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If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
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EBS20004 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. •...
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EBS20005 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 mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
EBS10003 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM DRIVE TRAIN ELECTRICAL SYSTEM TROUBLESHOOTING...
GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-3 OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) ..................1-3 INSTRUMENT FUNCTIONS ..............1-5 IMPORTANT INFORMATION ................. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7 GASKETS, OIL SEALS AND O-RINGS ............
IDENTIFICATION EBS20009 IDENTIFICATION EBS30003 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the frame. EBS30004 MODEL LABEL The model label “1” is affixed at the location in the illustration. This information will be needed to order spare parts.
FEATURES EBS20010 FEATURES EBS30007 OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
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FEATURES 1. Speed information from speed sensor b. Twists torsion bar 2. Engine RPM information from ECU c. Sends the torque sensor signal 3. Battery d. EPS control unit calculates assist power 4. EPS control unit e. Electricity output switched by EPS control unit 5.
FEATURES Clock mode EBS30008 INSTRUMENT FUNCTIONS Pushing the “CLOCK” button switches the dis- play between the clock mode “CLOCK” and the Multi-function display hour meter mode “HOUR” in the following order: CLOCK → HOUR → CLOCK To set the clock 1.
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FEATURES Self-diagnosis device 1. Fault code display 2. Engine trouble warning light This model is equipped with a self-diagnosis de- vice for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light will come on or flash and the multi-function display will indicate an fault code.
5. Keep all parts away from any source of fire. EBS30010 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...
IMPORTANT INFORMATION EBS30013 EBS30015 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.
BASIC SERVICE INFORMATION EBS20012 BASIC SERVICE INFORMATION EBS30016 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.
BASIC SERVICE INFORMATION ECB01520 EBS30017 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECB01460 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
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BASIC SERVICE INFORMATION ECB01480 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong shocks. sure that the battery voltage is at least 12 V. ECB01490 ECB01440 NOTICE NOTICE...
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BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
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BASIC SERVICE INFORMATION The resistance values shown were obtained at the standard measuring temperature of 20 °C (68 °F). If the measuring temperature is not 20 °C (68 °F), the specified measuring conditions will be shown. Intake air temperature sensor re- sistance 5.40–6.60 kΩ...
2.10 L (2.22 US qt, 1.85 Imp.qt) Quantity (disassembled) 2.60 L (2.75 US qt, 2.29 Imp.qt) Differential gear oil Type Yamaha Friction Modified Plus Shaft Drive Oil (Part No.: ACC-SHFTL-PL-32) or SAE 80 API GL-4 Hypoid gear oil Quantity 0.22 L (0.23 US qt, 0.19 Imp.qt) Quantity (disassembled) 0.23 L (0.24 US qt, 0.20 Imp.qt)
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ENGINE SPECIFICATIONS Oil pump Inner-rotor-to-outer-rotor-tip clearance limit 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing clearance limit 0.240 mm (0.0094 in) Oil pressure (hot) 50.0 kPa/1600 r/min (0.50 kgf/cm²/1600 r/min, 7.3 psi/1600 r/min) Cooling system Coolant quantity Radiator (including all routes) 1.76 L (1.86 US qt, 1.55 Imp.qt) Coolant reservoir (up to the maximum level mark) 0.25 L (0.26 US qt, 0.22 Imp.qt)
ELECTRICAL SPECIFICATIONS EBS20017 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Engine control unit Model/manufacturer F8T85873/MITSUBISHI (YF70GPLG, YF70GPSG, YFM70GPLG, YFM70GPSG) F8T85875/MITSUBISHI (YF70GPG, YFM700FWAD, YFM70GPHG, YFM70GPXG) F8T85876/MITSUBISHI (YF70GG, YFM70GDHG, YFM70GDXG) Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 7.0°/1600 r/min 152.0–228.0 Ω...
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ELECTRICAL SPECIFICATIONS Coolant temperature warning light Park indicator light Engine trouble warning light High-range indicator light Low-range indicator light Differential gear lock indicator light EPS warning light LED (YF70GPG, YF70GPLG, YF70GPSG, YFM700FWAD, YFM70GPHG, YFM70GPLG, YFM70GPSG, YFM70GPXG) Starter motor Power output 0.80 kW 0.005–0.015 Ω...
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ELECTRICAL SPECIFICATIONS Headlight fuse 10.0 A Signaling system fuse 10.0 A Ignition fuse 10.0 A Radiator fan motor fuse 20.0 A Auxiliary DC jack fuse 10.0 A Fuel injection system fuse 15.0 A Four-wheel-drive motor fuse 10.0 A EPS fuse 40.0 A (YF70GPG, YF70GPLG, YF70GPSG, YFM700FWAD, YFM70GPHG, YFM70GPLG, YFM70GPSG, YFM70GPXG)
TIGHTENING TORQUES EBS20018 TIGHTENING TORQUES EBS30018 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
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TIGHTENING TORQUES Cylinder head bolt and cylinder bolt 1. Temporarily tighten the cylinder head bolts (M6) and cylinder bolts (M6). 2. Tighten the cylinder head bolts (M11) to 30 Nm (3.0 m·kgf, 22 ft·lbf) in the proper tightening se- quence. 3.
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TIGHTENING TORQUES Oil pump bolt Tighten the oil pump bolts to 10 Nm (1.0 m·kgf, 7.2 ft·lbf) in the proper tightening sequence. 2-17...
LUBRICATION POINTS AND LUBRICANT TYPES EBS20094 LUBRICATION POINTS AND LUBRICANT TYPES EBS30021 ENGINE Lubrication point Lubricant/Sealant Oil seal lips Bearings O-rings Cylinder head bolt threads and washers Crankshaft seals Piston pin Cylinder inner surface, piston, piston rings and ring grooves Valve stems and stem ends (intake and exhaust) Valve stem seals (intake and exhaust) Valve lifter surfaces...
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LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant/Sealant Yamaha bond No.1215 Crankcase mating surface (Three Bond No.1215®) 2-24...
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CABLE ROUTING 1. Front brake hose 2. Throttle cable 3. Rear brake cable 4. Shift control cable 5. Rear brake hose 6. Front brake light switch lead 7. On-Command four-wheel-drive motor switch and differential gear lock switch lead 8. Meter assembly lead 9.
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CABLE ROUTING 1. Front brake light switch lead 2. On-Command four-wheel-drive motor switch and differential gear lock switch lead 3. Rear brake light switch lead 4. Handlebar switch lead (left) 5. Differential case breather hose 6. Radiator fan motor breather hose 7.
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CABLE ROUTING Engine (left side view) 2-37...
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CABLE ROUTING 1. Coolant reservoir hose 2. Radiator fan motor breather hose 3. Differential case breather hose 4. Ground lead 5. Coolant reservoir breather hose 6. Throttle body breather hose 7. TPS lead 8. Intake air pressure sensor lead 9. Final drive case breather hose 10.
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CABLE ROUTING 1. AC magneto/crankshaft position sensor lead 2. ISC unit lead 3. Final drive case breather hose 4. Negative battery lead 5. Starter motor lead 6. Throttle body breather hose 7. Coolant temperature sensor lead 8. Throttle cable 9. Wire harness 10.
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CABLE ROUTING Engine (right side view 2) 2-41...
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CABLE ROUTING 1. Tail/brake light lead 2. Fuel tank breather hose 3. Circuit breaker 4. Rectifier/regulator lead 5. AC magneto/crankshaft position sensor lead 6. Wire harness 7. Speed sensor lead 8. Final drive case breather hose 9. Fuel hose 10. Fuel pump lead A.
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CABLE ROUTING 1. Headlight lead (left) L. Pass the coolant reservoir breather hose through the guides on the electrical components tray and 2. Four-wheel-drive motor relay 1 route it under the positive battery lead and starter 3. Four-wheel-drive motor relay 2 motor lead.
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CABLE ROUTING 1. Throttle cable 2. Rear brake cable 3. Rear brake hose 4. Shift control cable 5. Front brake hose 6. Negative battery lead 7. Final drive case breather hose 8. Starter motor lead 9. Throttle body breather hose 10.
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CABLE ROUTING Front and rear brake hoses 2-47...
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CABLE ROUTING 1. Front brake pipe 2. Front brake hose 3. Rear brake pipe 4. Rear brake hose A. Face the mark on the front brake pipe upward. B. Route the front brake hose above the frame. C. Pass the front brake hose through the holder. D.
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 .......3-1 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUG ............... 3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5 CHECKING THE BREATHER HOSES .............3-8 CHECKING THE EXHAUST SYSTEM............3-8 ADJUSTING THE EXHAUST GAS VOLUME ...........3-8...
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LUBRICATING THE LEVERS ..............3-32 LUBRICATING THE PEDAL ..............3-32 ADJUSTING THE DRIVE SELECT LEVER CONTROL CABLE AND SHIFT ROD..................3-32 ADJUSTING THE THROTTLE LEVER FREE PLAY ......3-33 ADJUSTING THE SPEED LIMITER............3-34 REPLACING THE HANDLE MOUNTED LIGHT BULB......3-34 ADJUSTING THE HEADLIGHT AND HANDLE MOUNTED LIGHT BEAMS ....................
However, keep in mind that if the vehicle isn’t used for a long period of time, the month main- tenance intervals should be followed. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
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PERIODIC MAINTENANCE INITIAL EVERY month CHECK OR MAINTENANCE Whichever ITEM 1300 2500 2500 5000 comes first km (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) •...
