENGINE OIL LEVEL" on page 3-10. b.
ENGINE only as a reference when measuring the engine oil pressure. EWA12980 WARNING The engine, muffler and engine oil are extremely hot. Engine oil pressure Below specification • • • • Above specification Possible causes Faulty oil pump Clogged oil filter Leaking oil passage Broken or damaged oil seal • Leaking oil passage • Faulty oil filter • Oil viscosity too high 6. Install: • Oil gallery bolt “1” 4. Install: • Oil pressure gauge “1” • Adapter “2” Oil gallery bolt 8 Nm (0.8 m·kg, 5.
ENGINE 2. Adjust • Clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Turn the adjusting dial “1” in direction “b” or “c” until the specified clutch cable free play is obtained. Direction “b” Clutch cable free play is increased. Direction “c” Clutch cable free play is decreased. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS20960 REPLACING THE AIR FILTER ELEMENT 1. Remove: • Rider and passenger seat Refer to "GENERAL CHASSIS" on page 41. • Fuel tank Refer to "FUEL TANK" on page 7-1. 2.
ENGINE 4. Install: • Air filter case cover 1. Remove: • Rider and passenger seat Refer to "GENERAL CHASSIS" on page 41. • Fuel tank Refer to "FUEL TANK" on page 7-1. 2. Check: • Fuel hose “1” • Vacuum hose “2” • Breather hose “3” Cracks/damage → Replace. Loose connection → Connect properly. ECA14400 CAUTION: Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine.
ENGINE Refer to "FUEL TANK" on page 7-1. 2. Check: • Crankcase breather hose “1” Cracks/damage → Replace. Loose connection → Connect properly. Exhaust pipe nut 20 Nm (2.0 m·kg, 14 ft·lb) Exhaust pipe and exhaust pipe bracket bolt 20 Nm (2.0 m·kg, 14 ft·lb) Exhaust pipe and muffler bolt 20 Nm (2.0 m·kg, 14 ft·lb) Muffler and rear footrest bracket bolt 48 Nm (4.8 m·kg, 35 ft·lb) ECA13450 CAUTION: Make sure the crankcase breather hose is routed correctly.
ENGINE 2. Check: • EXUP system operation 5. Install: • EXUP valve pulley cover ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EXUP valve pulley cover bolt 14 Nm (1.4 m·kg, 10 ft·lb) a. Turn the main switch ON. b. Check that the EXUP valve operates properly. EAS28360 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE EXUP SERVO MOTOR 1. Check: • EXUP servo motor operation Out of specification → Replace. 3.
ENGINE and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, if distilled water is not available, soft water may be used. 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Check: • Coolant level NOTE: Before checking the coolant level, wait a few minutes until it settles. EAS21120 CHECKING THE COOLING SYSTEM 1.
ENGINE 7. Drain: • Coolant (from the water pump inlet pipe and outlet pipe) 8. Check: 4. Drain: • Coolant (from the coolant reservoir) 5. Remove: • Radiator cap “1” • Copper washers “1” 9. Install: • Coolant drain bolts “2” EWA13030 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury.
ENGINE Coolant is potentially harmful and should be handled with special care. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. EWA13040 WARNING 18. Install: • Rider and passenger seat Refer to "GENERAL CHASSIS" on page 41. • If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor. • If coolant splashes on your clothes, quickly wash it away with water and then with soap and water.
CHASSIS EAS21140 EAS21190 CHASSIS ADJUSTING THE REAR DISC BRAKE 1. Adjust: • Brake pedal position EAS21160 ADJUSTING THE FRONT DISC BRAKE 1. Adjust: • Brake lever position (distance “a” from the throttle grip to the brake lever) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Turn the adjusting bolt “2” in direction “a” or “b” until the specified brake pedal position is obtained. NOTE: Direction “a” Brake pedal is raised. Direction “b” Brake pedal is lowered.
CHASSIS the brake fluid and could cause vapor lock. EAS21240 CHECKING THE BRAKE FLUID LEVEL 1. Stand the vehicle on a level surface. ECA13540 NOTE: CAUTION: • Place the vehicle on a suitable stand. • Make sure the vehicle is upright. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 2. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level.
CHASSIS EAS21280 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: • Brake hose “1” Cracks/damage/wear → Replace. 2. Check: • Brake hose clamp “2” Loose Connection → Tighten the clamp bolt. 2. Check: • Brake hose clamp “2” Loose → Tighten the clamp bolt. 3. Hold the vehicle upright and apply the rear brake several times. 4. Check: • Brake hose Brake fluid leakage → Replace the damaged hose. Refer to "REAR BRAKE" on page 4-30. 3.
CHASSIS c. Connect a clear plastic hose “1” tightly to the bleed screw “2”. nut “2” in direction “a” or “b” until the rear brake light comes on at the proper time. Direction “a” Brake light comes on sooner. Direction “b” Brake light comes on later. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21350 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA13100 WARNING A. Front brake caliper B. Rear brake caliper Bleed the hydraulic brake system whenever: • The system is disassembled.
CHASSIS EWA13110 NOTE: WARNING Place the vehicle on a suitable stand so that the rear wheel is elevated. After bleeding the hydraulic brake system, check the brake operation. 2. Spin the rear wheel several times and find the tightest position of drive chain. 3. Check: • Drive chain slack “a” Out of specification → Adjust. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ET2D1006 ADJUSTING THE SHIFT PEDAL 1. Adjust: • Shift pedal position Drive chain slack 25–35 mm (0.98–1.38 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
CHASSIS Refer to "STEERING HEAD" on page 4-55. 4. Adjust: • Steering head d. Tighten both locknuts to specification. Locknut 16 Nm (1.6 m·kg, 12 ft·lb) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the lock washer “1”, the upper ring nut “2”, and the rubber washer “3”. e. Tighten the wheel axle nut to specification. Wheel axle nut 150 Nm (15 m·kg, 108 ft·lb) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ET2D1008 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts.
CHASSIS d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to "STEERING HEAD" on page 4-55. e. Install the rubber washer “3”. f. Install the upper ring nut “2”. g. Finger tighten the upper ring nut “2”, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h.
CHASSIS EWA13120 EWA13150 WARNING WARNING Securely support the vehicle so that there is no danger of it falling over. • Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. • Securely support the vehicle so that there is no danger of it falling over. 2. Check: • Inner tube “1” Damage/scratches → Replace. • Oil seal “2” Oil leakage → Replace. Spring preload ECA13570 CAUTION: • Grooves are provided to indicate the adjustment position.
CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping (Right side front fork) Compression damping (Left side front fork) EC2D1006 CAUTION: ECA13590 CAUTION: • Never go beyond the maximum or minimum adjustment positions. • When assembling the front forks, be careful not to assemble them to the opposite position because there are two kinds of forks (for the rebound side and for the compression side). • Never go beyond the maximum or minimum adjustment positions.
CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21620 Rebound damping ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ECA13590 CAUTION: EWA13120 Never go beyond the maximum or minimum adjustment positions. WARNING Securely support the vehicle so that there is no danger of it falling over. 1. Adjust: • Rebound damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Spring preload a. Turn the adjusting screw “1” in direction “a” or “b”.
CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Tire air pressure (measured on cold tires): Basic weight (with oil and a full fuel tank) U.S.A. 220kg (485 lb) California 221kg (487 lb) Loading condition* 0–90 kg (0–198 lb) Front 250 kPa (2.5 kg/cm2, 2.5 bar, 36 psi) Rear 290 kPa (2.9 kg/cm2, 2.9 bar, 42 psi) Loading condition* U.S.A. 90–190 kg (198–419 lb) California 90–189 kg (198–417 lb) Front 250 kPa (2.5 kg/cm2, 2.5 bar, 36 psi) Rear 290 kPa (2.9 kg/cm2, 2.9 bar, 42 psi) High speed riding: Front 250 kPa (2.
CHASSIS EWA14090 WARNING 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 concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehicle. 1. Tire tread depth 2. Side wall 3.
CHASSIS EAS21670 EAS21710 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: • Wheel Damage/out-of-round → Replace. LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. Recommended lubricant Lithium - soap - based grease EWA13260 WARNING EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Never attempt to make any repairs to the wheel.
ELECTRICAL SYSTEM • Headlight bulb “1” EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to "ELECTRICAL COMPONENTS" on page 8-77. EAS21770 CHECKING THE FUSES Refer to "ELECTRICAL COMPONENTS" on page 8-77. EAS21780 REPLACING THE HEADLIGHT BULBS 1. Disconnect: • Headlight coupler “1” EWA13320 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 5.
ELECTRICAL SYSTEM Direction “a” Headlight beam is raised. Direction “b” Headlight beam is lowered. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: • Headlight beam (horizontally) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. Direction “a” Headlight beam moves to the left. Direction “b” Headlight beam moves to the right.
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery Order 1 2 3 4 5 6 7 8 Job/Parts to remove Passenger seat Rider seat Battery band Battery cover Battery negative lead Battery positive lead Battery Battery seat Q’ty 1 1 1 1 1 1 1 1 Remarks For installation, reverse the removal procedure.
GENERAL CHASSIS Removing the front cowling 4 Order 1 2 3 4 5 6 7 8 Job/Parts to remove Inner panel Headlight assembly coupler Meter coupler Front cowling assembly Rear view mirror Cowling stay Meter assembly Headlight unit Q’ty 2 1 1 1 2 1 1 1 Remarks Disconnect. Disconnect. For installation, reverse the removal procedure.
GENERAL CHASSIS Removing the rear fender Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Parts to remove Rider and passenger seat Q’ty Licence plate light lead coupler Turn signal light lead coupler Reflector Reflector stay Licence plate bracket Mud guard assembly Rear fender Tail/brake light lead coupler Tail/brake light cover Rear fender side cover (left and right) Rear fender bracket Tail/brake light Tail cover 1 1 3 2 1 1 1 1 1 2 1 1 1 Remarks Refer to "GENERAL CHASSIS" on page 4-1. Disconnect.
GENERAL CHASSIS Removing the air filter case Order 1 2 3 4 5 6 7 8 Job/Parts to remove Rider and passenger seat Q’ty Fuel tank Intake air temperature sensor lead coupler Intake air temperature sensor Air filter case cover Air filter Funnel Air filter case Air induction system hose Crankcase breather hose 1 Remarks Refer to "GENERAL CHASSIS" on page 4-1. Refer to "FUEL TANK" on page 7-1. Disconnect. 1 1 1 2 1 1 1 For installation, reverse the removal procedure.
GENERAL CHASSIS EAS21840 REMOVING THE COVER 1. Remove: • Tail cover • Rear fender NOTE: To remove the quick fastener, push its center with a screwdriver, then pull the fastener out. EAS21850 INSTALLING THE COVER 1. Install: • Rear fender • Tail cover NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cover and push the pin “a” in with screwdriver. Make sure that the pin is flush with the fastener’s head.
FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order 1 2 3 4 5 6 7 8 9 10 Job/Parts to remove Brake hose holder (left and right) Reflector stay Reflector Front brake caliper (left and right) Front wheel axle pinch bolt Front wheel axle Collar (left and right) Dust cover Front wheel Front brake disc (left and right) Q’ty 2 2 2 2 1 1 2 2 1 2 Remarks For installation, reverse the removal procedure.
FRONT WHEEL Disassembling the front wheel Order 1 2 3 Job/Parts to remove Oil seal (left and right) Wheel bearing (left and right) Spacer Q’ty 2 2 1 Remarks For assembly, reverse the disassembly procedure.
FRONT WHEEL Refer to "CHECKING THE TIRES" on page 3-31 and "CHECKING THE WHEELS" on page 3-33. 3. Measure: • Radial wheel runout “1” • Lateral wheel runout “2” Over the specified limits → Replace. EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.
FRONT WHEEL • Adjust the front wheel static balance with the brake disc installed. 1. • 2. • Remove: Balancing weight(s) Find: Front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ c. Remove the wheel bearings “3” with a general bearing puller. a. Spin the front wheel. b. When the front wheel stops, put an “X1” mark at the bottom of the wheel. d. Install the new wheel bearings and oil seals in the reverse order of disassembly.
FRONT WHEEL a. Install a balancing weight “1” onto the rim exactly opposite the heavy spot “X”. EAS22000 INSTALLING THE FRONT WHEEL (DISC) The following procedure applies to both of the brake discs. 1. Lubricate: • Wheel axle • Oil seal lips NOTE: Start with the lightest weight. Recommended lubricant Lithium-soap-based grease 2. Lift the wheel up between the fork legs. 3. Insert the wheel axle. NOTE: Install the tire and wheel with the mark “1” pointing in the direction of wheel rotation. b.
FRONT WHEEL EWA13490 WARNING Make sure the brake cable is routed properly. NOTE: Make sure that there is enough space between the brake pads before installing the brake calipers onto the brake discs.
REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order 1 2 3 4 5 6 7 8 9 10 Job/Parts to remove Rear brake caliper Locknut (left and right) Adjusting bolt (left and right) Wheel axle nut Washer Rear wheel axle Adjusting block (left) Adjusting block (right) Rear wheel Brake caliper bracket Q’ty 1 2 2 1 1 1 1 1 1 1 Remarks Loosen. Loosen. For installation, reverse the removal procedure.
REAR WHEEL Removing the brake disc and rear wheel sprocket Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Rear brake disc Rear wheel sprocket Coller (left and right) Dust cover Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel Q’ty 1 1 2 2 1 1 1 6 1 Remarks For installation, reverse the removal procedure.
REAR WHEEL Disassembling the rear wheel Order 1 2 3 4 5 6 Job/Parts to remove Q’ty 1 1 1 1 1 1 Coller Bearing Spacer Oil seal Circlip Bearing Remarks For assembly, reverse the disassembly procedure.
REAR WHEEL EAS22040 REMOVING THE REAR WHEEL (DISC) 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • Brake caliper “1” 5. • • • • NOTE: Do not depress the brake pedal when removing the brake caliper. EAS22090 3. Loosen: • Locknut “1” • Adjusting bolt “2” 4.
REAR WHEEL Damage/wear → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS22120 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: • Rear wheel sprocket More than 1/4 tooth “a” wear → Replace the rear wheel sprocket. Bent teeth → Replace the rear wheel sprocket. EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed.
