Yamaha 2009 YZF-R1 (Y) Service Manual
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Yamaha 2009 YZF-R1 (Y) Service Manual

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Table of Contents

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2009
SERVICE MANUAL
YZF-R1(Y)
14B-28197-E0
Table of Contents
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Summary of Contents for Yamaha 2009 YZF-R1 (Y)

  • Page 1 2009 SERVICE MANUAL YZF-R1(Y) 14B-28197-E0...
  • Page 2 EAS20040 YZF-R1(Y) SERVICE MANUAL ©2008 by Yamaha Motor Co., Ltd. First edition, November 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3 EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 4: How To Use This Manual

    EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine Gear oil mounted Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
  • Page 7 EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: Table Of Contents

    MODEL LABEL..................1-1 FEATURES ....................1-2 OUTLINE OF THE FI SYSTEM ..............1-2 FI SYSTEM .....................1-3 YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake) ..........1-4 INSTRUMENT FUNCTIONS ..............1-8 IMPORTANT INFORMATION ..............1-16 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-16 REPLACEMENT PARTS...............1-16 GASKETS, OIL SEALS AND O-RINGS..........1-16 LOCK WASHERS/PLATES AND COTTER PINS .........1-16...

  • Page 10: Identification

    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 seat rail reinforcement under the passenger seat. This information will be needed to order spare parts.

  • Page 11: Outline Of The Fi System

    FEATURES EAS20170 FEATURES EAS30340 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 12: Fi System

    FEATURES EAS14B1017 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 324 kPa (3.24 kgf/cm², 47.0 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus- ing the fuel to be injected into the intake manifold only during the time the passage remains open.
  • Page 13 YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake) Mechanism characteristics Yamaha developed the YCC-T and YCC-I system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a faster, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
  • Page 14 FEATURES Aims and advantages of using YCC-I system • Improved power band By using a dual intake funnel system, YCC-I optimizes the effectiveness of the fuel injection sys- tem to deliver an incredibly precise air/fuel mixture to the combustion chamber. This degree of intake volume control gives both improved low to mid-range power, as well as improved power in the higher rpm range.
  • Page 15 FEATURES YCC-T/YCC-I system outline 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. ECU (engine control unit) 5. ETV main CPU (32 bit) 6. FI CPU (32 bit) 7. Throttle servo motor driver 8. Throttle servo motor driver operation sens- ing/shut off circuit 9.
  • Page 16 FEATURES YCC-T/YCC-I control outline 17.ECU (engine control unit) 1. Accelerator position sensor 18.Base map 2. Throttle position sensor 19.Idle speed control 3. Crankshaft position sensor 20.Calculated throttle valve opening angle 4. Speed sensor 21.Base map 5. D-mode switch 22.Air funnel position (Calculation value) 6.

  • Page 17: Instrument Functions

    FEATURES EAS14B1019 • A throttle opening position display INSTRUMENT FUNCTIONS • A fuel consumption display (instantaneous and average consumption functions) Multi-function meter unit • A self-diagnosis device • A display brightness, shift timing indicator light and throttle opening position display control mode •...
  • Page 18 FEATURES Clock and stopwatch modes Split-time history 1. Coolant temperature display/air intake tem- 1. Clock/stopwatch perature display To set the clock 2. Stopwatch 1. Push the “SELECT” button and “RESET” The split-time history displays up to 20 stored button together for at least two seconds. split times.
  • Page 19 FEATURES TRIP F → km/L or L/100 km → AV_ _._ km/L Odometer, tripmeter, instantaneous fuel or AV_ _._ L/100 km → ODO → TRIP 1 → consumption and average fuel consump- TRIP 2 → TRIP F tion modes (For the UK only) TRIP F →...
  • Page 20 FEATURES Average fuel consumption mode Transmission gear display 1. Average fuel consumption 1. Neutral indicator light “ ” 2. Transmission gear display The average fuel consumption display can be set to either “AV_ _._ km/L”, “AV_ _._ L/100 This display shows the selected gear. km”...
  • Page 21 FEATURES Drive mode display Air intake temperature display 1. Drive mode display 1. Air intake temperature display This display indicates which drive mode has The air intake temperature display indicates been selected: “STD”, “A” or “B”. the temperature of the air drawn into the air fil- For more details on the modes and on how to ter case.
  • Page 22 Yamaha dealer and have the standard tions. keys re-registered. b. Shift timing indicator light activity:...
  • Page 23 FEATURES 1. Push the “RESET” button to select the desired engine speed for activating the The display shows the current setting for each indicator light. function, except the shift timing indicator light 2. Push the “SELECT” button to confirm the activity function.
  • Page 24 FEATURES D-mode (drive mode) D-mode is an electronically controlled engine • The mode is set to “STD” by default. The performance system with three mode selec- “STD” mode resets when the key is turned to tions (“STD”, “A”, and “B”). “OFF”.

  • Page 25: Important Information

    EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 26: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals “1”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appro- priate.

  • Page 27: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 5. Check: CHECKING THE CONNECTIONS • Continuity Check the leads, couplers, and connectors for (with the pocket tester) stains, rust, moisture, etc. Pocket tester 1. Disconnect: 90890-03112 • Lead Analog pocket tester • Coupler YU-03112-C • Connector 2.

  • Page 28: Handling The Electronic Parts

    HANDLING THE ELECTRONIC PARTS EAS14B1120 HANDLING THE ELECTRONIC PARTS Electronic parts is very sensitive. Handle with care and do not give impact. Mankind has static electricity and it’s voltage is very high and electronic parts is very sensitive. It has possibility that inside small parts of elec- tronic parts is destroyed by static electricity.

  • Page 29: Special Tools

    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 inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-23, 4-72 90890-01403 Exhaust flange nut wrench YU-A9472 Damper rod holder 4-63, 4-65 90890-01506 YM-01506 Oil filter wrench 3-29 90890-01426 YU-38411 Rod holder 4-62, 4-67 90890-01434 Damper rod holder double ended YM-01434 Rod puller 4-66, 4-67...
  • Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller attachment (M10) 4-66, 4-67 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Fork spring compressor 4-62, 4-67 90890-01441 YM-01441 Fork seal driver 4-65, 4-66 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Vacuum gauge 3-10...
  • Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 Valve spring compressor 5-30, 5-36 90890-04019 YM-04019 Valve spring compressor attachment 5-30, 5-36 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Middle driven shaft bearing driver 6-14 90890-04058 Bearing driver 40 mm...
  • Page 33 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover (ø5) 5-32 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide remover (ø4.5) 5-32 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide installer (ø5) 5-32 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide installer (ø4.5) 5-32...

  • Page 34: Table Of Contents

    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pivot shaft wrench adapter 5-10 90890-01476 Valve lapper 90890-04101 Valve lapping tool YM-A8998 Oil pressure adapter H 3-30 90890-03139 Pressure gauge 3-30, 7-18 90890-03153 YU-03153 Fuel pressure adapter 7-18 90890-03176 YM-03176 Fuel injector pressure adapter 7-18 90890-03210 YU-03210...
  • Page 35 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder (22 mm) 4-81, 4-82 90890-01365 Drive chain cut & rivet tool 4-84, 4-85 90890-01550 YM-01550 Piston installing tool 5-83 90890-04161 YM-04161 Rotor puller 5-38 2K7-85555-00 Sheave holder 5-38, 5-41, 5- 90890-01701 42, 5-44 Primary clutch holder...
  • Page 36 Test harness-speed sensor (3P) 8-137, 8-141 90890-03208 YU-03208 Test harness-lean angle sensor (6P) 8-133 90890-03209 YU-03209 Test harness S-pressure sensor (3P) 8-140, 8-142 90890-03207 YU-03207 Yamaha bond No. 1215 5-24, 5-39, 5- (Three bond No. 1215®) 45, 5-73 90890-85505 1-27...
  • Page 37 SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-9 ELECTRICAL SPECIFICATIONS...............2-12 TIGHTENING TORQUES................2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-15 ENGINE TIGHTENING TORQUES ............2-16 CHASSIS TIGHTENING TORQUES ............2-20 LUBRICATION POINTS AND LUBRICANT TYPES ........2-24 ENGINE ....................2-24 CHASSIS ....................2-26 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-27 ENGINE OIL LUBRICATION CHART ...........2-27 LUBRICATION DIAGRAMS ..............2-29 COOLING SYSTEM DIAGRAMS ...............2-45...
  • Page 38 GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 14B1 (AUS, BEL, CHE, CZE, DNK, FIN, GBR, GRC, HUN, IRL, NLD, NOR, POL, PRT, SVN, SWE, ZAF) 14B2 (BEL, FRA) 14B3 (AUS) Dimensions Overall length 2070 mm (81.5 in) Overall width 715 mm (28.1 in) Overall height 1130 mm (44.5 in) Seat height...
  • Page 39 ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 998.0 cm³ Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 78.0 × 52.2 mm (3.07 × 2.06 in) Compression ratio 12.70 : 1 Standard compression pressure (at sea level) 1480 kPa/350 r/min (14.8 kgf/cm²/350 r/min, 210.5 psi/350 r/min) Minimum–Maximum...
  • Page 40 ENGINE SPECIFICATIONS Thermostat 71 °C (159.8 °F) Valve opening temperature 85 °C (185.0 °F) Valve full open temperature Valve lift (full open) More than 8 mm (0.31 in) Radiator core Width 383.0 mm (15.08 in) Height 250.6 mm (9.87 in) Depth 24.0 mm (0.94 in) Water pump...
  • Page 41 ENGINE SPECIFICATIONS Timing chain Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.11–0.20 mm (0.0043–0.0079 in) Exhaust 0.23–0.27 mm (0.0091–0.0106 in) Valve dimensions Valve head diameter A (intake) 30.90–31.10 mm (1.2165–1.2244 in) Valve head diameter A (exhaust) 24.90–25.10 mm (0.9803–0.9882 in) Valve face width B (intake) 1.200–2.475 mm (0.0472–0.0974 in)
  • Page 42 ENGINE SPECIFICATIONS Valve spring Inner spring Free length (intake) 39.33 mm (1.55 in) Limit 37.36 mm (1.47 in) Free length (exhaust) 37.96 mm (1.49 in) Limit 36.06 mm (1.42 in) Installed length (intake) 34.50 mm (1.36 in) Installed length (exhaust) 33.00 mm (1.30 in) Spring rate K1 (intake) 41.57 N/mm (4.24 kgf/mm, 237.36 lbf/in)
  • Page 43 ENGINE SPECIFICATIONS End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Limit 0.50 mm (0.0197 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring Ring type Taper Dimensions (B × T) 0.80 × 2.75 mm (0.03 × 0.11 in) End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Limit...
  • Page 44 ENGINE SPECIFICATIONS Clutch Clutch type Wet, multiple-disc Clutch release method Outer pull, rack and pinion pull Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.82 mm (0.111 in) Plate quantity 9 pcs Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in) Warpage limit...
  • Page 45 ENGINE SPECIFICATIONS Throttle position sensor Throttle position sensor resistance 1.2–2.8 kΩ Accelerator position sensor resistance 1.2–2.8 kΩ Output voltage (at idle) 0.63–0.73 V Fuel injection sensor 248–372 Ω at 20 °C (68 °F) Crankshaft position sensor resistance Cylinder identification sensor output voltage (ON) More than 4.8 V Cylinder identification sensor output voltage...
  • Page 46 CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 24.0° Trail 102.0 mm (4.02 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 47 CHASSIS SPECIFICATIONS Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.8 mm (0.03 in) Master cylinder inside diameter 16.00 mm (0.63 in) 24.05 mm × 3 (0.95 in × 3) Caliper cylinder inside diameter Recommended fluid DOT 4...
  • Page 48 CHASSIS SPECIFICATIONS Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 60.0 mm (2.36 in) Spring free length 159.5 mm (6.28 in) Installed length 147.5 mm (5.81 in) Spring rate K1 98.10 N/mm (10.00 kgf/mm, 560.15 lb/in) Spring stroke K1 0.0–60.0 mm (0.00–2.36 in) Optional spring available...
  • Page 49 ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system TCI (digital) Ignition timing (B.T.D.C.) 5.0°/1200 r/min Engine control unit Model/manufacturer TBDF64/DENSO (14B1, 14B3) TBDF65/DENSO (14B2) Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 0.85–1.15 Ω...
  • Page 50 ELECTRICAL SPECIFICATIONS Fuel level warning light Coolant temperature warning light Engine trouble warning light Steering damper warning light Immobilizer system indicator light Shift timing indicator light Electric starting system System type Constant mesh Starter motor Power output 0.90 kW Armature coil 0.0090–0.0110 Ω...
  • Page 51 ELECTRICAL SPECIFICATIONS Fuses Main fuse 50.0 A Headlight fuse 20.0 A Signaling system fuse 7.5 A Ignition fuse 15.0 A 15.0 A × 2 Radiator fan fuse Turn signal light fuse 7.5 A Fuel injection system fuse 15.0 A Steering damper fuse 7.5 A Backup fuse 7.5 A...
  • Page 52 TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each 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.
  • Page 53 TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plugs 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Cylinder head nut See TIP. Cylinder head nut See TIP. Cylinder head bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head cover bolt...
  • Page 54 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Throttle body and throttle body 3 Nm (0.3 m·kgf, 2.2 ft·lbf) joint clamp Throttle position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Accelerator position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Secondary injector assembly bolt 4 Nm (0.4 m·kgf, 2.9 ft·lbf) Fuel rail screw...
  • Page 55 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Generator rotor cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Drive sprocket cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Pickup rotor cover 2 bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
  • Page 56 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil level switch bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Starter motor bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Speed sensor bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head nut Use new nuts and washers.
  • Page 57 TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front side) 70 Nm (7.0 m·kgf, 50 ft·lbf) Engine mounting nut (rear side) 51 Nm (5.1 m·kgf, 37 ft·lbf) Engine mount adjusting bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Clutch cable locknut (engine side) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Clutch lever holder bolt...
  • Page 58 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Handlebar end grip bolt 4 Nm (0.4 m·kgf, 2.9 ft·lbf) Front brake hose joint bracket bolt 11 Nm (1.1 m·kgf, 8.0 ft·lbf) Coolant reservoir bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Air chamber bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Left lower cowling bracket bolt...
  • Page 59 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front wheel axle pinch bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) See TIP. Rider footrest bolt 28 Nm (2.8 m·kgf, 20 ft·lbf) Passenger footrest bolt 28 Nm (2.8 m·kgf, 20 ft·lbf) Rear frame lower reinforcement 13 Nm (1.3 m·kgf, 9.4 ft·lbf) and passenger footrest bolt...
  • Page 60 TIGHTENING TORQUES At this stage, it can be accepted if the end face of the axle becomes partially concave to the end face of the fork. 4. In the order from the pinch bolt “4” → pinch bolt “3” → pinch bolt “4”, tighten each bolt to 21 Nm (2.1 m·kgf, 15 ft·lbf) without performing temporary tightening.
  • Page 61 Oil/water pump assembly drive sprocket collar and washer Transmission gears (wheel and pinion) Main axle and drive axle Shift forks and shift fork guide bars Three bond Cylinder head cover mating surface No.1541C® Yamaha bond Cylinder head cover semicircular No.1215 (Three bond No.1215®) 2-24...
  • Page 62 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond Crankcase mating surface No.1215 (Three bond No.1215®) Yamaha bond Crankcase cover (lead grommet) No.1215 (Three bond No.1215®) 2-25...
  • Page 63 LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Throttle grip inner surface and throttle cable end Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Clutch cable end Engine mounting bolts (rear upper and lower side) Relay arm, connecting arm and rear shock absorber spacer...