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PERIODIC MAINTENANCE INITIAL EVERY month CHECK OR MAINTENANCE Whichever ITEM 1300 2500 2500 5000 comes first km (mi) (200) (800) (1600) (1600) (3200) hours • Check operation. √ √ √ √ √ Throttle lever • Check throttle lever free play, and adjust if necessary. •...
PERIODIC MAINTENANCE EBS30028 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
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PERIODIC MAINTENANCE b. Calculate the difference between the speci- fied valve clearance and the measured valve clearance. Example: Specified valve clearance = 0.10–0.20 mm (0.0039–0.0079 in) Measured valve clearance = 0.27 mm (0.0106 in) 0.27 mm (0.0106 in)–0.20 mm (0.0079 in) = 0.07 mm (0.0028 in) c.
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PERIODIC MAINTENANCE • Position the holes “a” in the intake camshaft Number “a” Thickness sprocket and exhaust camshaft sprocket 1.900 mm (0.07480 in) above the cylinder head mating surface “b” as 1.925 mm (0.07579 in) shown in the illustration, and align the marks “c”...
• Side panel (left) • To adjust the exhaust gas volume, use the CO Refer to “GENERAL CHASSIS (1)” on page adjustment mode of the Yamaha diagnostic 4-1. tool. For more information, refer to the opera- tion manual of the Yamaha diagnostic tool.
PERIODIC MAINTENANCE 1. Connect the Yamaha diagnostic tool to the Spark arrester bolt coupler. For information about connecting the 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Yamaha diagnostic tool, refer to “YAMAHA DIAGNOSTIC TOOL” on page 9-32. ▲ ▲▲▲ ▲ ▲▲▲...
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PERIODIC MAINTENANCE 5. Disassemble: b. After cleaning, squeeze the air filter element • Air filter element holder “1” to remove the excess solvent. • Air filter element “2” ECB01290 NOTICE • Air filter element frame “3” Do not twist the air filter element when ECB01800 NOTICE squeezing it.
PERIODIC MAINTENANCE g. Place the air filter element into the storage bag and repeatedly squeeze the element un- til the air filter element is saturated with oil. The air filter element should be wet but not drip- ping. 4. Install: •...
PERIODIC MAINTENANCE 2. Check: h. Adjust the drive select lever control cable. • Brake hose holders Refer to “ADJUSTING THE DRIVE SELECT Loose → Tighten the holder bolt. LEVER CONTROL CABLE AND SHIFT 3. Apply the brake several times. ROD” on page 3-32. 4.
PERIODIC MAINTENANCE 2. Check: A. Front brake • Brake hose holders B. Rear brake Loose → Tighten the holder bolt. EWB02790 3. Apply the brake several times. WARNING 4. Check: • Use only the designated brake fluid. Other • Brake hoses brake fluids may cause the rubber seals to Brake fluid leakage →...
PERIODIC MAINTENANCE • When bleeding the hydraulic brake system, h. Tighten the bleed screw, and then release make sure there is always enough brake fluid the brake lever. before applying the brake. Ignoring this pre- i. Repeat steps (e) to (h) until all of the air bub- caution could allow air to enter the hydraulic bles have disappeared from the brake fluid in brake system, considerably lengthening the...
Tire characteristics influence the handling of 32.0 kPa (0.320 kgf/cm², 4.6 vehicles. The tires listed below have been psi) approved by Yamaha Motor Co., Ltd. for this Rear model. If other tire combinations are used, 27.0 kPa (0.270 kgf/cm², 4.0 they can adversely affect your vehicle’s han-...
PERIODIC MAINTENANCE • The tire pressure gauge “1” is included as stan- The arrow mark “1” on the tire must point in the dard equipment. direction of wheel rotation. • In order to insure an accurate reading, make sure that the gauge is clean before use. EBS30055 CHECKING THE V-BELT 1.
PERIODIC MAINTENANCE EWB03770 WARNING Direction “a” Spring preload is increased (suspen- Always adjust the spring preload for both sion is harder). rear shock absorber assemblies to the same Direction “b” setting. Uneven adjustment can cause poor Spring preload is decreased (suspen- handling and loss of stability.
PERIODIC MAINTENANCE 6. Measure: (for EPS models) • Steering tension Above specification → Adjust. Steering tension 50 N (5.0 kgf) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main switch to “ ”...
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PERIODIC MAINTENANCE • After setting the toe-in to specification, run Toe-in (with tires touching the the vehicle slowly for some distance with ground) both hands lightly holding the handlebar 0.0–10.0 mm (0.00–0.39 in) and check that the handlebar responds cor- rectly.
PERIODIC MAINTENANCE EBS30038 CHECKING THE ENGINE OIL LEVEL After adjusting the toe-in, the handlebar should 1. Place the vehicle on a level surface. be centered. 2. Check the engine oil level on a cold engine. Refer to “INSTALLING THE HANDLEBAR” on page 4-50.
5. Fill: • Differential case (with the specified amount of the recom- mended differential gear oil) Type Yamaha Friction Modified Plus Shaft Drive Oil (Part No.: ACC- SHFTL-PL-32) or SAE 80 API GL-4 Hypoid gear oil Quantity (disassembled) 4. Check: 0.23 L (0.24 US qt, 0.20 Imp.qt)
Cracks/damage → Replace. Coolant leakage → Replace any damaged Type hose and pipe Yamaha Friction Modified Plus Refer to “RADIATOR” on page 6-4 and “WA- Shaft Drive Oil (Part No.: ACC- TER PUMP” on page 6-10. SHFTL-PL-32) or SAE 80 API...
PERIODIC MAINTENANCE EBS30035 CHECKING THE COOLANT LEVEL 1. Place the vehicle on a level surface. The coolant level must be checked on a cold en- gine since the level varies with engine tempera- ture. 2. Check: • Coolant level The coolant level should be between the maximum level mark “a”...
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PERIODIC MAINTENANCE 6. Remove: Coolant drain bolt • Radiator cap “1” 8 Nm (0.8 m·kgf, 5.8 ft·lbf) EWB02770 WARNING 10.Fill: A hot radiator is under pressure. Therefore, • Cooling system do not remove the radiator cap when the en- (with the specified amount of the recom- gine is hot.
PERIODIC MAINTENANCE 13.Install: Thermostat cover air bleed bolt • Coolant reservoir cap “1” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 15.Start the engine, warm it up for ten minutes, and then rev the engine five times.
PERIODIC MAINTENANCE 2. “H” (high) 3. “L” (low) Hold the cable end upright and pour a few drops 4. “R” (reverse) of lubricant into the cable sheath or use a suit- 5. “P” (park) able lubricating device. 6. Drive select lever shift control cable 3.
PERIODIC MAINTENANCE c. Release the brake lever so that “a” is 0 mm (0 EBS30446 ADJUSTING THE THROTTLE LEVER FREE in), and then verify that the drive select lever PLAY cannot be shifted to “R” (reverse) from “N” 1. Check: (neutral), or to “P”...
PERIODIC MAINTENANCE Speed limiter length If the free play cannot be adjusted here, adjust it 12 mm (0.5 in) at the handlebar side of the cable. 2. Adjust: ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
PERIODIC MAINTENANCE ECB02990 NOTICE Avoid touching the glass part of the handle mounted light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the handle mounted light bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lac- quer thinner.
CHASSIS GENERAL CHASSIS (1) ................. 4-1 REMOVING THE BATTERY COVER ............4-3 INSTALLING THE BATTERY COVER ............4-3 REMOVING THE TOP COVER..............4-3 INSTALLING THE TOP COVER ............... 4-4 REMOVING THE SIDE PANELS .............. 4-4 INSTALLING THE SIDE PANELS............. 4-5 GENERAL CHASSIS (2) ................. 4-6 REMOVING THE UPPER PANEL.............
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FRONT BRAKE ..................... 4-26 INTRODUCTION ..................4-31 CHECKING THE FRONT BRAKE DISCS..........4-31 REPLACING THE FRONT BRAKE PADS ..........4-32 DISASSEMBLING THE FRONT BRAKE CALIPERS......4-32 CHECKING THE FRONT BRAKE CALIPERS ........4-33 ASSEMBLING THE FRONT BRAKE CALIPERS........4-33 INSTALLING THE FRONT BRAKE CALIPERS ........4-33 CHECKING THE FRONT BRAKE MASTER CYLINDER......
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FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ..... 4-65 CHECKING THE FRONT ARMS............. 4-67 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ..... 4-67 CHECKING THE FRONT ARM BALL JOINTS ........4-67 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ..................4-68 INSTALLING THE FRONT ARM PROTECTORS ........
GENERAL CHASSIS (1) EBS20024 GENERAL CHASSIS (1) Removing the skid plates 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • •...
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GENERAL CHASSIS (1) Removing the seat and side panels 0.4 Nm (0.04 m kgf, 0.29 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...
GENERAL CHASSIS (1) d. Fit the projections “a” on the top cover into the ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ holes “b” in the side panels and slide the cov- EBS30452 er forward.
