Yamaha 2002 TDM900 Service Manual

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Page 3 EAS00000 TDM900 (P) 2002 SERVICE MANUAL  2001 by Yamaha Motor Co., Ltd. First edition, November 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 4: Important Manual Information
EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Page 5: How To Use This Manual
EAS00007 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. 1 The manual is divided into chapters.
Page 6: Specifications
EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system COOL 7 Fuel injection system 8 Electrical system...
Page 7: Table Of Contents
EAS00012 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
Page 10: Gen Info
INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ....... VEHICLE IDENTIFICATION NUMBER .
Page 11 INFO...
Page 12: General Information
MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL LABEL The model label 2 is affixed to the frame. This information will be needed to order spare parts.
Page 13: Features
FEATURES INFO FEATURES OUTLINE The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet that is used in the respective chamber.
Page 14: Fi System
FEATURES INFO FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 294 kPa (2.94 kg/cm , 2.94 bar) higher than the intake manifold pressure.
Page 15 FEATURES INFO Fuel control block The fuel control block consists of the following main components: Component Function Control block Total FI system control Throttle body Air volume control Pressure regulator Fuel pressure detection Sensor block Intake air pressure sensor Intake air pressure detection Atmospheric pressure sensor Atmospheric pressure detection Coolant temperature sensor...
Page 16: Ecu (Electronic Control Unit)
FEATURES INFO ECU (Electronic Control Unit) The main functions of the ECU are ignition control, fuel control, self-diagnosis, and load control. S ECU’s internal construction and functions The main components and functions of the ECU can be broadly divided into the following four items: A.
Page 17 FEATURES INFO S Ignition control The ignition control function of the ECU controls the ignition timing and the duration of ignition ener- gizing. The ignition timing control uses the signals from the throttle position sensor (to detect the angle of the throttle), and the crankshaft position sensor and speed sensor (to detect the speed of the en- gine).
Page 18 FEATURES INFO Fuel pump The fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps it to the injector. A filter that is provided in the fuel pump prevents any debris in the fuel tank from entering the fuel sys- tem downstream of the pump.
Page 19 FEATURES INFO Pressure regulator It regulates the fuel pressure that is applied to the injectors that are provided in the cylinders in order to maintain a constant pressure difference with the pressure in the intake manifold. The fuel that is delivered by the fuel pump fills the fuel chamber through the fuel inlet of the regulator and exerts pressure on the diaphragm in the direction for opening the valve.
Page 20 FEATURES INFO Fuel injector Upon receiving injection signals from the ECU, the fuel injector injects fuel. In the normal state, the core is pressed downward by the force of the spring, as illustrated. The needle that is integrated with the bottom of the core keeps the fuel passage closed.
Page 21 FEATURES INFO Crankshaft position sensor The crankshaft position sensor uses the signals of the pickup coil that is mounted on the right side of the crankshaft. When the rotation of the pickup rotor that is attached to the crankshaft causes the pro- jections on the rotor to pass by the pickup coil, an electromotive force is generated in the coil.
Page 22 FEATURES INFO Cylinder identification sensor The cylinder identification sensor is mounted on the exhaust head cover of the #1 cylinder. When the exhaust cam of the #1 cylinder rotates and the projection of the cam plate passes by the sensor, the sensor generates a signal and sends it to the ECU.
Page 23 FEATURES INFO Throttle position sensor The throttle position sensor measures the intake air volume by detecting the position of the throttle valve. It detects the mechanical angle of the throttle valve through the positional relationship between the moving contact that moves in unison with the throttle shaft and the resistor board. In actual opera- tion, the ECU supplies 5 V power to both ends of the resistor board and the voltage that is output by the throttle position sensor is used to determine the angle of the throttle valve.
Page 24 FEATURES INFO Intake air pressure sensor and atmospheric pressure sensor S Intake air pressure sensor The intake air pressure sensor is used for measuring the intake air volume. The intake air volume of every intake stroke is proportionate to the intake air pressure. Therefore, the intake air volume can be measured by measuring the intake air pressure.
Page 25 FEATURES INFO Coolant temperature sensor The signals from the coolant temperature sensor are used primarily for making fuel volume compensa- tions during starting and warm-up. The coolant temperature sensor converts the temperature of the coolant into electrical signals and sends them to the ECU. A Resistance kΩ...
Page 26 FEATURES INFO sensor The O sensor has been adopted to enable the catalyst to function at a high degree of efficiency by maintaining the air-fuel mixture near the stoichiometric ratio (14.7 : 1). This sensor, which is a zirconia type, utilizes the oxygen ion conductivity of the solid electrolyte for detecting the oxygen concentration levels.
Page 27 FEATURES INFO Lean angle cut-off switch The lean angle cut-off switch stops the supply of fuel to the engine in case the motorcycle overturns. When the motorcycle is in the normal state, the cut-off switch outputs a constant voltage of approxi- mately 1.0 V (low level).
Page 28: Three-Way Catalytic Converter System
FEATURES INFO THREE-WAY CATALYTIC CONVERTER SYSTEM System outline This is a highly efficient exhaust gas cleaning system that effects air-fuel control through a joint effort by the FI system, O sensor, and the three-way catalytic converter system. By effecting comprehensive control of the air-fuel ratio in this manner, this system reduces the CO, HC, and NOx in the exhaust gases.
Page 29 FEATURES INFO Functions of components Catalyst Because the conditions in which NOx is generated are directly opposed to those of CO and HC, there is a limit to the extent to which the concentration levels of these harmful elements can be reduced in the combustion stage.
Page 30: Air Induction System
FEATURES INFO AIR INDUCTION SYSTEM The air induction system (AI system) introduces fresh air into the exhaust port in order to burn the un- burned gas (which is present in the exhaust gas) in the exhaust pipe. The burning of the unburned gases in this manner enhances the efficiency of the catalyst and results in cleaner exhaust gases.
Page 31 FEATURES INFO Air cut-off valve The air cut-off valve consists of a plunger that is mounted inside the core of a solenoid coil, and a valve at the end of the plunger for opening and closing the air passage. Due to the force of a spring, the valve is in constant contact with valve block A, and thus keeps the air passage open.
Page 32: Instrument Panel
FEATURES INFO INSTRUMENT PANEL Clock TRIP/ ODO meter SELECT button RESET button Engine trouble warning light Function indication The indications of the self-diagnosis function can be checked and inspection operations can be per- formed through the use of the multi-function meter on the instrument panel. Based on the signals received from the sensors, the ECU inputs the signals into the multi-function me- ter.
Page 33 FEATURES INFO CO ADJUSTMENT MODE Cylinder identification For #1 For #2 CO data Example: lean rich –128 DIAGNOSTIC MONITORING MODE Diagnostic monitoring code Example: code “01” Monitoring data WHEN THE COMMUNICATION ERROR Error code OCCURRED BETWEEN ECU AND METER: Example: When the error code is “Er-1” For details of error codes, refer to “FAIL-SAFE ACTION TABLE”...
Page 34: Important Information
5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 35: Lock Washers/Plates And Cotter Pins
IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the...
Page 36: Checking The Connections
CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead S coupler S connector 2. Check: S lead S coupler S connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect sev- eral times.