  • Page 64: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-27...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Sub gallery 6. Oil filter cartridge 7. Main gallery 8. Mission shower 9. Drive axle 10.Main axle 11.Shift fork (upper) 12.Crankshaft 13.Oil nozzle 14.Balancer shaft 15.Timing chain tensioner 16.Intake camshaft...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-29...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil filter cartridge 5. Oil level switch 2-30...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Timing chain tensioner 4. Crankshaft 5. Balancer shaft 6. Oil cooler 7. Relief valve 8. Oil pipe 9. Oil strainer 10.Oil/water pump assembly 2-32...
  • Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil level switch 3. Oil strainer 4. Oil pipe 5. Relief valve 6. Oil cooler 2-34...
  • Page 72 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
  • Page 73 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil/water pump assembly 2-36...
  • Page 74 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
  • Page 75 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil delivery pipe 2 3. Drive axle 2-38...
  • Page 76 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
  • Page 77 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Shift fork guide bar 2. Shift fork-C 3. Shift drum assembly 4. Shift fork-R 5. Drive axle 6. Shift fork-L 2-40...
  • Page 78 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-41...
  • Page 79 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Oil nozzle 5. Crankshaft 2-42...
  • Page 80 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-43...
  • Page 81 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Balancer shaft 2. Crankshaft 2-44...

  • Page 82: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-45...
  • Page 83 COOLING SYSTEM DIAGRAMS 1. Oil/water pump assembly 2. Radiator 3. Radiator fan 4. Thermostat 5. Oil cooler 2-46...
  • Page 84 COOLING SYSTEM DIAGRAMS 2-47...
  • Page 85 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Radiator fan 4. Oil cooler 2-48...
  • Page 86 CABLE ROUTING EAS20430 CABLE ROUTING 2-49...
  • Page 87 CABLE ROUTING 1. Meter lead 2. Ground lead 3. Meter 4. Meter bracket 5. Right auxiliary light lead 6. Headlight sub-wire harness 7. Headlight lead 8. Intake air temperature sensor 9. Left auxiliary light lead 10.Right air intake air duct cover 11.Turn signal relay 12.Headlight relay 13.Left air intake air duct cover...
  • Page 88 CABLE ROUTING 2-51...
  • Page 89 CABLE ROUTING 1. Clutch cable 2. Main switch lead 3. Left handlebar switch lead 4. Steering damper lead 5. Horn lead 6. Horn 7. Brake hose 8. Front brake light switch lead 9. Throttle cable (decelerator cable) 10.Throttle cable (accelerator cable) 11.Right handlebar switch lead 12.Throttle cable 13.Steering damper bracket...
  • Page 90 CABLE ROUTING 2-53...
  • Page 91 CABLE ROUTING 1. Headlight sub-wire harness 2. Right radiator fan motor lead 3. AC magneto lead 4. Crankshaft position sensor 5. Coolant reservoir hose 6. Throttle cable 7. Right handlebar switch lead 8. Clutch cable 9. Main harness 10.Rectifier/regulator 11.Rectifier/regulator bracket 12.Right handlebar switch lead 13.Oil cooler outlet hose A.
  • Page 92 CABLE ROUTING 2-55...
  • Page 93 CABLE ROUTING 1. Ignition coil lead 2. Crankshaft position sensor lead 3. Rear brake light switch lead 4. O sensor lead A. Route the rear brake light switch lead out- side of the O sensor lead and push it to the occluding surface of the clutch cover.
  • Page 94 CABLE ROUTING 2-57...
  • Page 95 CABLE ROUTING Q. Route the rear brake light switch lead 1. Union bolt between the top and bottom frame bosses 2. Washer for installing the right footrest assembly 3. Exhaust chamber cover and to inside of the frame. 4. Right footrest assembly 5.
  • Page 96 CABLE ROUTING 2-59...
  • Page 97 CABLE ROUTING 1. Immobilizer unit lead 2. Left radiator fan motor lead 3. Radiator fan motor relay 4. ECU (engine control unit) 5. Cable guide 6. Radiator inlet pipe 7. ECU (engine control unit) bracket A. Insert the clamp winding the main harness into the ECU (engine control unit) bracket hole.
  • Page 98 CABLE ROUTING 2-61...
  • Page 99 CABLE ROUTING 1. Oil level switch lead 2. Gear position sensor lead 3. Speed sensor lead 4. Sidestand switch lead 5. Fuel tank breather hose 6. Fuel tank overflow hose 7. Coolant reservoir breather hose 8. Sidestand switch 9. AC magneto lead 10.Frame 11.Main harness holder 12.Main harness...
  • Page 100 CABLE ROUTING 2-63...
  • Page 101 CABLE ROUTING H. Clamp the starter motor lead and fuel 1. Right handlebar switch lead pump lead at the right of the vehicle. Do 2. Headlight sub-wire harness not cut off the end and face it to back of the 3.
  • Page 102 CABLE ROUTING 2-65...
  • Page 103 CABLE ROUTING AE.Install the water pump bypass hose with its clamp opening facing right of the vehicle. AF.Clamp the secondary injector sub-wire har- ness and throttle sub-wire harness at the protector. Face the end of the clamp down- ward. 2-66...
  • Page 104 CABLE ROUTING 2-67...
  • Page 105 CABLE ROUTING 1. Rear frame 2. Right upper tail cover bracket 3. License plate light lead 4. Right turn signal light lead 5. Left turn signal light lead 6. Battery box 2 7. Tail/brake light lead 8. Lean angle sensor lead 9.
  • Page 106 CABLE ROUTING 2-69...
  • Page 107 CABLE ROUTING 1. Fuel tank upper cover 2. Fuel tank breather hose 3. Fuel tank overflow hose 4. Fuel tank 5. Fuel pump 6. Frame 7. Fuel hose connector cover 8. Clip 9. Fuel hose A. Install the lip on the fuel pump gasket upward.
  • Page 108 CABLE ROUTING 2-71...
  • Page 109 CABLE ROUTING 1. Upper air filter case 2. Fuel hose (secondary injector fuel rail side) 3. Fuel hose (primary injector fuel rail side) 4. Primary injector fuel rail 5. Secondary injector sub-wire harness 6. Throttle cable (pull side) 7. Throttle cable (return side) 8.
  • Page 110 CABLE ROUTING 2-73...
  • Page 111 CABLE ROUTING 1. Cap case 2. Upper air filter case 3. Sub-wire harness 4. Secondary injector holder 5. Grommet 6. Plastic locking tie 7. Fuel rail A. Sub-wire harness should not be pinched under the bearing surface of the bolt. B.
  • Page 112 CABLE ROUTING 2-75...
  • Page 113 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART.....3-2 CHECKING THE FUEL LINE (Primary injector) ........3-4 CHECKING THE FUEL LINE (Secondary injector) ........3-4 CHECKING THE SPARK PLUGS............3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5 SYNCHRONIZING THE THROTTLE BODIES ........3-9 CHECKING THE THROTTLE BODY JOINTS ........3-11...
  • Page 114 CHECKING THE COOLANT LEVEL ............3-31 CHECKING THE COOLING SYSTEM ..........3-31 CHANGING THE COOLANT ..............3-32 CHECKING THE FRONT BRAKE LIGHT SWITCH ......3-33 ADJUSTING THE REAR BRAKE LIGHT SWITCH ......3-33 CHECKING AND LUBRICATING THE CABLES ........3-33 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-34 LUBRICATING THE REAR SUSPENSION ..........3-34 CHECKING AND CHARGING THE BATTERY........3-34 CHECKING THE FUSES..............3-34...
  • Page 116 UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 117: General Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE EAS14B1034 GENERAL MAINTENANCE AND LUBRICATION CHART ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) √ Air filter element •...
  • Page 118 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Change. √ √ √ √ √ √ Engine oil •...
  • Page 119 PERIODIC MAINTENANCE EAS21030 4. Install: CHECKING THE FUEL LINE (Primary injec- • Fuel tank tor) Refer to “FUEL TANK” on page 7-1. The following procedure applies to all of the 5. Install: fuel, vacuum and breather hoses. • Rider seat 1.
  • Page 120 PERIODIC MAINTENANCE 2. Remove: 10. Install: • Fuel tank • Spark plug Refer to “FUEL TANK” on page 7-1. Spark plug 3. Remove: 13 Nm (1.3 m·kgf, 9.4 ft·lbf) • Air filter case Refer to “AIR FILTER CASE” on page 7- Before installing the spark plug, clean the 4.
  • Page 121 PERIODIC MAINTENANCE • Air cut-off valve Refer to “AIR INDUCTION SYSTEM” on page 7-21. • Radiator • Radiator fan motor Refer to “RADIATOR” on page 6-1. 2. Remove: • Ignition coils • Spark plugs • Cylinder head cover • Cylinder head cover gasket Refer to “CAMSHAFTS”...
  • Page 122 PERIODIC MAINTENANCE f. Turn the crankshaft 180 degrees in clock- wise and position the pickup rotor T mark “a” upward. c. Measure the valve clearance #1 with a thickness gauge “1”. Thickness gauge b. 180° 90890-03180 Feeler gauge set g. Measure the valve clearance #2 with a YU-26900-9 thickness gauge.

  • Page 123: Valve Lapper

    PERIODIC MAINTENANCE Example: Specified valve clearance = 0.11–0.20 mm • Refer to “CAMSHAFTS” on page 5-13. (0.0043–0.0079 in) • When removing the timing chain and cam- Measured valve clearance = 0.23 mm shafts, fasten the timing chain with a wire to (0.0091 in) retrieve it if it falls into the crankcase.
  • Page 124 PERIODIC MAINTENANCE i. If the valve clearance is still out of specifi- Valve pad range No. 160–240 cation, repeat all of the valve clearance 1.60–2.40 mm adjustment steps until the specified clear- Valve pad thickness (0.0630–0.0945 in) ance is obtained. 17 thicknesses in ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 125 PERIODIC MAINTENANCE 4. Install: Adjusting the throttle body synchronization • Vacuum gauge “1” 1. Adjust: • Digital tachometer • Throttle body synchronization (Use goods on the market) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Start the engine, warm it up for several Vacuum gauge minutes, and then let it run at the specified 90890-03094 engine idling speed.
  • Page 126 PERIODIC MAINTENANCE Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 4. Install: • Fuel tank • Fuel tank side cover Refer to “FUEL TANK” on page 7-1. • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. 4. Install: EAS21010 CHECKING THE THROTTLE BODY JOINTS •...
  • Page 127 PERIODIC MAINTENANCE 11. Install: • Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. 12. Install: • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS20600 ADJUSTING THE EXHAUST GAS VOLUME Be sure to set the CO density level to stan- dard, and then adjust the exhaust gas volume.
  • Page 128 PERIODIC MAINTENANCE 5. Press the “SELECT” and “RESET” buttons 10. Turn the main switch to “OFF” to cancel the to select a cylinder. CO adjustment mode. EAS14B1099 CHECKING THE AIR INDUCTION SYSTEM Refer to “CHECKING THE AIR INDUCTION SYSTEM” on page 7-25. EAS20961 REPLACING THE AIR FILTER ELEMENT 1.
  • Page 129 PERIODIC MAINTENANCE 2. Adjust: • Clutch cable free play 6. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Air filter case cover Refer to “AIR FILTER CASE” on page 7- Handlebar side a. Turn the adjusting bolt “1” in direction “a” or ECA14401 “b” until the specified clutch lever free play is obtained.
  • Page 130 PERIODIC MAINTENANCE c. Tighten the locknuts “1”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS14B1088 CHECKING THE BRAKE OPERATION 1. Check: • Brake operation Brake not working properly → Check the brake system. Refer to “FRONT BRAKE” on page 4-30 and “REAR BRAKE” on page 4-43. A.
  • Page 131 PERIODIC MAINTENANCE EAS21160 1. Operate the brake. ADJUSTING THE FRONT DISC BRAKE 2. Check: 1. Adjust: • Front brake pad • Brake lever position Wear indicators “1” almost touch the (distance “a” from the throttle grip to the brake disc → Replace the brake pads as brake lever) a set.
  • Page 132 PERIODIC MAINTENANCE EWA13070 WARNING After adjusting the brake pedal position, check that the end of the adjusting bolt “c” is visible through the hole “d”. EAS21360 BLEEDING THE HYDRAULIC BRAKE SYS- EWA13100 WARNING c. Tighten the locknut “1” to specification. Bleed the hydraulic brake system when- Locknut ever:...
  • Page 133 PERIODIC MAINTENANCE the throttle grip or the brake pedal to fully extend. h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.
  • Page 134 PERIODIC MAINTENANCE EAS21290 CHECKING THE REAR BRAKE HOSE 1. Check: • Brake hose “1” Cracks/damage/wear → Replace. 2. Check: • Brake hose clamp “2” Loose Connection → Tighten the clamp bolt. EWA13180 WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
  • Page 135 250 kPa (2.50 kgf/cm², 36 psi, concerning handling characteristics can be 2.50 bar) given if a tire combination other than one Rear approved by Yamaha is used on this vehi- 290 kPa (2.90 kgf/cm², 42 psi, cle. 2.90 bar) High-speed riding...
  • Page 136 PERIODIC MAINTENANCE Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Move the rear wheel several times and find the tightest position of drive chain. 3. Check: • Drive chain slack “a” Out of specification → Adjust. EAS14B1089 CHECKING THE WHEEL BEARINGS The following procedure applies to all of the...
  • Page 137 PERIODIC MAINTENANCE EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Check: • Steering head Grasp the bottom of the front fork legs and gently rock the front fork.
  • Page 138 PERIODIC MAINTENANCE EAS14B1092 Steering nut wrench CHECKING THE STEERING DAMPER 90890-01403 Refer to “CHECKING THE STEERING Exhaust flange nut wrench DAMPER” on page 4-73. YU-A9472 EAS14B1093 CHECKING THE CHASSIS FASTENERS Lower ring nut (initial tightening Make sure that all nuts, bolts, and screws are torque) properly tightened.
  • Page 139 PERIODIC MAINTENANCE EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium-soap-based grease EAS14B1095 CHECKING THE SIDESTAND SWITCH Refer to “ELECTRICAL COMPONENTS” on page 8-117. 2. Adjust: EAS21530 • Installed shift rod length CHECKING THE FRONT FORK ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 140 PERIODIC MAINTENANCE Spring preload EWA14B1026 WARNING Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. ECA13570 • Grooves are provided to indicate the adjustment position. • Never go beyond the maximum or mini- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 141 PERIODIC MAINTENANCE Compression damping Spring preload ECA13590 ECA13590 Never go beyond the maximum or minimum Never go beyond the maximum or minimum adjustment positions. adjustment positions. 1. Adjust: 1. Adjust: • Compression damping (left side) • Spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
  • Page 142 PERIODIC MAINTENANCE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Minimum a. Turn the adjusting screw “1” in direction “a” 4 turn(s) out* or “b”. Standard Direction “a” 3 turn(s) out* Rebound damping increased Maximum (suspension is harder). 0 turn(s) out* Direction “b” * With the adjusting screw fully turned in Rebound damping decreased...
  • Page 143 PERIODIC MAINTENANCE Type SAE 10W-40, SAE 10W-50, SAE 15W-40, SAE 20W-40 or SAE 20W-50 (14B1, 14B2) YAMALUBE 10W-40 YAMALUBE 4 20W-50, SAE 10W-40 or SAE 20W-50 (14B3) Recommended engine oil grade API service SG type or higher, JASO standard MA ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 144 PERIODIC MAINTENANCE Before checking the engine oil level, wait a few minutes until the oil has settled. 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.