GENERAL CHASSIS (2) EBS20087 GENERAL CHASSIS (2) Removing the front carrier and front guard 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 34 Nm (3.4 m kgf, 25 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
GENERAL CHASSIS (3) EBS20088 GENERAL CHASSIS (3) Removing the front fenders and front grill 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
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GENERAL CHASSIS (3) Removing the rear carrier and rear fender 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 34 Nm (3.4 m kgf, 25 ft Ibf)
GENERAL CHASSIS (3) EBS30356 INSTALLING THE REAR FENDER 1. Install: • Rear fender Rear fender bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) The bolts may be tightened to the specified torque in any tightening sequence. However, in- stall the front bolts “1” and tighten them tempo- rarily before installing the rear bolts “2”.
GENERAL CHASSIS (4) EBS20089 GENERAL CHASSIS (4) Removing the electrical components tray 1/2 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...
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GENERAL CHASSIS (4) Removing the electrical components tray 1/2 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...
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GENERAL CHASSIS (4) Removing the electrical components tray 2/2 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks...
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GENERAL CHASSIS (4) Removing the electrical components tray 2/2 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks...
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GENERAL CHASSIS (4) Removing the footrest boards 16 Nm (1.6 m kgf, 12 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
GENERAL CHASSIS (4) EBS30357 INSTALLING THE FOOTREST BOARDS The following procedure applies to both of the footrest boards. 1. Install: • Footrest board Footrest board bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Tighten the footrest board bolts to the specified torque in the proper tightening sequence as shown.
GENERAL CHASSIS (5) EBS20090 GENERAL CHASSIS (5) Removing the air filter case 0.8 Nm (0.08 m kgf, 0.58 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
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GENERAL CHASSIS (5) Removing the air filter case 0.8 Nm (0.08 m kgf, 0.58 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) •...
GENERAL CHASSIS (5) EBS30457 INSTALLING THE AIR FILTER CASE 1. Install: • Intake air temperature sensor • Air filter case • Air filter case joint “1” (to the air filter case) Intake air temperature sensor screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Air filter case bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Air filter case joint clamp screw...
FRONT WHEELS EBS20095 FRONT WHEELS Removing the front wheels and brake discs 30 Nm (3.0 m kgf, 22 ft Ibf) • • 260 Nm (26 m kgf, 188 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
FRONT WHEELS EBS30358 REMOVING THE FRONT WHEELS Radial wheel runout limit 1. Place the vehicle on a level surface. 1.2 mm (0.05 in) 2. Elevate: Lateral wheel runout limit • Front wheels 1.2 mm (0.05 in) Place the vehicle on a suitable stand so that the front wheels are elevated.
FRONT WHEELS • Splines (wheel hub) “2” Wear/damage → Replace the wheel hub. 2. Check: • Brake disc Refer to “CHECKING THE FRONT BRAKE EBS30362 INSTALLING THE FRONT BRAKE DISCS DISCS” on page 4-31. The following procedure applies to both of the EBS30364 front brake discs.
REAR WHEELS 3. Check: EBS30365 REMOVING THE REAR WHEELS • Wheel balance 1. Place the vehicle on a level surface. Refer to “CHECKING THE FRONT 2. Elevate: WHEELS” on page 4-21. • Rear wheels EBS30368 CHECKING THE REAR WHEEL HUBS Place the vehicle on a suitable stand so that the The following procedure applies to both of the rear wheels are elevated.
REAR WHEELS 1. Install: • Wheel axle nut Rear wheel axle nut 260 Nm (26 m·kgf, 188 ft·lbf) • Do not apply oil to the threads of the nut. • After tightening the nut, stake the collar of the nut into the notch of the shaft. EBS30371 INSTALLING THE REAR WHEELS The following procedure applies to both of the...
FRONT BRAKE EBS20097 FRONT BRAKE Removing the front brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf)
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FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
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FRONT BRAKE Disassembling the front brake master cylinder ’ Order Job/Parts to remove Remarks Dust boot Circlip Brake master cylinder kit Brake master cylinder body 4-28...
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FRONT BRAKE Removing the front brake calipers 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
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FRONT BRAKE Disassembling the front brake calipers 17 Nm (1.7 m kgf, 12 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...
FRONT BRAKE EBS30372 INTRODUCTION EWB02930 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake ▲...
FRONT BRAKE d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲...
FRONT BRAKE 1. Install: • When refilling, be careful that water does • Brake caliper assembly not enter the brake fluid reservoir. Water • Brake caliper bolts “1” will significantly lower the boiling point of • Brake hose “2” the brake fluid and could cause vapor lock. •...
FRONT BRAKE EBS30379 EWB02870 ASSEMBLING THE FRONT BRAKE MASTER WARNING CYLINDER Proper brake hose routing is essential to in- EWB03590 sure safe vehicle operation. WARNING Refer to “CABLE ROUTING” on page 2-33. • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
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FRONT BRAKE 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-14. 5. Check: • Brake fluid level Below the minimum level mark → Add the specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
REAR BRAKE ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ • Brake lever bracket a. Connect a clear plastic hose “1” tightly to ECB02880 NOTICE the bleed screw “2”. Put the other end of the hose into an open container.
REAR BRAKE • Never use solvents on internal brake com- EBS30387 CHECKING THE REAR BRAKE CALIPERS ponents as they will cause the brake caliper The following procedure applies to both of the piston dust seals and brake caliper piston brake calipers. seals to swell and distort.
REAR BRAKE 3. Check: Specified brake fluid • Brake master cylinder reservoir DOT 4 Cracks/damage → Replace. • Brake master cylinder reservoir diaphragm EWB02790 Cracks/damage → Replace. WARNING 4. Check: • Use only the designated brake fluid. Other • Brake hoses brake fluids may cause the rubber seals to Cracks/damage/wear →...
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REAR BRAKE EWB02880 • Copper washers WARNING • Brake hose union bolt • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to Brake hose union bolt deteriorate, causing leakage and poor 27 Nm (2.7 m·kgf, 20 ft·lbf) brake performance.
HANDLEBAR EBS20099 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 0.5 Nm (0.05 m kgf, 0.36 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
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HANDLEBAR Removing the handlebar 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 0.5 Nm (0.05 m kgf, 0.36 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
HANDLEBAR EBS30393 REMOVING THE HANDLEBAR 1. Place the vehicle on a level surface. 2. Remove: • Handlebar grips “1” Blow compressed air between the handlebar end and the handlebar grip, and gradually push the grip off the handlebar. EBS30394 CHECKING THE HANDLEBAR 1.
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HANDLEBAR d. Wipe off any excess rubber adhesive with a clean rag. Be sure to fit the projection “a” on the handlebar EWB03690 “2” between the ends of the horn switch. WARNING Do not touch the handlebar grip until the rub- ber adhesive has fully dried.
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HANDLEBAR 8. Connect: • Throttle cable Lubricate the end of the throttle cable with a thin coat of lithium-soap-based grease. Throttle lever assembly cover bolt 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) 9. Adjust: • Rear brake lever free play Refer to “ADJUSTING THE REAR DISC BRAKE”...
STEERING STEM EBS20101 STEERING STEM Removing the steering stem (except for EPS models) 51 Nm (5.1 m kgf, 37 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 34 Nm (3.4 m kgf, 25 ft Ibf) •...
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STEERING STEM Removing the steering stem (except for EPS models) 51 Nm (5.1 m kgf, 37 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 34 Nm (3.4 m kgf, 25 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf)
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STEERING STEM Removing the steering stem (for EPS models) 51 Nm (5.1 m kgf, 37 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
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STEERING STEM Removing the steering stem (for EPS models) 51 Nm (5.1 m kgf, 37 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
STEERING STEM EBS30396 EBS30109 REMOVING THE BEARING RETAINER INSTALLING THE STEERING STEM (except (except for EPS models) for EPS models) 1. Remove: • Bearing retainer “1” Remove the bearing retainer with the damper rod holder “2”. Damper rod holder (30 mm) 90890-01327 Damper rod holder (30 mm) YM-01327...
TIE-RODS AND STEERING KNUCKLES EBS20100 TIE-RODS AND STEERING KNUCKLES Removing the tie-rods and steering knuckles 25 Nm (2.5 m kgf, 18 ft Ibf) • • 15 Nm (1.5 m kgf, 11 ft Ibf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) •...
TIE-RODS AND STEERING KNUCKLES 2. Check: EBS30401 REMOVING THE STEERING KNUCKLES • Front wheel bearing “1” The following procedure applies to both of the Rough movement/excessive free play → Re- steering knuckles. place. 1. Remove: ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼...
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TIE-RODS AND STEERING KNUCKLES ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Clean the surface of the steering knuckle. Ball joint remover 90890-01474 b. Remove the circlip “1”. Ball joint remover YM-01474 Ball joint remover attachment set 90890-01480...
TIE-RODS AND STEERING KNUCKLES h. Install a new circlip. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EBS30405 INSTALLING THE TIE-RODS The following procedure applies to both of the tie-rods. 1.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EBS20031 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies 45 Nm (4.5 m kgf, 33 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
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FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies 45 Nm (4.5 m kgf, 33 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 55 Nm (5.5 m kgf, 40 ft Ibf) •...
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES • Front shock absorber rod EBS30113 CHECKING THE FRONT ARMS Bends/damage → Replace the front shock The following procedure applies to both of the absorber assembly. front upper arms and front lower arms. •...