Page 37: Special Tools
SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 38 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration 90890-01403 Steering nut wrench This tool is used to loosen and tighten the steering ring nut. 90890-01701 Sheave holder This tool is used to hold the rotor when loosening and tightening the rotor bolt. 90890-06756 Vacuum/pressure pump gauge set This tool used to measure the vacuum...
Page 39 This tool is used to hold the clutch when removing or installing the clutch boss nut. 90890-06754 Ignition checker This instrument is necessary for checking the ignition system components. 90890-85505 Yamaha bond No. 1215 This sealant (bond) is used on crankcase mating surfaces, etc. 1-28...
Page 41: Spec
SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ........ENGINE SPECIFICATIONS .
Page 42 SPEC...
Page 43: Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5PS1 (for EUR) 5PS2 (for OCE) Dimensions Overall length 2,180 mm Overall width 800 mm Overall height 1,290 mm Seat height 825 mm Wheelbase 1,485 mm Minimum ground clearance 160 mm Minimum turning radius 2,900 mm...
Page 44: Engine Specifications
SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC Displacement 897 cm Cylinder arrangement Forward-inclined parallel 2-cylinder Bore stroke 92.0 67.5 mm Compression ratio 10.4 : 1 1,100 X 1,200 r/min Engine idling speed 33 X 36 kPa Vacuum pressure at engine idling speed Standard compression pressure...
Page 45 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Paper 40.0 X 80.0 kPa Bypass valve opening pressure (0.40 X 0.80 kg/cm , 0.40 X 0.80 bar) Oil pump Oil pump type Trochoid 0.00 X 0.12 mm Inner-rotor-to-outer-rotor- 0.20 mm tip clearance 0.03 X 0.08 mm...
Page 46 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) 25.000 X 25.021 mm Camshaft cap inside diameter 24.967 X 24.980 mm Camshaft journal diameter 0.020 X 0.054 mm Camshaft-journal-to-camshaft-cap 0.08 mm clearance Intake camshaft lobe dimensions 35.70 X 35.80 mm Measurement A 35.60 mm 27.95 X 28.05 mm...
Page 47 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links 82RH2015/138 Tensioning system Automatic Valve, valve seats, valve guides Valve clearance (cold) 0.15 X 0.20 mm Intake 0.23 X 0.28 mm Exhaust Valve dimensions Head Diameter Face Width Seat Width Margin Thickness Valve head diameter A 25.9 X 26.1 mm...
Page 48 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Free length Intake 37.3 mm 35.4 mm Exhaust 37.3 mm 35.4 mm Installed length (valve closed) Intake 30.4 mm Exhaust 30.4 mm Compressed spring force (installed) 98.1 X 113.8 N (10.0 X 11.6 kgf) Intake 98.1 X 113.8 N (10.0 X 11.6 kgf) Exhaust...
Page 49 SPEC ENGINE SPECIFICATIONS Item Standard Limit Cylinders Cylinder arrangement Forward inclined parallel 2-cylinder Bore stroke 92.0 67.5 mm Compression ratio 10.4 : 1 92.00 X 92.01 Bore Max. taper 0.05 mm Max. out-of-round 0.05 mm Pistons 0.025 X 0.050 mm Piston-to-cylinder clearance 0.11 mm 91.960 X 91.975 mm...
Page 50 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil ring Dimensions (B 2.5 mm 0.20 X 0.50 mm End gap (installed) 0.04 X 0.14 mm Ring side clearance Connecting rods 0.036 X 0.060 mm Crankshaft-pin-to-big-end-bearing 0.09 mm clearance Bearing color code 1 = Blue 2 = Black 3 = Brown 4 = Green 21.005 X 21.018 mm Small end inside diameter...
Page 51 SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch plates 1.9 X 2.1 mm Thickness Plate quantity Max. warpage 0.1 mm Clutch spring Free length 50 mm 47.5 mm Spring quantity Transmission Transmission type Constant mesh, 6-speed Primary reduction system Spur gear Primary reduction ratio 67/39 (1.718) Secondary reduction system...
Page 52 SPEC ENGINE SPECIFICATIONS Item Standard Limit Throttle bodies Model (manufacturer) quantity 38EIS (MIKUNI) 33 X 36 kPa Intake vacuum pressure 3 X 5 mm Throttle cable free play (at the flange of the throttle grip) ID mark 5PS1 00 Throttle valve size 2-10...
Page 53: Chassis Specifications
SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond Caster angle 25.5_ Trail 114 mm Front wheel Wheel type Cast wheel Size 18M/C MT3.50 Material Aluminum Wheel travel 150 mm Wheel runout Max. radial wheel runout 1 mm Max.
Page 54 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless Size 160/60ZR17M/C (69W) Model (manufacturer) MEZ4J (METZELER)/ D220STJ (DUNLOP) Tire pressure (cold) 0 X 90 kg 250 kpa (2.5 kgf/cm , 2.5 bar) 90 X 208 kg 290 kPa (2.9 kgf/cm , 2.9 bar) High-speed riding 250 kPa (2.5 kgf/cm...
Page 55 80 X 150 mm Spring stroke (K2) Optional spring available Fork oil Recommended oil Yamaha fork oil 10 WT or equivalent Quantity (each front fork leg) 507 cm Level (from the top of the inner 133 mm tube, with the inner tube fully...
Page 56 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension Suspension type Swingarm (link suspension) Rear shock absorber assembly type Coil spring/gas-oil damper Rear shock absorber assembly travel 61.5 mm Spring Free length 180 mm 176.4 mm Installed length 170 mm Spring rate (K1) 127.5 mm (12.75 kgf/mm) 0 X 61.5 mm Spring stroke (K1)
Page 57: Electrical Specifications
SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V Ignition system Ignition system type Transistorized coil ignition (digital) Ignition timing 10_ BTDC at 1,150 r/min Advancer type Electric 420.8 X 569.3 Ω/Gy-B Pickup coil resistance/color Transistorized coil ignition unit model F8T911 (MITSUBISHI) (manufacturer) Ignition coils...
Page 58 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Bulbs (voltage/wattage quantity) Headlight 12 V 55 W Auxiliary light 12 V 5 W Tail/brake light 12 V 5 W/21 W Turn signal light 12 V 10 W Meter light 14 V 2 W Electric starting system System type Constant mesh...
Page 59 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuses (amperage quantity) Main fuse 40 A Fuel injection system fuse 15 A Headlight fuse 15 A Signaling system fuse 7.5 A 1 (EUR) 1 (OCE) Ignition fuse 10 A Radiator fan motor fuse 20 A Hazard light fuse 10 A...
Page 60: Conversion Table
CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00029 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are SPECIFICATIONS listed in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC dard fasteners with a standard ISO thread unit data to IMPERIAL unit data.
Page 61: Tightening Torques
SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Cylinder head stud bolt (exhaust pipe) Bolt Camshaft cap Bolt Cylinder head bolt Bolt Cylinder head nut (initial) (2nd) 1.8* (final)
Page 62 SPEC TIGHTENING TORQUES Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Drive chain slider Bolt Engine bracket Bolt Starter clutch Bolt Clutch spring Screw Use a lock Clutch boss washer Bearing housing Screw Stake Use a lock Drive sprocket washer...
Page 63 SPEC TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence: Upper crankcase Lower crankcase 2-21...
Page 64: Chassis Tightening Torques
SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Thread torque Part to be tightened Remarks size size mSkg Upper bracket pinch bolt Steering stem nut 11.3 Lower ring nut See NOTE Lower bracket pinch bolt Horn bracket and lower bracket Brake hose union bolt Front cowling stay and frame Grip end Front brake master cylinder bracket...