  • Page 145: Oil Pressure Adapter H

    PERIODIC MAINTENANCE 3. Remove: Engine oil quantity • Main gallery bolt “1” Total amount 4.58 L (4.84 US qt, 4.03 Imp.qt) Without filter cartridge replacement 3.73 L (3.94 US qt, 3.28 Imp.qt) With oil filter cartridge replace- ment 3.93 L (4.15 US qt, 3.46 Imp.qt) 9.
  • Page 146 PERIODIC MAINTENANCE 3. Start the engine, warm it up for several Engine oil pressure Possible causes minutes, and then turn it off. • Faulty oil pump 4. Check: • Clogged oil filter • Coolant level Below specification • Leaking oil passage •...
  • Page 147 PERIODIC MAINTENANCE EAS21130 5. Remove: CHANGING THE COOLANT • Coolant drain bolt (engine) “1” 1. Remove: (along with the copper washer) • Lower cowlings • Side cowlings Refer to “GENERAL CHASSIS” on page 4-1. 2. Disconnect: • Coolant reservoir cap “1” 3.
  • Page 148 PERIODIC MAINTENANCE • If coolant splashes on your clothes, EAS14B1098 CHECKING THE FRONT BRAKE LIGHT quickly wash it away with water and then SWITCH with soap and water. Refer to “ELECTRICAL COMPONENTS” on • If coolant is swallowed, induce vomiting page 8-117.
  • Page 149 PERIODIC MAINTENANCE Replace damaged outer cable and inner Direction “a” cables as soon as possible. Throttle cable free play is increased. 1. Check: Direction “b” • Outer cable Throttle cable free play is decreased. Damage → Replace. c. Tighten the locknut “1”. 2.
  • Page 150 PERIODIC MAINTENANCE the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 5. Install: •...
  • Page 151 PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-36...
  • Page 152 PERIODIC MAINTENANCE 3-37...
  • Page 153 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE QUICK FASTENER (SCREW TYPE).......4-11 INSTALLING THE QUICK FASTENER (SCREW TYPE)......4-11 REMOVING THE QUICK FASTENER (PUSH TYPE) ......4-11 INSTALLING THE QUICK FASTENER (PUSH TYPE) ......4-11 REMOVING THE QUICK FASTENER (PULL TYPE) ......4-11 INSTALLING THE QUICK FASTENER (PULL TYPE) ......4-12 INSTALLING THE PASSENGER SEAT LOCK CYLINDER ....4-12 REMOVING THE FRONT TURN SIGNAL LIGHTS......4-12 INSTALLING THE FRONT TURN SIGNAL LIGHTS......4-12...
  • Page 154 CHECKING THE FRONT BRAKE CALIPERS ........4-38 ASSEMBLING THE FRONT BRAKE CALIPERS .........4-39 INSTALLING THE FRONT BRAKE CALIPERS........4-39 REMOVING THE FRONT BRAKE MASTER CYLINDER.....4-40 CHECKING THE FRONT BRAKE MASTER CYLINDER .....4-40 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER....4-41 INSTALLING THE FRONT BRAKE MASTER CYLINDER ....4-41 REAR BRAKE ....................4-43 INTRODUCTION ..................4-48 CHECKING THE REAR BRAKE DISC ..........4-48...
  • Page 155 SWINGARM ....................4-78 REMOVING THE SWINGARM .............4-80 CHECKING THE SWINGARM .............4-81 INSTALLING THE SWINGARM ............4-81 CHAIN DRIVE .....................4-83 REMOVING THE DRIVE CHAIN ............4-84 CHECKING THE DRIVE CHAIN ............4-84 CHECKING THE DRIVE SPROCKET ..........4-85 CHECKING THE REAR WHEEL SPROCKET ........4-85 CHECKING THE REAR WHEEL DRIVE HUB ........4-85 INSTALLING THE DRIVE CHAIN ............4-85...
  • Page 156 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats and battery Order Job/Parts to remove Q’ty Remarks Rider seat Passenger seat Battery negative lead Disconnect. Battery positive lead Disconnect. Tool band Tool Upper tail cover bracket Battery cover Battery Battery seat For installation, reverse the removal proce- dure.
  • Page 157 GENERAL CHASSIS Removing the side cowlings Order Job/Parts to remove Q’ty Remarks Front cowling inner panel Side cowling Front turn signal light coupler Disconnect. Front turn signal light Lower cowling Side cowling inner panel For installation, reverse the removal proce- dure.
  • Page 158 GENERAL CHASSIS Removing the ECU and rectifier/regulator Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. ECU coupler Disconnect. Radiator fan motor relay coupler Disconnect. Radiator fan motor relay ECU bracket Rectifier/regulator coupler Disconnect. Stator coil lead coupler Disconnect.
  • Page 159 GENERAL CHASSIS Removing the Air ducts Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. ECU and rectifier/regulator Refer to “GENERAL CHASSIS” on page 4-1. Air chamber cover Air chamber Air chamber bracket Air intake air duct cover Rear intake air duct upper Rear intake air duct lower Front intake air duct...

  • Page 160: General Chassis

    GENERAL CHASSIS Removing the front cowling assembly Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. ECU and Rectifier/regulator Refer to “GENERAL CHASSIS” on page 4-1. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Intake air temperature sensor coupler Disconnect.
  • Page 161 GENERAL CHASSIS Removing the meter and headlight Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. ECU and Rectifier/regulator Refer to “GENERAL CHASSIS” on page 4-1. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Front cowling assembly Refer to “GENERAL CHASSIS”...
  • Page 162 GENERAL CHASSIS Removing the meter and headlight Order Job/Parts to remove Q’ty Remarks Windshield Intake air temperature sensor Headlight assembly Front cowling For installation, reverse the removal proce- dure.
  • Page 163 GENERAL CHASSIS Disassembling the headlight assembly Order Job/Parts to remove Q’ty Remarks Auxiliary light socket Auxiliary light bulb Headlight bulb cover Headlight bulb Headlight harness Headlight grille For installation, reverse the removal proce- dure.
  • Page 164 GENERAL CHASSIS Removing the rear fender Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. Upper tail cover bracket Refer to “GENERAL CHASSIS” on page 4-1. Upper tail cover Muffler Refer to “ENGINE REMOVAL”...
  • Page 165 GENERAL CHASSIS Disassembling the license plate/turn signal light assembly Order Job/Parts to remove Q’ty Remarks License plate/turn signal light stay License plate/turn signal light stay plate Cover Rear turn signal light License plate light Rear reflector Mudguard For installation, reverse the removal proce- dure.
  • Page 166 GENERAL CHASSIS EAS14B1029 REMOVING THE QUICK FASTENER (SCREW TYPE) To remove the quick fastener, turn its center with a screwdriver counterclockwise, then pull the fastener out. EAS14B1032 INSTALLING THE QUICK FASTENER (PUSH TYPE) To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert EAS14B1030 the fastener into the cover and push the pin “a”...
  • Page 167 GENERAL CHASSIS EAS14B1038 REMOVING THE FRONT TURN SIGNAL LIGHTS EAS14B1104 1. Remove: INSTALLING THE QUICK FASTENER (PULL • Stay “1” TYPE) • Front turn signal light “2” To install the quick fastener, pull the pin, then Remove the stay “1” first and then remove the insert the fastener into the cover and push the front turn signal light “2”...
  • Page 168 GENERAL CHASSIS EAS14B1040 REMOVING THE LOWER COWLINGS 1. Remove: • Lower cowling “1” Slide the lower cowling to the forward and remove. EAS14B1043 INSTALLING THE SIDE COWLING INNER PANELS 1. Install: • Side cowling inner panel “1” Install the grommet “2” to the side cowling inner panel and insert them into the projection EAS14B1041 “a”...
  • Page 169 GENERAL CHASSIS EAS14B1045 INSTALLING THE AIR CHAMBER COVERS 1. Install: • Air chamber cover “1” Insert the air chamber cover tab “a” downward into the hole “b” of the air chamber “2”. EAS14B1048 INSTALLING THE AIR INTAKE DUCTS 1. Install: •...
  • Page 170 GENERAL CHASSIS EAS14B1051 INSTALLING THE MIRROR FITTING PLATES 1. Install: • Mirror fitting plate “1” (to meter bracket “2”) Face the mirror fitting plate concave “a” up and install it to the meter bracket. EAS14B1049 REMOVING THE WINDSHIELD 1. Remove: •...
  • Page 171 GENERAL CHASSIS 2. Install: • Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS14B1054 INSTALLING THE TAIL/BRAKE LIGHT 1. Install: • Tail/brake light “1” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS14B1002 Fit the tail/brake light tabs “a” into the holes “b” INSTALLING THE UPPER TAIL COVER of the lower tail cover “2”.
  • Page 172 GENERAL CHASSIS Exhaust chamber cover bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) e. Install the rider footrest bolts. Rider footrest bolt 28 Nm (2.8 m·kgf, 20 ft·lbf) c. Adjusting the right rider footrest “1”. • Install the end “a” of the exhaust chamber cover “1”...
  • Page 173 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Left brake hose holder Right brake hose holder Left front brake caliper Right front brake caliper Front wheel axle pinch bolt Loosen. Front wheel axle bolt Front wheel axle Collar (left and right)
  • Page 174 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly pro- cedure. 4-19...
  • Page 175 FRONT WHEEL 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. Place the vehicle on a suitable stand so that the front wheel is elevated.
  • Page 176 FRONT WHEEL • Adjust the front wheel static balance with the brake disc installed. 1. Remove: • Balancing weight(s) 2. Find: • Front wheel’s heavy spot Place the front wheel on a suitable balancing stand. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ c. Remove the wheel bearings “3” with a gen- a.
  • Page 177 FRONT WHEEL EAS22000 INSTALLING THE FRONT WHEEL Start with the lightest weight. 1. Lubricate: • Wheel axle • Oil seal lips Recommended lubricant Lithium-soap-based grease 2. Lift the wheel up between the fork legs. 3. Insert the wheel axle. Install the tire and wheel with the mark “1” pointing in the direction of wheel rotation.
  • Page 178 FRONT WHEEL EWA13530 WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” on page 2-49. Make sure that there is enough space between the brake pads before installing the brake cali- pers on to the brake discs. 4-23...
  • Page 179 REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Rear brake caliper Refer to “REAR BRAKE” on page 4-43. Locknut (left and right) Loosen. Adjusting bolt (left and right) Loosen. Rear wheel axle nut Washer Rear wheel axle Adjusting block (left)
  • Page 180 REAR WHEEL Removing the brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar Dust cover Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel For installation, reverse the removal proce- dure.
  • Page 181 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly pro- cedure. 4-26...
  • Page 182 REAR WHEEL EAS22040 REMOVING THE REAR 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. Place the vehicle on a suitable stand so that the rear wheel is elevated.
  • Page 183 REAR WHEEL EAS22110 CHECKING THE REAR WHEEL DRIVE HUB Tighten the self-locking nuts in stages and in a 1. Check: crisscross pattern. • Rear wheel drive hub “1” Cracks/damage → Replace. • Rear wheel drive hub dampers “2” Damage/wear → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 184 REAR WHEEL 3. Tighten: • Rear wheel axle nut • Rear brake caliper bolts Rear wheel axle nut 150 Nm (15 m·kgf, 110 ft·lbf) Rear brake caliper bolt (front side) 27 Nm (2.7 m·kgf, 19 ft·lbf) Rear brake caliper bolt (rear side) 22 Nm (2.2 m·kgf, 16 ft·lbf) EWA13530...
  • Page 185 FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake hose holder Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad kit Bleed screw For installation, reverse the removal proce-...
  • Page 186 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-17. Stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Brake lever...
  • Page 187 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Bleed screw Brake master cylinder body For installation, reverse the removal proce- dure. 4-32...

  • Page 188: Front Brake

    FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-17. Union bolt Washer Brake hose Brake caliper For installation, reverse the removal proce-...
  • Page 189 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks Brake pad clip Brake pad pin Brake pad spring Brake pad kit Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For installation, reverse the removal proce- dure.
  • Page 190 FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 191 FRONT BRAKE 1. Remove: • Brake hose holder “1” • When installing the brake disc, align the • Brake caliper “2” arrow “1” on the brake disc and arrow “2” on the wheel in the direction of wheel rotation. • Tighten the brake disc bolts in stages and in a crisscross pattern.
  • Page 192 FRONT BRAKE d. Install new brake pads and a new brake Brake lining thickness pad springs. (inner) 4.5 mm (0.18 in) The arrow mark “a” on the brake pad springs Limit must point in the direction of disc rotation. 0.8 mm (0.03 in) Brake lining thickness...
  • Page 193 FRONT BRAKE EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • Union bolt “1” • Washers “2” •...
  • Page 194 FRONT BRAKE • Brake caliper cylinders “2” 2. Install: Scratches/wear → Replace the brake cal- • Brake caliper “1” iper assembly. • Copper washers • Brake caliper body “3” • Brake hose “2” Cracks/damage → Replace the brake • Union bolt “3” caliper assembly.
  • Page 195 FRONT BRAKE EAS22490 REMOVING THE FRONT BRAKE MASTER Recommended fluid CYLINDER DOT 4 EWA13090 Before removing the front brake master cylin- WARNING der, drain the brake fluid from the entire brake • Use only the designated brake fluid. system. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and 1.
  • Page 196 FRONT BRAKE 2. Check: Front brake master cylinder • Brake fluid reservoir tank “1” holder bolt Cracks/damage → Replace. 13 Nm (1.3 m·kgf, 9.4 ft·lbf) • Brake fluid reservoir diaphragm “2” Damage/wear → Replace. • Brake fluid reservoir diaphragm holder “3” •...
  • Page 197 FRONT BRAKE a. 36° 6. Check: b. 3 mm (0.12 in) • Brake lever operation Soft or spongy feeling → Bleed the brake 3. Fill: system. • Brake fluid reservoir Refer to “BLEEDING THE HYDRAULIC (with the specified amount of the recom- BRAKE SYSTEM”...
  • Page 198 REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad kit Bleed screw Brake pad spring For installation, reverse the removal proce- dure.
  • Page 199 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-17. Footrest plate Brake fluid reservoir cap Rear brake fluid reservoir diaphragm holder Rear brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Union bolt...
  • Page 200 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Adjusting nut Brake master cylinder kit Dust cover Circlip Hose joint O-ring Brake master cylinder body For installation, reverse the removal proce- dure.
  • Page 201 REAR BRAKE Removing the rear brake calipers Order Job/Parts to remove Q’ty Remarks Union bolt Washer Brake hose Brake caliper For installation, reverse the removal proce- dure. 4-46...
  • Page 202 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Brake pad kit Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For installation, reverse the removal proce- dure.