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES d. Attach the special tools and new ball joint “5” e. Hold the base “12” in place while turning in to the front upper arm “4”. the long bolt “6” to install the new ball joint “5” into the front upper arm “4”.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES b. Tighten the bolt “b”. Steering knuckle and front upper arm nut 30 Nm (3.0 m·kgf, 22 ft·lbf) Steering knuckle and front lower arm nut 30 Nm (3.0 m·kgf, 22 ft·lbf) d. Install the new cotter pins. e.
REAR KNUCKLES AND STABILIZER EBS20032 REAR KNUCKLES AND STABILIZER Removing the rear knuckles and stabilizer 56 Nm (5.6 m kgf, 41 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
REAR KNUCKLES AND STABILIZER EBS30119 CHECKING THE REAR KNUCKLES AND Rear arm protector bolt REAR WHEEL BEARINGS 7 Nm (0.7 m·kgf, 5.1 ft·lbf) The following procedure applies to both of the Rear arm protector nut rear knuckles and rear wheel bearings. 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 1.
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES • Rear shock absorber rod EBS30122 CHECKING THE REAR ARMS Bends/damage → Replace the rear shock The following procedure applies to both of the absorber assembly. rear upper arms and rear lower arms. •...
ENGINE ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL (1) ................... 5-3 INSTALLING THE EXHAUST PIPE AND MUFFLER........5-4 INSTALLING THE V-BELT COOLING DUCTS......... 5-4 ENGINE REMOVAL (2) ................... 5-6 INSTALLING THE DRIVE SELECT LEVER UNIT ........5-7 ENGINE REMOVAL (3) ................... 5-8 INSTALLING THE ENGINE..............
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ELECTRIC STARTER ...................5-40 CHECKING THE STARTER MOTOR .............5-42 ASSEMBLING THE STARTER MOTOR..........5-42 OIL PUMP SPROCKETS ................5-44 REMOVING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVEN SPROCKET...........5-45 CHECKING THE OIL PUMP SPROCKETS ..........5-45 INSTALLING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVEN SPROCKET...........5-45 SHIFT LEVER....................5-47 CHECKING THE STOPPER LEVER ............5-48...
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CRANKSHAFT AND OIL PUMP ..............5-70 REMOVING THE CRANKSHAFT ............5-72 CHECKING THE OIL PUMP ..............5-72 CHECKING THE OIL STRAINER ............5-72 CHECKING THE RELIEF VALVE ............5-72 CHECKING THE CRANKSHAFT ............5-73 ASSEMBLING THE OIL PUMP...............5-73 INSTALLING THE CRANKSHAFT ............5-73 INSTALLING THE OIL PUMP ..............5-74 TRANSMISSION....................
ENGINE INSPECTION 7. Measure: EBS20105 ENGINE INSPECTION • Compression pressure Out of specification → Refer to steps (b) and EBS30135 (c). MEASURING THE COMPRESSION PRESSURE Standard compression pressure (at sea level) Insufficient compression pressure will result in a 650–1000 kPa (6.5–10.0 kgf/cm², loss of performance.
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ENGINE INSPECTION • Top cover Refer to “GENERAL CHASSIS (2)” on page 4-6.
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ENGINE REMOVAL (2) EBS20093 ENGINE REMOVAL (2) Removing the drive select lever unit 7 Nm (0.7 m kgf, 5.1 ft Ibf) 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
ENGINE REMOVAL (2) EBS30553 INSTALLING THE DRIVE SELECT LEVER UNIT 1. Install: • Shift arm “1” • Drive select lever unit “2” • Drive select lever shift rod “3” Shift arm bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) LOCTITE® Drive select lever unit bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive select lever shift rod lock- nut (select lever unit side)
ENGINE REMOVAL (3) EBS20120 ENGINE REMOVAL (3) Disconnecting the leads, cables and hoses 17 Nm (1.7 m kgf, 12 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (4)” on page Footrest board 4-11. Refer to “GENERAL CHASSIS (5)” on page Air filter case 4-17.
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ENGINE REMOVAL (3) Disconnecting the leads, cables and hoses 17 Nm (1.7 m kgf, 12 ft Ibf) • • ’ Order Job/Parts to remove Remarks Cylinder head breather hose Coolant temperature sensor coupler Disconnect. Spark plug cap Shift control cable Disconnect.
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ENGINE REMOVAL (3) Removing the engine 42 Nm (4.2 m kgf, 30 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
CAMSHAFTS EBS20106 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf)* • • Specified angle 30–45˚* 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
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CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) •...
CAMSHAFTS 3. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.037–0.075 mm (0.0015–0.0030 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the camshafts into the cylinder head EBS30433 CHECKING THE CAMSHAFTS (without the camshaft cap).
CAMSHAFTS EBS30435 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • Timing chain tensioner Cracks/damage/rough movement → Re- place. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand.
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CAMSHAFTS 3. Install: • Bearing stoppers • Camshaft cap “1” Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ECB02450 NOTICE • The camshaft cap bolts must be tightened evenly or damage to the cylinder head, b. Position the mark “a” on the AC magneto ro- camshaft cap, and camshafts will result.
CAMSHAFTS c. Install a new gasket and the timing chain ten- 7. Measure: sioner cap bolt. • Valve clearance Out of specification → Adjust. Timing chain tensioner cap bolt Refer to “ADJUSTING THE VALVE CLEAR- 5 Nm (0.5 m·kgf, 3.6 ft·lbf) ANCE”...
CYLINDER HEAD, CYLINDER, AND PISTON EBS20107 CYLINDER HEAD, CYLINDER, AND PISTON Removing the cylinder head 30 Nm (3.0 m kgf, 22 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • Loosen 360˚ 30 Nm (3.0 m kgf, 22 ft Ibf) •...
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CYLINDER HEAD, CYLINDER, AND PISTON Removing the cylinder head 30 Nm (3.0 m kgf, 22 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • Loosen 360˚ 30 Nm (3.0 m kgf, 22 ft Ibf) • •...
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CYLINDER HEAD, CYLINDER, AND PISTON Removing the cylinder and piston ’ Order Job/Parts to remove Remarks Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring 5-21...
CYLINDER HEAD, CYLINDER, AND PISTON • Before removing the piston pin, deburr the pis- EBS30438 REMOVING THE CYLINDER HEAD ton pin clip grooves and the piston pin bore ar- 1. Remove: ea. If both areas are deburred and the piston •...
CYLINDER HEAD, CYLINDER, AND PISTON EBS30439 CHECKING THE CYLINDER HEAD To ensure an even surface, rotate the cylinder 1. Eliminate: head several times. • Combustion chamber carbon deposits (with a rounded scraper) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
CYLINDER HEAD, CYLINDER, AND PISTON b. If out of specification, replace the cylinder, Top ring and replace the piston and piston rings as a Ring side clearance limit set. 0.12 mm (0.0047 in) c. Measure piston skirt diameter “P” with a mi- 2nd ring crometer.
CYLINDER HEAD, CYLINDER, AND PISTON EBS30150 INSTALLING THE PISTON AND CYLINDER Top ring 1. Install: End gap (installed) limit • Oil ring expander “1” 0.50 mm (0.0197 in) 2nd ring • Lower oil ring rail “2” End gap (installed) limit •...
CYLINDER HEAD, CYLINDER, AND PISTON Recommended lubricant Engine oil 5. Install: ×4 • Cylinder “1” • Timing chain guide (exhaust side) ×4 • While compressing the piston rings with one hand, install the cylinder with the other hand. • Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity.
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CYLINDER HEAD, CYLINDER, AND PISTON Oil hose union bolt (crankcase to cylinder) 18 Nm (1.8 m·kgf, 13 ft·lbf) Tighten the clamp screw of each clamp “2” until 6 slots are visible in the area “a” of the clamp as shown in the illustration. 5-27...
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VALVES AND VALVE SPRINGS EBS20037 VALVES AND VALVE SPRINGS Removing the valves and valve springs 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • Order Job/Parts to remove ’ Remarks Refer to “CYLINDER HEAD, CYLINDER, Cylinder head AND PISTON” on page 5-19. Valve lifter Valve pad Valve cotter...
VALVES AND VALVE SPRINGS EBS30141 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.
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VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) limit b. Install the new valve guide with the valve 0.080 mm (0.0032 in) guide installer “2”...
VALVES AND VALVE SPRINGS After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
VALVES AND VALVE SPRINGS EBS30441 CHECKING THE VALVE LIFTERS • Make sure each valve is installed in its original The following procedure applies to all of the place. valve lifters. • Install the valve springs with the larger pitch “a” 1.
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VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECB01370 NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad •...
AC MAGNETO AND STARTER CLUTCH EBS20039 AC MAGNETO AND STARTER CLUTCH Removing the AC magneto and starter clutch 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •...
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AC MAGNETO AND STARTER CLUTCH Removing the AC magneto and starter clutch 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •...
AC MAGNETO AND STARTER CLUTCH • Make sure the flywheel puller is centered over EBS30151 REMOVING THE AC MAGNETO ROTOR the AC magneto rotor. 1. Remove: • AC magneto cover Flywheel puller (M38 X P1.5) 90890-04178 Loosen each bolt 1/4 of a turn at a time, in stag- Flywheel puller (M38 X P1.5) es and in a crisscross pattern.