Page 65 SPEC TIGHTENING TORQUES Tightening Thread torque Part to be tightened Remarks size size mSkg Footrest bracket and frame Rear brake master cylinder and bracket Rear footrest and footrest bracket Front wheel axle Rear wheel axle and nut 15.0 Front brake caliper Rear brake caliper and caliper bracket Front brake disc and wheel Rear brake disc and wheel...
Page 66: Lubrication Points And Lubricant Types
Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft right side and crankcase Shift pedal bolt Cylinder head cover mating surface Yamaha bond No. 1215 Cylinder head cover Yamaha bond No. 1215 Crankcase mating surface Yamaha bond No.
Page 67: Chassis Lubrication Points And Lubricant Types
SPEC LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal pivot Rear footrest pivoting point...
Page 68: Oil Flow Diagrams
SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS Scavenge pump Feed pump Oil strainer Oil filter element Oil drain bolt (oil tank) Oil tank Oil level switch 2-26...
Page 69 SPEC OIL FLOW DIAGRAMS Front balancer shaft Oil strainer Feed pump Relief valve Scavenge pump 2-27...
Page 70 SPEC OIL FLOW DIAGRAMS Cam shaft Rear balancer shaft Main axle Drive axle Oil drain bolt (engine) Front balancer shaft 2-28...
Page 71 SPEC OIL FLOW DIAGRAMS Cylinder head Rear balancer shaft Crankshaft Oil drain bolt (engine) 2-29...
Page 72 SPEC OIL FLOW DIAGRAMS Main axle Drive axle 2-30...
Page 73: Cooling System Diagrams
SPEC COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS Radiator Water pump Radiator outlet hose Thermostat assembly Thermostat inlet hose Radiator inlet hose 2-31...
Page 74 SPEC COOLING SYSTEM DIAGRAMS Radiator Radiator outlet hose Water pump Coolant reservoir tank hose 2-32...
Page 75 SPEC COOLING SYSTEM DIAGRAMS Thermostat assembly Thermostat inlet hose Liner control valve 2-33...
Page 76: Cable Routing
SPEC CABLE ROUTING CABLE ROUTING Throttle cables Clamp Headlight adjusting knob Clutch cable Front turn signal light (right) Handlebar switch lead (left) Stay 1 Main switch lead Meter assembly Cover 7 Auxiliary light Horn lead Meter lead Horn Auxiliary light lead Cover 8 Front turn signal light (left) Front brake hose...
Page 77 SPEC CABLE ROUTING A Fasten the handlebar switch lead (left) to the han- F Route the handlebar switch lead (right) and throttle dlebar with a band. cable (2 cables) through the cover 8. B Through the handlebar switch lead (left) and clutch G Route the brake hose through the guide.
Page 78 SPEC CABLE ROUTING L Fasten the main switch lead with a clamp so that it Q Route the wire harness so that it passes by the out- faces the front side of the vehicle. side of bolt. M Fasten the turn signal lead (right) together with the R To the ECU coupler to the stay 1.
Page 79 SPEC CABLE ROUTING Plate Battery negative lead sensor Stay 3 Seat lock cable sensor lead Ignition coil Alarm coupler Cylinder identification sensor Neutral switch lead Tail/ brake light lead Headlight relay (for OCE) sensor lead Rear turn signal light (left) Speed sensor lead Rear turn signal light lead ECU lead...
Page 80 SPEC CABLE ROUTING A To the headlight H Fasten the tail / brake light lead to the outside of the B Connect the headlight sub-wire harness in front of frame with a clamp. Connect the tail / brake light ECU and make it not to route inside or above the lead coupler between rear cover and frame, posi- ECU lead.
Page 81 SPEC CABLE ROUTING K The O sensor lead should not stick out from the O Route the fuel drain hose (2 hoses), air filter case boss seat face to the outside of the vehicle. drain hose and radiator reservoir tank drain hose L Bind the neutral switch, O sensor, speed sensor, through the guide located behind the swingarm...
Page 82 SPEC CABLE ROUTING Hose 2 A Route the clutch cable through the guide of stay 2. Hose B Pass the fuel hose between the fuel drain hoses. Ignition coil C Direct the take out port of rear brake light switch lead to the front. Stay 2 Radiator Clutch cable...
Page 83 SPEC CABLE ROUTING Throttle cables Atmospheric pressure sensor Fuel pump lead 1 Handlebar switch lead (right) Main fuse Sub wire harness (throttle body) Stay Starter relay Radiator fan motor lead Thermo wax hose Rear turn signal light lead (right) Cylinder identification sensor Intake air vacuum hose Rear turn signal light (right) lead...
Page 84 SPEC CABLE ROUTING A For the wire harness routing, use clamps to fasten G Route the starter motor lead under the rear frame the wire harness to the outer hole of the cover 2. attaching boss section. B To the AI system H Route the starter motor lead by the right side of the C Plug in the ignition coil lead terminals as shown in battery and coolant reservoir tank.
Page 85 SPEC CABLE ROUTING L Route the rear turn signal lead (left) through the left T Pass the wire harness, cylinder identification sensor side hole of fender. and radiator fan motor leads under the bracket 1. M Route the rear turn signal light leads (right and left) U Pass the wire harness, cylinder identification sen- between the ribs of rear fender.
Page 86 SPEC CABLE ROUTING Z Fasten the cylinder identification sensor and radia- tor fan motor lead to the frame with a clamp. Posi- tion the clamp tip to face downward. AA Route the wire harness through the smaller diam- eter and the radiator reservoir tank drain hose through the larger diameter and clamp them.
Page 88: Chk Adj
CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..........PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .
Page 89 CHASSIS ........... . . 3-43 ADJUSTING THE FRONT BRAKE .
Page 90: Periodic Checks And Adjustments
S The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. S From 50,000 km, repeat the maintenance intervals starting from 10,000 km. S Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (...
Page 91 INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ODOMETER READING ( 1,000 km) ANNUAL ITEM ITEM CHECK OR MAINTENANCE JOB CHECK OR MAINTENANCE JOB CHECK Chassis fasteners S Make sure that all nuts, bolts and screws are properly tightened. 15 * (See page 2-22) S Check operation.
Page 92: Seat
SEAT EAS00038 SEAT Order Job/Part Q’ty Remarks Removing the seat Remove the parts in the order listed. Seat For installation, reverse the removal procedure.
Page 93: Front Cowlings
FRONT COWLINGS FRONT COWLINGS Order Job/Part Q’ty Remarks Removing the front cowlings Remove the parts in the order listed. Windshield Inner panel Turn signal light connector Disconnect. Side cowling (left and right) Front cowling Air intake grile Headlight assembly For installation, reverse the removal procedure.
Page 94: Fuel Tank
FUEL TANK EAS00040 FUEL TANK 16 Nm (1.6 mSkg) 7 Nm (0.7 mSkg) 16 Nm (1.6 mSkg) 4 Nm (0.4 mSkg) 4 Nm (0.4 mSkg) Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Seat Refer to “SEAT”.
Page 95: Removing The Fuel Tank
REMOVING THE FUEL TANK/ REMOVING THE FUEL PUMP REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: S fuel return hose S fuel hose CAUTION: Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remain- ing in it.