REAR WHEEL EWA13500 WARNING Make sure the brake hose is routed properly.
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Brake hose holder Reflector stay Reflector Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw Q’ty 1 1 1 1 2 1 1 2 1 Remarks For installation, reverse the removal procedure.
FRONT BRAKE Removing the front brake master cylinder Order 1 2 3 4 5 6 7 8 9 10 Job/Parts to remove Brake fluid Q’ty Remarks Drain. Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 324. Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder diaphragm Brake lever Front brake light switch lead coupler Front brake light switch Union bolt Copper washer Master cylinder bracket Master cylinder assembly 1 1 1 1 1 1 1 2 1 1 Disconnect.
FRONT BRAKE Disassembling the front brake master cylinder Order 1 2 Job/Parts to remove Brake master cylinder kit Brake master cylinder body Q’ty 1 1 Remarks For assembly, reverse the disassembly procedure.
FRONT BRAKE Removing the front brake calipers Order 1 2 3 4 5 6 Job/Parts to remove Brake fluid Q’ty Union bolt Copper washer Brake hose Reflector stay Reflector Brake caliper Remarks Drain. Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 324. 1 2 1 1 1 1 For installation, reverse the removal procedure.
FRONT BRAKE Disassembling the front brake calipers Order 1 2 3 4 5 6 7 Job/Parts to remove Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw Q’ty 2 1 1 2 4 8 1 Remarks For assembly, reverse the disassembly procedure.
FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. • Never use solvents on internal brake components.
FRONT BRAKE NOTE: Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 18 Nm (1.8 m·kg, 13 ft·lb) LOCTITE® d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f.
FRONT BRAKE 1. • • • NOTE: The arrow mark “a” on the brake pad spring must point in the direction of disc rotation. Remove: Union bolt “1” Copper washers “2” Brake hose “3” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. • • • Install: Brake pad pins Brake pad clips Brake caliper NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. EAS22360 Brake caliper bolt 40 Nm (4.
FRONT BRAKE c. Remove the brake caliper piston seals. d. Repeat the previous steps to force out the right side pistons from the brake caliper. EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS EWA13620 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort.
FRONT BRAKE “a” touches the projection “b” on the brake caliper. ECA13540 CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 2. • 3. • • • • • • 5. Bleed: • Brake system Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-24. 6. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to "CHECKING THE BRAKE FLUID LEVEL" on page 3-22.
FRONT BRAKE • Union bolt “1” • Copper washers “2” • Brake hose “3” EAS22740 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” • Brake master cylinder bracket “2” NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. Brake master cylinder bracket bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: • Install the brake master cylinder holder with the “UP” mark “a” facing up.
FRONT BRAKE other parts (e.g., wire harness, cables, leads). Correct if necessary. • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to "CHECKING THE BRAKE FLUID LEVEL" on page 3-22. EC2D1004 CAUTION: Attach the brake hose so that its angle is 23° to 33° against the straight line in parallel with the ceiling plane of the master cylinder. 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake system.
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order 1 2 3 4 5 6 7 Job/Parts to remove Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad Bleed screw Brake pad spring Q’ty 1 1 1 4 2 1 1 Remarks For installation, reverse the removal procedure.
REAR BRAKE Removing the rear brake master cylinder Order 1 2 3 4 5 6 7 8 9 10 11 Job/Parts to remove Brake fluid Q’ty Remarks Drain. Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 324. Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Hose joint Bushing Union bolt Copper washer Brake hose Brake master cylinder 1 1 1 1 1 1 1 1 2 1 1 For installation, reverse the removal procedure.
REAR BRAKE Disassembling the rear brake master cylinder Order 1 2 3 4 Job/Parts to remove Brake master cylinder kit Hose joint Bushing Brake master cylinder body Q’ty 1 1 1 1 Remarks For assembly, reverse the disassembly procedure.
REAR BRAKE Removing the rear brake caliper Order 1 2 3 4 Job/Parts to remove Union bolt Copper washer Brake hose Barke caliper Q’ty 1 2 1 1 Remarks For installation, reverse the removal procedure.
REAR BRAKE Disassembling the rear brake caliper Order 1 2 3 4 5 6 7 8 Job/Parts to remove Screw plug Brake pad pin Brake pad Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw Q’ty 1 1 2 4 1 1 2 1 Remarks For assembly, reverse the disassembly procedure.
REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit 4.5 mm (0.18 in) EWA14100 WARNING 5. Adjust: • Brake disc deflection Refer to "CHECKING THE FRONT BRAKE DISCS" on page 4-23. Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary.
REAR BRAKE a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. Refer to "CHECKING THE BRAKE FLUID LEVEL" on page 3-22. 5. Check: • Brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-24. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. Bleed screw 5 Nm (0.5 m·kg, 3.
REAR BRAKE Scratches/wear → Replace the brake caliper assembly. • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. EWA13610 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a. Secure the brake caliper pistons with a piece of wood “a”. b. Blow compressed air into the brake hose joint opening “b” to force out the piston from the brake caliper.
REAR BRAKE • Brake caliper Refer to "REPLACING THE REAR BRAKE PADS" on page 4-35. EAS22670 INSTALLING THE REAR BRAKE CALIPER 1. Install: • Brake caliper “1” (temporarily) Brake caliper bolt (front) 27 Nm (2.7 m·kg, 20 ft·lb) Brake caliper bolt (rear) 22 Nm (2.2 m·kg, 16 ft·lb) • Copper washers “2” • Brake hose “3” • Union bolt “4” 4. Fill: • Brake fluid reservoir (with the specified amount of the recommended brake fluid) Brake hose union bolt 30 Nm (3.
REAR BRAKE 3. Check: • Brake fluid reservoir Cracks/damage → Replace. • Brake fluid reservoir diaphragm Cracks/damage → Replace. 4. Check: • Brake hose Cracks/damage/wear → Replace. EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 7. Check: • Brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-24.
REAR BRAKE 5. Check: • Brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-24. 6. Adjust: • Brake pedal position Refer to "ADJUSTING THE REAR DISC BRAKE" on page 3-21. 7. Adjust: • Rear brake light operation timing Refer to "ADJUSTING THE REAR BRAKE LIGHT SWITCH" on page 3-23. 2.
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Job/Parts to remove Front cowling Q’ty Front brake light switch connector Front master cylinder bracket Front brake master cylinder assembly Right handlebar switch Throttle cable housing Throttle cable Grip end Throttle grip Clutch cable Handlebar grip Left handlebar switch Clutch lever holder Upper handlebar holder Handlebar 4-41 2 1 1 1 1 2 2 1 1 1 1 1 1 1 Remarks Refer to "GENERAL CHASSIS" on page 4-1.
HANDLEBAR Removing the handlebar Order 15 Job/Parts to remove Lower handlebar holder Q’ty 2 Remarks For installation, reverse the removal procedure.
HANDLEBAR EAS22860 EWA13120 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Install: • Lower handlebar holders “1” 2. Remove: • Handlebar grip “1” Temporarily tighten the nuts “2”.
HANDLEBAR 4. Tighten: • Lower handlebar holder nuts EW2D1007 WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried. Lower handlebar holder nut 32 Nm (3.2 m·kg, 23 ft·lb) NOTE: 5. Install: • Clutch lever holder “1” • Clutch cable There should be 1–3 mm (0.04–0.12 in) of clearance “a” between the handlebar grip and the grip end. NOTE: Align the slit in the clutch lever holder with the punch mark "a" in the handlebar. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 8. • • • • 6.
HANDLEBAR 10. Install: • Front brake master cylinder assembly • Front brake master cylinder holder “1” Front brake master cylinder bracket bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) ECS2D1010 CAUTION: • Install the brake master cylinder bracket with the “UP” mark facing up. • First, tighten the upper bolt, then the lower bolt. NOTE: Align the end of the brake master cylinder holder with the punch mark “a” on the handlebar. 11.
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order 1 2 3 4 5 Job/Parts to remove Front wheel Front brake calipers Q’ty Front fender Cap bolt Upper bracket pinch bolt Lower bracket pinch bolt Front fork leg 1 1 1 2 1 Remarks Refer to "CHECKING THE TIRES" on page 3-31 and "CHECKING THE WHEELS" on page 3-33. Loosen. Loosen. Loosen. For installation, reverse the removal procedure.
FRONT FORK Disassembling the front fork legs Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Job/Parts to remove Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Cap bolt O-ring Damper adjusting rod Nut Washer Spacer Fork spring Dust seal Oil seal clip Oil seal Washer Damper rod assembly bolt Copper washer Damper rod assembly Inner tube Outer tube Remarks For assembly, reverse the disassembly procedure.
FRONT FORK • Nut “3” EAS22970 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Press down on the spacer with the fork spring compressor “4”. b. Install the rod holder “5” between the nut “3” and the spacer “2”.
FRONT FORK A. Compression side B. Rebound side NOTE: While holding the damper rod with the damper rod holder “1”, loosen the damper rod assembly bolt. Damper rod holder 90890-01423 Damping rod holder YM-01423 3. Remove: • Oil seal clip “1” (with a flat-head screwdriver) ECA14180 CAUTION: Do not scratch the inner tube. EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • Inner tube “1” • Outer tube “2” Bends/damage/scratches → Replace. 4.
FRONT FORK • Damper rod assembly bolt • Copper washer EC2D1013 CAUTION: For the damper rod assembly, the right side is used for the rebound operation and left side for the compression. Pay attention not to mistake the right and left. NOTE: 3. Check: • Damper rod “1” Damage/wear → Replace. Obstruction → Blow out all of the oil passages with compressed air. • Damper adjusting rod Bends/damage → Replace.
FRONT FORK 4. • • • • 6. Install: • Oil seal clip “1” Install: Dust seal “1” Oil seal clip “2” Oil seal “3” Washer “4” NOTE: Adjust the oil seal clip so that it fits into the outer tube’s groove. ECA14220 CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil.
FRONT FORK Rod puller 90890-01437 Rod puller attachment (M10) 90890-01436 11. Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed. NOTE: Be sure to bleed the front fork leg of any residual air. 9. Fill: • Front fork leg (with the specified amount of the recommended fork oil) 12.
FRONT FORK ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the rod puller and adapter. b. Install the nut. c. Install the fork spring and spacer. f. Remove the rod puller and the rod puller attachment. g. Install the nut “1” and position it as specified “b”. NOTE: Install the spring with the smaller pitch “a” facing up “A”. Distance “b” 12 mm (0.47 in) d. Press down in the spacer with the fork spring compressor “1” e.
FRONT FORK EW2D1003 WARNING • The fork spring is compressed. • Always use a new cap bolt O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. NOTE: 3. • • • Each front fork leg is eqipped with a spring preload adjusting bolt, the right fork leg is equipped with a rebound damping force adjusting screw and left front fork is equipped with a compression damping force adjusting screw.
STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Front wheel Q’ty Front brake calipers Front cowling Handlebar Front fork legs 1 2 3 4 5 6 Main switch connector Steering stem nut Upper bracket Front brake hose joint Front brake hose joint bracket Horn 2 1 1 1 1 1 4-55 Remarks Refer to "FRONT WHEEL" on page 4-6. Refer to "FRONT BRAKE" on page 4-18. Refer to "GENERAL CHASSIS" on page 4-1. Refer to "HANDLEBAR" on page 441. Refer to "FRONT FORK" on page 446.
STEERING HEAD Removing the lower bracket Order 7 8 9 10 11 12 13 14 15 16 17 18 19 Job/Parts to remove Horn bracket Lock washer Upper ring nut Rubber washer Lower ring nut Lower bracket Lower bearing Lower bearing dust seal Lower bearing inner race Bearing cover Upper bearing inner race Upper bearing Bearing outer race Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 2 Remarks For installation, reverse the removal procedure.
STEERING HEAD Damage/pitting → Replace. EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. • • • • Remove: Upper ring nut “1” Rubber washer Lower ring nut “2” Lower bracket 3. Replace: • Bearings • Bearing races ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: a. Remove the bearing races from the steering head pipe with a long rod “1” and hammer. b.
STEERING HEAD 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. Steering stem nut 113 Nm (11.3 m·kg, 82 ft·lb) EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing • Bearing races Recommended lubricant Lithium-soap-based grease 2. • • • • Install: Lower ring nut “1” Rubber washer “2” Upper ring nut “3” Lock washer “4” Refer to "INSTALLING THE STEERING HEAD" on page 4-58. 3. • • 4.
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Rider and passenger seat Q’ty Side cover (left and right) Brake fluid reservoir tank bolt 1 2 3 4 5 6 7 8 9 10 Self-locking nut/bolt Self-locking nut/bolt Self-locking nut/bolt Self-locking nut/bolt/collar Rear shock absorber assembly Oil seal/bearing/collar Collar/self-locking nut/bolt Connecting arm Oil seal/bearing/collar Relay arm 1/1 1/1 1/1 1/1/1 1 6/3/3 1/1/1 2
REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty 4-60 Remarks For installation, reverse the removal procedure.
REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the rear wheel is elevated. EWA13740 WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber.
REAR SHOCK ABSORBER ASSEMBLY • • • • Gas leaks/oil leaks → Replace the rear shock absorber assembly. Spring Damage/wear → Replace the rear shock absorber assembly. Bushings Damage/wear → Replace. Dust seals Damage/wear → Replace. Bolts Bends/damage/wear → Replace. 3. Tighten: • Rear shock absorber assembly upper nut Rear shock absorber assembly upper nut 44 Nm (4.4 m·kg, 32 ft·lb) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 44 Nm (4.
SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Rear wheel Q’ty Rear brake caliper Rear shock absorber Drive sprocket 1 2 3 4 5 6 7 Rear fender cover Drive chain guard Brake hose holder Drive chain adjusting bolt/locknut Pivot shaft nut/washer Pivot shaft Swingarm 1 1 1 2/2 1/1 1 1 4-63 Remarks Refer to "REAR WHEEL" on page 412. Refer to "REAR BRAKE" on page 430. Refer to "REAR SHOCK ABSORBER ASSEMBLY" on page 4-59. Refer to "ENGINE REMOVAL" on page 5-1.