AC MAGNETO AND STARTER CLUTCH 3. Check: Starter clutch bolt • Starter clutch gear contact surfaces 14 Nm (1.4 m·kgf, 10 ft·lbf) Damage/pitting/wear → Replace the defec- tive part(s). 4. Check: While holding the AC magneto rotor “2” with the •...
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AC MAGNETO AND STARTER CLUTCH 2. Tighten: • AC magneto rotor nut “1” AC magneto rotor nut 160 Nm (16 m·kgf, 116 ft·lbf) Hold the AC magneto rotor “2” with the rotor holding tool “3” while tightening the AC magneto rotor nut.
ELECTRIC STARTER EBS20040 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “ENGINE REMOVAL (1)” on page Muffler 5-3.
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ELECTRIC STARTER Disassembling the starter motor 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • ’ Order Job/Parts to remove Remarks Starter motor front cover Starter motor rear cover Brush set Armature assembly Starter motor yoke...
ELECTRIC STARTER EBS30157 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600-grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Cut the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. ▲...
OIL PUMP SPROCKETS EBS30524 REMOVING THE OIL PUMP DRIVE Install the oil pump drive sprocket so that the SPROCKET AND OIL PUMP DRIVEN protruding portion “a” of the sprocket is facing to- SPROCKET ward the crankcase. 1. Loosen: • Oil pump driven sprocket nut “1” •...
SHIFT LEVER EBS20042 SHIFT LEVER Removing the shift levers and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •...
SHIFT LEVER EBS30163 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Damage/wear → Replace. • Stopper lever spring Damage/wear → Replace. EBS30164 CHECKING THE SHIFT LEVERS 1. Check: • Shift lever 1 3. Install: • Shift lever 2 • Shift lever 1 “1” Damage/wear →...
PRIMARY AND SECONDARY SHEAVES EBS20043 PRIMARY AND SECONDARY SHEAVES Removing the primary and secondary sheaves 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 100 Nm (10.0 m kgf, 72 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
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PRIMARY AND SECONDARY SHEAVES Disassembling the primary sheave * Apply Yamaha Grizzly grease or Yamaha grease F. ’ Order Job/Parts to remove Remarks Primary sheave cap Primary sheave slider Primary sheave cam Primary sheave weight Spacer Oil seal Primary sliding sheave...
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PRIMARY AND SECONDARY SHEAVES Disassembling the secondary sheave ® * Apply Yamaha grease H or POLYREX EM ’ Order Job/Parts to remove Remarks Secondary sheave spring retaining nut Upper spring seat Compression spring Lower spring seat Guide pin Secondary sliding sheave...
PRIMARY AND SECONDARY SHEAVES 2. Check: • Primary sliding sheave • Primary fixed sheave Cracks/damage → Replace. EBS30171 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: • Primary sheave weight ▲...
• Spacer inner surface • Primary sliding sheave inner surface Recommended lubricant Yamaha Grizzly grease or Yamaha grease F • Apply Yamaha Grizzly grease or Yamaha grease F (2.5 g) to the inner surface of the EBS30174 ASSEMBLING THE PRIMARY SHEAVE spacer.
PRIMARY AND SECONDARY SHEAVES ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Attach the sheave fixed block “5”, locknut wrench “6” and sheave spring compressor “7” to the secondary sheave. Sheave fixed block 90890-04135 Sheave fixed bracket...
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PRIMARY AND SECONDARY SHEAVES A. Correct position B. Incorrect position 3. Tighten: • Primary sheave assembly nut “1” Primary sheave assembly nut 140 Nm (14 m·kgf, 100 ft·lbf) Use the rotor holding tool “2” to hold the primary sheave. 2. Check: •...
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PRIMARY AND SECONDARY SHEAVES Shift the transmission into “L” (low) or “H” (high), set the parking brake, and then tighten the sec- ondary sheave assembly nut. 5. Lubricate: • Bearing housing bearing inner surface and ball (with the recommended lubricant) Recommended lubricant Shell Sunlight Grease 3®...
CLUTCH EBS20044 CLUTCH Removing the clutch 190 Nm (19 m kgf, 137 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove ’ Remarks Refer to “PRIMARY AND SECONDARY Drive belt case SHEAVES”...
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CLUTCH Disassembling the clutch housing assembly ’ Order Job/Parts to remove Remarks Oil seal Circlip Bearing housing Circlip Bearing Seal ring One-way clutch bearing Bearing Clutch housing 5-60...
CLUTCH • One-way clutch bearing EBS30177 REMOVING THE CLUTCH Chafing/wear/damage → Replace. 1. Remove: • Clutch housing assembly • Replace the one-way clutch bearing and clutch housing as a set. Working in crisscross pattern, loosen each bolt • The one-way clutch bearing must be installed 1/4 of a turn.
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CLUTCH • Tighten the bolts in stages, using a crisscross pattern. • After tightening the bolts, check that the clutch housing assembly rotates smoothly. 5-63...
CRANKCASE EBS20045 CRANKCASE Separating the crankcase 7 Nm (0.7 m kgf, 5.1 ft Ibf) 17 Nm (1.7 m kgf, 12 ft Ibf) 18 Nm (1.8 m kgf, 13 ft Ibf) • • • • • • 35 Nm (3.5 m kgf, 25 ft Ibf) •...
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CRANKCASE Separating the crankcase 7 Nm (0.7 m kgf, 5.1 ft Ibf) 17 Nm (1.7 m kgf, 12 ft Ibf) 18 Nm (1.8 m kgf, 13 ft Ibf) • • • • • • 35 Nm (3.5 m kgf, 25 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft...
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CRANKCASE Removing the crankcase bearings 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “CRANKSHAFT AND OIL PUMP” Crankshaft/Oil pump on page 5-70. Middle drive shaft/Middle driven shaft Refer to “MIDDLE GEAR” on page 5-81. Transmission Refer to “TRANSMISSION”...
CRANKCASE EBS30182 SEPARATING THE CRANKCASE 1. Remove: • Crankcase bolts Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EBS30183 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1.
2. Thoroughly clean the crankcase mating sur- faces. 3. Apply: • Sealant “1” ×3 ×2 ×1 (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) Do not allow any sealant to come into contact with the oil gallery. 5-68...
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CRANKCASE ×3 ×2 ×6 A. Crankcase (right) B. Crankcase (left) 7. Apply: • 4-stroke engine oil (onto the crankshaft pin, bearings and oil de- livery hole) 8. Check: • Crankshaft and transmission operation Rough operation → Repair. 9. Install: • Gasket •...
CRANKSHAFT AND OIL PUMP EBS20046 CRANKSHAFT AND OIL PUMP Removing the crankshaft and oil pump 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove ’ Remarks Separate.
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CRANKSHAFT AND OIL PUMP Disassembling the oil pump 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • ’ Order Job/Parts to remove Remarks Oil pump housing cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing 5-71...
CRANKSHAFT AND OIL PUMP EBS30188 REMOVING THE CRANKSHAFT 1. Remove: • Crankshaft “1” • Balancer “2” • Remove the crankshaft with the crankcase separating tool “3”. • Make sure the crankcase separating tool is centered over the crankshaft. • Remove the crankshaft “1” and balancer “2” at 1.
TRANSMISSION EBS20047 TRANSMISSION Removing the transmission, shift drum and shift forks 18 Nm (1.8 m kgf, 13 ft Ibf) • • Order Job/Parts to remove ’ Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-64. Middle driven gear Refer to “MIDDLE GEAR” on page 5-81. Shift drum stopper bolt Spring Ball...
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TRANSMISSION Removing the transmission, shift drum and shift forks 18 Nm (1.8 m kgf, 13 ft Ibf) • • ’ Order Job/Parts to remove Remarks Secondary shaft Drive axle assembly Collar Reverse idle gear Bearing Reverse idle gear shaft Stopper lever Stopper lever shaft 5-76...
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TRANSMISSION Disassembling the drive axle assembly ’ Order Job/Parts to remove Remarks Washer Collar High wheel gear Washer Clutch dog Circlip Washer Collar Low wheel gear Washer Circlip Middle drive gear Circlip Washer Bearing Reverse wheel gear Stopper wheel Drive axle 5-77...
TRANSMISSION EBS30194 REMOVING THE TRANSMISSION 1. Remove: • Shift drum “1” • Shift fork assembly “2” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pull out the guide bar from the left crankcase, and then remove the shift fork cam followers.
TRANSMISSION EBS30199 CHECKING THE SECONDARY SHAFT 1. Check: • Gear teeth Blue discoloration/pitting/wear → Replace. EBS30555 CHECKING THE STOPPER LEVER AND STOPPER WHEEL 1. Check: • Stopper lever pawl “1” EBS30198 Bends/damage/wear → Replace the stopper CHECKING THE TRANSMISSION 1. Measure: lever and stopper wheel as a set.
MIDDLE GEAR EBS20048 MIDDLE GEAR Removing the middle drive shaft 190 Nm (19 m kgf, 137 ft lbf) • • 38 Nm (3.8 m kgf, 27 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • Order Job/Parts to remove ’...
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MIDDLE GEAR Removing the middle driven shaft 115 Nm (11.5 m kgf, 83 ft lbf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • 130 Nm (13 m kgf, 94 ft lbf) •...
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MIDDLE GEAR Removing the middle driven shaft 115 Nm (11.5 m kgf, 83 ft lbf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • 130 Nm (13 m kgf, 94 ft lbf) •...