Page 96: Installing The Fuel Pump
INSTALLING THE FUEL PUMP/ INSTALLING THE FUEL HOSE INSTALLING THE FUEL PUMP 1. Install: S fuel pump 4 Nm (0.4 mSkg) NOTE: S Do not damage the installation surfaces of the fuel tank when installing the fuel pump. S Always use a new fuel pump gasket. S Install the fuel pump as shown in the illustra- tion.
Page 97: Rear Cowling
REAR COWLING EAS00042 REAR COWLING 23 Nm (2.3 mSkg) 23 Nm (2.3 mSkg) 19 Nm (1.9 mSkg) 7 Nm (0.7 mSkg) 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Removing the rear cowling Remove the parts in the order listed. Seat Refer to “SEAT”.
Page 98: Air Filter Case
AIR FILTER CASE EAS00043 AIR FILTER CASE 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Side cowlings Seat Refer to “SEAT”. Fuel tank Refer to “FUEL TANK”. Cylinder head breather hose AI system hose Solenoid valve hose Solenoid valve coupler...
Page 99: Engine
ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
Page 100 ADJUSTING THE VALVE CLEARANCE a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the generator rotor with the mark b on the crankcase cover. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.
Page 101 ADJUSTING THE VALVE CLEARANCE 8. Adjust: S valve clearance a. Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 . Valve lapper 90890-04101 NOTE: S Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.
Page 102 ADJUSTING THE VALVE CLEARANCE EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm (0.058 in)) Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number.
Page 103 ADJUSTING THE VALVE CLEARANCE INTAKE INSTALLED PAD NUMBER MEASURED 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 CLEARANCE 0.00 X 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.05 X 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.10 X 0.14...
Page 104: Synchronizing The Throttle Bodies
9. Apply: S sealant (onto the cylinder head cover) Yamaha bond No.1215 90890-85505 10. Install: S cylinder head cover 10 Nm (1.0 mSkg) EAS00050...
Page 105 SYNCHRONIZING THE THROTTLE BODIES 4. Install: S engine tachometer (to the spark plug lead of cyl. #1) S vacuum gauge (to the throttle body) Vacuum gauge 90890-03094 Engine tachometer 90890-03113 5. Install: S fuel tank Refer to “FUEL TANK”. 6. Start the engine and let it warm up for several minutes.
Page 106 SYNCHRONIZING THE THROTTLE BODIES CAUTION: Do not use the throttle valve adjusting screws 1 to adjust the throttle body syn- chronization. Carburetor angle driver 90890-03158 Vacuum pressure at engine idling speed 33.0 X 36.0 kPa (248 X 270 mm Hg) NOTE: The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa...
Page 107: Checking And Adjusting The Exhaust Gas At Idle
CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE (Measuring the exhaust gas at idle [when the air induction system does not operate]) 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure the motorcycle is upright.
Page 108 CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE 5. Install: S air filter case Refer to “AIR FILTER CASE”. S fuel tank Refer to “FUEL TANK”. 6. Start the engine and warm it up until the spe- cified oil temperature is reached. Oil temperature 60 X 80_C 7.
Page 109 ADJUSTING THE EXHAUST GAS VOLUME ADJUSTING THE EXHAUST GAS VOLUME NOTE: Be sure to set the carbon monoxide density to standard, and then adjust the exhaust gas. Setting steps NOTE: If the battery is not fully charged errors one to four will be indicated on the display.
Page 110 ADJUSTING THE EXHAUST GAS VOLUME NOTE: The exhaust gas volume will be indicated on the display. S Push the “RESET” button to increase the vol- ume. S Push the “SELECT” button to decrease the volume. S Release the button to set the volume. S Push the “SELECT”...
Page 111 CHECKING THE EXHAUST GAS AT IDLE CHECKING THE EXHAUST GAS AT IDLE (Measuring the exhaust gas at idle [when air in- duction system is operating]) 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure the motorcycle is upright.
Page 112 CHECKING THE EXHAUST GAS AT IDLE 7. Install: S carbon monoxide and hydrocarbon tester 1 S sampling probe 2 NOTE: S Since it is necessary to insert the sampling probe 600 mm into the exhaust pipe, be sure to use a heat-resistant rubber tube as shown in the illustration.
Page 113 ADJUSTING THE ENGINE IDLING SPEED EAS00052 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the throttle bodies synchronization should be ad- justed properly, the air filter element should be clean, and the engine should have adequate compression.
Page 114 ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00055 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and throttle bodies synchro- nization should be adjusted properly. 1. Check: S throttle cable free play a Out of specification ! Adjust.
Page 115 ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play is Direction increased. Throttle cable free play is Direction decreased. e. Tighten the locknuts. NOTE: If the specified throttle cable free play cannot be obtained on the carburetor side of the cable, use the adjusting nut on the handlebar side.
Page 116 CHECKING THE SPARK PLUGS EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Disconnect: S spark plug cap 2. Remove: S spark plug CAUTION: Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from fal- ling into the cylinders.
Page 117 CHECKING THE IGNITION TIMING EAS00064 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Remove: S timing plug 1 2.
Page 118 MEASURING THE COMPRESSION PRESSURE EAS00065 MEASURING THE COMPRESSION PRES- SURE The following procedure applies to all of the cyl- inders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: S valve clearance Out of specification ! Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE”.
Page 119 MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING To prevent sparking, ground all spark plug leads before cranking the engine.
Page 120 CHECKING THE ENGINE OIL LEVEL 3. Check: S engine oil level Wipe the dipstick clean, insert it into the oil filler hole (without screw it in and direct the arrow mark on the cap upward.), and then re- move it to check the oil level. The engine oil level should be between the minimum level mark a and maximum level mark b .
Page 121 CHANGING THE ENGINE OIL EAS00075 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: S engine oil filler cap S engine oil drain bolt (engine) 1 (along with the gasket) S engine oil drain bolt (oil tank) 2...
Page 122 CHANGING THE ENGINE OIL CAUTION: The engine should be filled with oil in two steps. First fill the engine with 3.0 liters of oil. Then start the engine and race it five or six time. Stop the engine and fill it with oil to the specified level.
Page 123 ADJUSTING THE CLUTCH CABLE FREE PLAY EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm 2.
Page 124 CHECKING THE AIR FILTER ELEMENT EAS00086 CHECKING THE AIR FILTER ELEMENT 1. Remove: S fuel tank Refer to “FUEL TANK”. 2. Remove: S air filter case cover S air filter element 3. Check: S air filter element Damage ! Replace. NOTE: Replace the air filter element at periodic inter- vals of 40,000 km travel.
Page 125 CHECKING THE FUEL AND VACUUM HOSES/ CHECKING THE CRANKCASE BREATHER HOSE EAS00096 CHECKING THE FUEL AND VACUUM HOSES The following procedure applies to all of the fuel and vacuum hoses. 1. Remove: S fuel tank Refer to “FUEL TANK”. S air filter case Refer to “AIR FILTER CASE”.
Page 126 CHECKING THE EXHAUST SYSTEM EAS00100 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipes, mufflers and gaskets. 1. Check: S exhaust pipe 1 S muffler 2 Cracks/damage ! Replace. S gasket 3 Exhaust gas leaks ! Replace. 2.
Page 127 CHECKING THE COOLANT LEVEL EAS00102 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure the motorcycle is upright. 2. Remove: S seat Refer to “SEAT”. 3.