  • Page 203: Rear Brake

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 4.5 mm (0.18 in) WARNING 5. Adjust: Disc brake components rarely require dis- • Brake disc deflection assembly. Therefore, always follow these Refer to “CHECKING THE FRONT preventive measures: BRAKE DISCS” on page 4-35. •...
  • Page 204 REAR BRAKE 3. Measure: c. Tighten the bleed screw. • Brake pad wear limit “a” Out of specification → Replace the brake Bleed screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) pads as a set. d. Install a new brake pad shim “3” onto each Brake lining thickness...
  • Page 205 REAR BRAKE EAS22590 • Never try to pry out the brake caliper pis- REMOVING THE REAR BRAKE CALIPER ton. Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • Union bolt “1” • Copper washers “2” •...
  • Page 206 REAR BRAKE EAS22670 INSTALLING THE REAR BRAKE CALIPER 1. Install: • Brake caliper “1” (temporarily) • Washers • Brake hose “2” • Union bolt “3” Rear brake hose union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) EWA14B1005 EWA13530 WARNING WARNING Whenever a brake caliper is disassembled, Proper brake hose routing is essential to replace the brake caliper piston dust seal...
  • Page 207 REAR BRAKE 4. Fill: 7. Check: • Brake fluid reservoir • Brake pedal operation Soft or spongy feeling → Bleed the brake (with the specified amount of the recom- mended brake fluid) system. Refer to “BLEEDING THE HYDRAULIC Recommended fluid BRAKE SYSTEM”...
  • Page 208 REAR BRAKE 2. Check: Rear brake hose union bolt • Brake fluid reservoir tank “1” Cracks/damage → Replace. 30 Nm (3.0 m·kgf, 22 ft·lbf) • Brake fluid reservoir diaphragm “2” EWA13530 Cracks/damage → Replace. WARNING • Brake fluid reservoir diaphragm holder “3” Proper brake hose routing is essential to Cracks/damage →...
  • Page 209 REAR BRAKE • Refill with the same type of brake fluid Brake pedal position (from the that is already in the system. Mixing brake top of the brake pedal to the fluids may result in a harmful chemical center of the bolt mount on the reaction, leading to poor brake perfor- rider footrest bracket) mance.
  • Page 210 HANDLEBARS EAS22850 HANDLEBARS Removing the handlebars Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. ECU and rectifier/regulator Refer to “GENERAL CHASSIS” on page 4-1. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Front cowling Refer to “GENERAL CHASSIS”...
  • Page 211 HANDLEBARS Removing the handlebars Order Job/Parts to remove Q’ty Remarks Throttle grip Brake switch connector Right handlebar switch Handlebar pinch bolt Loosen. Handlebar bolt Loosen. Upper bracket pinch bolt Loosen. Steering stem nut Main switch coupler Disconnect. Immobilizer unit coupler Disconnect.
  • Page 212 HANDLEBARS EAS22870 EWA13690 REMOVING THE HANDLEBAR WARNING 1. Stand the vehicle on a level surface. Do not attempt to straighten a bent handle- EWA13120 bar as this may dangerously weaken it. WARNING Securely support the vehicle so that there is no danger of it falling over. 2.
  • Page 213 HANDLEBARS • Align the projection “a” on the left handlebar switch with the hole “b” on the left handlebar. • There should be 2.0–2.5 mm (0.08–0.10 in) of clearance between left handlebar switch and clutch lever holder. 4. Install: • Throttle grip •...
  • Page 214 FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies both of the front fork legs. Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Front wheel Refer to “FRONT WHEEL” on page 4-18. Front fender Upper bracket pinch bolt Loosen.
  • Page 215 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Washer Spacer Upper spring seat Fork spring Lower spring seat Outer tube Dust seal Oil seal clip Oil seal Washer...
  • Page 216 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Damper rod assembly Damper adjusting rod Damper adjusting valve Damper adjusting valve spring Inner tube For installation, reverse the removal proce- dure. 4-61...

  • Page 217: Front Fork

    FRONT FORK EAS14B1006 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Each front fork leg is equipped with a spring preload adjusting bolt, the right fork leg is equipped with a rebound damping force adjusting screen and left front fork is equipped with a compression damping force adjusting screw.
  • Page 218 FRONT FORK Use the side of the rod holder that is marked “B”. 4. Remove: • Dust seal • Oil seal clip “1” (with a flat-head screwdriver) • Oil seal c. Hold the spring preload adjusting bolt “6” • Washer and loosen the nut “3”.
  • Page 219 FRONT FORK EAS23010 • When disassembling and assembling the CHECKING THE FRONT FORK LEGS front fork leg, do not allow any foreign The following procedure applies to both of the material to enter the front fork. front fork legs. 1. Check: •...
  • Page 220 FRONT FORK • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil. 2. Lubricate: • Inner tube’s outer surface Recommended oil Suspension oil M1 or equiva- lent 3.
  • Page 221 FRONT FORK 8. Install: 10. Fully compress the front fork leg. • Dust seal “1” 11. Fill: (with the fork seal driver weight “2”) • Front fork leg (with the specified amount of the recom- Fork seal driver mended fork oil) 90890-01442 Adjustable fork seal driver (36–...
  • Page 222 FRONT FORK Be sure to bleed the front fork leg of any resid- Install the spring with the smaller diameter “a” ual air. facing up “A”. 14. Measure: • Front fork leg oil level “a” (from the top of the outer tube, with the outer tube fully compressed and without the fork spring) Out of specification →...
  • Page 223 FRONT FORK j. Remove the rod puller and rod puller o. Remove the rod holder and fork spring attachment. compressor. k. Install the nut “1” all the way onto the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ damper rod assembly. 16. Install: • Cap bolt (to the outer tube) •...
  • Page 224 FRONT FORK Fasten the front brake hose to the right front fork leg with the plastic locking tie. 3. Tighten: • Cap bolt “1” Cap bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) 6. Adjust: • Spring preload • Handlebar bolt “2” •...
  • Page 225 STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Front fork legs Refer to “FRONT FORK” on page 4-59. Handlebars Refer to “HANDLEBARS”...
  • Page 226 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Lower ring nut Lower bracket Upper bearing cover Upper bearing inner race Upper bearing Lower bearing Lower bearing inner race Lower bearing dust seal Upper bearing outer race Lower bearing outer race For installation, reverse the removal proce- dure.
  • Page 227 STEERING HEAD EAS23110 3. Replace: REMOVING THE LOWER BRACKET • Bearings 1. Stand the vehicle on a level surface. • Bearing races EWA13120 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a. Remove the bearing races “1” from the Securely support the vehicle so that there steering head pipe with a long rod “2”...
  • Page 228 STEERING HEAD EAS23140 • Bearing INSTALLING THE STEERING HEAD Damage/pitting → Replace. 1. Lubricate: (It replace with the assembly.) • Upper bearing • Lower bearing • Bearing races Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” • Rubber washer “2” •...
  • Page 229 REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK”...
  • Page 230 REAR SHOCK ABSORBER ASSEMBLY EAS14B1010 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that EWA14B1013 the rear wheel is elevated. WARNING This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Rear shock absorber assembly lower bolt the rear shock absorber, read and make “1”...
  • Page 231 REAR SHOCK ABSORBER ASSEMBLY • Spring Installed depth of bearing “a” Damage/wear → Replace the rear shock 4.0 mm (0.16 in) absorber assembly. Installed depth of oil seal “b” • Bearing 1.0 mm (0.04 in) Damage/wear → Replace. • Bolts Bends/damage/wear →...
  • Page 232 REAR SHOCK ABSORBER ASSEMBLY Rear shock absorber assembly bracket and frame nut 92 Nm (9.2 m·kgf, 66 ft·lbf) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 40 Nm (4.0 m·kgf, 29 ft·lbf) 4. Install: • Connecting arm When installing the connecting arm, lift up the swingarm.
  • Page 233 SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-24. Refer to “REAR SHOCK ABSORBER Rear shock absorber assembly ASSEMBLY” on page 4-74. Drive chain guard Rear fender Left footrest Drive chain guide Brake hose holder Pivot shaft nut/washer...
  • Page 234 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Oil seal Circlip Bearing Bearing For installation, reverse the removal proce- dure. 4-79...
  • Page 235 SWINGARM EAS23350 REMOVING THE SWINGARM Swingarm side play (at the end 1. Stand the vehicle on a level surface. of the swingarm) 1.0 mm (0.04 in) EWA13120 WARNING d. Check the swingarm vertical movement “B” Securely support the vehicle so that there by moving the swingarm up and down.
  • Page 236 SWINGARM 3. Wash: Damper rod holder (22 mm) • Pivot shaft 90890-01365 • Dust cover • Spacer • Washers • Bearings Recommended cleaning solvent Kerosene 4. Check: • Dust cover “1” • Spacer “2” • Collar “3” • Bearings “4” Damage/wear →...
  • Page 237 SWINGARM Ring nut wrench 90890-01507 YM-01507 5. Dust cover 6. Collar 7. Swingarm 8. Pivot shaft A. Left side 5. Install: B. Right side • Pivot shaft nut “1” 3. Install: Pivot shaft nut • Pivot shaft “1” 105 Nm (10.5 m·kgf, 75 ft·lbf) Pivot shaft 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Tighten the pivot shaft with the damper rod...
  • Page 238 CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain Order Job/Parts to remove Q’ty Remarks Refer to “ADJUSTING THE DRIVE CHAIN Drive chain SLACK” on page 3-21. Locknut Shift rod Shift arm Shift pedal Drive sprocket cover Drive sprocket nut Washer Drive chain guide (drive sprocket side)
  • Page 239 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. Place the vehicle on a suitable stand so that the rear wheel is elevated.
  • Page 240 CHAIN DRIVE use only kerosene to clean the drive EAS23460 CHECKING THE DRIVE SPROCKET chain. 1. Check: • Do not soak the drive chain in kerosene • Drive sprocket for more than ten minutes, otherwise the More than 1/4 tooth “a” wear → Replace O-rings can be damaged.
  • Page 241 CHAIN DRIVE • Stake the drive sprocket nut at cutouts, “a” in the drive axle. b. After riveting, make sure the diameter between the edges “b” of the connecting pin “2” is 5.7–6.0 mm (0.22–0.24 in). ECA14300 Never install a new drive chain onto worn drive chain sprockets;...
  • Page 242 CHAIN DRIVE 4-87...
  • Page 243 ENGINE ENGINE INSPECTION..................5-1 MEASURING THE COMPRESSION PRESSURE .........5-1 ENGINE REMOVAL ..................5-3 INSTALLING THE ENGINE ..............5-10 INSTALLING THE EXHAUST PIPE AND MUFFLER......5-11 CAMSHAFTS....................5-13 REMOVING THE CAMSHAFTS ............5-17 CHECKING THE CAMSHAFTS ............5-18 CHECKING THE TIMING CHAIN AND SPROCKET......5-19 CHECKING THE TIMING CHAIN GUIDES ..........5-20 CHECKING THE TIMING CHAIN TENSIONER ........5-20 INSTALLING THE CAMSHAFTS ............5-20 CYLINDER HEAD..................5-25...
  • Page 244 OIL PUMP ....................5-51 REMOVING THE OIL PAN ..............5-54 CHECKING THE SPROCKET AND CHAIN .........5-54 CHECKING THE OIL PUMP ..............5-54 CHECKING THE RELIEF VALVE ............5-55 CHECKING THE OIL DELIVERY PIPES..........5-55 CHECKING THE OIL STRAINER............5-55 ASSEMBLING THE OIL PUMP ............5-56 INSTALLING THE OIL/WATER PUMP ASSEMBLY......5-56 INSTALLING THE OIL PAN ..............5-57 CLUTCH......................5-59 REMOVING THE CLUTCH..............5-63...
  • Page 245 TRANSMISSION..................5-92 REMOVING THE TRANSMISSION ............5-96 CHECKING THE SHIFT FORKS ............5-96 CHECKING THE SHIFT DRUM ASSEMBLY........5-97 CHECKING THE TRANSMISSION ............5-97 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ......5-98 INSTALLING THE TRANSMISSION.............5-98...
  • Page 246 ENGINE INSPECTION EAS14B1052 ENGINE INSPECTION EAS14B1053 MEASURING THE COMPRESSION PRES- SURE The following procedure applies to all of the cylinders. Insufficient compression pressure will result in a loss of performance. 6. Measure: 1. Measure: • Compression pressure • Valve clearance Out of specification →...
  • Page 247 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage → Replace. Same as without oil Piston, valves or cyl- inder head gasket possibly defective → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Install: •...
  • Page 248 ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the exhaust pipe and muffler Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. Upper tail cover Refer to “GENERAL CHASSIS” on page 4-1. Side cowling Refer to “GENERAL CHASSIS”...
  • Page 249 ENGINE REMOVAL Removing the exhaust pipe and muffler Order Job/Parts to remove Q’ty Remarks Left muffler Left muffler gasket Right muffler clamp Loosen. Right muffler Right muffler gasket Rear brake light switch coupler Disconnect. Right footrest assembly Exhaust chamber cover Rear brake light switch sensor lead coupler Disconnect.
  • Page 250 ENGINE REMOVAL Removing the exhaust pipe and muffler Order Job/Parts to remove Q’ty Remarks Exhaust chamber protector Exhaust chamber pipe protector clamp Loosen. Exhaust chamber pipe protector Exhaust chamber bracket Exhaust pipe Exhaust pipe gasket For installation, reverse the removal proce- dure.
  • Page 251 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Battery negative lead Refer to “GENERAL CHASSIS” on page 4-1. Battery positive lead Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Side cowling air duct Refer to “GENERAL CHASSIS”...
  • Page 252 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Speed sensor lead coupler Disconnect. Oil level switch lead coupler Disconnect. Gear position sensor coupler Disconnect. Engine ground lead Disconnect. Clutch cable Disconnect. For installation, reverse the removal proce- dure.
  • Page 253 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Left lower cowling bracket Right lower cowling bracket Left inner panel bracket Right inner panel bracket Sidestand assembly Sidestand switch Holder Sidestand switch bracket Engine mounting bolt (front right side) Engine mount collar (front right side) Engine mount collar (front right side) Engine mounting bolt (front left side)
  • Page 254 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Engine mount nut (rear lower side) Engine mount bolt (rear upper side) Engine mount bolt (rear lower side) Engine Engine mount adjusting bolt For installation, reverse the removal proce- dure.