MIDDLE GEAR EBS30203 REMOVING THE MIDDLE DRIVE SHAFT Coupling gear/middle shaft tool 1. Straighten: 90890-01229 • Punched portion of the middle drive pinion Gear holder gear nut YM-01229 2. Loosen: • Middle drive pinion gear nut “1” Wrap the middle drive shaft in a folded rag, and then secure it in a vise.
MIDDLE GEAR • Install a suitable socket “2” on the middle Ring nut wrench driven pinion gear end to protect the thread 90890-01430 from damage. Ring nut wrench c. Press the middle driven pinion gear end and YM-38404 remove the bearing housing. ECB01750 NOTICE The middle driven shaft bearing retainer has...
MIDDLE GEAR a. 44.9 mm (1.77 in) b. 19.7 mm (0.78 in) d. Measure the gear lash while rotating the mid- dle driven shaft back and forth. Measure the gear lash at 4 positions. Rotate the middle driven gear 90° each time. e.
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MIDDLE GEAR If the driven pinion gear is marked “+02”, Therefore, “B” is 0.81. “g” is 49.02 “B” = 77.53 - 49.02 + 80.40 - 99.98 - 8.12 = 0.81 Round off hundredth digit and select appro- priate shim(s). In the above example, the calculated shim thickness is 0.81 mm.
COOLING SYSTEM OIL COOLER....................6-1 CHECKING THE OIL COOLER ..............6-3 INSTALLING THE OIL COOLER .............. 6-3 RADIATOR ...................... 6-4 CHECKING THE RADIATOR..............6-6 INSTALLING THE RADIATOR..............6-6 THERMOSTAT ....................6-7 CHECKING THE THERMOSTAT.............. 6-8 INSTALLING THE THERMOSTAT............6-8 WATER PUMP....................6-10 DISASSEMBLING THE WATER PUMP..........6-12 CHECKING THE WATER PUMP ............
OIL COOLER Refer to “CHANGING THE COOLANT” on EBS30211 CHECKING THE OIL COOLER page 3-29. 1. Check: • Crankcase • Oil cooler (with the specified amount of the recom- Cracks/damage → Replace. mended engine oil) 2. Check: Refer to “CHANGING THE ENGINE OIL” on •...
RADIATOR EBS20051 RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • Order Job/Parts to remove ’ Remarks Front skid plate/Center skid plate/Top cov- Refer to “GENERAL CHASSIS (1)” on page er/Side panels 4-1.
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RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • ’ Order Job/Parts to remove Remarks Coolant reservoir Radiator outlet hose Radiator inlet hose Radiator Radiator fan...
RADIATOR EBS30213 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
THERMOSTAT EBS20052 THERMOSTAT Removing the thermostat 20 Nm (2.0 m kgf, 14 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove ’ Remarks Refer to “GENERAL CHASSIS (1)” on page Top cover/Side panel (right) 4-1.
THERMOSTAT 2. Check: EBS30215 CHECKING THE THERMOSTAT • Thermostat housing cover 1. Check: • Thermostat housing (cylinder head) • Thermostat Cracks/damage → Replace. Does not open at 69–73 °C (156.2–163.4 °F) → Replace. EBS30216 INSTALLING THE THERMOSTAT 1. Install: • Copper washer •...
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THERMOSTAT 5. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-6.
WATER PUMP EBS20053 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
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WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
WATER PUMP EBS30217 DISASSEMBLING THE WATER PUMP Install the oil seal with a socket that matches its 1. Remove: outside diameter. • Mechanical seal “1” Installed depth of oil seal “a” Remove the mechanical seal from the inside of 0 mm (0 in) the AC magneto cover.
WATER PUMP 3. Install: • Water pump outlet hose “2” (onto the water • Impeller “1” jacket joint) • Water jacket joint “3” Impeller 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the clamp screw of each clamp “1” until 4 slots remain in the area “a” of the clamp as shown in the illustration.
FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 CHECKING THE FUEL TANK BREATHER HOSE JOINT .......7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-3 THROTTLE BODY................... 7-4 REMOVING THE THROTTLE BODY ASSEMBLY ........7-6 CHECKING THE INJECTOR ..............
FUEL TANK EBS20054 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove ’...
FUEL TANK EBS30221 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose connector holder • Fuel hose EWB03050 WARNING Cover fuel hose connections with a cloth when disconnecting them.
FUEL TANK ECB02010 NOTICE • Do not damage the installation surfaces of the When installing the fuel hose, make sure that fuel tank when installing the fuel pump. it is securely connected, and that the fuel • Always use a new fuel pump gasket. hose holder is in the correct position, other- •...
THROTTLE BODY EBS20056 THROTTLE BODY Removing the throttle body 0.8 Nm (0.08 m kgf, 0.58 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) •...
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THROTTLE BODY Disassembling the throttle body assembly 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • ’ Order Job/Parts to remove Remarks Intake air pressure sensor Intake air pressure sensor hose...
THROTTLE BODY d. Connect the pressure gauge “3” and adapter ECB02370 NOTICE “4” to the fuel pump and fuel hose. When connecting the fuel hose, make sure Pressure gauge that it is securely connected, and that the 90890-03153 fuel hose connector cover is in the correct Pressure gauge position, otherwise the fuel hose will not be YU-03153...
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THROTTLE BODY • Positive tester probe yellow (wire harness color) • Negative tester probe black/blue (wire harness color) Test harness– TPS (3P) 90890-03204 Test harness– TPS (3P) YU-03204 Digital circuit tester 90890-03174 Model 88 Multimeter with ta- chometer YU-A1927 c. Turn the main switch to “ ”...
AIR INDUCTION SYSTEM EBS20057 AIR INDUCTION SYSTEM...
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AIR INDUCTION SYSTEM 1. Air induction system hose (air filter case to air cut-off valve) 2. Air cut-off valve 3. Air induction system hose (air cut-off valve to reed valve assembly) 4. Reed valve assembly 7-10...
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AIR INDUCTION SYSTEM Removing the air cut-off valve 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Seat/Side panels 4-1. Air cut-off valve coupler Disconnect. Air induction system hose (air filter case to air cut-off valve) Air induction system hose (air cut-off valve to reed valve assembly)
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AIR INDUCTION SYSTEM Removing the reed valve 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Reed valve cover Reed valve assembly Reed valve plate 7-12...
AIR INDUCTION SYSTEM 2. Check: EBS30235 CHECKING THE AIR INDUCTION SYSTEM • Reed valve • Reed valve stopper Air injection • Reed valve seat The air induction system burns unburned ex- Cracks/damage → Replace the reed valve haust gases by injecting fresh air (secondary air) assembly.
TROUBLESHOOTING EBS20058 TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” movement A. Bearing damage. during acceleration, deceleration, or sustained B. Improper gear backlash. speed. (This must not be confused with engine C.
TROUBLESHOOTING b. Apply a leak-localizing compound or dry pow- EBS30237 CHECKING NOISES der spray to the shaft drive. 1. Investigate any unusual noises. c. Road test the vehicle for the distance neces- sary to locate the leak. ▼ ▼▼▼ ▼ ▼▼▼ ▼...
TROUBLESHOOTING EBS30238 TROUBLESHOOTING CHART When basic conditions (a) and (b) exist, check the following points: YES → Replace the wheel bearing. (Refer to “TIE- 1. Elevate and spin both wheels. Feel RODS AND STEERING KNUCKLES” on for wheel bearing damage. page 4-61 and “REAR KNUCKLES AND STABILIZER”...
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT EBS20059 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT Removing the front constant velocity shaft assemblies, differential assembly and front drive shaft 55 Nm (5.5 m kgf, 40 ft Ibf) 55 Nm (5.5 m...
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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT Removing the front constant velocity shaft assemblies, differential assembly and front drive shaft 55 Nm (5.5 m kgf, 40 ft Ibf) 55 Nm (5.5 m kgf, 40 ft Ibf) •...
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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT Disassembling the front constant velocity shaft assemblies A: Wheel side B: Differential side ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front constant velocity shaft assemblies. Clip Boot band Boot band...
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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT Disassembling the differential assembly 24 Nm (2.4 m kgf, 17 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 62 Nm (6.2 m kgf, 45 ft Ibf) •...
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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT Disassembling the differential assembly 24 Nm (2.4 m kgf, 17 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 62 Nm (6.2 m kgf, 45 ft Ibf) •...
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT EBS30240 DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the front constant velocity shaft assemblies. 1. Remove: • Boot bands • Clip “1” •...
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT 2. Install: EBS30242 ASSEMBLING THE FRONT CONSTANT • Dust boot VELOCITY SHAFT ASSEMBLIES • Ball bearing “1” The following procedure applies to both of the • Circlip “2” front constant velocity shaft assemblies.
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT EBS30244 REMOVING THE DIFFERENTIAL GEAR • The new boot bands may differ from the origi- ASSEMBLY nal ones. 1. Remove: • The dust boots should be fastened with the •...
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ECB01930 NOTICE a. Slide the shift fork sliding gear “1”, which is in- stalled to the differential case cover, to the left Do not disassemble the differential motor or as shown in the illustration to put it into the...
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT ECB01250 NOTICE Finger tighten the bolt until it holds the ring gear. Otherwise, the ring gear will be dam- aged. 4. Attach: • Gear lash measurement tool “2” •...
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FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT 2. Adjust: • Gear backlash ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Select the suitable shims using the following chart.