Page 128 CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Remove: S fuel tank Refer to “FUEL TANK”. S air filter case Refer to “AIR FILTER CASE”. 2. Check: S radiator 1 S radiator inlet hose 2 S radiator outlet hose 3 S radiator reservoir tank hose 4 S radiator cover 5 Cracks/damage ! Replace.
Page 129 CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove: S seat Refer to “SEAT”. 2. Disconnect: S coolant reservoir hose 1 3. Drain: S coolant (from the coolant reservoir tank) 4. Remove: S coolant reservoir tank cap 2 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot.
Page 130 CHANGING THE COOLANT 8. Connect: S coolant reservoir hose 9. Fill: S cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 1.7 L Coolant reservoir capacity...
Page 131 CHANGING THE COOLANT 12. Install: S coolant reservoir cap 13. Start the engine, warm it up for several min- utes, and then stop it. 14. Check: S coolant level Refer to “CHECKING THE COOLANT LEV- EL”. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled.
Page 132: Chassis
ADJUSTING THE FRONT BRAKE EASD0107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position.
Page 133: Adjusting The Rear Brake
ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Check: S brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification ! Adjust. Brake pedal position (below the top of the rider footrest) 32 mm 2.
Page 134: Checking The Brake Fluid Level
ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL 3. Adjust: S rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure the motorcycle is upright.
Page 135: Checking The Front And Rear Brake Pads
CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE FRONT AND REAR BRAKE PADS NOTE: In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal. EAS00122 CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads.
Page 136: Adjusting The Rear Brake Light Switch
ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT AND REAR BRAKE HOSES EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by move- ment of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.
Page 137: Bleeding The Hydraulic Brake System
BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00134 BLEEDING THE HYDRAULIC BRAKE SYS- WARNING Bleed the hydraulic brake system whenev- S the system is disassembled. S a brake hose is loosened, disconnected or replaced. S the brake fluid level is very low. S brake operation is faulty.
Page 138: Adjusting The Shift Pedal
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.
Page 139: Adjusting The Drive Chain Slack
ADJUSTING THE DRIVE CHAIN SLACK EAS00140 ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swin- garm or cause an accident.
Page 140: Lubricating The Drive Chain
ADJUSTING THE DRIVE CHAIN SLACK/ LUBRICATING THE DRIVE CHAIN 4. Adjust: S drive chain slack a. Loosen the brake caliper bracket bolt 1 . b. Loosen the wheel axle nut 2 . c. Loosen locknuts 3 (left and right). d. Turn the each side adjusting bolts 4 in direc- tion a or b until the specified drive chain slack is obtained.
Page 141: Checking And Adjusting The Steering Head
CHECKING AND ADJUSTING THE STEERING HEAD EAS00146 CHECKING AND ADJUSTING THE STEER- ING HEAD 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
Page 142 CHECKING AND ADJUSTING THE STEERING HEAD 4. Adjust: S steering head a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 . b. Loosen the lower ring nut 4 and then tighten it to specification with a steering nut wrench NOTE: Set the torque wrench at a right angle to the...
Page 143 CHECKING AND ADJUSTING THE STEERING HEAD 5. Install: S upper bracket 26 Nm (2.6 mSkg) S steering stem nut 113 Nm (11.3 mSkg) S handlebar 23 Nm (2.3 mSkg) 6. Measure: S steering head tension NOTE: Make sure all of the cables and wires are prop- erly routed.
Page 144: Checking The Front Fork
CHECKING THE FRONT FORK/ ADJUSTING THE FRONT FORK LEGS EAS00149 CHECKING THE FRONT FORK 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Check: S inner tube 1 Damage/scratches ! Replace.
Page 145 ADJUSTING THE FRONT FORK LEGS 1. Adjust: S spring preload a. Turn the adjusting bolt 1 in direction a or Spring preload is Direction increased (suspension is harder). Spring preload is Direction decreased (suspension is softer). Adjusting positions Minimum: 8 Standard: 7 Maximum: 1 Rebound damping...
Page 146: Adjusting The Rear Shock Absorber Assembly
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EAS00158 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1.
Page 147 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Rebound damping CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S rebound damping a. Turn the adjusting knob 1 in direction a or Rebound damping is Direction increased (suspension is harder).
Page 148: Checking The Tires
CHECKING THE TIRES EAS00166 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: S tire pressure Out of specification ! Regulate. WARNING S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
Page 149 Ltd. for this model. The front and rear tires should always be by the same manufactur- er and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. 3-60...
Page 150: Checking The Wheels
CHECKING THE TIRES/ CHECKING THE WHEELS Front tire Manufacturer Size Model 120/70ZR18 DUNLOP D220FSTJ M/C (59W) 120/70ZR18 MEZ4J METZELER M/C (59W) Front BRIDGE- 120/70ZR18 BT020F STONE M/C (59W) MTR23 120/70ZR18 DRAGON PIRELLI M/C (59W) Front Rear tire Manufacturer Size Model 160/60ZR17 DUNLOP D220STJ...
Page 151: Checking And Lubricating The Cables
CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION EAS00170 CHECKING LUBRICATING CABLES The following procedure applies to all of the in- ner and outer cables. WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement.
Page 152: Electrical System
CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries.
Page 153 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Page 154 CHECKING AND CHARGING THE BATTERY 5. Charge: Charging S battery Ambient temperature 20_C (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger Ambient since it forces a high-amperage current...
Page 155 CHECKING AND CHARGING THE BATTERY Charging method using a variable voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charged and NOTE: AMP meter to the battery Set the charging voltage at 16 X 17 V.
Page 156 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
Page 157: Checking The Fuses
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: S battery 7. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1 , and then the negative battery lead 2 . 8. Check: S battery terminals Dirt ! Clean with a wire brush.
Page 158 CHECKING THE FUSES Pocket tester 90890-03132 b. If the pocket tester indicates “∞”, replace the fuse. 3. Replace: S blown fuse a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage rating. c. Set on the switches to verify if the electrical circuit is operational.
Page 159: Replacing The Headlight Bulbs
REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: S headlight coupler 1 2. Remove: S headlight bulb holder cover 2 3. Remove: S headlight bulb holder 1 4.
Page 160: Adjusting The Headlight Beams
ADJUSTING THE HEADLIGHT BEAMS EAS00185 ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: S headlight beam (vertically) a. To adjust the height of headlight, use the No.2 Phillips screwdriver 1 and then adjust the headlight height by inserting it from the downside. b.
Page 163: Chas
CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS ......FRONT WHEEL ..........REMOVING THE FRONT WHEEL .
Page 164 CHAS FRONT FORK ..........4-44 REMOVING THE FRONT FORK LEGS .
Page 165: Front Wheel And Brake Discs
CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 40 Nm (4.0 mSkg) 40 Nm (4.0 mSkg) 40 Nm (4.0 mSkg) 72 Nm (7.2 mSkg) 20 Nm (2.0 mSkg) 40 Nm (4.0 mSkg) 18 Nm (1.8 mSkg) 18 Nm (1.8 mSkg) Order Job/Part...
Page 166: Front Wheel
CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 FRONT WHEEL Order Job/Part Q’ty Remarks Disassembling the front wheel Disassembly the parts in the order listed. Oil seal Bearing Collar For assembly, reverse the disassembly procedure.