SWINGARM Removing the swingarm Order 8 9 10 11 12 Job/Parts to remove Drive chain Dust cover Drive chain guide Spacer Bearing Q’ty 1 2 1 1 2 Remarks For installation, reverse the removal procedure.
SWINGARM If swingarm vertical movement is not smooth or if there is binding, check the spacers, bearings, washers, and dust covers. EAS23350 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2.
SWINGARM 5. Check: • Connecting arms “1” • Relay arm “2” Damage/wear → Replace. 6. Check: • Bearings “3” • Oil seals “4” Damage/pitting → Replace. 7. Check: • Collars “5” Damage/scratches → Replace. 3. Install: • Rear shock absorber assembly • Rear wheel Refer to "INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY" on page 4-62 and "INSTALLING THE REAR WHEEL (DISC)" on page 4-16. 4. Adjust: • Drive chain slack Refer to "ADJUSTING THE DRIVE CHAIN SLACK" on page 3-25. Drive chain slack 25–35 mm (0.98–1.
CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain Order 1 2 Job/Parts to remove Drive sprocket Q’ty Drive chain guard Drive chain Remarks Refer to "ENGINE REMOVAL" on page 5-1. 1 1 For installation, reverse the removal procedure.
CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: 2. Check: • Drive chain Stiffness → Clean and lubricate or replace. Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • Drive chain (with the drive chain cutter) NOTE: Only cut the drive chain if it or the swingarm is to be replaced. EAS23440 CHECKING THE DRIVE CHAIN 1.
CHAIN DRIVE • Drive sprocket More than 1/4 tooth “a” wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. b. Correct 1. Drive chain roller 2. Drive chain sprocket EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to "CHECKING AND REPLACING THE REAR WHEEL SPROCKET" on page 4-16. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • O-rings “1” Damage → Replace the drive chain. • Drive chain rollers “2” Damage/wear → Replace the drive chain.
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the drive sprocket Order 1 2 3 4 5 6 7 8 Job/Parts to remove Q’ty 2 1 1 1 1 1 1 1 Locknut Shift rod Shift arm Drive sprocket cover Drive sprocket nut Lock washer Drive sprocket Plate Remarks For installation, reverse the removal procedure.
ENGINE REMOVAL Removing the exhaust pipe 5 Order Job/Parts to remove Rider and passenger seat Q’ty 1 2 3 4 5 EXUP pulley cover EXUP servo motor cover EXUP cables EXUP servo motor O2 sensor 1 1 2 1 1 6 7 8 9 10 11 Exhaust pipe assembly Exhaust pipe gasket Muffler Muffler gasket Muffler cover Muffler end cover 1 4 1 1 1 1 Remarks Refer to "GENERAL CHASSIS" on page 4-1. For installation, reverse the removal procedure.
ENGINE REMOVAL Disassembling the exhaust valve pipe Order 1 2 3 4 Job/Parts to remove Q’ty 1 1 1 1 Nut Pulley Spring Spring seat Remarks For assembly, reverse the disassembly procedure.
ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Fuel tank Air filter case Q’ty Throttle body assembly Engine oil Oil cooler Air cut-off valve Starter motor 1 2 3 4 5 Battery negative lead Battery positive lead Clutch cable Ground lead Stator coil assembly coupler 1 1 1 2 1 5-4 Remarks Refer to "FUEL TANK" on page 7-1. Refer to "GENERAL CHASSIS" on page 4-1. Refer to "THROTTLE BODIES" on page 7-4. Drain. Refer to "CHANGING THE ENGINE OIL" on page 3-11.
ENGINE REMOVAL Disconnecting the leads and hoses Order 6 7 8 9 10 Job/Parts to remove Crankshaft position sensor lead coupler Oil level switch connector Neutral switch connector Cylinder identification sensor coupler Speed sensor coupler 5-5 Q’ty 1 1 1 1 1 Remarks Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. For assembly, reverse the removal procedure.
ENGINE REMOVAL Removing the engine Order 1 2 3 4 5 6 7 8 Job/Parts to remove Right front engine mounting bolt 1 Left front engine mounting bolt Upper self-locking nut Upper engine mounting bolt Lower self-locking nut Lower engine mounting bolt Engine mounting adjust bolt Engine Q’ty 1 1 1 1 1 1 2 1 Remarks For assembly, reverse the removal procedure.
ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Right front engine mounting bolt 2 “1” Refer to "CYLINDER HEAD" on page 5-18. 2. Tighten: • Right front engine mounting bolt 2 Right front engine mounting bolt 2 50 Nm (5.0 m·kg, 36 ft·lb) 7. Tighten: • Engine mounting adjust bolts 3. Install: • Engine mounting adjust bolts (temporarily tighten) 4. Install: • Engine 5.
ENGINE REMOVAL Left front engine mounting bolt 45 Nm (4.5 m·kg, 33 ft·lb) Right front engine mounting bolt 1 45 Nm (4.5 m·kg, 33 ft·lb) 8. Tighten: • Lower self-locking nut “1” • Upper self-locking nut “2” Upper self-locking nut 51 Nm (5.1 m·kg, 37 ft·lb) Lower self-locking nut 51 Nm (5.1 m·kg, 37 ft·lb) NOTE: First tighten the lower self-locking nut, and then tighten the upper self-locking nut. 9.
CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Fuel tank Throttle body assembly Q’ty Radiator assembly Air cut-off valve 1 2 3 4 5 6 7 Ignition coil Spark plug Cylinder head cover Cylinder head cover gasket Timing chain guide (top side) Cylinder identification sensor O-ring Remarks Refer to "FUEL TANK" on page 7-1. Refer to "THROTTLE BODIES" on page 7-4. Refer to "RADIATOR" on page 6-1. Refer to "AIR INDUCTION SYSTEM" on page 7-13.
CAMSHAFTS Removing the camshafts Order Job/Parts to remove Pickup rotor cover Q’ty 1 2 3 4 5 Camshaft sprocket bolt Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Dowel pin 4 1 1 3 6 6 7 Exhaust camshaft cap Dowel pin 3 6 8 9 10 Intake camshaft Exhaust camshaft Camshaft sprocket 1 1 2 Remarks Refer to "CRANKSHAFT POSITION SENSOR" on page 5-37. Loosen. Refer to "REMOVING THE CAMSHAFTS" on page 5-11. Refer to "REMOVING THE CAMSHAFTS" on page 5-11.
CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: • Pickup rotor cover Refer to "CRANKSHAFT POSITION SENSOR" on page 5-37. 2. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compression stroke, align the “T” mark “a” on the pickup rotor with the crankcase mating surface “b”. 5.
CAMSHAFTS 3. Measure: • Camshaft runout Out of specification → Replace. EAS23850 CHECKING THE CAMSHAFTS 1. Check: • Camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification → Replace the camshaft. Camshaft runout limit 0.03 mm (0.0012 in) Camshaft lobe dimension limit Intake camshaft “a” 32.50–32.60 mm (1.280–1.284 in) Limit 32.40 mm (1.276 in) Intake camshaft “b” 24.95–25.05 mm (0.982–0.986 in) Limit 24.
CAMSHAFTS 2. Check: • Camshaft sprocket More than 1/4 tooth wear “a” → Replace the camshaft sprockets and the timing chain as a set. a. b. 1. 2. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Measure: • Camshaft journal diameter “a” Out of specification → Replace the camshaft. Within specification → Replace the cylinder head and the camshaft caps as a set.
CAMSHAFTS b. Squeeze the timing chain tensioner clip “2” and push the timing chain tensioner rod “3”. NOTE: Squeeze the timing chain tensioner clip, and then remove the timing chain tensioner spring and timing chain tensioner rod. NOTE: When the timing chain tensioner rod “3” is pushed while holding the grip of the timing chain tensioner clip “2”, make sure not to release the timing chain tensioner rod “3” before releasing the timing chain tensioner clip “2”.
CAMSHAFTS EAS24000 INSTALLING THE CAMSHAFTS 1. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b. When position #1 is at TDC, align the “T” mark “a” with the crankcase mating surface “b”. 4. • • • Install: Dowel pins Intake camshaft caps Exhaust camshaft caps NOTE: • Make sure each camshaft cap is installed in its original place.
CAMSHAFTS • Timing chain tensioner “1” • Timing chain tensioner bolts “2” • The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. • Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. Timing chain tensioner bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) EC2D1003 6. Tighten: • Camshaft sprocket bolts “1” CAUTION: The arrow mark “a” on the timing chain tensioner should face up.
CAMSHAFTS 11. Measure: • Valve clearance Out of specification → Adjust. Refer to "ADJUSTING THE VALVE CLEARANCE" on page 3-4. 12. Install: • Pickup coil rotor cover "CRANKSHAFT POSITION SENSOR" on page 5-37.
CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Engine Refer to "ENGINE REMOVAL" on page 5-1. Refer to "CAMSHAFTS" on page 5-9. Refer to "CAMSHAFTS" on page 5-9. Intake camshaft Exhaust camshaft 1 2 3 4 5 6 7 Remarks Cylinder head Cylinder head gasket Dowel pin Coolant pipe O-ring Thermo wax outlet hose Right front engine mounting bolt 2 1 1 2 1 1 1 1 For assembly, reverse the removal procedure.
CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to "REMOVING THE CAMSHAFTS" on page 5-11. 2. Remove: • Cylinder head nuts • Cylinder head bolts ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place a straightedge “1” and a thickness gauge “2” across the cylinder head. 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. b. Measure the warpage. c.
CYLINDER HEAD 5. Install: • Exhaust camshaft • Intake camshaft Refer to "INSTALLING THE CAMSHAFTS" on page 5-15. • Gasket “1” • Dowel pins 3. Install: • Cylinder head NOTE: Pass the timing chain through the timing chain cavity. 4. Tighten: • Cylinder head nuts “1” – “10” Cylinder head nut (1st) 19 Nm (1.9 m·kg, 14 ft·lb) Cylinder head nut (2nd) 67 Nm (6.7 m·kg, 48 ft·lb) • Cylinder head bolts “11” “12” Cylinder head bolt 12 Nm (1.2 m·kg, 8.
VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Job/Parts to remove Cylinder head Q’ty Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve stem seal Intake valve lower spring seat Intake valve Intake valve guide Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve stem se
VALVES AND VALVE SPRINGS Removing the valves and valve springs Order 16 17 18 Job/Parts to remove Exhaust valve lower spring seat Exhaust valve Exhaust valve guide Q’ty 8 8 8 Remarks For installation, reverse the removal procedure.
VALVES AND VALVE SPRINGS EAS24280 NOTE: REMOVING THE VALVES The following procedure applies to all of the valves and related components. Remove the valve cotters by compressing the valve spring with the valve spring compressor “2” and the valve spring compressor attachment “3”. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal.
VALVES AND VALVE SPRINGS EAS24290 NOTE: CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100°C (212°F) in an oven. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover “1”.
VALVES AND VALVE SPRINGS Intake Valve guide remover (ø4) 90890-04111 YM-04111 Exhaust Valve guide remover (ø4.5) 90890-04116 YM-04116 Intake Valve guide installer (ø4) 90890-04112 YM-04112 Exhaust Valve guide installer (ø4.5) 90890-04117 YM-04117 Intake Valve guide reamer (ø4) 90890-04113 YM-04113 Exhaust Valve guide reamer (ø4.5) 90890-04118 YM-04118 6. Measure: • Valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide.
VALVES AND VALVE SPRINGS NOTE: Valve seat width Intake 0.90–1.10 mm (0.0354–0.0433 in) Exhaust 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.063 in) 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. ECA13790 CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
VALVES AND VALVE SPRINGS h. Install the valve into the cylinder head. i. Press the valve through the valve guide and onto the valve seat to make a clear impression. j. Measure the valve seat width “c” again. If the valve seat width is out of specification, reface and lap the valve seat. 2. Measure: • Compressed valve spring force “a” Out of specification → Replace the valve spring. Compressed valve spring force (installed) Intake valve spring 127.4–144.6 N (12.99–14.74 kg, 28.64–32.51 lb) at 32.65 mm (1.
VALVES AND VALVE SPRINGS 3. • • • • • EAS24320 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters. 1. Check: • Valve lifter Damage/scratches → Replace the valve lifters and cylinder head. Install: Valve “1” Lower spring seat “2” Valve stem seal “3” Valve spring “4” Upper spring seat “5” (into the cylinder head) NOTE: • Make sure each valve is installed in its original place. Refer to the following embossed marks.
VALVES AND VALVE SPRINGS • Each valve lifter and valve pad must be reinstalled in its original position. Valve spring compressor 90890-04019 YM-04019 Intake Valve spring compressor attachment 90890-04114 YM-04114 Exhaust Valve spring compressor attachment 90890-04108 YM-04108 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a softface hammer. ECA13800 CAUTION: Hitting the valve tip with excessive force could damage the valve. 6.
GENERATOR EAS24480 GENERATOR Removing the generator Order Job/Parts to remove Rider and passenger seat Q’ty Fuel tank Engine oil 1 2 3 4 5 6 7 8 9 10 Startor coil assembly lead coupler Plug Generator rotor cover Gasket Dowel pin Generator rotor assembly Startor coil assembly Dowel pin Bearing housing Collar 1 1 1 1 2 1 1 2 1 1 5-30 Remarks Refer to "GENERAL CHASSIS" on page 4-1. Refer to "FUEL TANK" on page 7-1. Drain. Refer to "CHANGING THE ENGINE OIL" on page 3-11. Disconnect.
GENERATOR Removing the generator Order 11 12 13 14 15 16 Job/Parts to remove Bearing Startor coil assembly lead holder Idler gear Idler gear shaft Washer Bearing Q’ty 1 1 1 1 1 1 Remarks For assembly, reverse the removal procedure.
GENERATOR EAS24490 REMOVING THE GENERATOR 1. Remove: • Plug • Generator rotor cover “1” NOTE: • While pushing generator rotor, remove the generator rotor cover. • Loosen each bolt 1/4 of a turn a time, in stages and in a crisscross pattern. • After all of the bolts are fully loosened, remove them. EAS24500 INSTALLING THE GENERATOR 1. Install: • Idle gear shaft • Idle gear “1” • Washer • Idle gear shaft bolt “2” Idle gear shaft bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) 2.