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT EBS20060 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Removing the rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 55 Nm (5.5 m kgf, 40 ft Ibf) •...
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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Removing the rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 55 Nm (5.5 m kgf, 40 ft Ibf) • • 66 Nm (6.6 m kgf, 48 ft Ibf) •...
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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the rear constant velocity shaft assemblies A: Wheel side B: Final drive side ’ Order Job/Parts to remove Remarks The following procedure applies to both of the rear constant velocity shaft assemblies. Clip Boot band Boot band...
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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the final drive assembly 23 Nm (2.3 m kgf, 17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the final drive assembly 23 Nm (2.3 m kgf, 17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the final drive assembly 23 Nm (2.3 m kgf, 17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT EBS30253 DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the rear constant velocity shaft assemblies. 1. Remove: • Boot band “1” Use the boot band installation tool “2”. Boots band installation tool 90890-01526 Boots band installation tool...
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT EBS30254 CHECKING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the rear constant velocity shaft assemblies. 1. Check: • Double offset joint splines •...
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Boots band installation tool 90890-01526 Boots band installation tool YM-01526 B. Final drive side 3. Apply: • Molybdenum disulfide grease (into the double offset joint, constant velocity joint, and dust boots) ▲...
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT If “-01” is stamped on the final drive case, “e” = a numeral (usually a decimal number) “d” = 100 - 0.01 on the final drive case either added to or sub- = 99.99 tracted from “71.6”...
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Hundredth Rounded value 3, 4, 5, 6, 7 8, 9 Shim and thrust washer are supplied in the following thicknesses. Final driven pinion gear shims (fi- nal drive case side) “1” Thickness (mm) If “-12”...
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place four pieces of Plastigauge® between Measure the thickness of the originally fitted the originally fitted shim(s) and the final driv- shim(s), and then calculate the required new en pinion gear assembly.
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT ECB01250 NOTICE Wheel gear thrust clearance 0.03–0.07 mm (0.0012–0.0028 in) Finger tighten the bolt until it holds the ring gear. Otherwise, the ring gear will be dam- aged. 4.
IGNITION SYSTEM EBS30265 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Top cover 4. Side panels (left and right) 5. Storage compartment 6. V-belt cooling exhaust duct NG →...
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IGNITION SYSTEM NG → 8. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the handlebar switch (left). SWITCHES” on page 9-81. OK ↓ NG → 9. Check the lean angle sensor. Refer to “CHECKING THE LEAN Replace the lean angle sensor.
ELECTRIC STARTING SYSTEM EBS30267 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ ” (on) (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: •...
ELECTRIC STARTING SYSTEM EBS30268 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Top cover 4. Side panels (left and right) 5. V-belt cooling exhaust duct NG → 1. Check the fuses. (Main, ignition and signaling sys- tem) Replace the fuse(s).
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ELECTRIC STARTING SYSTEM NG → 8. Check the start switch. The start switch is faulty. Replace the han- Refer to “CHECKING THE dlebar switch (left). SWITCHES” on page 9-81. OK ↓ NG → 9. Check the rear brake light switch. Refer to “CHECKING THE Replace the rear brake light switch.
CHARGING SYSTEM EBS30270 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Top cover 4. Side panel (right) 5. V-belt cooling exhaust duct NG → 1. Check the fuse. (Main) Replace the fuse.
LIGHTING SYSTEM EBS30272 TROUBLESHOOTING Any of the following fail to light: Handle mounted light, headlight or taillight. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Handle mounted light cover NG → 1. Check the condition of handle mounted light bulb and bulb socket.
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LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 9-15. OK ↓ Replace the headlight unit or tail/brake light unit. 9-18...
SIGNALING SYSTEM EBS30274 TROUBLESHOOTING • Any of the following fail to light: warning light, brake light or an indicator light. • The fuel meter fails to come on. • The speedometer fails to operate. • The horn fails to sound. (except for CDN) •...
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SIGNALING SYSTEM NG → 2. Check the rear brake light switch. Refer to “CHECKING THE Replace the rear brake light switch. SWITCHES” on page 9-81. OK ↓ NG → 3. Check the diode. Refer to “CHECKING THE DIODE” Replace the diode. on page 9-90.
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SIGNALING SYSTEM The differential gear lock indicator light and /or four-wheel-drive indicator light fails to come on. NG → 1. Check the four-wheel-drive motor switch (differential motor). Replace the differential motor. Refer to “CHECKING THE SWITCHES” on page 9-81. OK ↓ NG →...
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SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 9-19. OK ↓ Replace the meter assembly or ECU. The fuel level indicator fails to come on. NG →...
COOLING SYSTEM EBS20079 COOLING SYSTEM EBS30275 CIRCUIT DIAGRAM 9-25...
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COOLING SYSTEM 4. Main switch 5. Main fuse 6. Battery 9. Engine ground 11.Joint coupler 16.ECU (Engine Control Unit) 21.Coolant temperature sensor 56.Radiator fan motor 57.Radiator fan motor circuit breaker 58.Radiator fan motor relay 61.Ignition fuse 64.Radiator fan motor fuse 66.Frame ground 1 A.
COOLING SYSTEM EBS30276 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Top cover 4. Side panels (left and right) 5. Front fenders NG → 1. Check the fuses. (Main, ignition and radiator fan mo- tor) Replace the fuse(s).
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COOLING SYSTEM NG → 8. Check the entire cooling system wiring. Properly connect or repair the cooling sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 9-25. OK ↓ Replace the ECU. 9-28...
FUEL INJECTION SYSTEM EBS30278 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
▼ ▼ ▼▼▼ ▼ ▼▼▼▼ ▼▼ ▼ a. Check the fault code number displayed on the meter or Yamaha diagnostic tool. b. Identify the faulty system with the fault code. c. Identify the probable cause of the malfunction. ▲ ▲▲▲...
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FUEL INJECTION SYSTEM For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231 Features of the Yamaha diagnostic tool You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth- ods.
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FUEL INJECTION SYSTEM Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area. 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed.
Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the Yamaha diagnos- tic tool or multi-function meter display according to the “Confirmation of service completion”.
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FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from the Item crankshaft position sensor. Improperly connected → Con- Connection of crankshaft posi- Crank the engine. tion sensor coupler. nect the coupler securely or re- Fault code number is not dis- played →...
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FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Indicated Displays the intake air pressure. Set the engine stop switch to “ ”, and then operate the throttle while Procedure pushing the start switch “ ”.
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FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ ” sensor. (Code No. 03) (on). When engine is stopped: Fault code number is not dis- played →...
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FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged or de- Item tached hose). Clogged or detached hose → Condition of intake air pressure Start the engine and let it idle sensor hose. Repair or replace the sensor for approximately 5 seconds.
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FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected → Con- Connection of throttle position Turn the main switch to “ ” sensor coupler. nect the coupler securely or re- (on). Check the locking condition of place the wire harness.
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FUEL INJECTION SYSTEM Fault code No. 16 • If fault code numbers “15” and “16” are both indicated, take the actions specified for fault code number “15” first. • If fault code numbers “16” and “37” are both indicated, take the actions specified for fault code number “16”...
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FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Improperly connected → Con- Connection of coolant tempera- Turn the main switch to “ ” ture sensor coupler. nect the coupler securely or re- (on). Check the locking condition of place the wire harness.
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FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Indicated Displays the intake air temperature. Compare the actually measured intake air temperature with the indicated Procedure value.
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FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Defective intake air temperature Execute the diagnostic mode. Turn the main switch to “ ” sensor. (Code No. 05) (on). When engine is cold: Fault code number is not dis- played →...
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Actuates the ignition coil five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Check that a spark is generated five times. Procedure •...
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Fully closes the ISC valve, and then opens the valve. This operation takes approximately 3 seconds. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on during the operation. Procedure The operating sound can be heard when ISC valve operates.
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Fully closes the ISC valve, and then opens the valve. This operation takes approximately 3 seconds. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on during the operation. Procedure The operating sound can be heard when ISC valve operates.
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Diagnostic code No. Actuates fuel injector five times at one-second intervals. The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen Actuation come on each time the fuel injector is actuated. Disconnect the fuel pump coupler, and then check that fuel injector is ac- Procedure tuated five times by listening for the operating sound.
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FUEL INJECTION SYSTEM Fault code No. Item Fuel injector: open or short circuit detected. Improperly connected → Con- Connection of fuel injector cou- Execute the diagnostic mode. pler. nect the coupler securely or re- (Code No. 36) Operating sound → Go to item Check the locking condition of place the wire harness.
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FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Improperly connected → Con- Connection of lean angle sen- Turn the main switch to “ ” sor coupler. nect the coupler securely or re- (on), then to “ ”...
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FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sen- Item sor. Check that the number increases when the rear wheels are rotated. The Procedure number is cumulative and does not reset each time the wheel is stopped. Probable cause of malfunc- Confirmation of service com- Item...
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” on the Yamaha di- agnostic tool screen go off. When the relay is off, the “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on.) Check that the fuel injection system relay is actuated five times by listen- Procedure ing for the operating sound.
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FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector Item and fuel pump. Open or short circuit → Replace Wire harness continuity. Start the engine and let it idle the wire harness. for approximately 5 seconds. Between fuel injection system Fault code number is not dis- played →...