  • Page 255: Pivot Shaft Wrench Adapter

    ENGINE REMOVAL EAS23720 5. Install: INSTALLING THE ENGINE • Engine mount collars (front right side) “1” ECA14B1021 • Engine mount collar (front right side) “2” • Engine mounting bolt (front right side) “3” Do not hold the radiator inlet pipe when (temporary tighten) removing the engine and moving the engine by itself.
  • Page 256 ENGINE REMOVAL Engine mounting bolt (front left side) 70 Nm (7.0 m·kgf, 50 ft·lbf) 7. Tighten: • Engine mounting nut (rear lower side) “1” • Engine mounting nut (rear upper side) “2” Engine mounting nut (rear 9. Tighten: lower side) •...
  • Page 257 ENGINE REMOVAL Installed depth of gasket “c” 3.5 mm (0.14 in) 5-12...
  • Page 258 CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Radiator Refer to “RADIATOR”...
  • Page 259 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-14...
  • Page 260 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Pickup coil cover 2 Refer to “PICKUP ROTOR” on page 5-43. Generator cover Refer to “GENERATOR” on page 5-37. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Exhaust camshaft cap Intake camshaft Exhaust camshaft Intake camshaft sprocket...
  • Page 261 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Crankshaft sprocket Collar Straight key For installation, reverse the removal proce- dure. 5-16...
  • Page 262 CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: • Pickup rotor cover 2 Refer to “PICKUP ROTOR” on page 5-43. 2. Align: • “K” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ECA14B1034 When turning the crankshaft with a tool, remove all the spark plugs.
  • Page 263 CAMSHAFTS Camshaft lobe dimension limit Intake A 37.350–37.450 mm (1.4705– 1.4744 in) Limit 37.250 mm (1.4665 in) Intake B 28.034–28.134 mm (1.1037– 1.1076 in) Limit 7. Remove: 27.934 mm (1.0998 in) • Dowel pins Exhaust A • Timing chain guide (intake side) 36.450–36.550 mm (1.4350–...
  • Page 264 CAMSHAFTS 4. Measure: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Camshaft-journal-to-camshaft-cap clear- 5. Measure: ance • Camshaft journal diameter “a” Out of specification → Measure the cam- Out of specification → Replace the cam- shaft journal diameter. shaft. Within specification → Replace the cylin- Camshaft-journal-to-camshaft- der head and the camshaft caps as a set.
  • Page 265 CAMSHAFTS a. 1/4 tooth b. Correct 3. Hand press 1. Timing chain 4. Bearing 2. Camshaft sprocket or crankshaft sprocket b. Keep pressing the timing chain tensioner EAS23950 rod, mount clip “5” into groove “6”, and lock CHECKING THE TIMING CHAIN GUIDES the timing chain tensioner rod.
  • Page 266 CAMSHAFTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b. When position #1 is at BTDC 105°, align the “K” mark “a” with the crankcase mating surface “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • Intake camshaft sprocket “1” • Exhaust camshaft sprocket “2” Camshaft sprocket bolt 24 Nm (2.4 m·kgf, 17 ft·lbf) Camshaft wrench 90890-04143...
  • Page 267 CAMSHAFTS • When installing the camshaft cap, face the hole with the screw thread “b” on the cam- shaft cap to the left side of the engine. 6. Install: • Exhaust camshaft “1” • Intake camshafts “2” • Hang the timing chain on the sprocket from A.
  • Page 268 When turning the crankshaft with a tool, der head cover gasket. remove all the spark plugs. • Apply bond Yamaha bond No.1215 (Three 11. Check: bond No.1215®) “2” onto the mating surfaces • “K” mark “a”...
  • Page 269 CAMSHAFTS • Tighten the cylinder head cover bolts stages and in a crisscross pattern. Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 5-24...
  • Page 270 CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-3. Intake camshaft Refer to “CAMSHAFTS” on page 5-13. Exhaust camshaft Refer to “CAMSHAFTS” on page 5-13. Coolant temperature sensor Cylinder head Cylinder head gasket Dowel pin...
  • Page 271 CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAM- SHAFTS” on page 5-17. 2. Remove: • Cylinder head nuts • Cylinder head bolts • Loosen the nuts in the proper sequence as ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 272 CYLINDER HEAD 5. Install: • Exhaust camshaft • Intake camshaft Refer to “INSTALLING THE CAM- SHAFTS” on page 5-20. 3. Install: • Cylinder head • Washers • Cylinder head nuts • Cylinder head bolts • Pass the timing chain through the timing chain cavity.
  • Page 273 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-25. Intake valve lifter Intake valve pad Intake valve cotter Intake valve spring retainer Intake valve spring Intake valve Intake valve stem seal...
  • Page 274 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve spring retainer Exhaust valve spring Exhaust valve Exhaust valve stem seal Exhaust valve spring seat Exhaust valve guide For installation, reverse the removal proce- dure.
  • Page 275 VALVES AND VALVE SPRINGS EAS24280 3. Remove: REMOVING THE VALVES • Valve cotters 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 Before removing the internal parts of the cylin- “1”...
  • Page 276 VALVES AND VALVE SPRINGS EAS24290 CHECKING THE VALVES AND VALVE To ease valve guide removal and installation, GUIDES and to maintain the correct fit, heat the cylinder The following procedure applies to all of the head to 100 °C (212 °F) in an oven. valves and valve guides.
  • Page 277 VALVES AND VALVE SPRINGS Valve guide remover (ø4.5) 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide remover (ø5) 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø4.5) 90890-04117 Valve guide installer (4.5 mm) 6. Measure: YM-04117 • Valve stem runout Valve guide installer (ø5) Out of specification →...
  • Page 278 VALVES AND VALVE SPRINGS Valve seat width After replacing the cylinder head or replacing Valve seat width (intake) the valves and valve guides, the valve seat and 0.90–1.10 mm (0.0354–0.0433 valve face should be lapped. Limit ECA14B1031 1.60 mm (0.06 in) Valve seat width (exhaust) This model uses titanium intake valves.
  • Page 279 VALVES AND VALVE SPRINGS Valve spring free length Free length (intake) 39.33 mm (1.55 in) Limit 37.36 mm (1.47 in) Free length (exhaust) 37.96 mm (1.49 in) Limit 36.06 mm (1.42 in) e. Apply a fine lapping compound to the valve face and repeat the above steps.
  • Page 280 VALVES AND VALVE SPRINGS 3. Measure: • Valve spring tilt “a” Out of specification → Replace the valve spring. Spring tilt limit Spring tilt (intake) 2.5°/1.7 mm (0.067 in) Spring tilt (exhaust) 2.5°/1.7 mm (0.067 in) 2. Lubricate: • Valve stem “1” •...
  • Page 281 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. ECA13800 Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad •...
  • Page 282 GENERATOR EAS24480 GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Stator coil lead coupler Refer to “GENERAL CHASSIS”...
  • Page 283 GENERATOR EAS24490 4. Remove: REMOVING THE GENERATOR • Stator coil lead holder “1” 1. Remove: • Stator coil assembly “2” • Generator cover • Generator cover gasket • Dowel pins 2. Remove: • Generator rotor bolt “1” • Washer While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt.
  • Page 284 GENERATOR 4. Apply: • Sealant (onto the stator coil lead grommet “1”) Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 5-39...
  • Page 285 STARTER CLUTCH EAS24550 STARTER CLUTCH Removing the starter clutch Order Job/Parts to remove Q’ty Remarks Clutch housing assembly Refer to “CLUTCH” on page 5-59. Starter clutch gear Bearing Starter clutch assembly Starter idle gear For installation, reverse the removal proce- dure.
  • Page 286 STARTER CLUTCH EAS24560 REMOVING THE STARTER CLUTCH 1. Remove: • Starter clutch bolt “1” • While holding the clutch housing assembly “2” with the sheave holder “3”, remove the starter clutch bolt. • Fix the flat surface of the clutch housing assembly with the sheave holder.
  • Page 287 STARTER CLUTCH • Fix the flat surface of the clutch housing assembly with the sheave holder. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 5-42...
  • Page 288 PICKUP ROTOR EAS14B1058 PICKUP ROTOR Removing the pickup rotor Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Generator cover Refer to “GENERATOR” on page 5-37. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Timing check bolt Pickup rotor cover 1 O-ring...
  • Page 289 PICKUP ROTOR EAS14B1059 REMOVING THE PICKUP ROTOR 1. Remove: • Pickup rotor bolt “1” • Washer • Pickup rotor While holding the generator rotor “2” with the sheave holder “3”, loosen the pickup rotor bolt. Sheave holder 2. Tighten: 90890-01701 •...
  • Page 290 PICKUP ROTOR Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 5-45...
  • Page 291 ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Battery negative lead Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Refer to “THROTTLE BODIES”...
  • Page 292 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Front cover Lock washer Washer Starter motor yoke Armature assembly Gasket Brush holder O-ring Rear cover For installation, reverse the removal proce- dure. 5-47...
  • Page 293 ELECTRIC STARTER EAS24790 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ CHECKING THE STARTER MOTOR a. Measure the armature assembly resis- 1. Check: tances with the digital circuit tester. • Commutator Dirt → Clean with 600 grit sandpaper. Digital circuit tester 2. Measure: 90890-03174 • Commutator diameter “a” Model 88 Multimeter with Out of specification →...
  • Page 294 ELECTRIC STARTER 6. Measure: • Brush spring force Out of specification → Replace the brush holder. Brush spring force 5.28–7.92 (538–808 19.01–28.51 oz) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: • Rear cover “1” Align the tab “a” on the brush holder “2” with the tab “b”...
  • Page 295 ELECTRIC STARTER Align the match marks “a” on the starter motor yoke with the match marks “b” on the front and rear covers. 5-50...
  • Page 296 OIL PUMP EAS24921 OIL PUMP Removing the oil pan and oil/water pump assembly Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Lower cowling Refer to “GENERAL CHASSIS” on page 4-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”...
  • Page 297 OIL PUMP Removing the oil pan and oil/water pump assembly Order Job/Parts to remove Q’ty Remarks Dowel pin Drain pipe Oil strainer Oil pipe Oil delivery pipe 1 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...
  • Page 298 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil/water pump driven sprocket Circlip Oil pump housing Bearing Dowel pin Oil pump outer rotor Oil pump inner rotor For installation, reverse the removal proce- dure. 5-53...
  • Page 299 OIL PUMP EAS24930 EAS24960 REMOVING THE OIL PAN CHECKING THE OIL PUMP 1. Remove: 1. Check: • Oil level switch “1” • Oil pump driven gear “1” Cracks/damage/wear → Replace. • Oil level switch lead holder “2” • Oil pan “3” •...
  • Page 300 OIL PUMP EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes. 1. Check: • Oil delivery pipe 1 “1” • Oil pipe “2” Damage → Replace. Obstruction → Wash and blow out with compressed air.
  • Page 301 OIL PUMP EAS25010 ASSEMBLING THE OIL PUMP 1. Lubricate: • Inner rotor • Outer rotor • Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: 4. Check: • Pin “1” • Oil pump operation • Inner rotor “2” Refer to “CHECKING THE OIL PUMP”...
  • Page 302 OIL PUMP ECA14B1018 After installing the oil/water pump assem- bly drive chain and drive sprocket, make sure the oil/water pump turns smoothly. 5. Install: • Relief valve assembly “1” • O-ring Relief valve assembly bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 3.
  • Page 303 OIL PUMP Oil pan bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil level switch bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Engine oil drain bolt • Gasket Engine oil drain bolt 43 Nm (4.3 m·kgf, 31 ft·lbf) Tighten the oil pan bolts in stages and in a crisscross pattern.
  • Page 304 CLUTCH EAS25061 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Pull lever cover Clutch cable Disconnect. Clutch cover Clutch cover gasket Dowel pin Oil filler cap For installation, reverse the removal proce- dure. 5-59...
  • Page 305 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing For installation, reverse the removal proce- dure. 5-60...
  • Page 306 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Compression spring Pressure plate 1 Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Clutch plate 2 Clutch plate 3 Friction plate 1 Clutch boss nut Spring Clutch boss Pressure plate 2 Conical spring washer...
  • Page 307 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Thrust washer Clutch housing assembly Bearing Washer For installation, reverse the removal proce- dure. 5-62...
  • Page 308 CLUTCH EAS25080 4. Remove: REMOVING THE CLUTCH • Clutch plate 1 “1” 1. Remove: • Friction plate 2 • Pull lever cover “1” • Clutch plate 2 • Clutch cover “2” • Clutch plate 3 • Gasket Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.
  • Page 309 CLUTCH • Pressure plate 2 2. Measure: • Conical spring washer • Clutch plate warpage • Thrust washer (with a surface plate and thickness gauge • Clutch housing assembly “1”) Out of specification → Replace the clutch EAS25100 plates as a set. CHECKING THE FRICTION PLATES The following procedure applies to all of the Warpage limit...
  • Page 310 CLUTCH Clutch plate “1” Part No. Thickness 4B1-16324-00 1.6 mm (0.063 in) 5VY-16325-00 2.0 mm (0.079 in) 4B1-16325-00 2.3 mm (0.091 in) Clutch plate “2” Part No. Thickness 5VY-16325-00 2.0 mm (0.079 in) 4B1-16325-00 2.3 mm (0.091 in) EAS25150 CHECKING THE CLUTCH HOUSING 1.
  • Page 311 CLUTCH EAS25220 EAS25170 CHECKING THE PULL LEVER SHAFT AND CHECKING THE PRESSURE PLATE PULL ROD 1. Check: 1. Check: • Pressure plate 1 “1” • Pull lever shaft pinion gear teeth “1” • Pressure plate 2 “2” Cracks/damage → Replace. •...
  • Page 312 CLUTCH • Stake the clutch boss nut at a cutout “a” in the main axle. Universal clutch holder 90890-04086 YM-91042 2. Install: • Pressure plate 2 “1” • Clutch boss “2” Fit the groove “a” of the pressure plate 2 to the projection “b”...
  • Page 313 CLUTCH • Tighten the clutch cover bolts in stages and in a crisscross pattern. 6. Install: • Bearing (into the pressure plate 1) • Pull rod • Pressure plate 1 7. Install: • Clutch springs • Clutch spring bolts “1” Clutch spring bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the clutch spring bolts in stages and in...
  • Page 314 SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Shift arm Refer to “CHAIN DRIVE” on page 4-83. Clutch assembly Refer to “CLUTCH” on page 5-59. Circlip Washer Shift shaft Washer Circlip Washer Stopper lever...