Page 167: Removing The Front Wheel
CHAS FRONT WHEEL AND BRAKE DISCS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
Page 168: Checking The Front Wheel
CHAS FRONT WHEEL AND BRAKE DISCS EAS00525 CHECKING THE FRONT WHEEL 1. Check: S wheel axle Roll the wheel axle on a flat surface. Bends ! Replace. WARNING Do not attempt to straighten a bent wheel axle. 2. Check: S tire Refer to “CHECKING THE TIRES”...
Page 169: Checking The Brake Discs
CHAS FRONT WHEEL AND BRAKE DISCS EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: S brake disc Damage/galling ! Replace. 2. Measure: S brake disc deflection Out of specification ! Correct the brake disc deflection or replace the brake disc.
Page 170: Adjusting The Front Wheel Static Balance
CHAS FRONT WHEEL AND BRAKE DISCS 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. EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE...
Page 171: Disassembling The Front Wheel
CHAS FRONT WHEEL AND BRAKE DISCS 3. Adjust: S front wheel static balance a. Install a balancing weight 1 onto the rim ex- actly opposite the heavy spot “X”. NOTE: Start with the lightest weight. b. Turn the front wheel 90_ so that the heavy spot is positioned as shown.
Page 172: Assembling The Front Wheel
CHAS FRONT WHEEL AND BRAKE DISCS EAS00539 ASSEMBLING THE FRONT WHEEL 1. Install: S wheel bearings S oil seals a. Install the new wheel bearings and oil seals in the reverse order of disassembly. CAUTION: Do not contact the wheel bearing inner race 1 or balls 2 .
Page 173: Rear Wheel, Brake Disc And Rear Wheel Sprocket
REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET EAS00550 REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET REAR WHEEL 40 Nm (4.0 mSkg) 27 Nm (2.7 mSkg) 150 Nm (15.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed.
Page 174 REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET 20 Nm (2.0 mSkg) 69 Nm (6.9 mSkg) Order Job/Part Q’ty Remarks Removing the brake disc and rear wheel sprocket Collar Rear wheel sprocket Oil seal Bearing Rear wheel drive hub Collar Damper Rear brake disc...
Page 175 REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET EAS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Disassembly the parts in the order listed. Bearing Oil seal Spacer For installation, reverse the disassembly procedure. 4-11...
Page 176: Removing The Rear Wheel
REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
Page 177: Checking The Rear Wheel Drive Hub
REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET 2. Check: S tire Refer to “CHECKING THE TIRES” in chap- ter3. S rear wheel Damage/wear ! Replace. 3. Measure: S radial wheel runout S lateral wheel runout Refer “CHECKING FRONT WHEEL”.
Page 178: Installing The Rear Wheel
REAR WHEEL, BRAKE DISC, CHAS AND REAR WHEEL SPROCKET EAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: S wheel axle S wheel bearings S oil seal lips Recommended lubricant Lithium-soap-based grease 2. Install: S rear wheel drive hub damper S rear wheel drive hub S left collar 3.
Page 179: Adjusting The Rear Wheel Static Balance
REAR WHEEL, BRAKE DISC, CHAS AND REAR WHEEL SPROCKET EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. S Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed.
Page 180: Front And Rear Brakes
CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 6 Nm (0.6 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Brake caliper bolt Brake pad clip Brake pad pin Brake pad spring...
Page 181: Rear Brake Pads
CHAS FRONT AND REAR BRAKES REAR BRAKE PADS 6 Nm (0.6 mSkg) 27 Nm (2.7 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake pads. Remove the parts in the order listed. Rear brake caliper Brake pad Brake pad shim Bleed screw For installation, reverse the removal procedure.
Page 182: Replacing The Front Brake Pads
CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.
Page 183 CHAS FRONT AND REAR BRAKES 2. Remove: S brake pad clips 1 S brake pad pin 2 S brake pad spring 3 S brake pads (along with the brake pad shims) 3. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set.
Page 184 CHAS FRONT AND REAR BRAKES 5. Install: S brake pad spring 1 S brake pad pin 2 S brake pad clips 3 S brake caliper 40 Nm (4.0 mSkg) 6. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.
Page 185: Replacing The Rear Brake Pads
CHAS FRONT AND REAR BRAKES EAS00583 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. Remove: S brake caliper 1 S brake caliper bolts 2 2.
Page 186 CHAS FRONT AND REAR BRAKES d. Install a new brake pad shim onto each new brake pad. 5. Lubricate: S brake caliper bolt Recomended lubricant Lithium-sope-based grease 6. Install: S brake caliper 1 S brake caliper bolts 2 27 Nm (2.7 mSkg) 7.
Page 187: Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain. Brake lever Front brake light switch lead coupler Disconnect.
Page 188: Disassembling The Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake Disassembly the parts in the order listed. master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder body For assembly, reverse the disassembly procedure. 4-24...
Page 189 CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 30 Nm (3.0 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder Brake fluid Drain. Brake fluid reservoir cap Rear brake fluid reservoir diaphragm holder Rear brake fluid reservoir diaphragm...
Page 190 CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake master Disassemble the parts in the order listed. cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder body For assembly, reverse the disassembly procedure. 4-26...
Page 191: Disassembling The Rear Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: S brake switch coupler (from the brake switch) 2. Remove: S union bolt 1 S copper washers 2 S brake hose 3...
Page 192: Checking The Front And Rear Brake Master Cylinders
CHAS FRONT AND REAR BRAKES EAS00592 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: S brake master cylinder 1 Damage/scratches/wear ! Replace. S brake fluid delivery passages (brake master cylinder body) Obstruction ! Blow out with compressed air.
Page 193: Assemblying And Installing The Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00598 ASSEMBLING INSTALLING FRONT BRAKE MASTER CYLINDER WARNING Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake com- ponents. Recommended brake fluid DOT 4 1.
Page 194 CHAS FRONT AND REAR BRAKES 3. Install: S front brake lever 4. Connect: S brake switch coupler (to the brake switch) 5. Fill: S brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid.
Page 195: Assembling The Rear Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: S master cylinder kit S circlip 2. Install: S rear brake master cylinder assembly 3. Install: S pin (to the brake pedal link) 4. Connect: S brake fluid reservoir hose 5.
Page 196 CHAS FRONT AND REAR BRAKES CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 3. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.
Page 197: Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.
Page 198 CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. calipers The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad...
Page 199: Rear Brake Caliper
CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 mSkg) 27 Nm (2.7 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal...
Page 200 CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Disassemble the parts in the order listed. Brake pad Shim Brake pad spring Brake caliper piston Brake caliper piston seal kit Bleed screw For assembly, reverse the disassembly procedure.
Page 201: Disassembling The Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S brake caliper bolts S union bolt 1 S copper washers 2 S brake hose 3...
Page 202: Disassembling The Rear Brake Caliper
CHAS FRONT AND REAR BRAKES EAS00626 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S brake caliper bolts 1 S union bolt 2 S copper washers 3 S brake hose S brake caliper NOTE:...
Page 203: Checking The Front And Rear Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Every two years and whenever the Brake fluid brake is disas- sembled 1.