GENERATOR Generator rotor cover bolt (M6) 12 Nm (1.2 m·kg, 8.7 ft·lb) Generator rotor cover bolt (M8) 22 Nm (2.2 m·kg, 16 ft·lb) NOTE: • First tighten the M8 bolts and then tighten the M6 bolts. • Tighten the generator rotor cover bolts in stages and in a crisscross pattern.
STARTER CLUTCH EAS24550 STARTER CLUTCH Removing the starter clutch Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Generator rotor Damper Driven gear Washer Starter clutch drive gear Collar Washer Spacer O-ring Q’ty 1 3 1 1 1 1 1 1 1 Remarks For assembly, reverse the removal procedure.
STARTER CLUTCH EAS24560 REMOVING THE STARTER CLUTCH 1. Remove: • Spacer “1” • O-ring “2” • Washer “3” EAS24570 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch rollers “1” Damage/wear → Replace. 2. • • • 3. • • • Remove: Starter clutch drive gear “1” Collar “2” Washer “3” 2. Check: • Starter clutch idle gear “1” • Starter clutch drive gear “2” Burrs/chips/roughness/wear → Replace the defective part(s). Remove: Driven gear “1” Dampers “2” Generator rotor “3” 3.
STARTER CLUTCH otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch drive gear clockwise “B”, it should turn freely, otherwise the starter clutch is faulty and must be replaced. 3. Install: • Washer “1” • O-ring “2” • Spacer “3” NOTE: Lubricate the engine oil to O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS24600 INSTALLING THE STARTER CLUTCH 1.
CRANKSHAFT POSITION SENSOR EAS24520 CRANKSHAFT POSITION SENSOR Removing the crankshaft position sensor Order Job/Parts to remove Rider and passenger seat Q’ty Fuel tank Engine oil 1 2 3 4 5 6 Crankshaft position sensor lead coupler Crankshaft position sensor O-ring Pickup rotor cover Gasket Cover 1 1 1 1 1 1 Remarks Refer to "GENERAL CHASSIS" on page 4-1. Refer to "FUEL TANK" on page 7-1. Drain. Refer to "CHANGING THE ENGINE OIL" on page 3-11. Disconnect.
CRANKSHAFT POSITION SENSOR EAS24530 REMOVING THE CRANKSHAFT POSITION SENSOR 1. Disconnect: • Crankshaft position sensor lead coupler 2. Remove: • Crankshaft position sensor • O-ring • Pickup coil rotor cover “1” NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Connect • Crankshaft position sensor lead coupler EAS24540 INSTALLING THE CRANKSHAFT POSITION SENSOR 1.
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Rider and passenger seat Q’ty Fuel tank Throttle body assembly 1 2 Starter motor lead Starter motor Remarks Refer to "GENERAL CHASSIS" on page 4-1. Refer to "FUEL TANK" on page 7-1. Refer to "THROTTLE BODIES" on page 7-4. 1 1 For assembly, reverse the removal procedure.
ELECTRIC STARTER Disassembling the starter motor Order 1 2 3 4 5 6 7 8 9 10 Job/Parts to remove Q’ty 1 1 1 1 1 1 2 2 1 1 O-ring Front cover Lock washer Washer Starter motor yoke Armature assembly O-ring Starter motor lead Brush holder Rear cover Remarks For assembly, reverse the disassembly procedure.
ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Commutator diameter “a” Out of specification → Replace the starter motor. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Armature coil Commutator resistance “1” 0.0250–0.0350 Ω at 20°C (68°F) Insulation resistance “2” Above 1 MΩ at 20°C (68°F) Commutator wear limit 27.0 mm (1.06 in) b. If any resistance is out of specification, replace the starter motor. 3.
ELECTRIC STARTER NOTE: Align the match marks “a” on the starter motor yoke with the match marks “b” on the front and starter motor rear covers. 7. Check: • Gear teeth Damage/wear → Replace the gear. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush seat “1” EAS24810 INSTALLING THE STARTER MOTOR 1. Install: • Starter motor “1” • Starter motor bolts “2” NOTE: Align the tab “a” on the brush seat with the tab “b” in the starter motor rear cover. Starter motor bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) 2.
CLUTCH EAS25060 CLUTCH Removing the clutch cover Order 1 2 3 4 5 Job/Parts to remove Engine oil Q’ty Clutch cable Clutch cover Clutch cover gasket Dowel pin Oil filler cap Remarks Drain. Refer to "CHANGING THE ENGINE OIL" on page 3-11. 1 1 1 2 1 For installation, reverse the removal procedure.
CLUTCH Removing the pull lever shaft Order 1 2 3 4 5 6 Job/Parts to remove Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing Q’ty 2 1 1 1 1 2 Remarks For installation, reverse the removal procedure.
CLUTCH Removing the clutch Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Job/Parts to remove Compression spring Pressure plate Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Wire circlip Clutch plate 2 Friction plate 3 Clutch damper spring Clutch damper spring seat Clutch boss nut Washer Clutch boss assembly Thrust plate Clutch housing Bearing Q’ty 6 1 1 1 1 7 7 1 1 1 1 1 1 1 1 1 1 1 5-45 Remarks
CLUTCH Removing the clutch Order Job/Parts to remove Q’ty 5-46 Remarks For assembly, reverse the removal procedure.
CLUTCH 4. Remove: • Clutch plate 1 “1” • Friction plate 2 EAS25080 REMOVING THE CLUTCH 1. Remove: • Clutch cover “1” • Gasket NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 5. Straighten the clutch boss nut rib “1”. 2. • • • • Remove: Compression spring bolts “1” Compression springs Pressure plate “2” Pull rod “3” 6.
CLUTCH 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. • Thrust plate 8. Remove: • Wire circlip “1” NOTE: There is a built-in damper between the clutch boss and the clutch plate. It is not necessary to remove the wire circlip “1” and disassemble the built-in damper unless there is serious clutch chattering. NOTE: Measure the friction plate at four places.
CLUTCH 2. Check: • Bearing Damage/wear → Replace the bearing and clutch housing. EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: • Clutch spring Damage → Replace the clutch springs as a set. 2. Measure: • Clutch spring free length “a” Out of specification → Replace the clutch springs as a set. EAS25160 CHECKING THE CLUTCH BOSS 1. Check: • Clutch boss splines Damage/pitting/wear → Replace the clutch boss.
CLUTCH • Pull lever shaft pinion gear teeth “1” • Pull rod teeth “2” Damage/wear → Replace the pull rod and pull lever shaft pinion gear as a set. 3. Install: • Wire circlip “1” 2. Check: • Pull rod bearing Damage/wear → Replace. 4. Install: • Clutch housing “1” NOTE: EAS25240 Align the projection of clutch housing “a” and hollow of the oil pump drive gear “b”. INSTALLING THE CLUTCH 1. Install: • Clutch damper spring seat “1” • Clutch damper spring “2” 5. • • • 2.
CLUTCH • Lock the threads on the clutch boss nut by staking them with a drift punch at the point aligned with the groove in the axle. • While holding the clutch boss assembly “1” with the clutch holding tool “3”, tighten the clutch boss nut. Universal clutch holder 90890-04056 YM-91042 8. Install: • Friction plate 1 “1” NOTE: Install the last friction plate shifting half phase. 9. • • • • • 6.
CLUTCH 12. Tighten • Clutch cover bolts “1” 10. Install: • Pull lever Clutch cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) NOTE: Install the pull lever with the “O“ mark facing toward lower side. • Clutch cover bolt “2” Clutch cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) LOCTITE® NOTE: Tighten the clutch cover bolts in a stages and in a crisscross pattern. 11. Install: • Clutch cover • Clutch cover gasket NOTE: • Install the pull rod so that the teeth a face towards the rear of the vehicle.
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Parts to remove Clutch assembly Shift arm and shift rod Q’ty Circlip Washer Shift shaft Collar Shift shaft spring Washer Stopper screw Stopper lever Washer Oil seal Bearing Bearing Stopper lever spring 1 1 1 1 1 1 1 1 1 1 1 1 1 5-53 Remarks Refer to "CLUTCH" on page 5-43. Refer to "ENGINE REMOVAL" on page 5-1.
SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty 5-54 Remarks For installation, reverse the removal procedure.
SHIFT SHAFT ET2D1011 REMOVING THE SHIFT SHAFT 1. Remove: • Clutch assembly Refetr to "CLUTCH" on page 5-43 2. Remove: • Shift arm • Shift rod Refetr to "ENGINE REMOVAL" on page 51 3. Remove: • Circlip “1” • Washer “2” (left side of the engine) 4. • • • • EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear → Replace. • Shift shaft spring “2” • Collar “3” Damage/wear → Replace. Remove Shift shaft “1” Shift shaft spring “2” Collar Washer EAS25430 CHECKING THE STOPPER LEVER 1.
SHIFT SHAFT • Stopper lever spring “3” 2. • • • • • Shift rod • Shift arm Refer to "ENGINE REMOVAL" on page 51. 5. Install: • Clutch assembly Refer to "CLUTCH" on page 5-43. Install: Washer Collar Shift shaft spring “1” Shift shaft “2” NOTE: • Mesh the stopper lever with the shift drum segment assembly. • Lubricate the oil seal lips with lithium soap base grease. • Install the end of the shift shaft spring onto the shift shaft spring stopper. 3. Install: • Washer “1” • Circlip “2” 4.
OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Engine oil Q’ty Remarks 1 Drain. Refer to "CHANGING THE ENGINE OIL" on page 3-11. Refer to "ENGINE REMOVAL" on page 5-1. Refer to "ENGINE REMOVAL" on page 5-1. Refer to "ENGINE REMOVAL" on page 5-1. Refer to "ENGINE REMOVAL" on page 5-1. Refer to "CLUTCH" on page 5-43. Refer to "OIL COOLER" on page 64. Refer to "OIL COOLER" on page 64. Disconnect.
OIL PUMP Removing the oil pan and oil pump Order 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Job/Parts to remove Oil level switch Oil level switch lead holder Oil pan Oil pan gasket Dowel pin Drain pipe Oil strainer Oil pipe Oil delivery pipe Relief valve assembly Oil/water pump assembly drive chain guide Collar Oil/water pump assembly drive sprocket Washer Oil/water pump assembly drive chain Dowel pin 5-58 Q’ty 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 Remarks
OIL PUMP Removing the oil pan and oil pump Order 18 Job/Parts to remove Oil/water pump assembly Q’ty 1 Remarks For assembly, reverse the removal procedure.
OIL PUMP Disassembling the oil pump Order 1 2 3 4 5 6 7 8 Job/Parts to remove Oil/water pump driven sprocket Collar Oil pump housing Bearing Pin Oil pump outer roter Oil pump inner roter Pin Q’ty 1 1 1 1 2 1 1 1 Remarks For assembly, reverse the disassembly procedure.
OIL PUMP EAS24930 EAS24960 REMOVING THE OIL PAN 1. Remove: • Oil level switch “1” • Oil pan “2” • Oil pan gasket • Dowel pins CHECKING THE OIL PUMP 1. Check: • Oil pump driven gear “1” • Oil pump rotor housing “2” • Oil pump cover Cracks/damage/wear → Replace the defective part(s). NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.
OIL PUMP EAS24970 CHECKING THE RELIEF VALVE 1. Check: • Relief valve body “1” • Relief valve “2” • Spring “3” • O-ring “4” Damage/wear → Replace the defective part(s). EAS25600 CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles. 1. Check: • Oil nozzle “1” Damage/wear → Replace the oil nozzles. • O-ring “2” Damage/wear → Replace. • Oil nozzle passage Obstruction → Blow out with compressed air. EAS24980 CHECKING THE OIL DELIVERY PIPES 1.
OIL PUMP NOTE: When installing the inner rotor, align the pin “1” in the oil pump shaft with the groove in the inner rotor “2”. 2. • • • • 3. Install: • Oil/water pump driven sprocket “1” Install: Washer Oil/water pump assembly drive chain “1” Oil/water pump assembly drive sprocket “2” Collar NOTE: Install the oil/water pump assembly drive chain “1” onto the oil/water pump assembly drive sprocket “2”. Oil/water pump driven sprocket bolt 10 Nm (1.0 m·kg, 7.
OIL PUMP EAS25050 INSTALLING THE OIL PAN 1. Install: • Dowel pins 4. Install: • Oil delivery pipe “1” Oil delivery pipe bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) LOCTITE® • Gasket • Oil pan “1” Oil pan bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) • Oil level switch “2” Oil level switch bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) • Engine oil drain bolt “3” Engine oil drain bolt 43 Nm (4.3 m·kg, 31 ft·lb) 5. Install: • Relief valve “1” EWA12820 WARNING • O-ring • Oil strainer “2” Always use new copper washers.
CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Air filter case Q’ty Throttle body assembly Engine Cylinder head Generator Starter clutch Shift shaft Crankshaft position sensor Clutch 5-65 Remarks Refer to "GENERAL CHASSIS" on page 4-1. Refer to "THROTTLE BODIES" on page 7-4. Refer to "ENGINE REMOVAL" on page 5-1. Refer to "CYLINDER HEAD" on page 5-18. Refer to "GENERATOR" on page 530. Refer to "STARTER CLUTCH" on page 5-34. Refer to "SHIFT SHAFT" on page 553.
CRANKCASE Separating the crankcase Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Oil pump Starter motor Q’ty Timing chain Timing chain guide (intake side) Pin Timing chain guide (exhaust side) Left side cover O-ring Lower crankcase Dowel pin Damper Remarks Refer to "OIL PUMP" on page 5-57. Refer to "ELECTRIC STARTER" on page 5-39. 1 1 2 1 1 1 1 3 1 For assembly, reverse the removal procedure.
CRANKCASE EAS25550 NOTE: DISASSEMBLING THE CRANKCASE 1. Place the engine upside down. 2. Remove: • Crankcase bolts Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place. NOTE: EAS25580 • Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration).
CRANKCASE Crankcase bolt Bolt “1”–“10” 1st: 20 Nm (2.0 m·kg, 14 ft·lb) 2nd*: 20 Nm (2.0 m·kg, 14 ft·lb) 3rd: +60° Bolt “11”–“16” 24 Nm (2.4 m·kg, 17 ft·lb) Bolt “17”–“26” 12 Nm (1.2 m·kg, 8.7 ft·lb) *Following the tightening order, loosen the bolt one by one and then retighten it to the specific torque. 3. Install: • Dowel pin 4. Set the shift drum assembly and transmission gears in the neutral position. 5.