  • Page 315: Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear → Replace. • Shift shaft spring “2” • Collar Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stop- per lever.
  • Page 316 CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-3. Cylinder head Refer to “CYLINDER HEAD” on page 5-25. Refer to “ELECTRIC STARTER” on page 5- Starter motor Stator coil assembly Refer to “GENERATOR”...
  • Page 317 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Crankcase breather cover Crankcase breather cover gasket Crankcase breather case Crankcase breather case gasket Lower crankcase Dowel pin Crankcase baffle plate For installation, reverse the removal proce- dure. * Following the tightening order, loosen the bolt one by one and then retighten it to the specific torque.
  • Page 318 • Sealant order (refer to the numbers in the illustration). (onto the crankcase mating surfaces) • The numbers embossed on the crankcase Yamaha bond No.1215 indicate the crankcase tightening sequence. (Three Bond No.1215®) 90890-85505 Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.
  • Page 319 CRANKCASE EWA14B1030 WARNING If the crankcase bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Instead, replace the crankcase bolt with a new one and perform the procedure again. ECA14B1043 Do not use a torque wrench to tighten the 6.
  • Page 320 CONNECTING RODS AND PISTONS EAS14B1024 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-71. Connecting rod cap Big end lower bearing Big end upper bearing Connecting rod Piston pin clip Piston pin...
  • Page 321 CONNECTING RODS AND PISTONS 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” • Connecting rod • Big end bearings • Identify the position of each big end bear- ing so that it can be reinstalled in its origi- nal place.
  • Page 322 CONNECTING RODS AND PISTONS 2. Measure: • Piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cylinder. Then, find the average of the mea- surements.
  • Page 323 CONNECTING RODS AND PISTONS Piston ring side clearance Piston ring end gap Top ring Top ring 0.030–0.065 (0.0012– 0.15–0.25 mm (0.0059–0.0098 0.0026 in) Limit Limit 0.115 mm (0.0045 in) 0.50 mm (0.0197 in) 2nd ring 2nd ring 0.020–0.055 (0.0008– 0.30–0.45 mm (0.0118–0.0177 0.0022 in) Limit Limit...
  • Page 324 CONNECTING RODS AND PISTONS 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 bear- ing into the connecting rod cap. Align the projections “a”...
  • Page 325 CONNECTING RODS AND PISTONS • After installing the big end bearing, assemble the connecting rod and connecting rod cap • Do not move the connecting rod or crank- without installing them onto the crankshaft. shaft until the clearance measurement has been completed.
  • Page 326 CONNECTING RODS AND PISTONS 2. Select: • Big end bearings (P1–P4) • The numbers “A” stamped into the crank- shaft web and the numbers “1” on the con- necting rods are used to determine the replacement big end bearings sizes. •...
  • Page 327 CONNECTING RODS AND PISTONS EAS26190 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ INSTALLING THE CONNECTING ROD AND a. Replace the connecting rod bolts with new PISTON ones. The following procedure applies to all of the b. Clean the connecting rod bolts and lubri- connecting rods and pistons. cate the bolt threads and seats with molyb- 1.
  • Page 328 CONNECTING RODS AND PISTONS Recommended lubricant Engine oil 6. Offset: • Piston ring end gaps 4. Install: • Piston “1” (onto the respective connecting rod “2”) • Piston pin “3” • Piston pin clip “4” a. Top ring b. 2nd ring •...
  • Page 329 CONNECTING RODS AND PISTONS Fit the projection “a” of the piston installing tool “3” and blunt-edged part “b” of the cylinder, fix the position of the piston installing tool, and then push the piston down to the cylinder. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Tighten the connecting rod bolts using the fol- lowing procedure.
  • Page 330 CONNECTING RODS AND PISTONS EWA13400 WARNING If the connecting rod bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Instead, replace the connecting rod bolt with a new one and perform the procedure again. ECA13950 Do not use a torque wrench to tighten the connecting rod bolt to the specified angle.
  • Page 331 CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-71. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS” on page 5-76. Balancer shaft Balancer shaft journal lower bearing Balancer shaft journal upper bearing Crankshaft Crankshaft journal lower bearing...
  • Page 332 CRANKSHAFT EAS25980 REMOVING THE CRANKSHAFT AND BAL- ANCER SHAFT 1. Remove: • Balancer shaft “1” • Balancer shaft journal bearings • Crankshaft assembly “2” • Crankshaft journal bearings Identify the position of each balancer shaft journal bearings and crankshaft journal bear- ings so that it can be reinstalled in its original 2.
  • Page 333 CRANKSHAFT g. Remove the lower crankcase and the crankshaft journal lower bearings. h. Measure the compressed Plastigauge® width “a” on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specifica- tion, select replacement crankshaft journal bearings. d. Put a piece of Plastigauge® “1” on each crankshaft journal.
  • Page 334 CRANKSHAFT ECA14B1020 Do not interchange the balancer shaft jour- nal bearings. To obtain the correct balancer shaft-journal-to-balancer shaft-journal- bearing clearance and prevent engine dam- age, the balancer shaft journal bearings must be installed in their original positions. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the balancer shaft journal bearings, balancer shaft journals, and bearing por- tions of the crankcase.
  • Page 335 CRANKSHAFT • If J –J are the same, use the same size for all of the bearings. • Align the projections “a” of the balancer shaft journal lower bearings with the notches “b” in For example, if the crankcase J and bal- the lower crankcase.
  • Page 336 CRANKSHAFT • Align the projections “a” on the crankshaft journal bearings “1” with the notches “b” in the crankcases. • Be sure to install each crankshaft journal bearing in its original place. EAS14B1028 INSTALLING THE BALANCER ASSEMBLY 1. Install: • Balancer journal upper bearings (into the upper crankcase) •...
  • Page 337 TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Lower crankcase Refer to “CRANKCASE” on page 5-71. Drive axle assembly Shift drum retainer Spring Shift fork guide bar Shift fork-L Shift fork-R Shift drum assembly Shift fork-C...
  • Page 338 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd/4th pinion gear Circlip Washer 5th pinion gear Collar Main axle Bearing housing Bearing For installation, reverse the removal proce- dure.
  • Page 339 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip Bearing 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 5-94...
  • Page 340 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip 6th wheel gear Circlip Washer 2nd wheel gear Collar Collar Oil seal Circlip Bearing Drive axle For installation, reverse the removal proce- dure. 5-95...
  • Page 341 TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainers “2” • Shift fork guide bars • Shift fork “L” and “R” • Shift drum assembly • Shift fork “C” EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks.
  • Page 342 TRANSMISSION 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 →...
  • Page 343 TRANSMISSION 5. Check: marks “e” with the alignment mark “d” on the • Transmission gear movement retainer. Rough movement → Replace the defec- tive part(s). 6. Check: • Circlips Bends/damage/looseness → Replace. EAS29020 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1.
  • Page 344 TRANSMISSION • Install shift fork-R into the groove “a” in the 5th wheel gear and shift fork-L into the groove “b” in the 6th wheel gear on the drive axle. • Install the shift drum retainer with its “OUT” mark “c” facing outward. •...
  • Page 345 COOLING SYSTEM RADIATOR....................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR ..............6-3 OIL COOLER ....................6-5 CHECKING THE OIL COOLER..............6-7 INSTALLING THE OIL COOLER ............6-7 THERMOSTAT ....................6-8 CHECKING THE THERMOSTAT............6-10 ASSEMBLING THE THERMOSTAT ASSEMBLY .........6-10 INSTALLING THE THERMOSTAT ASSEMBLY ........6-11 WATER PUMP ....................6-12 DISASSEMBLING THE WATER PUMP..........6-13 CHECKING THE WATER PUMP ............6-13 ASSEMBLING THE WATER PUMP............6-13...
  • Page 346 RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-32. Refer to “GENERAL CHASSIS” on page 4-1. Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Rectifier/regulator Refer to “GENERAL CHASSIS” on page 4-1. Radiator cap Coolant reservoir hose Disconnect.
  • Page 347 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Radiator bracket Radiator fan Thermostat bypass hose 2 Disconnect. Thermostat bypass hose 3 Radiator inlet pipe Radiator inlet hose For installation, reverse the removal proce- dure.
  • Page 348 RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. Straighten any flattened fins with a thin, flat- head screwdriver. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.
  • Page 349 RADIATOR b. Apply 137.3 kPa (1.37 kgf/cm , 19.9 psi) of pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3.
  • Page 350 OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-32. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-29. Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Lower cowling Refer to “GENERAL CHASSIS”...
  • Page 351 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Water jacket joint O-ring Water pump outlet pipe O-ring O-ring For installation, reverse the removal proce- dure.
  • Page 352 OIL COOLER EAS26420 3. Fill: CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage → Replace. Refer to “CHANGING THE COOLANT” 2. Check: on page 3-32. • Oil cooler inlet hose •...
  • Page 353 THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-32. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Refer to “THROTTLE BODIES”...
  • Page 354 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Thermostat bypass hose 2 Water pump bypass hose Joint Thermostat bypass hose 1 Engine outlet pipe O-ring For installation, reverse the removal proce- dure.
  • Page 355 THERMOSTAT EAS26450 CHECKING THE THERMOSTAT If the accuracy of the thermostat is in doubt, 1. Check: replace it. A faulty thermostat could cause seri- • Thermostat “1” ous overheating or overcooling. Does not open at 71–85 °C (159.8–185.0 °F) → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 356 THERMOSTAT EAS26480 INSTALLING THE THERMOSTAT ASSEM- 1. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-32. 2. Check: • Cooling system Leaks → Repair or replace any faulty part.
  • Page 357 WATER PUMP EAS26500 WATER PUMP Disassembling the water pump Order Job/Parts to removes Q’ty Remarks Oil/water pump assembly Refer to “OIL PUMP” on page 5-51. Oil pump rotor Refer to “OIL PUMP” on page 5-51. Water pump cover O-ring Impeller shaft (along with the impeller) Water pump seal Oil seal O-ring...
  • Page 358 WATER PUMP EAS26520 EAS26540 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Water pump seal “1” • Water pump housing cover “1” • Impeller shaft “2” Cracks/damage/wear → Replace. Remove the water pump seal from the inside •...
  • Page 359 WATER PUMP ECA14090 Mechanical seal installer 90890-04132 Make sure the rubber damper and rubber Water pump seal installer damper holder are flush with the impeller. YM-33221-A Middle driven shaft bearing Impeller shaft tilt limit driver 0.15 mm (0.006 in) 90890-04058 Bearing driver 40 mm YM-04058 1.
  • Page 360 WATER PUMP 6-15...
  • Page 361 FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK SIDE COVERS ........7-3 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP...............7-3 CHECKING THE FUEL PUMP BODY ............7-3 CHECKING THE FUEL PUMP OPERATION .........7-3 INSTALLING THE FUEL PUMP..............7-3 INSTALLING THE FUEL TANK...............7-4 INSTALLING THE FUEL TANK SIDE COVERS ........7-4 AIR FILTER CASE ..................7-5 CHECKING THE SECONDARY INJECTORS...
  • Page 362 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank and fuel pump Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank side cover Bolt Bolt/collar/washer 2/2/2 Fuel tank breather hose Disconnect. Fuel tank overflow hose Disconnect.
  • Page 363 FUEL TANK Removing the fuel tank and fuel pump Order Job/Parts to remove Q’ty Remarks Fuel pump bracket Fuel pump Fuel pump gasket For installation, reverse the removal proce- dure.

  • Page 364: Fuel Tank

    FUEL TANK EAS14B1078 REMOVING THE FUEL TANK SIDE COVERS The following procedure applies to both of the fuel tank side covers. 1. Remove: • Fuel tank side cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the screw on the fuel tank side cover. b.
  • Page 365 FUEL TANK • Do not damage the installation surfaces of Install the fuel hose securely onto the fuel the fuel tank when installing the fuel pump. pump until a distinct “click” is heard. • Always use a new fuel pump gasket. •...
  • Page 366 AIR FILTER CASE EAS14B1062 AIR FILTER CASE Removing the air filter case and secondary injectors Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Crankcase breather hose Disconnect. Sub-wire harness coupler Disconnect. Fuel hose (secondary injector fuel rail side) Disconnect.
  • Page 367 AIR FILTER CASE Removing the air filter case and secondary injectors Order Job/Parts to remove Q’ty Remarks Intake funnel servo motor rod assembly Intake funnel assembly Intake funnel servo motor For installation, reverse the removal proce- dure.
  • Page 368 AIR FILTER CASE EAS14B1105 EAS14B1106 CHECKING THE SECONDARY INJECTORS REMOVING THE SECONDARY INJECTORS (BEFORE REMOVING) EWA14B1027 WARNING 1. Check: • Injectors • Check the injectors in a well-ventilated Use the diagnostic code number “D:40– area free of combustible materials. Make D:43”.
  • Page 369 AIR FILTER CASE 4. Remove: EAS14B1077 REMOVING THE INTAKE FUNNEL ASSEM- • Sub-wire harness • Secondary injectors 1. Remove: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Intake funnel servo motor rod assembly a. Remove the fuel rail screws “1” as shown. • Intake funnel assembly •...
  • Page 370 AIR FILTER CASE 2. Check: EAS14B1067 INSTALLING THE INTAKE FUNNEL AND • Injector resistance LOWER AIR FILTER CASE Refer to “CHECKING THE FUEL INJEC- 1. Install: TORS” on page 8-144. • Intake funnel servo motor • Intake funnel servo motor rod assembly EAS14B1113 CHECKING THE AIR FILTER CASE SEAL •...
  • Page 371 AIR FILTER CASE EAS14B1107 5. Install: INSTALLING THE SECONDARY INJEC- • Upper air filter case seal “1” TORS • Secondary injector assembly seal “2” ECA14B1046 • Always use new O-rings. • When checking the injectors, do not allow The matching adhesion portion of the seal any foreign material to enter or adhere to should be positioned within a range of “a”.
  • Page 372 AIR FILTER CASE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS14B1069 INSTALLING THE FUEL HOSE (PRIMARY INJECTOR JOINT SIDE AND SECONDARY INJECTOR JOINT SIDE) 1. Connect: • Fuel hose (primary injector joint side and secondary injector joint side) ECA14B1033 When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position, otherwise the fuel...
  • Page 373 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle body assembly Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Throttle position sensor coupler Disconnect.
  • Page 374 THROTTLE BODIES Removing the throttle body assembly Order Job/Parts to remove Q’ty Remarks Crankshaft position sensor coupler Disconnect. Heat protector Throttle body joint For installation, reverse the removal proce- dure. 7-13...
  • Page 375 THROTTLE BODIES Removing the primary injectors Order Job/Parts to remove Q’ty Remarks Primary injector coupler #1 Disconnect. Primary injector coupler #2 Disconnect. Primary injector coupler #3 Disconnect. Primary injector coupler #4 Disconnect. Sub-wire harness Intake air pressure sensor hose Intake air pressure sensor Fuel rail Primary injector joint Primary injector...
  • Page 376 THROTTLE BODIES EAS14B1108 CHECKING THE PRIMARY INJECTORS (BEFORE REMOVING) 1. Check: • Injectors Use the diagnostic code number “D:36– D:39”. Refer to “DIAGNOSTIC MODE” on page 8-38. EAS14B1109 REMOVING THE PRIMARY INJECTORS EAS14B1110 EWA14B1028 CHECKING THE PRIMARY INJECTORS WARNING 1. Check: •...
  • Page 377 THROTTLE BODIES If the protector “a” is scratched or damaged, replace the throttle bodies as a set. c. Push the lever in the direction shown in the illustration to hold the throttle valves in the open position. EWA14B1022 WARNING When cleaning the throttle bodies, be care- 2.
  • Page 378 THROTTLE BODIES ECA14B1029 • If an injector is subject to strong shocks or excessive force, replace it. • If installing the original fuel rails and • Do not use a tool, such as a wire brush, to remove the carbon deposits; otherwise, bolts, remove the white paint marks using a cleaning solvent.

  • Page 379: Fuel Pressure Adapter

    THROTTLE BODIES EWA14B1001 Pressure gauge WARNING 90890-03153 Cover fuel hose connections with a cloth YU-03153 when disconnecting them. Residual pres- Fuel injector pressure adapter sure in the fuel lines could cause fuel to 90890-03210 spurt out when removing the hoses. YU-03210 ECA14B1003 Be sure to disconnect the fuel hose by...
  • Page 380 THROTTLE BODIES EAS14B1073 ADJUSTING THE THROTTLE POSITION SENSOR EWA14B1023 WARNING • Handle the throttle position sensor with special care. • Never subject the throttle position sensor to strong shocks. If the throttle position sensor is dropped, replace it. 1. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 381 THROTTLE BODIES “dIAG” appears on the odometer LCD. f. Diagnostic code number “D:14” is selected. g. Adjust the position of the accelerator posi- tion sensor angle so that 12–22 can appear in the meter. h. After adjusting the accelerator position sen- sor angle, tighten the accelerator position sensor screws “1”.