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FUEL INJECTION SYSTEM Fault code No. 46 If fault code numbers “37” and “46” are both indicated, take the actions specified for fault code number “46” first. Fault code No. Item Charging voltage is abnormal. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
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FUEL INJECTION SYSTEM Fault code No. Er-1 ECU (Engine Control Unit) internal malfunction (output signal error): Item signals cannot be transmitted between the ECU and the multi-func- tion meter. Indicated — Procedure — Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check...
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FUEL INJECTION SYSTEM Fault code No. Er-2 ECU (Engine Control Unit) internal malfunction (output signal error): Item no signals are received from the ECU within the specified duration. Improperly connected → Con- Connection of meter assembly Turn the main switch to “ ”...
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FUEL INJECTION SYSTEM Fault code No. Er-3 ECU (Engine Control Unit) internal malfunction (output signal error): Item data from the ECU cannot be received correctly. Improperly connected → Con- Connection of ECU coupler. Turn the main switch to “ ” Check the locking condition of nect the coupler securely or re- (on).
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FUEL INJECTION SYSTEM Fault code No. Er-4 ECU (Engine Control Unit) internal malfunction (input signal error): Item non-registered data has been received from the meter assembly. Open or short circuit → Replace Wire harness continuity. Turn the main switch to “ ”...
FUEL PUMP SYSTEM EBS30283 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Top cover 4. Side panels (left and right) 5. Rear fender NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
2WD/4WD SELECTING SYSTEM EBS20082 2WD/4WD SELECTING SYSTEM EBS30448 CIRCUIT DIAGRAM 9-63...
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2WD/4WD SELECTING SYSTEM 4. Main switch 5. Main fuse 6. Battery 9. Engine ground 11.Joint coupler 16.ECU (Engine Control Unit) 37.On-Command four-wheel-drive motor switch and differential lock switch 38.Differential motor 41.Four-wheel-drive motor relay 1 42.Four-wheel-drive motor relay 2 61.Ignition fuse 62.Four-wheel-drive motor fuse 66.Frame ground 1 A.
2WD/4WD SELECTING SYSTEM EBS30285 TROUBLESHOOTING The four-wheel-drive motor indicator light fails to come on. • Before troubleshooting, remove the following part(s): 1. Battery cover NG → 1. Check the fuses. (Main, Ignition and four-wheel-drive motor) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
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2WD/4WD SELECTING SYSTEM NG → 8. Check the entire 2WD/4WD select- ing system wiring. Properly connect or repair the 2WD/4WD Refer to “CIRCUIT DIAGRAM” on selecting system wiring. page 9-63. OK ↓ Replace the ECU. 9-66...
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) EBS30287 EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION The EPS control unit is equipped with a self-diagnostic function. If this function detects a malfunction in the EPS system, it lights the EPS warning light to alert the rider that a malfunction has occurred in the system.
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) e. “ ” (on) f. Off g. Comes on. h. Initial lighting: 2 seconds i. Goes off. EBS30289 DIAGNOSTIC MODE Setting the diagnostic mode (present and past malfunctions) 1. Disconnect the EPS self-diagnosis signal connector “1”. 2.
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EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Example 1: Fault code No. 23 0.5 × 3 0.5 × 5 a. EPS self-diagnosis signal connector B. Display of the present malfunctions stops when the past malfunction display mode is b. Diagnostic mode selected.
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) After the mode selection judgment is completed (present display or past malfunction mode), the current fault code signaling stops immediately, and then the EPS warning light starts flashing at 1.5-second in- tervals. Deleting fault codes To delete fault codes, ground the EPS self-diagnosis signal connector 3 or more times within 5 seconds while the present or past malfunction mode is activated.
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Fault code Probable cause of mal- Item Symptom function • Faulty battery. • Malfunction in the charging system. EPS control unit Battery voltage has dropped. Refer to “CHARGING SYSTEM” on page 9-11. •...
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EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Fault code No. 21 Fault code No. Symptom Speed sensor: no normal signals are received from the speed sensor. Order Item/components and probable cause Check or maintenance job Reinstatement method Connections • Check the locking condition of the Starting the en- •...
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EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Fault code No. 41, 42, 43, 45 Fault code No. 41, 42, Symptom EPS motor: no normal signals are received from the EPS motor. 43, 45 Order Item/components and probable cause Check or maintenance job Reinstatement method Connections...
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EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Fault code No. 54 Fault code No. Symptom Relay contacts in the EPS control unit are welded together. Order Item/components and probable cause Check or maintenance job Reinstatement method Malfunction in EPS control unit. Replace the EPS control unit.
ELECTRICAL COMPONENTS EBS30292 CHECKING THE SWITCHES Br/Y Br/Y R Br/L Br ( BLACK ) R Br/L Br R/Y L Y R/Y Y (GRAY) PUSH L/W G/R LOCK Gy W 1. Main switch 8. Gear position switch 2. Light switch 9. Reverse switch 3.
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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. ECB02380 NOTICE 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.
ELECTRICAL COMPONENTS • Avoid touching the glass part of a handle EBS30293 CHECKING THE BULBS AND BULB mounted light bulb to keep it free from oil, SOCKETS otherwise the transparency of the glass, the life of the bulb, and the luminous flux Do not check any of the lights that use LEDs.
ELECTRICAL COMPONENTS Pocket tester Pocket tester 90890-03112 90890-03112 Analog pocket tester Analog pocket tester YU-03112-C YU-03112-C Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ▼ ▼▼▼ ▼ ▼▼▼ ▼...
ELECTRICAL COMPONENTS cal system, cause the lighting and ignition be charged as explained in the charging systems to malfunction and could possibly method. If the battery is overcharged, the cause a fire. electrolyte level will drop considerably. Therefore, take special care when charging ▲...
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ELECTRICAL COMPONENTS EWB03650 WARNING • The charge state of a VRLA (Valve Regulated Do not quick charge a battery. Lead Acid) battery can be checked by measur- ing its open-circuit voltage (i.e., the voltage ECB02580 NOTICE when the positive battery terminal is discon- •...
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ELECTRICAL COMPONENTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ B. Time (minutes) Charging method using a constant volt- C. Charging age charger D. Ambient temperature 20 °C (68 °F) a.
ELECTRICAL COMPONENTS Four-wheel-drive motor relay 2 Pocket tester First step: 90890-03112 Analog pocket tester YU-03112-C The pocket tester or the analog pocket tester readings are shown in the following table. No continuity Positive tester probe → black/yellow “1” 1. Positive tester probe Negative tester probe →...
ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester 65˚ 65˚ YU-03112-C • Positive tester probe L Y/G B/L gray “1” • Negative tester probe black “2” c. Set the main switch to “ ” (on). d. Tilt the lean angle sensor to 65°. e.
ELECTRICAL COMPONENTS c. Measure the radiator fan motor movement. EBS30312 CHECKING THE COOLANT TEMPERATURE ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ SENSOR 1. Remove: EBS30311 CHECKING THE RADIATOR FAN MOTOR •...
TROUBLESHOOTING • Sucked-in air EBS20085 TROUBLESHOOTING Electrical system EBS30321 1. Battery GENERAL INFORMATION • Discharged battery • Faulty battery The following guide for troubleshooting does not 2. Fuse(s) cover all the possible causes of trouble. It should • Blown, damaged or incorrect fuse be helpful, however, as a guide to basic trouble- •...
TROUBLESHOOTING EBS30325 FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” movement A. Bearing damage. during acceleration, deceleration, or sustained B. Improper gear backlash. speed. (This must not be confused with engine C.
TROUBLESHOOTING Poor starting performance EBS30326 FAULTY GEAR SHIFTING 1. V-belt • V-belt slips Shifting is difficult • Oil or grease on the V-belt Refer to “FAULTY CLUTCH” on page 10-4. 2. Primary sliding sheave • Faulty operation EBS30327 SHIFT LEVER DOES NOT MOVE •...
TROUBLESHOOTING Fuel system EBS30334 UNSTABLE HANDLING 1. Throttle body 1. Handlebar • Damaged or loose throttle body joint • Bent or improperly installed handlebar 2. Air filter 2. Steering • Clogged air filter element • Incorrect toe-in • Bent steering stem Chassis •...
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TROUBLESHOOTING • Too many electrical accessories • Incorrect connection • Faulty tail/brake light assembly 10-6...
ECU (Engine Control Unit) internal malfunction (input signal error): non-registered data has Er-4 been received from the meter assembly. EBS30338 DIAGNOSTIC CODE: SENSOR OPERATION TABLE The diagnostic code numbers cannot be displayed on the multi-function meter. To display the diagnos- tic code numbers, use the Yamaha diagnostic tool. 10-7...
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SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Display Procedure code No. Throttle angle Check with throttle valve fully closed. • Fully closed position 14–20 Pressure difference Displays the intake air pres- Set the engine stop switch to (atmospheric pressure and sure.
Check that a spark is generat- The “CHECK” indicator and Ignition coil ed five times. “ ” on the Yamaha diagnostic • Connect an ignition checker. tool screen come on each time the ignition coil is actuated. Actuates the fuel injector five Disconnect the fuel pump times at one-second intervals.
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(2 seconds on, 3 sec- onds off) The “CHECK” indicator and “ ” on the Yamaha diagnostic Check that the radiator fan tool screen come on each time motor relay is actuated five Radiator fan motor relay the relay is actuated.