CRANKSHAFT EAS25950 CRANKSHAFT Removing the connecting rods and pistons Order 1 2 3 4 5 6 7 8 9 10 11 12 Job/Parts to remove Lower crankcase Q’ty Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring Oil ring Cylinder Cylinder gasket Remarks Refer to "CRANKCASE" on page 565. 4 4 4 8 4 4 4 4 4 4 1 1 For installation, reverse the removal procedure.
CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Crankcase Q’ty Separate. Refer to "CRANKCASE" on page 565. Refer to "REMOVING THE CONNECTING RODS AND PISTONS" on page 5-71. Connecting rod and connecting rod caps 1 2 3 4 5 6 7 Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Washer Crankshaft drive gear Pin Pickup rotor Remarks 1 5 5 1 1 1 1 For assembly, reverse the disassembly procedure.
CRANKSHAFT EAS26030 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: • Connecting rod cap “1” • Big end bearings Piston pin puller set 90890-01304 Piston pin puller YU-01304 NOTE: • Idetify the position of each big end bearing so that it can be reinstalled in its original place.
CRANKSHAFT 4 mm (0.16 in) “a” from the bottom edge of the piston NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. Piston size “P” 76.975 - 76.990 mm (3.0305 - 3.0311 in) EAS24390 CHECKING THE CYLINDER AND PISTON 1. Check: • Piston wall • Cylinder wall Vertical scratches → Replace the cylinder, and the piston and piston rings as a set. 2. Measure: • Piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
CRANKSHAFT Piston ring side clearance Top ring 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring 0.020–0.055 mm (0.0008–0.0022 in) Limit 0.115 mm (0.0045 in) Piston ring end gap Top ring 0.15–0.25 mm (0.0059–0.0098 in) Limit 0.50 mm (0.0197 in) 2nd ring 0.30–0.45 mm (0.0118–0.0177 in) Limit 0.80 mm (0.0315 in) Oil ring 0.10–0.40 mm (0.0039–0.0157 in) EAS24440 CHECKING THE PISTON PINS The following procedure applies to all of the piston pins. 1.
CRANKSHAFT end bearings must be installed in their original positions. Piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in) Limit 17.043 mm (0.6710 in) a. Clean the big end bearings, crankshaft pins, and the inside of the connecting rods halves. b. Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap. NOTE: Align the projections “a” on the big end bearings with the notches “b” in the connecting rod and connecting rod cap. 4.
CRANKSHAFT j. Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condition. k. Tighten the connecting rod bolts. e. Tighten the connecting rod bolts. Connecting rod bolt 20 Nm (2.0 m·kg, 14 ft·lb) +150° NOTE: Install by carrying out the following procedures in order to assemble in the most suitable condition.
CRANKSHAFT p. After the installation, check that the section shown “a” is flush with each other by touching the surface. • Side machined face “a” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Select: • Big end bearings (P1 – P4) NOTE: EWA13120 • The numbers “A” stamped into the crankshaft wed and the numbers “1” on the connecting rods are used to determine the replacement big end bearings sizes. • “P1” - ”P4” refer to the bearings shown in the crankshaft illustration.
CRANKSHAFT (with the recommended lubricant) EAS26190 INSTALLING THE CONNECTING ROD AND PISTON The following procedure applies to all of the connecting rods and pistons. 1. Install: • Top ring “1” • 2nd ring “2” • Upper oil ring rail “3” • Oil ring expander “4” • Lower oil ring rail “5” Recommended lubricant Engine oil 4. Offset: • Piston ring end gaps NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers “a” face up. a. b. c. d. e. 5. • • • 2.
CRANKSHAFT NOTE: • Install by carrying out the following procedures in order to assemble in the most suitable condition. • First tighten the bolts to 15 Nm (1.5 m·kg, 11 ft·lb) • Retighten the bolts to 29.4 Nm (3.0 m·kg, 21 ft·lb) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Replace the connecting rod bolts with new ones. b. Clean the connecting rod bolts. c. After installing the big end bearing, assemble the connecting rod and connecting rod cap once using a single unit of the connecting rod. d.
CRANKSHAFT ECA14980 CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. a. Clean the connecting rod bolts. b. Tighten the connecting rod bolts. c. Put a mark “1” on the connecting rod bolt “2” and the connecting rod cap “3”. 11. Install: • Cylinder assembly “1” • Connecting rod caps “2” NOTE: • Make sure that the “Y” marks “a” on the connecting rods face towards the left side of the crankshaft.
CRANKSHAFT • If they are not flush with each other, remove the connecting rod bolt and big end bearing and restart from step “9”. In this case, make sure to replace the connecting rod bolt. ECA14680 CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle. • Tighten the bolt until it is at the specified angles. ET2D1020 CHECKING THE CRANKSHAFT JOURNAL BEARINGS 1.
CRANKSHAFT Crankcase bolt Bolt “1”–“10” 1st: 20 Nm (2.0 m·kg, 14 ft·lb) 2nd: 20 Nm (2.0 m·kg, 14 ft·lb) 3rd: +60° Bolt “11”–“16” 24 Nm (2.4m·kg, 17 ft·lb) Bolt “17”–“26” 12 Nm (1.2m·kg, 8.7 ft·lb) M9 x 105 mm (4.1 in) bolts: “1”–“10” M8 x 60 mm (2.4 in) bolt: “11” LOCTITE® M8 x 60 mm (2.4 in) bolts: “12”, “16” M6 x 70 mm (2.8 in) bolts: “19”, “21”, “23” M6 x 65 mm (2.5 in) bolts: “17”, “18” M6 x 60 mm (2.4 in) bolt and washer: “22” M6 x 60 mm (2.4 in) bolts: “24”, “25” M6 x 50 mm (2.
CRANKSHAFT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Select: • Crankshaft journal bearings (J1–J5) NOTE: • The numbers “A” stamped into the crankshaft web and the numbers “1” stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. • “J1–J5” refer to the bearings shown in the crankshaft illustration. • If “J1–J5” are the same, use the same size for all of the bearings. • If the size is the same for all “J1 to J5” one digit for that size is indicated.
CRANKSHAFT NOTE: • Align the projections “a” on the crankshaft journal upper bearings with the notches “b” in the upper crankcase. • Be sure to install each crankshaft journal upper bearing in its original place. 3. • 4. • 5. • • • Install: Crankshaft Install: Crankcase (lower) Refer to "CRANKCASE" on page 5-65. Install: Pin Pickup rotor “1” Drive sprocket “2” Drive sprocket bolt 60 Nm (6.
TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Parts to remove Crankcase lower Q’ty Drive axle assembly Circlip Oil seal Bearing Washer Shift fork guide bar retainer Spring Shift fork guide bar Shift fork “L” Shift fork “R” Shift drum assembly Shift fork “C” Main axle retainer 1 1 1 1 1 2 2 2 1 1 1 1 1 5-84 Remarks Separate. Refer to "CRANKCASE" on page 565.
TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order 14 15 16 17 Job/Parts to remove Main axle assembly Oil pipe O-rng Oil baffle plate Q’ty 1 1 2 1 Remarks For installation, reverse the removal procedure.
TRANSMISSION Disassembling the main axle assenbly Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Job/Parts to remove 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Main axle Bearing housing Bearing Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Remarks For assembly, reverse the disassembly procedure.
TRANSMISSION Disassembling the drive axle assenbly Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Job/Parts to remove Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer Collar 2nd wheel gear Collar Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5-87 Remarks
TRANSMISSION Disassembling the drive axle assenbly Order 21 22 23 Job/Parts to remove Oil seal Bearing Drive axle Q’ty 1 1 1 Remarks For assembly, reverse the disassembly procedure.
TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Drive axle asseembly “1” • Shift drum retainers “2” • Shift fork guide bars • Shift fork “L” and “R” • Shift drum assembly • Shift fork “C” 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. Remove: • Bearing housing “1” • Main axle assembly “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
TRANSMISSION Out of specification → Replace the main axle. Main axle runout limit 0.08 mm (0.0032 in) 3. Check: • Shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift forks and shift fork guide bar as a set. 2. Measure: • Drive axle runout (with a centering device and dial gauge “1”) Out of specification → Replace the drive axle. Drive axle runout limit 0.08 mm (0.0032 in) EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1.
TRANSMISSION EAS26350 INSTALLING THE TRANSMISSION 1. Install: • Bearing “1” NOTE: Make the seal side of bearing face to the outside and install it close to the right end face of the crankcase. • Oil pipe “2” 3. • • • • Install: Shift fork “L” “1” and “R” “2” Drive axle assembly “3” Shift fork guide bar Shift fork guide bar retainer “4” Shift fork guide bar retainer bolt 10 Nm (1.0 m·kg, 7.
TRANSMISSION 4. Check: • Transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly.
RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Rider and passenger seat Q’ty Fuel tank Air filter case Coolant 1 2 3 4 5 6 7 8 9 Radiator side covers Coolant reservoir hose Radiator front cover Radiator Radiator fan motor Radiator inlet hose Oil cooler outlet hose Water pump breather hose Radiator outlet hose 2 1 1 1 2 1 1 1 1 6-1 Remarks Refer to "GENERAL CHASSIS" on page 4-1. Refer to "FUEL TANK" on page 7-1. Refer to "GENERAL CHASSIS" on page 4-1. Drain.
RADIATOR Removing the radiator Order 10 11 Job/Parts to remove Water pump inlet pipe O-ring Q’ty 1 1 Remarks For installation, reverse the removal procedure.
RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • Radiator fan Damage → Replace. Malfunction → Check and repair. Refer to "RADIATOR" on page 6-1. EAS26400 INSTALLING THE RADIATOR 1.
OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order 1 2 3 4 5 6 7 8 9 10 11 12 Job/Parts to remove Engine oil Q’ty Remarks Drain. Refer to "CHANGING THE ENGINE OIL" on page 3-11. Oil cooler inlet hose Oil cooler bolt Washer Oil cooler O-ring Water pump outlet pipe O-ring Water jacket joint inlet hose O-ring Water jacket joint Stay O-ring 1 1 1 1 1 1 1 1 1 1 1 1 For assembly, reverse the removal procedure.
OIL COOLER 3. Fill: • Cooling system (with the specified amount of the recommended coolant) Refer to "CHANGING THE COOLANT" on page 3-18. • Crankcase (with the specified amount of the recommended engine oil) Refer to "CHANGING THE ENGINE OIL" on page 3-11. 4. Check: • Cooling system Leaks → Repair or replace any faulty part. 5. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to "CHECKING THE RADIATOR" on page 6-3. EAS26420 CHECKING THE OIL COOLER 1.
THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly Order Job/Parts to remove Rider and passenger seat Q’ty Fuel tank Air filter case Coolant 1 2 3 4 Thermostat assembly outlet hose Thermostat assembly Thermostat assembly inlet hose Band Remarks Refer to "GENERAL CHASSIS" on page 4-1. Refer to "FUEL TANK" on page 7-1. Refer to "GENERAL CHASSIS" on page 4-1. Drain. Refer to "CHANGING THE COOLANT" on page 3-18. 1 1 1 2 For installation, reverse the removal procedure.
THERMOSTAT Disassembling the thermostat assembly Order 1 2 3 4 Job/Parts to remove Thermostat housing cover Thermostat Thermostat housing O-ring Q’ty 1 1 1 1 Remarks For assembly, reverse the disassembly procedure.
THERMOSTAT • Thermostat housing “2” Cracks/damage → Replace. EAS26450 CHECKING THE THERMOSTAT 1. Check: • Thermostat Does not open at 71 – 85°C (160 – 185°F) → Replace. EAS26460 ASSEMBLING THE THERMOSTAT ASSEMBLY 1. Install: • Thermostat housing “1” • Thermostat “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “3” in a container “4” filled with water. b. Slowly heat the water “2”. c. Place a thermometer “1” in the water. d.
THERMOSTAT Below the specified pressure → Replace the radiator cap. Refer to "CHECKING THE RADIATOR" on page 6-3.
WATER PUMP EAS26500 WATER PUMP Removing the impeller shaft Order 1 2 3 4 5 6 7 8 Job/Parts to remove Oil/water pump assembly Oil pump roter Water pump cover O-ring Pin Impeller shaft (along with the impeller) Water pump seal Oil seal Bearing O-ring Q’ty Remarks Refer to "OIL PUMP" on page 5-57. Refer to "OIL PUMP" on page 5-57. 1 1 2 1 1 1 1 1 For installation, reverse the removal procedure.
WATER PUMP EAS26520 DISASSEMBLING THE WATER PUMP 1. Remove: • Water pump seal “1” • Water pump housing “2” NOTE: Tap out the water pump seal from the inside of the water pump housing. EAS26540 2. • • • CHECKING THE WATER PUMP 1. Check: • Water pump housing cover “1” • Water pump housing “2” • Impeller “3” • Rubber damper “4” • Rubber damper holder “5” • Water pump seals • Oil seal Cracks/damage/wear → Replace.
WATER PUMP NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. 2. Install: • Water pump seal “1” ECA14080 CAUTION: Never lubricate the water pump seal surface with oil or grease. 4. Measure: • Impeller shaft tilt Out of specification → Repeat steps (3) and (4). NOTE: • Install the water pump seal with the special tools. • Before installing the water pump seal, apply Yamaha bond No.1215 (Three Bond No.1215® ) “2” to the water pump housing “3”.
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order 1 2 3 4 5 6 7 8 Job/Parts to remove Rider and passenger seat Q’ty Fuel hose Fuel sender coupler Fuel pump coupler Fuel tank drain hose Fuel tank breather hose Fuel tank Fuel tank cover Fuel pump 1 1 1 1 1 1 1 1 Remarks Refer to "GENERAL CHASSIS" on page 4-1. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. For installation, reverse the removal procedure.