  • Page 382: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-21...
  • Page 383 AIR INDUCTION SYSTEM 1. Lower air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover) 7-22...
  • Page 384 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Side air filter case duct Atmospheric pressure sensor coupler Disconnect.
  • Page 385 AIR INDUCTION SYSTEM Removing the reed valves Order Job/Parts to remove Q’ty Remarks Reed valve cover Reed valve assembly Reed valve plate For installation, reverse the removal proce- dure. 7-24...
  • Page 386 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 emis- sion of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.
  • Page 387 AIR INDUCTION SYSTEM 4. Check: A. Exhaust side • Air cut-off valve Cracks/damage → Replace. 3. Install: • Reed valve cover 5. Check: • Air induction system solenoid Reed valve cover bolt (air induc- Refer to “CHECKING THE AIR INDUC- tion system) TION SYSTEM SOLENOID”...
  • Page 388 AIR INDUCTION SYSTEM 7-27...

  • Page 389: General Information

    ELECTRICAL SYSTEM IGNITION SYSTEM..................8-1 CIRCUIT DIAGRAM................8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION .....8-3 TROUBLESHOOTING ................8-5 ELECTRIC STARTING SYSTEM..............8-7 CIRCUIT DIAGRAM................8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-9 TROUBLESHOOTING ................8-11 CHARGING SYSTEM .................8-13 CIRCUIT DIAGRAM................8-13 TROUBLESHOOTING ................8-15 LIGHTING SYSTEM ...................8-17 CIRCUIT DIAGRAM................8-17 TROUBLESHOOTING ................8-19 SIGNALING SYSTEM.................8-21 CIRCUIT DIAGRAM................8-21 TROUBLESHOOTING ................8-23...
  • Page 390 ELECTRICAL COMPONENTS..............8-117 CHECKING THE SWITCHES.............8-121 CHECKING THE BULBS AND BULB SOCKETS.......8-124 CHECKING THE FUSES..............8-125 CHECKING AND CHARGING THE BATTERY........8-125 CHECKING THE RELAYS..............8-129 CHECKING THE TURN SIGNAL/HAZARD RELAY ......8-130 CHECKING THE RELAY UNIT (DIODE) ..........8-131 CHECKING THE IGNITION COILS ............8-132 CHECKING THE CRANKSHAFT POSITION SENSOR .....8-133 CHECKING THE LEAN ANGLE SENSOR .........8-133 CHECKING THE STARTER MOTOR OPERATION......8-134 CHECKING THE STATOR COIL............8-134...
  • Page 392 IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 393 IGNITION SYSTEM 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 12.Relay unit 15.Sidestand switch 21.ECU (engine control unit) 22.Ignition coil #1 23.Ignition coil #2 24.Ignition coil #3 25.Ignition coil #4 26.Spark plug 41.Crankshaft position sensor 45.Cylinder identification sensor 46.Lean angle sensor 64.Right handlebar switch...
  • Page 394 IGNITION SYSTEM EAS14B1082 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
  • Page 395 IGNITION SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. ECU (engine control unit) 9. Sidestand switch 10.Relay unit (diode) 11.Gear position sensor 12.Battery negative lead 13.Engine ground...
  • Page 396 IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Air filter case duct 4. Side cowlings 1. Check the fuses. NG→...
  • Page 397 IGNITION SYSTEM 7. Check the cylinder identification NG→ sensor. Replace the cylinder identification Refer to “CHECKING THE CYLIN- sensor. DER IDENTIFICATION SENSOR” on page 8-141. OK↓ 8. Check the main switch. NG→ Replace the main switch/immobilizer Refer to “CHECKING THE unit assembly.

  • Page 398: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 399 ELECTRIC STARTING SYSTEM 1. Main switch 4. Main fuse 8. Battery 10.Starter relay 11.Starter motor 12.Relay unit 13.Starting circuit cut-off relay 15.Sidestand switch 64.Right handlebar switch 67.Engine stop switch 68.Start switch 69.Gear position sensor 71.Left handlebar switch 76.Clutch switch 100.Ignition fuse 101.Engine ground 102.Battery negative lead...
  • Page 400 ELECTRIC STARTING SYSTEM EAS14B1036 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: •...
  • Page 401 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.
  • Page 402 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Heat protector 4. Side cowlings 1. Check the fuses. NG→ (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
  • Page 403 ELECTRIC STARTING SYSTEM 8. Check the main switch. NG→ Replace the main switch/immobilizer Refer to “CHECKING THE unit. SWITCHES” on page 8-121. OK↓ 9. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-121. OK↓...
  • Page 404 CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-13...
  • Page 405 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Main fuse 8. Battery 101.Engine ground 102.Battery negative lead 8-14...
  • Page 406 CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Right side cowling 1. Check the fuse. NG→ (Main) Replace the fuse. Refer to “CHECKING THE FUSES” on page 8-125. OK↓...
  • Page 407 CHARGING SYSTEM 8-16...
  • Page 408 LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-17...
  • Page 409 LIGHTING SYSTEM 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 21.ECU (engine control unit) 47.Meter assembly 59.High beam indicator light 62.Meter light 71.Left handlebar switch 73.Pass switch 74.Dimmer switch 83.Headlight 84.Auxiliary light 85.Ground (cord headlight) 86.License plate light 88.Tail/brake light 89.Headlight relay...
  • Page 410 LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight or license plate light. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Left side cowling 3. Air intake air duct covers 4.
  • Page 411 LIGHTING SYSTEM 8. Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-17. OK↓ Replace the ECU or meter assembly. 8-20...

  • Page 412: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21...
  • Page 413 SIGNALING SYSTEM 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 12.Relay unit 17.Fuel sender 21.ECU (engine control unit) 39.Speed sensor 42.Coolant temperature sensor 47.Meter assembly 49.Fuel level warning light 50.Oil level warning light 51.Neutral indicator light 52.Tachometer 53.Shift timing indicator light 54.Multi-function meter...
  • Page 414 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. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3.
  • Page 415 SIGNALING SYSTEM 3. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-21. OK↓ This circuit is OK. The tail/brake light fails to come on. 1. Check the front brake light switch. NG→...
  • Page 416 SIGNALING SYSTEM 4. Check the turn signal/hazard relay. NG→ Refer to “CHECKING THE TURN Replace the turn signal/hazard relay. SIGNAL/HAZARD RELAY” on page 8-130. OK↓ 5. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring.
  • Page 417 SIGNALING SYSTEM 2. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-21. OK↓ Replace the meter assembly. The fuel level warning light fails to come on. 1.
  • Page 418 SIGNALING SYSTEM 2. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-21. OK↓ Replace the ECU or meter assembly. The shift timing indicator light fails to come on. 1.
  • Page 419 SIGNALING SYSTEM 8-28...
  • Page 420 COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-29...
  • Page 421 COOLING SYSTEM 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 21.ECU (engine control unit) 42.Coolant temperature sensor 90.Radiator fan motor relay 91.Right radiator fan motor fuse 92.Left radiator fan motor fuse 93.Right radiator fan motor 94.Left radiator fan motor 100.Ignition fuse 101.Engine ground...
  • Page 422 COOLING SYSTEM EAS27320 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings 1. Check the fuses. NG→ (Main, ignition, radiator fan motor and fuel injection system) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-125.
  • Page 423 COOLING SYSTEM 8-32...

  • Page 424: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-33...
  • Page 425 FUEL INJECTION SYSTEM 1. Main switch 4. Main fuse 7. ETV (Electronic Throttle Valve) fuse 8. Battery 9. Fuel injection system fuse 12.Relay unit 13.Starting circuit cut-off relay 14.Fuel pump relay 15.Sidestand switch 16.Fuel pump 18.Throttle position sensor 19.Accelerator position sensor 20.O sensor 21.ECU (engine control unit)
  • Page 426 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.
  • Page 427 FUEL INJECTION SYSTEM ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.
  • Page 428 FUEL INJECTION SYSTEM EAS14B1115 The engine operation is not normal but the TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1. Check the operation of following sensors engine trouble warning light comes on. and actuators in the Diagnostic mode.
  • Page 429 FUEL INJECTION SYSTEM EAS14B1084 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. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.
  • Page 430 FUEL INJECTION SYSTEM Sensor operation table Diag- nostic Item Meter display Checking method code D:01 Throttle position sensor sig- nal 1 • Fully closed position 12–21 Check with throttle valves fully closed. • Fully opened position 97–106 Check with throttle valves fully open.
  • Page 431 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:13 Throttle position sensor sig- nal 2 • Fully closed position 9–23 Check with throttle valves fully closed. • Fully opened position 94–108 Check with throttle valves fully open. D:14 Accelerator position sensor signal 1...
  • Page 432 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:61 Malfunction history code — display • No history • History exists Fault codes 11–70 • (If more than one code number is detected, the dis- play alternates every two seconds to show all the detected code numbers.
  • Page 433 FUEL INJECTION SYSTEM Actuator operation table Diag- nostic Item Actuation Checking method code D:30 Cylinder-#1 ignition coil Actuates the cylinder-#1 igni- Check the spark five times. tion coil five times at one-sec- • Connect an ignition ond intervals. checker. Illuminates the engine trou- ble warning light.
  • Page 434 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code D:40 Secondary injector #1 Actuates the secondary injec- Check the operating sound tor #1 five times at one-sec- of the secondary injector #1 ond intervals. five times. Illuminates the engine trou- ble warning light.
  • Page 435 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code D:51 Radiator fan motor relay Actuates the radiator fan Check the operating sound motor relay for five cycles of of the radiator fan motor five seconds. (ON 2 sec- relay five times. onds, OFF 3 seconds) Illuminates the engine trou- ble warning light.
  • Page 436 FUEL INJECTION SYSTEM EAS14B1085 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the meter display according to the reinstatement method.
  • Page 437 FUEL INJECTION SYSTEM Fault code No. Normal signals are not received from the cylinder identification sen- Symptom sor. Engine startup: Impossible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 438 FUEL INJECTION SYSTEM Fault code No. Normal signals are not received from the crankshaft position sen- Symptom sor. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 439 FUEL INJECTION SYSTEM If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code No. Symptom Open or short circuit of intake air pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:03...
  • Page 440 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:03 ing code No. Meter display Displays the intake air pressure. Set the engine stop switch to “ ”, and then push the start switch Checking method “...
  • Page 441 FUEL INJECTION SYSTEM If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code No. The intake air pressure sensor has failed (due to clogging of hose or Symptom sensor disconnection). Engine startup: Possible Fail-safe action Riding: Possible...
  • Page 442 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:01 ing code No. D:13 Throttle position sensor signal 1 Meter display •...
  • Page 443 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:01 ing code No. D:13 Throttle position sensor signal 1 Meter display •...
  • Page 444 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:01 ing code No. D:13 Throttle position sensor signal 1 Meter display •...
  • Page 445 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of ECU input line (Blue/Yellow lead) Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:20 ing code No. Sidestand switch Meter display • ON (stand retracted) • OFF (stand extended) Checking method Set on/off the sidestand switch.
  • Page 446 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of ECU input line (Blue/Yellow lead) Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:20 ing code No. Sidestand switch Meter display • ON (stand retracted) • OFF (stand extended) Checking method Set on/off the sidestand switch.
  • Page 447 FUEL INJECTION SYSTEM Fault code No. When the main switch is ON, there is a big difference in voltage Symptom value of the intake air pressure sensor and atmospheric pressure sensor Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:03 ing code No.
  • Page 448 FUEL INJECTION SYSTEM Fault code No. When the main switch is ON, there is a big difference in voltage Symptom value of the intake air pressure sensor and atmospheric pressure sensor Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:03 ing code No.
  • Page 449 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of coolant temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:06 ing code No. When engine is cold: Displays temperature closer to air temperature Meter display When engine is hot: Displays current coolant temperature Compare the actually measured coolant temperature with the meter Checking method...
  • Page 450 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of coolant temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:06 ing code No. When engine is cold: Displays temperature closer to air temperature Meter display When engine is hot: Displays current coolant temperature Compare the actually measured coolant temperature with the meter Checking method...
  • Page 451 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:05 ing code No. When engine is cold: Displays temperature closer to air temperature Meter display When engine is hot: Air temperature + approx.
  • Page 452 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of atmospheric pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:02 ing code No. Meter display Displays the atmospheric pressure. Compare the actually measured atmospheric pressure with the Checking method meter display value.
  • Page 453 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of atmospheric pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:02 ing code No. Meter display Displays the atmospheric pressure. Compare the actually measured atmospheric pressure with the Checking method meter display value.
  • Page 454 FUEL INJECTION SYSTEM Fault code No. The O sensor does not operate. Symptom Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure sensor installation status...
  • Page 455 FUEL INJECTION SYSTEM Fault code No. The O sensor does not operate. Symptom Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure sensor malfunction...
  • Page 456 FUEL INJECTION SYSTEM Fault code No. Symptom Turnover of vehicle Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:08 ing code No. Lean angle sensor Meter display • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Checking method Remove the lean angle sensor and incline it more than 45 degrees. Item/components and Sensor inspection proce- Check or maintenance job...
  • Page 457 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #1 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:30 ing code No. Actuates the cylinder-#1 ignition coil five times at one-second inter- Meter display vals.
  • Page 458 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #1 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:30 ing code No. Actuates the cylinder-#1 ignition coil five times at one-second inter- Meter display vals.
  • Page 459 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #2 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:31 ing code No. Actuates the cylinder-#2 ignition coil five times at one-second inter- Meter display vals.
  • Page 460 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #2 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:31 ing code No. Actuates the cylinder-#2 ignition coil five times at one-second inter- Meter display vals.
  • Page 461 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #3 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:32 ing code No. Actuates the cylinder-#3 ignition coil five times at one-second inter- Meter display vals.
  • Page 462 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #3 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:32 ing code No. Actuates the cylinder-#3 ignition coil five times at one-second inter- Meter display vals.
  • Page 463 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #4 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:33 ing code No. Actuates the cylinder-#4 ignition coil five times at one-second inter- Meter display vals.
  • Page 464 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #4 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:33 ing code No. Actuates the cylinder-#4 ignition coil five times at one-second inter- Meter display vals.
  • Page 465 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of primary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:36 Diagnostic monitor- D:37 ing code No.
  • Page 466 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of primary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:36 Diagnostic monitor- D:37 ing code No.
  • Page 467 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of primary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:36 Diagnostic monitor- D:37 ing code No.
  • Page 468 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of secondary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:40 Diagnostic monitor- D:41 ing code No.
  • Page 469 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of secondary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:40 Diagnostic monitor- D:41 ing code No.
  • Page 470 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of secondary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:40 Diagnostic monitor- D:41 ing code No.
  • Page 471 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of secondary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:40 Diagnostic monitor- D:41 ing code No.
  • Page 472 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of lean angle sensor lead Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:08 ing code No. Lean angle sensor Meter display • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Checking method Remove the lean angle sensor and incline more than 45 degrees.
  • Page 473 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of lean angle sensor lead Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:08 ing code No. Lean angle sensor Meter display • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Checking method Remove the lean angle sensor and incline more than 45 degrees.
  • Page 474 FUEL INJECTION SYSTEM Fault code No. Symptom A. Normal signals are not received from the speed sensor. B. Open or short circuit of gear position sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitoring D:07 (Speed sensor) code No. Meter display Vehicle speed pulses: 0–999 Make sure that the indication value increases when the rota-...
  • Page 475 FUEL INJECTION SYSTEM A. Speed sensor system malfunction Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection → Connect Connection of speed sensor Start the engine, and check (meter) coupler it securely, or repair/replace the connection of the coupler Check the connection of the the wire harness.
  • Page 476 FUEL INJECTION SYSTEM B. Gear position sensor system malfunction Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection → Recon- Connection of gear position Start the engine, and check sensor coupler nect or repair the coupler. the secure connection of the Check the connection of the coupler.
  • Page 477 FUEL INJECTION SYSTEM Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Shift drum (that detects the Check the gear shift drum Start the engine, and check neutral position) malfunction (that detects the neutral posi- the secure connection of the tion).
  • Page 478 FUEL INJECTION SYSTEM Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Open short circuit → Replace Continuity of wire harness Start the engine, and check the wire harness. the secure connection of the Black/Yellow–Black/Yellow coupler. Blue/Yellow–Blue/Yellow Ride the vehicle at a low speed (approx.
  • Page 479 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage supplied to the fuel injector and fuel pump Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:50 ing code No. Meter display Approximately 12.0 Set the engine stop switch to “ ”, and then compare with the actu- Checking method ally measured battery voltage.
  • Page 480 FUEL INJECTION SYSTEM Fault code No. Symptom An error is detected while reading or writing on EEP-ROM Engine startup: Under certain conditions Fail-safe action Riding: Under certain conditions Diagnostic monitor- D:60 ing code No. The in self diagnostic code 44 detected EEP-ROM errors are indi- cated.
  • Page 481 FUEL INJECTION SYSTEM Fault code No. Symptom An error is detected while reading or writing on EEP-ROM Engine startup: Under certain conditions Fail-safe action Riding: Under certain conditions Diagnostic monitor- D:60 ing code No. The in self diagnostic code 44 detected EEP-ROM errors are indi- cated.
  • Page 482 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage is supplied to the ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection →...
  • Page 483 FUEL INJECTION SYSTEM Fault code No. Symptom ECU memory malfunction Engine startup: Under certain conditions Fail-safe action Riding: Under certain conditions Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure ECU malfunction...
  • Page 484 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of accelerator position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:14 ing code No. D:15 Accelerator position sensor signal 1 Meter display •...
  • Page 485 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of accelerator position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:14 ing code No. D:15 Accelerator position sensor signal 1 Meter display •...
  • Page 486 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of accelerator position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:14 ing code No. D:15 Accelerator position sensor signal 1 Meter display •...
  • Page 487 FUEL INJECTION SYSTEM Fault code No. Symptom Defect Found in YCC-T Drive Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 488 FUEL INJECTION SYSTEM Fault code No. Symptom Defect Found in YCC-T Drive Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 489 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of steering damper solenoid lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:47 ing code No. Meter display The steering damper warning light lights up. The engine warning light flashes according to the ON/OFF switch- Checking method ing.
  • Page 490 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signal is received from the ECU. Engine startup: Impossible if ECU Failure Fail-safe action Riding: Impossible if ECU Failure Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job...
  • Page 491 FUEL INJECTION SYSTEM Fault code No. Er-2 Symptom No signal is sent from ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection →...
  • Page 492 FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Correct data cannot be received from the ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 493 FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom No registration data can be received from the meter unit. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 494 FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-103...
  • Page 495 FUEL PUMP SYSTEM 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 12.Relay unit 14.Fuel pump relay 16.Fuel pump 21.ECU (engine control unit) 64.Right handlebar switch 67.Engine stop switch 100.Ignition fuse 101.Engine ground 102.Battery negative lead 8-104...
  • Page 496 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Passenger seat 4. Left side cowling 1. Check the fuses. NG→ (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 497 FUEL PUMP SYSTEM 7. Check the entire fuel pump sys- NG→ tem’s wiring. Properly connect or repair the fuel Refer to “CIRCUIT DIAGRAM” on pump system’s wiring. page 8-103. OK↓ Replace the ECU. 8-106...