Page 204: Assembling And Installing The Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00638 ASSEMBLING INSTALLING FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
Page 205 CHAS FRONT AND REAR BRAKES 4. Fill: S brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Page 206: Assembling And Installing The Rear Brake Caliper
CHAS FRONT AND REAR BRAKES EAS00642 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
Page 207 CHAS FRONT AND REAR BRAKES 5. Fill: S brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Page 208: Front Fork
CHAS FRONT FORK EAS00647 FRONT FORK 26 Nm (2.6 mSkg) 28 Nm (2.8 mSkg) 10 Nm (1.0 mSkg) 6 Nm (0.6 mSkg) 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
Page 209 CHAS FRONT FORK EAS00648 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the front fork legs Disassembly the parts in the order listed. Cap bolt O-ring Washer Spacer Washer Fork spring Damper rod bolt Dust seal Oil seal clip Oil seal Washer...
Page 210 CHAS FRONT FORK 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Oil lock piece Outer tube bushing Outer tube For assembly, reverse the disassembly procedure. 4-46...
Page 211: Removing The Front Fork Legs
CHAS FRONT FORK EAS00651 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
Page 212: Disassembling The Front Fork Legs
CHAS FRONT FORK EAS00655 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: S cap bolt S washers S spacer S spring 2. Drain: S fork oil 3. Remove: S dust seal 1 S oil seal clip 2 (with a flat-head screwdriver) CAUTION:...
Page 213: Checking The Front Fork Legs
CHAS FRONT FORK EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: S inner tube 1 S outer tube 2 Bends/damage/scratches ! Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.
Page 214: Assembling The Front Fork Legs
Be careful not to dam- age the inner tube. 2. Lubricate: S inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil 5W or equivalent 3. Tighten: S damper rod assembly bolt 1 ...
Page 215 CHAS FRONT FORK NOTE: While holding the damper rod assembly with the damper rod holder 1 and T-handle 2 , tighten the damper rod assembly bolt. Damper rod holder (29 mm) 90890-01375 T-handle 90890-01326 4. Install: S outer tube bushing 1 (with the fork seal driver weight 2 and fork seal driver attachment 3 ) Fork seal driver weight...
Page 216 (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.507 L Recommended oil Yamaha fork and shock oil 10W or equivalent CAUTION: S Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.
Page 217 CHAS FRONT FORK 11. Measure: S front fork leg oil level a Out of specification ! Correct. Front fork leg oil level (from the top of the inner tube, with the inner tube fully compressed, and without the spring) 133 mm 12.
Page 218: Installing The Front Fork Legs
CHAS FRONT FORK EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: S front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure the inner fork tube is flush with the top of the handlebar holder.
Page 219: Handlebar
CHAS HANDLEBAR EAS00664 HANDLEBAR 23 Nm (2.3 mSkg) 26 Nm (2.6 mSkg) 10 Nm (1.0 mSkg) 26 Nm (2.6 mSkg) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Band Clutch cable Clutch switch lead coupler Disconnect.
Page 220 CHAS HANDLEBAR 23 Nm (2.3 mSkg) 26 Nm (2.6 mSkg) 10 Nm (1.0 mSkg) 26 Nm (2.6 mSkg) Order Job/Part Q’ty Remarks Upper handlebar holder Handlebar Rear view mirror For installation, reverse the removal procedure. 4-56...
Page 221: Removing The Handlebar
CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S throttle cable housing 1 S throttle grip 2 NOTE: While removing the throttle cable housing, pull back the rubber cover 3 .
Page 222: Checking The Handlebar
CHAS HANDLEBAR EAS00668 CHECKING THE HANDLEBAR 1. Check: S handlebar 1 Bends/cracks/damage ! Replace. WARNING Do not attempt to straighten a bent handle- bar as this may dangerously weaken it. 2. Install: S handlebar grip a. Apply a thin coat of rubber adhesive onto the left end of the handlebar.
Page 223: Installing The Handlebar
CHAS HANDLEBAR EAS00670 INSTALLING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Install: S handlebar 1 S upper handlebar holders 2 23 Nm (2.3 mSkg) CAUTION: S First, tighten the bolts on the front side of the handlebar holder, and then on the rear...
Page 224 CHAS HANDLEBAR 5. Install: S clutch cable 6. Connect: S clutch switch coupler NOTE: Lubricate the end of the clutch cable with a thin coat of lithium-soap-based grease. 7. Adjust: S clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY”...
Page 225 CHAS STEERING HEAD EAS00676 STEERING HEAD 10 Nm (1.0 mSkg) 7 Nm (0.7 mSkg) 52 Nm (5.2 mSkg) 15 Nm (1.5 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
Page 226 CHAS STEERING HEAD 10 Nm (1.0 mSkg) 7 Nm (0.7 mSkg) 52 Nm (5.2 mSkg) 15 Nm (1.5 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Rubber washer Lower ring nut Lower bracket Bearing cover Bearing inner race Upper bearing Lower bearing Bearing outer race Dust seal...
Page 227: Steering Head
CHAS STEERING HEAD EAS00679 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove S steering stem nut 3. Remove: S upper ring nut S lower ring nut 1 (with the special tool 2 ) Steering nut wrench 90890-01403...
Page 228: Checking The Steering Head
CHAS STEERING HEAD EAS00682 CHECKING THE STEERING HEAD 1. Wash: S bearings (upper and lower) S bearing races Recommended cleaning solvent Kerosene 2. Check: S bearinsgs 1 S bearing races 2 Damage/pitting ! Replace. 3. Replace: S bearings S bearing races a.
Page 229: Installing The Steering Head
CHAS STEERING HEAD EAS00683 INSTALLING THE STEERING HEAD 1. Lubricate: S upper bearing S lower bearing S bearing races Recommended lubricant Lithium-soap-based grease 2. Install: S lower ring nut 1 S rubber washer 2 S upper ring nut 3 S lock washer 4 Refer to “CHECKING THE STEERING HEAD”...
Page 230: Rear Shock Absorber Assembly
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 44 Nm (4.4 mSkg) 52 Nm (5.2 mSkg) 40 Nm (4.0 mSkg) 49 Nm (4.9 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Seat Refer to “SEAT”...
Page 231 CHAS REAR SHOCK ABSORBER ASSEMBLY 44 Nm (4.4 mSkg) 52 Nm (5.2 mSkg) 40 Nm (4.0 mSkg) 49 Nm (4.9 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Collar Connecting arm Relay arm For installation, reverse the removal procedure. 4-67...
Page 232: Handling The Rear Shock Absorber And Gas Cylinder
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you under- stand following information.
Page 233: Removing The Rear Chock Absorber Assembly
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00694 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
Page 234: Checking The Rear Shock Absorber Assembly And Gas Cylinder
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00696 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 1. Check: S rear shock absorber rod Bends/damage ! Replace the rear shock absorber assembly. S rear shock absorber Gas leaks/oil leaks ! Replace the rear shock absorber assembly.
Page 235 CHAS REAR SHOCK ABSORBER ASSEMBLY 3. Tighten: S rear shock absorber assembly upper nut 40 Nm (4.0 mSkg) S rear shock absorber assembly lower nut 1 40 Nm (4.0 mSkg) S connecting arm nut 2 40 Nm (4.0 mSkg) S rear shock absorber upper bracket nut 52 Nm (5.2 mSkg) 4.
Page 236: Swingarm And Drive Chain
CHAS SWINGARM AND DRIVE CHAIN EAS00700 SWINGARM AND DRIVE CHAIN 95 Nm (9.5 mSkg) 5 Nm (0.5 mSkg) 7 Nm (0.7 mSkg) 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Removing the swingarm and drive Remove the parts in the order listed. chain Rear wheel Refer to “REAR WHEEL, BRAKE DISC,...