FUEL TANK EAS26630 ECA14720 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose connector cover • Fuel hose • Fuel sender coupler • Fuel pump coupler • Fuel tank breather hose • Fuel tank drain hose CAUTION: • Do not drop the fuel pump or give it a strong shock. • Do not touch the base section of the fuel sender. EAS26670 CHECKING THE FUEL PUMP BODY 1. Check: • Fuel pump body Obstruction → Clean.
FUEL TANK ET2D1023 INSTALLING THE FUEL TANK 1. Install: • Fuel hose • Fuel hose connector cover ECA14740 CAUTION: When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct position, otherwise the fuel hose will not be properly installed. NOTE: Install the fuel hose connector securely onto the fuel tank until a distinct “click” is heard, and then make sure that it does not come loose.
THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Rider and passenger seat Q’ty Fuel tank Air filter case 1 2 3 4 5 6 7 8 9 10 Sub-wire harness coupler Coolant temperature sensor coupler Thermo wax inret hose Thermo wax outlet hose Idle adjust screw wire Throttle body joint clamp Throttle bodies Throttle cables Throttle body joint Fuel hose 7-4 2 1 1 1 1 4 1 2 4 1 Remarks Refer to "GENERAL CHASSIS" on page 4-1. Refer to "FUEL TANK" on page 7-1.
THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty 7-5 Remarks For installation, reverse the removal procedure.
THROTTLE BODIES Removing the injectors Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Job/Parts to remove Throttle position sensor coupler Sub-throttle position sensor coupler Sub-throttle motor assembly coupler Intake air pressure sensor coupler Cylinder #1-injector coupler Cylinder #2-injector coupler Cylinder #3-injector coupler Cylinder #4-injector coupler Sub-wire harness Negative pressure hose Intake air pressure sensor Fuel distributor Injector Spring Thermo wax assembly Idle adjust screw wire
THROTTLE BODIES Removing the injectors Order 19 20 21 22 23 Job/Parts to remove Washer Link Sub-throttle servo motor assembly Throttle position sensor Throttle body assembly Q’ty 2 1 1 1 1 Remarks For installation, reverse the removal procedure.
THROTTLE BODIES EAS26980 CHECKING THE INJECTORS 1. Check: • Injectors Damage → Replace. c. Connect the pressure gauge “2” and adapter “3” to the fuel hose (fuel tank to primary injector fuel rail). EAS26990 CHECKING THE THROTTLE BODIES 1. Check: • Throttle bodies Cracks/damage → Replace the throttle bodies as a set. 2. Check: • Fuel passages Obstructions → Clean.
THROTTLE BODIES 1. Check: • Throttle position sensor Refer to "CHECKING THE THROTTLE POSITION SENSOR" on page 8-97. 2. Adjust: • Throttle position sensor angle ET2D1024 ADJUSTING THE SUB-THROTTLE POSITION SENSOR 1. Check: • Sub-throttle position sensor Refer to "CHECKING THE SUB-THROTTLE POSITION SENSOR" on page 8-97. 2. Adjust: • Sub-throttle position sensor full open angle ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the throttle position sensor coupler to the wire harness. b.
THROTTLE BODIES 4. Adjust: • Sub-throttle position sensor voltage ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the sub-throttle position sensor coupler to the wire harness. b. Connect the digital circuit tester to the subthrottle position sensor. • Positive tester probe Green/Yellow terminal “1” • Negative tester probe Black/Blue terminal “2” Digital circuit tester 90890-03174 A. Front side B. Rear side c. Move the sub-throttle position sensor to adjust to be in the specified range.
THROTTLE BODIES Out of specification → Replace. a. Before adjusting the distance, push the rod “b” in order to be fitted in several times by hand. b. Measure the outside air temperature, and adjust the distance “a” by turning the adjusting screw “2”. Refer to the thermo wax tolerance table based on the measured outside air temperature for correct adjustment. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check whether or not the sub-throttle valve is seized.
THROTTLE BODIES it shorter when the coolant temperature is high.) • In case of turning the adjusting bolt two-third turn, the temperature varies about 10°C (50°F).
AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses Order 1 2 3 4 5 6 7 8 Job/Parts to remove Air cut-off valve coupler Air cut-off valve hose 1 Air cut-off valve hose 2 Air cut-off valve hose 3 Air cut-off valve Reed valve cap Reed valve assembly Plate Q’ty 1 1 1 1 1 2 2 4 Remarks Disconnect. Disconnect. Disconnect. Disconnect. For assembly, reverse the removal procedure.
AIR INDUCTION SYSTEM EAS27060 CHECKING THE AIR INDUCTION SYSTEM Air injection The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approximately 600 to 700°C.
AIR INDUCTION SYSTEM Out of specification → Replace the reed valve. Plate Reed valve assembly Reed valve cap 2. Install: Air cut-off valve Air cut-off valve hose 1 Air cut-off valve hose 2 Air cut-off valve hose 3 Air cut-off valve coupler Reed valve bending limit 0.4 mm (0.016 in) 4. Check: • Air cut-off valve Cracks/damage → Replace. 5. Check • Air induction system solenoid ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the air induction system solenoid coupler from the wire harness. b.
B L L R 78 80 L/Y L/B L/B L/Y R B L Gy L Br/G Br/L Br/L Br/L B 79 77 R 76 75 74 81 R/W R/Y Br 2 R B W W W B R/W R Br/L W W W W W W 3 L/B R/Y Y/B B B/Y B/L 73 B/L B/Y Y B/G B 72 Y B/G Y/B C Y/B 82 B Br Y R R B B R L 71 B R 9 Y 8 7 R/W L/W Y L/R B Br B R/B R/B B Br 56 R/W L/W G/Y R G/Y L/W R/W 52 6 B B B B L/R R Br R G/Y L/B L/Y 5 L/W R/W R 53 Br R R R/W Br/W R/Y R/B 70 Y Dg L/R C L/R B/Y Br B/Y B B/R Ch
IGNITION SYSTEM 1. Main switch 5. Fuse (main) 6. Battery 10.Starting circuit cut-off relay 11.Relay unit (diode) 13.Neutral switch 14.Sidestand switch 16.Crankshaft position sensor 20.Lean angle sensor 22.ECU 23.Ignition coil #1 24.Ignition coil #2 25.Ignition coil #3 26.Ignition coil #4 27.Spark plug 54.Engine stop switch 58.Clutch switch 74.
IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 1 Check the fuses. (Main and ignition) Refer to "CHECKING THE FUSES" on page 8-85. NG→ Replace the fuse(s). OK↓ 2 Check the battery. Refer to "CHECKING AND CHARGING THE BATTERY" on page 8-85. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3 Check the spark plugs.
IGNITION SYSTEM 8 Check the engine stop switch. Refer to "CHECKING THE SWITCHES" on page 8-81. NG→ Replace the right handlebar switch. OK↓ 9 Check the neutral switch. Refer to "CHECKING THE SWITCHES" on page 8-81. NG→ Replace the neutral switch. OK↓ 10 Check the sidestand switch. Refer to "CHECKING THE SWITCHES" on page 8-81. NG→ Replace the sidestand switch. OK↓ 11 Check the clutch switch. Refer to "CHECKING THE SWITCHES" on page 8-81. NG→ Replace the clutch switch.
B L L R 78 80 L/Y L/B L/B L/Y R B L Gy L Br/G Br/L Br/L Br/L B 79 77 R 76 75 74 81 R/W R/Y Br 2 R B W W W B R/W R Br/L W W W W W W 3 L/B R/Y Y/B B B/Y B/L 73 B/L B/Y Y B/G B 72 Y B/G Y/B C Y/B 82 B Br Y R R B B R L 71 B R 9 Y 8 7 R/W L/W Y L/R B Br B R/B R/B B Br 56 R/W L/W G/Y R G/Y L/W R/W 52 6 B B B B L/R R Br R G/Y L/B L/Y 5 L/W R/W R 53 Br R R Br/W R/Y R/B R/W 70 Y Dg L/R C L/R B/Y Br B/Y B B/R Ch
ELECTRIC STARTING SYSTEM 1. Main switch 5. Fuse (main) 6. Battery 8. Starter relay 9. Starter motor 10.Starting circuit cut-off relay 11.Relay unit (diode) 13.Neutral switch 14.Sidestand switch 54.Engine stop switch 55.Start switch 58.Clutch switch 74.
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral switch is closed). • The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
ELECTRIC STARTING SYSTEM 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. Starting circuit cut-off relay 7. Diode 8. Clutch switch 9. Sidestand switch 10.Neutral switch 11.Start switch 12.Starter relay 13.
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the fuses. (Main and ignition) Refer to "CHECKING THE FUSES" on page 8-85. NG→ Replace the fuse(s). OK↓ 2 Check the battery. Refer to "CHECKING AND CHARGING THE BATTERY" on page 8-85. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3 Check the starter motor operation.
ELECTRIC STARTING SYSTEM 8 Check the main switch. Refer to "CHECKING THE SWITCHES" on page 8-81. NG→ Replace the main switch. OK↓ 9 Check the engine stop switch. Refer to "CHECKING THE SWITCHES" on page 8-81. NG→ Replace the right handlebar switch. OK↓ 10 Check the neutral switch. Refer to "CHECKING THE SWITCHES" on page 8-81. NG→ Replace the neutral switch. OK↓ 11 Check the sidestand switch. Refer to "CHECKING THE SWITCHES" on page 8-81. NG→ Replace the sidestand switch.
1 OFF R Br/L L/Y L/B R Br/L L/B L/Y Br/L B R W W W 74 2 R B ON R/W W W W W W W 3 R/G R L/B Br/L L/Y R 82 R R 5 R 6 R B B 4 R R 8-11 9 8 7 R/W L/W B B R L/W R/W R CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM R B
CHARGING SYSTEM 2. 3. 5. 6. Rectifier/regulator A.C.
CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 1 Check the fuse. (Main) Refer to "CHECKING THE FUSES" on page 8-85. NG→ Replace the fuse. OK↓ 2 Check the battery. Refer to "CHECKING AND CHARGING THE BATTERY" on page 8-85. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3 Check the startor coil. Refer to "CHECKING THE STATOR COIL" on page 8-93.
B L L R 78 80 L/Y L/B L/B L/Y R B L Gy L Br/G Br/L Br/L Br/L B 79 77 R 76 75 74 81 R/W R/Y Br 2 R B W W W B R/W R Br/L W W W W W W 3 L/B R/Y Y/B B B/Y B/L 73 B/L B/Y Y B/G B 72 Y B/G Y/B C Y/B 82 B Br Y R R B B R L 71 B R 9 Y 8 7 R/W L/W Y L/R B Br B R/B R/B B Br 56 R/W L/W G/Y R G/Y L/W R/W 52 6 B B B B L/R R Br R G/Y L/B L/Y 5 L/W R/W R 53 Br R R R/W Br/W R/Y R/B 70 Y Dg L/R C L/R B/Y Br B/Y B B/R Ch
LIGHTING SYSTEM 1. Main switch 5. Fuse (main) 6. Battery 22.ECU 47.High beam indicator light 50.Meter light 59.Dimmer switch 69.Headlight 70.License plate light 71.Tail/brake light 72.Headlight relay (on/off) 73.Headlight relay (dimmer) 76.
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the each bulbs and bulb sockets condition. Refer to "CHECKING THE BULBS AND BULB SOCKETS" on page 884. NG→ Replace the bulb(s) and bulb socket(s). OK↓ 2 Check the fuses.
LIGHTING SYSTEM 8 Check the headlight relay (dimmer) Refer to "CHECKING THE RELAYS" on page 8-88. NG→ Replace the headlight relay. OK↓ 9 Check the entire lighting system’s wiring. Refer to "CIRCUIT DIAGRAM" on page 8-15. NG→ Properly connect or repair the lighting system’s wiring. OK↓ This circuit is OK.
B L L R 78 80 L/Y L/B L/B L/Y R B L Gy L Br/G Br/L Br/L Br/L B 79 77 R 76 75 74 81 R/W R/Y Br 2 R B W W W B R/W R Br/L W W W W W W 3 L/B R/Y Y/B B B/Y B/L 73 B/L B/Y Y B/G B 72 Y B/G Y/B C Y/B 82 B Br Y R R B B R L 71 B R 9 Y 8 7 R/W L/W Y L/R B Br B R/B R/B B Br 56 R/W L/W G/Y R G/Y L/W R/W 52 6 B B B B L/R R Br R G/Y L/B L/Y 5 L/W R/W R 53 Br R R R/W Br/W R/Y R/B 70 Y Dg L/R C L/R B/Y Br B/Y B B/R Ch
SIGNALING SYSTEM 1. Main switch 5. Fuse (main) 6. Battery 10.Starting circuit cut-off relay 13.Neutral switch 15.Fuel pump 18.Speed sensor 22.ECU 40.Fuel level warning light 41.Oil level warning light 42.Neutral indicator light 43.Tacho meter 44.Multi function meter 46.Coolant temperature indicator light 48.Turn signal indicator light (left) 49.Turn signal indicator light (right) 51.Oil level switch 53.Front brake light switch 56.Rear brake light switch 60.Hazard switch 61.Turn signal switch 62.
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the fuses. (Main, ignition and signal) Refer to "CHECKING THE FUSES" on page 8-85. NG→ Replace the fuse(s). OK↓ 2 Check the battery. Refer to "CHECKING AND CHARGING THE BATTERY" on page 8-85.
SIGNALING SYSTEM 3 Check the entire signaling system’s wiring. Refer to "CIRCUIT DIAGRAM" on page 8-19. NG→ Properly connect or repair the signaling system wiring. OK↓ This circuit is OK. The tail/brake light fails to come on. 1 Check the tail/brake light bulb and socket. Refer to "CHECKING THE BULBS AND BULB SOCKETS" on page 884. NG→ Replace the tail/brake light bulb, socket or both. OK↓ 2 Check the front brake light switch. Refer to "CHECKING THE SWITCHES" on page 8-81.
SIGNALING SYSTEM 3 Check the turn signal relay. Refer to "CHECKING THE RELAYS" on page 8-88. NG→ Replace the turn signal relay. OK↓ 4 Check the entire signaling system’s wiring. Refer to "CIRCUIT DIAGRAM" on page 8-19. NG→ Properly connect or repair the signaling system’s wiring. OK↓ This circuit is OK. The neutral indicator light fails to come on. 1 Check the neutral switch. Refer to "CHECKING THE SWITCHES" on page 8-81. NG→ Replace the neutral switch.