  • Page 498: Immobilizer System

    IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-107...
  • Page 499 IMMOBILIZER SYSTEM 1. Main switch 4. Main fuse 5. Backup fuse 6. Immobilizer unit 8. Battery 9. Fuel injection system fuse 21.ECU (engine control unit) 47.Meter assembly 48.Immobilizer system indicator light 54.Multi-function meter 100.Ignition fuse 101.Engine ground 102.Battery negative lead 8-108...
  • Page 500 IMMOBILIZER SYSTEM EAS27671 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • A code re-registering key (with a red bow) • Two standard keys (with a black bow) that can be re-registered with new codes •...
  • Page 501 IMMOBILIZER SYSTEM EAS27691 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS In the course of use, you may encounter the following cases where replacement of parts and regis- tration of code re-registering/standard keys are required. Each standard key is registered during production, therefore re-registering at purchase is not neces- sary.
  • Page 502 IMMOBILIZER SYSTEM Standby mode d. LED off a. Main switch “ON” e. Standby mode on b. Main switch “OFF” f. Standby mode off c. LED on Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
  • Page 503 IMMOBILIZER SYSTEM Standard key registration i. Registration mode a. Main switch “ON” b. Main switch “OFF” A. Registration of the second standard key is c. LED on complete. d. LED off B. Immobilizer system indicator light stops e. Less than 5.0 s flashing when the registration of the second f.
  • Page 504 IMMOBILIZER SYSTEM EAS27701 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. 1. Check the fuses. NG→ (Main, ignition, backup and fuel injection system) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-125.
  • Page 505 IMMOBILIZER SYSTEM EAS27721 SELF-DIAGNOSIS FAULT CODE INDICATION When a system failure occurs, the error code number is indicated in the LCD display of meter and the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code.
  • Page 506 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Key code registra- Same standard key was UNIT tion malfunction. attempted to be regis- Register another tered two consecutive standard key. times. Undefinition code is Noise interference or dis- 1. Check the wire received.
  • Page 507 IMMOBILIZER SYSTEM 8-116...
  • Page 508 ELECTRICAL COMPONENTS EAS27972 ELECTRICAL COMPONENTS 8-117...
  • Page 509 ELECTRICAL COMPONENTS 1. Main switch 2. Immobilizer unit 3. Front brake light switch 4. Clutch switch 5. Ignition coil 6. Battery 7. Fuse box 8. Main fuse 9. Fuel injection system fuse 10.Starter relay 11.Rear brake light switch 12.Gear position sensor 13.Sidestand switch 14.O sensor...
  • Page 510 ELECTRICAL COMPONENTS 8-119...
  • Page 511 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Headlight relay 3. Turn signal/hazard relay 4. Atmospheric pressure sensor 5. Intake air pressure sensor 6. Intake funnel servo motor 7. Fuel pump 8. Relay unit 9. Lean angle sensor 10.Coolant temperature sensor 11.Crankshaft position sensor 12.Throttle servo motor 13.Throttle position sensor...
  • Page 512 ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-121...
  • Page 513 ELECTRICAL COMPONENTS 1. Horn switch 2. Clutch switch 3. Main switch 4. Dimmer switch 5. Pass switch 6. Turn signal switch 7. Hazard switch 8. Sidestand switch 9. Gear position sensor 10.Oil level switch 11.Front brake light switch 12.Engine stop switch 13.Start switch 14.Rear brake light switch 8-122...
  • Page 514 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 Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
  • Page 515 ELECTRICAL COMPONENTS EAS27990 otherwise it may be pulled out of the ter- CHECKING THE BULBS AND BULB SOCK- minal in the coupler. • Avoid touching the glass part of the head- light bulb to keep it free from oil, other- Do not check any of the lights that use LEDs.

  • Page 516: Chassis

    ELECTRICAL COMPONENTS d. If the fuse immediately blows again, check the electrical circuit. Check each bulb socket for continuity in the same manner as described in the bulb section; Amperage Fuses Q’ty however, note the following. rating Main 50 A ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 517 ELECTRICAL COMPONENTS • DO NOT SMOKE when charging or han- ECA13640 dling batteries. • KEEP BATTERIES AND ELECTROLYTE First, disconnect the battery negative lead OUT OF REACH OF CHILDREN. “1”, and then battery positive lead “2”. • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.
  • Page 518 ELECTRICAL COMPONENTS • When charging a battery, be sure to remove it from the vehicle. (If charging has to be done with the battery mounted on the vehicle, disconnect the battery negative lead from the battery terminal.) • To reduce the chance of sparks, do not plug in the battery charger until the bat- tery charger leads are connected to the battery.

  • Page 519: Engine

    ELECTRICAL COMPONENTS Voltage should be measured 30 minutes after Voltage should be measured 30 minutes after the engine is stopped. the engine is stopped. b. Connect a charged and ammeter to the b. Connect a charger and ammeter to the bat- battery and start charging.
  • Page 520 ELECTRICAL COMPONENTS 9. Lubricate: Relay unit (starting circuit cut-off relay) • Battery terminals Recommended lubricant Dielectric grease 10. Install: • Battery cover • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELAYS 1. Positive battery terminal Check each switch for continuity with the 2.
  • Page 521 ELECTRICAL COMPONENTS Headlight relay Turn signal/hazard relay input voltage DC 12 V ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the turn signal/hazard relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1. Positive battery terminal •...
  • Page 522 ELECTRICAL COMPONENTS Continuity Positive tester probe Sky blue “1” Negative tester probe Black/Yellow “2” No continuity Positive tester probe Black/Yellow “2” Negative tester probe Sky blue “1” Continuity b. Turn the main switch to “ON”. Positive tester probe c. Measure the turn signal/hazard relay out- Sky blue “1”...
  • Page 523 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Check: a. Disconnect the relay unit coupler from the • Secondary coil resistance Out of specification → Replace. wire harness. b. Connect the pocket tester (Ω × 1) to the Secondary coil resistance relay unit terminal as shown. 8.50–11.50 kΩ...
  • Page 524 ELECTRICAL COMPONENTS b. Measure the crankshaft position sensor 2. Ignition coil resistance. b. Turn the main switch to “ON” and engine ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ stop switch to “ ”. c. Measure the ignition spark gap “a”. EAS28130 d. Crank the engine by pushing the start CHECKING THE LEAN ANGLE SENSOR 1.
  • Page 525 ELECTRICAL COMPONENTS EAS28150 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.112–0.168 Ω at 20 °C (68 °F) c.
  • Page 526 ELECTRICAL COMPONENTS EAS28170 2. Check: CHECKING THE RECTIFIER/REGULATOR • Rectifier/regulator output voltage 1. Check: Out of specification → Replace the recti- • Rectifier/regulator input voltage fier/regulator. Out of specification → Correct the stator coil condition. Rectifier/regulator output volt- Refer to “CHECKING THE STATOR COIL”...
  • Page 527 ELECTRICAL COMPONENTS b. Connect the pocket tester (Ω × 1) to the Pocket tester horn terminals. 90890-03112 Pocket tester Analog pocket tester 90890-03112 YU-03112-C Analog pocket tester YU-03112-C Minimum level position “A” • Positive tester probe • Positive tester probe Connector (White) “1”...
  • Page 528 ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe Green/White “1” • Negative tester probe Black “2” c. Turn the main switch to “ON”. d. Elevate the rear wheel and slowly rotate it. e. Measure the voltage. 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.
  • Page 529 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 100) to the coolant temperature sensor as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Immerse the coolant temperature sensor “1” in a container filled with coolant “2”. Make sure the coolant temperature sensor ter- minals do not get wet.
  • Page 530 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Throttle position sensor resis- a. Connect the pocket tester (Ω × 1 k) to the tance accelerator position sensor terminal as 1.2–2.8 kΩ shown. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Pocket tester a. Connect the pocket tester (Ω × 1 k) to the 90890-03112 throttle position sensor terminal as shown.
  • Page 531 ELECTRICAL COMPONENTS • Positive tester probe Do not use old batteries to operate the throttle Orange “1” servo motor. • Negative tester probe Green “2” c. Measure the air induction system solenoid resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28380 CHECKING THE ATMOSPHERIC PRES- SURE SENSOR 1.
  • Page 532 ELECTRICAL COMPONENTS • Positive tester probe Pocket tester Pink (wire harness color) 90890-03112 • Negative tester probe Analog pocket tester Black/blue (wire harness color) YU-03112-C Test harness-speed sensor (3P) 90890-03208 YU-03208 • Positive tester probe White/Black (wire harness color) • Negative tester probe Black/Blue (wire harness color) c.
  • Page 533 ELECTRICAL COMPONENTS b. Connect the digital circuit tester (DCV) to Intake air temperature sensor the test harness S-pressure sensor (3P). resistance 5.4–6.6 kΩ at 0 °C (32 °F) Digital circuit tester 290–390 Ω at 80 °C (176 °F) 90890-03174 Model 88 Multimeter with ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 534 ELECTRICAL COMPONENTS 2. Check: Pocket tester • Steering damper solenoid resistance 90890-03112 Out of specification → Replace the steer- Analog pocket tester ing damper assembly. YU-03112-C Steering damper solenoid resis- tance Result 49.82–56.18 Ω at 20 °C (68 °F) Neutral position Continuity ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 535 ELECTRICAL COMPONENTS EAS14B1101 CHECKING THE FUEL INJECTORS 1. Remove: • Fuel tank Refer to “FUEL TANK” on page 7-1. • Air filter upper cover (for secondary injec- tor) Refer to “AIR FILTER CASE” on page 7- 2. Check: • Fuel injector resistance Out of specification →...
  • Page 536 ELECTRICAL COMPONENTS 8-145...
  • Page 537 TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED ..........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING ..............9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ...................9-2 OVERHEATING ..................9-2 OVERCOOLING ..................9-3 POOR BRAKING PERFORMANCE ............9-3 FAULTY FRONT FORK LEGS ..............9-3 UNSTABLE HANDLING................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........9-4...
  • Page 538 TROUBLESHOOTING EAS28451 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does • Improperly installed fuse not cover all the possible causes of trouble. It 3.
  • Page 539 TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •...

  • Page 540: Cooling System

    TROUBLESHOOTING 2. Engine oil • Faulty brake caliper kit • Incorrect oil level • Faulty brake caliper seal • Incorrect oil viscosity • Loose union bolt • Inferior oil quality • Damaged brake hose • Oil or grease on the brake disc Cooling system •...

  • Page 541: Troubleshooting

    TROUBLESHOOTING 6. Tire(s) Turn signal blinks quickly • Uneven tire pressures (front and rear) • Incorrect turn signal bulb • Incorrect tire pressure • Faulty turn signal/hazard relay • Uneven tire wear • Burnt-out turn signal bulb 7. Wheel(s) Horn does not sound •...
  • Page 542 EAS28740 55. Transmission gear display Light green WIRING DIAGRAM 56. Steering damper warning light Orange 57. Engine trouble warning light YZF-R1(Y) Pink 58. Coolant temperature warning 1. Main switch light Sky blue 2. AC magneto 59. High beam indicator light Violet 3.
  • Page 544 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 545 WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES YZF-R1(Y) YZF-R1(Y) YZF-R1(Y) YZF-R1(Y) DE YZF-R1(Y)
  • Page 546 WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES YZF-R1(Y) YZF-R1(Y) YZF-R1(Y) YZF-R1(Y) DE YZF-R1(Y)

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