SIGNALING SYSTEM 2 Check the entire signaling system’s wiring. Refer to "CIRCUIT DIAGRAM" on page 8-19. NG→ Properly connect or repair the signaling system’s wiring. OK↓ This circuit is OK. The speedometer fails to operate. 1 Check the speed sensor. Refer to "CHECKING THE SPEED SENSOR" on page 8-95. NG→ Replace the speed sensor. OK↓ 2 Check the entire signaling system’s wiring. Refer to "CIRCUIT DIAGRAM" on page 8-19. NG→ Properly connect or repair the signaling system’s wiring.
B L L R 78 80 L/Y L/B L/B L/Y R B L Gy L Br/G Br/L Br/L Br/L B 79 77 R 76 75 74 81 R/W R/Y Br 2 R B W W W B R/W R Br/L W W W W W W 3 L/B R/Y Y/B B B/Y B/L 73 B/L B/Y Y B/G B 72 Y B/G Y/B C Y/B 82 B Br Y R R B B R L 71 B R 9 Y 8 7 R/W L/W Y L/R B Br B R/B R/B B Br 56 R/W L/W G/Y R G/Y L/W R/W 52 6 B B B B L/R R Br R G/Y L/B L/Y 5 L/W R/W R 53 Br R R Br/W R/Y R/B R/W 70 Y Dg L/R C L/R B/Y Br B/Y B B/R Ch
COOLING SYSTEM 1. Main switch 5. Fuse (main) 6. Battery 22.ECU 37.Coolant temperature sensor 74.Fuse (ignition) 77.Radiator fan motor relay 78.Fuse (radiator fan motor left) 79.Fuse (radiator fan motor right) 80.Radiator fan motor (left) 81.
COOLING SYSTEM EAS27320 TROUBLESHOOTING NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the fuses. (Main, ignition and radiator fan motor) Refer to "CHECKING THE FUSES" on page 8-85. NG→ Replace the fuse(s). OK↓ 2 Check the battery. Refer to "CHECKING AND CHARGING THE BATTERY" on page 8-85. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3 Check the main switch.
B L L R 78 80 L/Y L/B L/B L/Y R B L Gy L Br/G Br/L Br/L Br/L B 79 77 R 76 75 74 81 R/W R/Y Br 2 R B W W W B R/W R Br/L W W W W W W 3 L/B R/Y Y/B B B/Y B/L 73 B/L B/Y Y B/G B 72 Y B/G Y/B C Y/B 82 B Br Y R R B B R L 71 B R 9 Y 8 7 R/W L/W Y L/R B Br B R/B R/B B Br 56 R/W L/W G/Y R G/Y L/W R/W 52 6 B B B B L/R R Br R G/Y L/B L/Y 5 L/W R/W R 53 Br R R R/W Br/W R/Y R/B 70 Y Dg L/R C L/R B/Y Br B/Y B B/R Ch
FUEL INJECTION SYSTEM 1. Main switch 4. Fuse (backup) 5. Fuse (main) 6. Battery 7. Fuse (fuel injection) 10.Starting circuit cut-off relay 11.Relay unit (diode) 12.Fuel pump relay 13.Neutral switch 14.Sidestand switch 15.Fuel pump 16.Crankshaft position sensor 17.Cylinder identification sensor 18.Speed sensor 19.Atmospheric pressure sensor 20.Lean angle sensor 21.O2 sensor 22.ECU 23.Ignition coil #1 24.Ignition coil #2 25.Ignition coil #3 26.Ignition coil #4 27.Spark plug 28.Injector #1 29.Injector #2 30.
FUEL INJECTION SYSTEM EAS27370 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the fuses. (Main, backup, fuel injection and ignition) Refer to "CHECKING THE FUSES" on page 8-85. NG→ Replace the fuse(s). OK↓ 2 Check the battery. Refer to "CHECKING AND CHARGING THE BATTERY" on page 8-85. NG→ • Clean the battery terminals.
FUEL INJECTION SYSTEM 8 Check the main switch. Refer to "CHECKING THE SWITCHES" on page 8-81. NG→ Replace the main switch. OK↓ 9 Check the engine stop switch. Refer to "CHECKING THE SWITCHES" on page 8-81. NG→ Replace the right handlebar switch. OK↓ 10 Check the neutral switch. Refer to "CHECKING THE SWITCHES" on page 8-81. NG→ Replace the neutral switch. OK↓ 11 Check the sidestand switch. Refer to "CHECKING THE SWITCHES" on page 8-81. NG→ Replace the sidestand switch.
FUEL INJECTION SYSTEM 17 Checking the atmospheric pressure sensor. Refer to "CHECKING THE ATMOSPHERIC PRESSURE SENSOR" on page 8-99. NG→ Replace the atmospheric pressure sensor. OK↓ 18 Check the injector. Refer to "CHECKING THE INJECTORS" on page 7-8. NG→ Replace the injector. OK↓ 19 Check the throttle position sensor. Refer to "CHECKING THE THROTTLE POSITION SENSOR" on page 8-97. NG→ Replace the throttle position sensor. OK↓ 20 Check the sub-throttle position sensor.
FUEL INJECTION SYSTEM 24 Check the entire ignition system’s wiring. Refer to "CIRCUIT DIAGRAM" on page 8-1. NG→ Properly connect or repair the ignition system’s wiring OK↓ Replace the ECU.
FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is stored in the memory of the ECU.
FUEL INJECTION SYSTEM a. b. c. d. Main switch “OFF” Main switch “ON” Engine trouble warning light off Engine trouble warning light on for 1.4 seconds EAS27362 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
FUEL INJECTION SYSTEM Fault code No.
FUEL INJECTION SYSTEM Fault code No. Item Injector (open circuit) Symptom Injector: open circuit detected. 39 41 42 43 44 46 47 48 50 Lean angle sensor Lean angle sensor: (open or short-circuit) open or short circuit detected. Speed sensor No normal signals are received from the speed sensor. Neutral switch Neutral switch: open or short circuit detected. Fuel system voltage Power supply to the injectors and the fuel (monitoring voltage) pump is not normal.
FUEL INJECTION SYSTEM Fault code No. Er-2 Er-3 Er-4 Able/ unable to start Able/ unable to drive No signals are received from the ECU within the specified duration. Unable Unable Data from the ECU cannot be received correctly. Unable Unable Non-registered data has been received from the meter.
FUEL INJECTION SYSTEM If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts. If no malfunction is detected in the sensors and actuators, check and repair inner parts of the engine. EAS27420 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3.
FUEL INJECTION SYSTEM The data representing the operating conditions of the sensor appears on the odometer/tripmeter/fuel reserve tripmeter LCD. • Actuator operation Set the engine stop switch to “ ” to operate the actuator. NOTE: If the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ 9. Turn the main switch to “OFF” to cancel the diagnostic mode. 8-41 ” again.
FUEL INJECTION SYSTEM Fault code table Fault code No. 11 12 13 14 15 16 17 18 19 20 Symptom • No normal signals are received from the cylinder identification sensor when the engine is started or while the vehicle is being driven. No normal signals are received from the crankshaft position sensor. Intake air pressure sensor: open or short circuit detected. Intake air pressure sensor: faulty intake air pressure sensor system. Throttle position sensor: open or short circuit detected.
FUEL INJECTION SYSTEM Fault code No. Symptom 21 Coolant temperature sensor: open or short circuit detected. 22 Intake air temperature sensor: open or short circuit detected. 23 Atmospheric pressure sensor: open or short circuit detected. 24 30 No normal signal is received from the O2 sensor. No normal signal is received from the lean angle sensor. 33 Open circuit detected in the primary lead of the cylinder#1 ignition coil.
FUEL INJECTION SYSTEM Fault code No. 41 42 43 44 46 47 48 50 Er-1 Er-2 Er-3 Er-4 Symptom Probable cause of malfunction Lean angle sensor: open or • Open or short circuit in wire harness. short circuit detected. • Defective lean angle sensor. • Malfunction in ECU. No normal signals are • Open or short circuit in wire harness. recieved from the speed • Malfunction in speed sensor. sensor. • Malfunction in ECU. Neutral switch: • Open or short circuit in wire haraness.
FUEL INJECTION SYSTEM Sensor operation table Diagnostic code No. 01 Item Atmospheric pressure 02 Intake air pressure 03 Intake air temperature 05 Coolant temperature 06 Vehicle speed pulse 07 Lean angle sensor • Upright • Overturned Fuel system voltage (battery voltage) Check with throttle valve fully closed. 95–100 Check with throttle valve fully opened. Displays the atmospheric Compare the actually meapressure. sured atmospheric pressure with the meter display value.
FUEL INJECTION SYSTEM Diagnostic code No. Item EEPROM fault cylinder No • No fault • Fault detected 60 Malfunction history code • No history • History exists 61 Malfunction history code erasure • No history • History exists 62 Malfunction code reinstate • No mulfunction code • Malfunction code exists 63 70 Control number Meter display 00 01–04 (fault cylinder No.) • (If more than one cylinder is defective, the display changes every two seconds to show all the detected cylinder numbers.
FUEL INJECTION SYSTEM Actuator operation table Diagnostic code No. Item Cylinder-#1 ignition coil 30 Cylinder-#2 ignition coil 31 Cylinder-#3 ignition coil 32 Cylinder-#4 ignition coil 33 Injector #1 36 Injector #2 37 Injector #3 38 Injector #4 39 Air induction system solenoid 48 Actuation Checking method Actuates the cylinder-#1 ignition coil five times at one second intervals. Illuminates the engine trouble warning light.
FUEL INJECTION SYSTEM Diagnostic code No. Item Fuel injection system relay 50 Radiator fan motor relay 51 Headlight relay 52 Exup servo motor 53 Sub-throttle servo motor 56 Actuation Checking method Actuates the fuel injection system relay five times at one-second intervals. Illuminates the engine trouble warning light. (The engine trouble warning light is OFF when the relay is ON, and the engine trouble warning light is ON when the relay is OFF).
FUEL INJECTION SYSTEM No normal signals are received from the cylinder identifiFault code No. 11 Symptom cation sensor when the engine is started or while the vehicle is being driven. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Installed condition of cylinder identifi- Check for looseness or pinching. Starting the 1 cation sensor. engine and Connections • Check the coupler for any pins operate it at idle.
FUEL INJECTION SYSTEM No normal signals are received from the crankshaft position sensor. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method 1 Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the tion sensor engine. 2 Connections • Check the couplers for any pins • Crankshaft position sensor coupler that may have pulled out. • Main wire harness ECU coupler • Check the locking condition of the couplers.
FUEL INJECTION SYSTEM Fault code No. 13 Symptom Intake air pressure sensor:open or short circuit detected. Diagnostic code No. 03 Intake air pressure sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turn the main • Intake air pressure sensor coupler that may have pulled out. switch to ON. • Main wire harness ECU coupler • Check the locking condition of 1 • Sub-wire harness coupler the couplers.
FUEL INJECTION SYSTEM Fault code No. 15 Symptom Throttle position sensor:open or short circuit detected. Diagnostic code No. 01 Throttle position sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Installed condition of throttle position • Check for looseness or pinchTurning the sensor. ing. main switch to 1 • Check that is installed in the “ON”. specified position.
FUEL INJECTION SYSTEM Fault code No. 16 Symptom Stuck throttle position sensor detected. Diagnostic code No. 01 Throttle position sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Installed condition of throttle position • Check the installed area for Reinstated by sensor. looseness or pinching. starting the • Check that is installed in the engine, operat1 specified position. ing it at idle, and Refer to "THROTTLE BODIES" then racing it. on page 7-4 section.
FUEL INJECTION SYSTEM Fault code No. 18 Symptom Diagnostic code No. 53 Item/components and probable Order cause Connections • EXUP servo motor coupler • Main wire harness ECU coupler 1 Open or short circuit in wire harness. 2 Defective EXUP servo motor 3 4 Defective EXUP valve, pulley, and cables EXUP servo motor is stuck. EXUP servo motor Reinstatement method • Check the couplers for any pins Turning the that may be pulled out. main switch to • Check the locking condition of “ON”. the coupler.
FUEL INJECTION SYSTEM When the main switch is turned to “ON”, the atmospheric Fault code No. 20 Symptom pressure sensor voltage and intake air pressure sensor voltage differ greatly. 02 Atmospheric pressure sensor Diagnostic code No. 03 Intake air pressure sensor Reinstatement Item/components and probable Check or maintenance job Order method cause Defective intake air pressure sensor or • Execute the diagnostic mode. Turning the atmospheric pressure sensor. (Code Nos.
FUEL INJECTION SYSTEM Intake air temperature sensor:open or short circuit detected. Diagnostic code No. 05 Intake air temperature sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the • Intake air temperature sensor couthat may be pulled out. main switch to pler • Check the locking condition of “ON”. 1 • Main wire harness ECU coupler the couplers.
FUEL INJECTION SYSTEM Atmospheric pressure sensor:open or short circuit detected. Diagnostic code No. 02 Atmospheric pressure sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the • Atmospheric pressure sensor couthat may be pulled out. main switch to pler • Check the locking condition of “ON”. 1 • Main wire harness ECU coupler the couplers.
FUEL INJECTION SYSTEM No normal signal is received from the O2 sensor. Fault code No. 24 Symptom Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Installed state of O sensor. Check for looseness or pinching. Start and warm 1 2 Connections • Check the couplers for any pins up the engine until the cool• O2 sensor coupler that may be pulled out.
FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder#1 ignition coil. Diagnostic code No. 30 Cylinder-#1 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the • Cylinder-#1 ignition coil coupler that may be pulled out. engine and • Main wire harness ECU coupler • Check the locking condition of operating it at 1 • Sub-wire harness 1 coupler the couplers. idle.
FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder#2 ignition coil Diagnostic code No. 31 Cylinder-#2 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the • Cylinder-#2 ignition coil coupler that may be pulled out. engine and • Main wire harness ECU coupler • Check the locking condition of operating it at 1 • Sub-wire harness 1 coupler the couplers. idle.
FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder#3 ignition coil Diagnostic code No. 32 Cylinder-#3 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the • Cylinder-#3 ignition coil coupler that may be pulled out. engine and • Main wire harness ECU coupler • Check the locking condition of operating it at 1 • Sub-wire harness 1 coupler the couplers. idle.
FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder#4 ignition coil Diagnostic code No. 33 Cylinder-#4 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the • Cylinder-#4 ignition coil coupler that may be pulled out. engine and • Main wire harness ECU coupler • Check the locking condition of operating it at 1 • Sub-wire harness 1 coupler the couplers. idle.
FUEL INJECTION SYSTEM Fault code No. 39 Symptom 36 37 Diagnostic code No. 38 39 Item/components and probable Order cause Connections • Injector coupler • Main wire harness ECU coupler 1 • Sub-wire harness coupler • • • Open or short circuit in wire harness and/or sub-wire harness. • • 2 Defective primary injector. 3 • • Open circuit detected in a injector.
FUEL INJECTION SYSTEM Fault code No. 41 Symptom Lean angle sensor:open or short circuit detected. Diagnostic code No. 08 Lean angle sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the • Lean angle sensor coupler that may be pulled out. main switch to • Main wire harness ECU coupler • Check the locking condition of “ON”. 1 the couplers. • If there is a malfunction, repair it and connect the coupler securely.
FUEL INJECTION SYSTEM A. No normal signals are received from the speed senFault code No. 42 Symptom sor. B. Open circuit is detected in the neutral switch. A 07 Speed sensor Diagnostic code No. B 21 Neutral switch Item/components and probable Reinstatement Order Check or maintenance job cause method Installed state of speed sensor. • Check for looseness or pinchStarting the A-1 ing.
FUEL INJECTION SYSTEM A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. A 07 Speed sensor Diagnostic code No. B 21 Neutral switch Reinstatement Item/components and probable Check or maintenance job Order method cause Installed state of neutral switch. • Check for looseness or pinchStarting the B-1 ing. engine, and Connections • Check the couplers for any pins activating the speed sensor • Neutral switch coupler that may be pulled out.
FUEL INJECTION SYSTEM Power supply to the injectors and fuel pump is not normal. Diagnostic code No. 09 Fuel system voltage (battery voltage) Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the • Relay unit coupler (fuel pump relay) that may be pulled out. engine and • Main wire harness ECU coupler • Check the locking condition of operating it at 1 the couplers. idle.
FUEL INJECTION SYSTEM Power supply to the fuel injection system relay is not normal. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Connections. • Check the coupler for any pins Starting the • Main wire harness ECU coupler that may be pulled out. engine and • Check the locking condition of operating it at 1 the coupler. idle. • If there is a malfunction, repair it and connect the coupler securely.
FUEL INJECTION SYSTEM Fault code No. 47 Symptom Sub-throttle position sensor:open or short circuit detected. Diagnostic monitor56 ing code No. Item/components and probable Order cause Installed state of sub-throttle position sensor. 1 2 3 4 Sub-throttle servo motor Check or maintenance job • Check for looseness or pinching. • Check that the sensor is installed in the specified position. Connections • Check the couplers for any pins • Sub-throttle position sensor coupler that may be pulled out.
FUEL INJECTION SYSTEM Fault code No. 48 Symptom Diagnostic code No. 56 Item/components and probable Order cause Connections • Sub-throttle servo motor coupler • Main wire harness ECU coupler 1 • • • Open or short circuit in wire harness. • • 2 Defective sub-throttle servo motor • • 3 Sub-throttle servo motor:stuck. Sub-throttle servo motor Reinstatement Check or maintenance job method Check the couplers for any pins Turning the that may be pulled out.
FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom Diagnostic code No. — Item/components and probable Order cause Connections • Main wire harness ECU coupler • Main wire harness meter assembly 1 coupler • Sub-wire harness coupler Open or short circuit in wire harness. 2 3 4 Malfunction in meter assembly. Malfunction in ECU. No signals are received from the ECU. — Reinstatement Check or maintenance job method • Check the couplers for any pins Turning the that may be pulled out.
FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the • Main wire harness ECU coupler that may be pulled out. main switch to • Main wire harness meter assembly • Check the locking condition of “ON”. 1 coupler the couplers.
B L L R 78 80 L/Y L/B L/B L/Y R B L Gy L Br/G Br/L Br/L Br/L B 79 77 R 76 75 74 81 R/W R/Y Br 2 R B W W W B R/W R Br/L W W W W W W 3 L/B R/Y Y/B B B/Y B/L 73 B/L B/Y Y B/G B 72 Y B/G Y/B C Y/B 82 B Br Y R R B B R L 71 B R 9 Y 8 7 R/W L/W Y L/R B Br B R/B R/B B Br 56 R/W L/W G/Y R G/Y L/W R/W 52 6 B B B B L/R R Br R G/Y L/B L/Y 5 L/W R/W R 53 Br R R R/W Br/W R/Y R/B 70 Y Dg L/R C L/R B/Y Br B/Y B B/R Ch
FUEL PUMP SYSTEM 1. Main switch 5. Fuse (main) 6. Battery 7. Fuse (fuel injection) 12.Relay unit (fuel pump) 15.Fuel pump 22.ECU 44.Multi function meter 54.Engine stop switch 74.
FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the fuses. (Main, ignition and fuel injection system) Refer to "CHECKING THE FUSES" on page 8-85. NG→ Replace the fuse(s). OK↓ 2 Check the battery. Refer to "CHECKING AND CHARGING THE BATTERY" on page 8-85. NG→ • Clean the battery terminals. • Recharge or replace the battery.
ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-77
ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Starter relay 4. Battery 5. Fuse box 6. Rear brake light switch 7. Neutral switch 8. Sidestand switch 9. Oil level switch 10.Radiator fan motor 11.Horn 12.
ELECTRICAL COMPONENTS 8-79
ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Intake air temperature sensor 3. Intake air pressure sensor 4. Fuel pump 5. ECU 6. Lean angle sensor 7. Starting circuit cut-off relay 8. Headlight relay (on/off) 9. Headlight relay (dimmer) 10.Radiator fan motor relay 11.Turn signal relay 12.Recifier/regulator 13.Throttle position sensor 14.
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-81
ELECTRICAL COMPONENTS 1. Main switch 2. Horn switch 3. Dimmer switch 4. Turn signal switch 5. Hazard switch 6. Clutch switch 7. Sidestand switch 8. Fuse box 9. Engine stop switch 10.Front brake light switch 11.Start switch 12.Oil level switch 13.O2 sensor 14.Neutral switch 15.
ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “1”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
ELECTRICAL COMPONENTS hands away from the bulb until it has cooled down. EAS27990 CHECKING THE BULBS AND BULB SOCKETS 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 both. Improperly connected → Properly connect. No continuity → Repair or replace the bulb, bulb socket or both. ECA14380 CAUTION: • Be sure to hold the socket firmly when removing the bulb.
ELECTRICAL COMPONENTS The following procedure applies to all of the bulb sockets. 1. Check: • Bulb socket (for continuity) (with the pocket tester) No continuity → Replace. 3. Replace: • Blown fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage rating. c. Set on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit.
ELECTRICAL COMPONENTS • DO NOT SMOKE when charging or handling batteries. • KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL • Skin — Wash with water. • Eyes — Flush with water for 15 minutes and get immediate medical attention. INTERNAL • Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil.
ELECTRICAL COMPONENTS • • • • • • • c. Make sure that the current is higher than the standard charging current written on the battery. into the battery quickly and can cause battery overheating and battery plate damage. If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. When charging a battery, be sure to remove it from the vehicle.
ELECTRICAL COMPONENTS EAS28040 NOTE: CHECKING THE RELAYS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, replace the relay. If the current is lower than the standard charging current written on the battery, this type of battery charger cannot charge the MF battery. A variable voltage charger is recommended. Pocket tester 90890-03112 Analog pocket tester YU-03112-C d. Charge the battery until the battery’s charging voltage is 15 V.
ELECTRICAL COMPONENTS 3. Positive tester probe 4. Negative tester probe Result Continuity/No continuity (between “3” to “4”) (between “3” to “5”) Radiator fan motor relay 1. 2. 3. 4. Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe Result Continuity/No continuity (between “3” to “4”) Headlight relay (on/off) 1. 2. 3. 4.
ELECTRICAL COMPONENTS EAS28050 • Positive tester probe → Brown “1” • Negative tester probe → Ground CHECKING THE RELAY UNIT (DIODE) 1. Check: • Relay unit (diode) Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C NOTE: The pocket tester and the analog pocket tester readings are shown in the following table. b. Turn the main switch to “ON”. c. Measure the turn signal/hazard relay input voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2.
ELECTRICAL COMPONENTS a. Disconnect the relay unit coupler from the wire harness. b. Connect the pocket tester (Ω×1) to the relay unit terminal as shown. c. Check the relay unit (diode) for continuity. d. Check the relay unit (diode) for no continuity.
ELECTRICAL COMPONENTS Secondary coil resistance 8.5–11.5 kΩ at 20°C (68°F) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the ignition coil leads from the wire harness. b. Connect the pocket tester (Ω × 1k) to the ignition coil as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1. Spark plug cap c. Set the main switch to “ON”. d. Measure the ignition spark gap “a”. e. Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs.
ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ET2D1034 CHECKING THE STARTOR MOTOR OPERATION 1. Check: • Starter motor operation Does not operate → Perform the electric starting system troubleshooting, starting with step5. Refer to "TROUBLESHOOTING" on page 8-9. b. Measure the crankshaft position sensor resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28130 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ CHECKING THE LEAN ANGLE SENSOR 1. Remove: • Lean angle sensor 2.
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Pocket tester 90890-03112 Analog pocket tester YU-03112-C a. Connect the pocket tester (Ω × 1) to the stator coil coupler as shown.
ELECTRICAL COMPONENTS a. Connect the pocket tester (Ω × 10) to the fuel sender terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe Green/white “1” • Negative tester probe Black “2” c. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • Horn sound Faulty sound → Adjust or replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a battery (12 V) to the horn. b.
ELECTRICAL COMPONENTS b. Set the main switch to “ON”. c. Elevate the rear wheel and slowly rotate it. d. Measure the voltage (DC 5 V) of White/Yellow and Blue. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V. Coolant temperature sensor resistance 0°C (32°F) : 5.21–6.37 kΩ 80°C (176°F) : 0.29–0.35 kΩ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1k) to the coolant temperature sensor “1” as shown.
ELECTRICAL COMPONENTS d. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range. The resistance does not change or it changes abruptly → Replace the throttle position sensor. d. Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table. e. Check the coolant temperature sensor for continuity at the temperatures indicated in the table.
ELECTRICAL COMPONENTS • Tester positive lead → Blue “1” • Tester negative lead → Black/Blue “2” e. Check the throttle position sensor maximum resistance. Out of specification → Replace the throttle position sensor. Maximum sub-throttle position sensor resistance 4–6 kΩ at 20°C (68°F) f. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Sub-throttle position sensor Connect the pocket tester (Ω × 1k) to the throttle position sensor as shown.
ELECTRICAL COMPONENTS EAS28390 CHECKING THE CYLINDER IDENTIFICATION SENSOR 1. Check: • Cylinder identification sensor output voltage Out of specification → Replace. Cylinder identification sensor output voltage When sensor is on 4.8 V or more When sensor is off 0.8 V or less c. Measure the Air induction system solenoid resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28380 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ CHECKING THE ATMOSPHERIC PRESSURE SENSOR 1.
ELECTRICAL COMPONENTS a. Connect the pocket tester (Ω × 100) to the intake air temperature sensor terminal as shown. Intake air pressure sensor output voltage 3.75–4.25 V Pocket tester 90890-03112 Analog pocket tester YU-03112-C ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the intake air pressure sensor coupler (wire harness side) as shown.
TROUBLESHOOTING • Sucked-in air EAS28450 TROUBLESHOOTING Electrical system 1. Battery • Discharged battery • Faulty battery 2. Fuse(s) • Blown, damaged or incorrect fuse • Improperly installed fuse 3. Spark plug(s) • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or damaged insulator 4. Ignition coil(s) • Cracked or broken ignition coil body • Broken or shorted primary or secondary coils 5.
TROUBLESHOOTING • Improperly assembled transmission • Improper throttle cable free play • Flooded throttle body • Faulty air induction system EAS28550 JUMPS OUT OF GEAR Electrical system 1. Battery • Discharged battery • Faulty battery 2. Spark plug(s) • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or damaged insulator 3. Ignition coil(s) • Broken or shorted primary or secondary coils • Cracked or broken ignition coil 4.
TROUBLESHOOTING 2. • • • Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality • • • • • • Cooling system 1. Coolant • Low coolant level 2. Radiator • Damaged or leaking radiator • Faulty radiator cap • Bent or damaged radiator fin 3.
TROUBLESHOOTING • • • 7. • • • • • 8.
FZS10V/FZS10VC WIRING DIAGRAM
FZS10V/FZS10VC WIRING DIAGRAM D C HEADLIGHT WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS B HEADLIGHT SUB-WIRE HARNESS 1 A WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 1 4 5 23 27 1 24 ON OFF 2 3 6 27 7 25 8 82 27 10 9 26 11 16 12 27 17 28 18 74 19 15 14 29 13 20 30 52 31 53 22 54 55 OFF FREE RUN PUSH 21 32 39 75 40 38 41 76 42 57 37 43 56 59 B B 60 61 62 HI ON R OFF LO OFF N ON L 33 36 44 B 58 45 77 63 46 72 34 64 51 47 35 48
EAS28740 WIRING DIAGRAM 1. Main switch 2. Rectifier/regulator 3. A.C.magneto 4. Fuse (backup) 5. Fuse (main) 6. Battery 7. Fuse (fuel injection) 8. Starter relay 9. Starter motor 10. Starting circuit cut-off relay 11. Relay unit (diode) 12. Relay unit (fuel pump) 13. Neutral switch 14. Sidestand switch 15. Fuel pump 16. Crankshaft position sensor 17. Cylinder identification sensor 18. Speed sensor 19. Atmospheric pressure sensor 20. Lean angle sensor 21. O2 sensor 22. E.C.U. 23. Ignition coil #1 24.