Page 237 CHAS SWINGARM AND DRIVE CHAIN 95 Nm (9.5 mSkg) 5 Nm (0.5 mSkg) 7 Nm (0.7 mSkg) 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Bearing Collar Oil seal Washer Spacer Rear fender Chain protector Pivot shaft adjusting bolt Drive chain For installation, reverse the removal procedure.
Page 238: Removing The Swingarm
CHAS SWINGARM AND DRIVE CHAIN EAS00703 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
Page 239: Removing The Drive Chain
CHAS SWINGARM AND DRIVE CHAIN EAS00706 REMOVING THE DRIVE CHAIN 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
Page 240: Disassembling The Swingarm
CHAS SWINGARM AND DRIVE CHAIN DISASSEMBLING THE SWINGARM 1. Remove: S dust covers 1 S spacer 2 S oil seals 3 S bearings 4 2. Check: S oil seals 3 Damage/wear ! Replace. S bearings 4 Damage/pitting ! Replace. CHECKING THE CONECTING ARM AND RELAY ARMS 1.
Page 241: Checking The Drive Chain
CHAS SWINGARM AND DRIVE CHAIN EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: S ten-link section a of the drive chain Out of specification ! Replace the drive chain. Ten-link drive chain section limit (maximum) 150.1 mm NOTE: S While measuring the ten-link section, push down on the drive chain to increase its tension.
Page 242 CHAS SWINGARM AND DRIVE CHAIN 4. Check: S O-rings 1 Damage ! Replace the drive chain, drive sprocket and rear wheel sprocket as a set. S drive chain rollers 2 Damage/wear ! Replace the drive chain, drive sprocket and rear wheel sprocket as a set.
Page 243: Installing The Swingarm
CHAS SWINGARM AND DRIVE CHAIN EAS00711 INSTALLING THE SWINGARM 1. Lubricate: S bearings S spacers S dust covers S pivot shaft Recommended lubricant Molybdenum disulfide grease 2. Lubricate: S drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 3.
Page 244 CHAS SWINGARM AND DRIVE CHAIN 8. Install: S drive sprocket 1 S washer 2 S drive sprocket nut 3 85 Nm (8.5 mSkg) S drive chain guide 4 NOTE: While applying the rear brake, tighten the drive sprocket nut. 9. Bend the lock washer tab a along a flat side of the nut.
Page 246: Eng
CHAPTER 5 ENGINE ENGINE ............EXHAUST PIPES .
Page 247 CHECKING THE PRESSURE PLATE ......5-47 CHECKING THE PULL LEVER SHAFT AND PULL ROD ..5-48 CHECKING THE PRIMARY DRIVE .
Page 248 INSTALLING THE CONNECTING RODS ..... . 5-80 INSTALLING THE CRANKSHAFT ......5-82 ASSEMBLING THE CRANKCASE .
Page 250: Engine
ENGINE EAS00188 ENGINE ENGINE EXHAUST PIPES * Anti-seize lubricart (high-temparature grade) 24 Nm (2.4 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 24 Nm (2.4 mSkg) Order Job/Part Q’ty Remarks Removing the exhaust pipes Remove the parts in the order listed. CAUTION: First, disconnect the negative battery lead, and then the positive battery lead.
Page 251: Drive Sprocket
ENGINE DRIVE SPROCKET 12 NM (1.2 mSkg) 85 Nm (8.5 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Removing the drive sprocket Remove the parts in the order listed. Drive sprocket cover Shift arm Shift rod Cover 1 Speed sensor rotor Cover 2...
Page 252: Leads And Hoses
ENGINE EAS00190 LEADS AND HOSES Order Job/Part Q’ty Remarks Removing the leads and hoses Remove the parts in the order listed. Seat Side cover Refer to “SEAT”, “FUEL TANK”, “AIR Side cowlings FILTER CASE” in chapter 3. Fuel tank Air filter case Throttle body Refer to “FUEL INJECTION SYSTEM”...
Page 253 ENGINE Order Job/Part Q’ty Remarks Neutral switch lead coupler Disconnect. Generator lead coupler Disconnect. Throttle body sub-wire harness coupler Disconnect. Speed sensor lead Disconnect. For installation, reverse the removal procedure.
Page 254 ENGINE EAS00191 ENGINE 45 Nm (4.5 mSkg) 55 Nm (5.5 mSkg) 7 Nm (0.7 mSkg) 26 Nm (2.6 mSkg) 26 Nm (2.6 mSkg) 45 Nm (4.5 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine.
Page 255: Installing The Engine
ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: S collars 1 S adjusting bolt 2 S engine mounting nut (rear lower) 3 S engine mounting nut (rear upper) 4 S engine mounting bolts (front) 5 S pinch bolts 6 S engine bracket bolts 7 NOTE: S Lubricate the rear mounting bolt threads with lithium soap base grease.
Page 256: Camshaft
CAMSHAFT EAS00194 CAMSHAFT CYLINDER HEAD COVER 10 Nm (1.0 mSkg) 4 Nm (0.4 mSkg) 18 Nm (1.8 mSkg) Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Side cowlings Refer to “FRONT COWLINGS”...
Page 257: Camshafts
CAMSHAFT EAS00196 CAMSHAFTS 7 Nm (0.7 mSkg) 18 Nm (1.8 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 24 Nm (2.4 mSkg) Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Spark plug Timing chain tensioner/Gascket Camshaft cap Dowel pin Intake camshaft...
Page 258: Removing The Camshafts
CAMSHAFT EAS00199 REMOVING THE CAMSHAFTS 1. Remove: S cylinder head cover 2. Align: S “T” mark on the generator rotor a (with the stationary pointer on the generator cover b ) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “T”...
Page 259 CAMSHAFT CAUTION: To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 7. Remove: S intake camshaft 1 S exhaust camshaft 2 S timing chain guide (exhaust side) NOTE: To prevent the timing chain from falling into the...
Page 260: Checking The Camshafts
CAMSHAFT EAS00204 CHECKING THE CAMSHAFTS 1. Check: S camshaft lobes Blue discoloration/pitting/scratches ! Re- place the camshaft. 2. Measure: S camshaft lobe dimensions a and b Out of specification ! Replace the cam- shaft. Camshaft lobe dimension limit Intake camshaft a 35.60 mm b 27.85 mm Exhaust camshaft...
Page 261 CAMSHAFT a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps).  b. Position strip of Plastigauge 1 onto the camshaft journal as shown. c. Install the dowel pins and camshaft caps. NOTE: S Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.
Page 262: Checking The Camshaft Sprockets And Timing Chain Guides
CAMSHAFT EAS00208 CHECKING CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: S camshaft sprocket More than 1/4 tooth wear a ! Replace the camshaft sprockets and the timing chain as a set.
Page 263: Checking The Timing Chain Tensioner
CAMSHAFT EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: S timing chain tensioner Cracks/damage ! Replace. 2. Check: S one-way cam operation Rough movement ! Replace the timing chain tensioner assembly. a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand.
Page 264: Installing The Camshafts
CAMSHAFT INSTALLING THE CAMSHAFTS 1. Align: S “T” mark on the generator rotor a (with the stationary pointer on the generator cover b ) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC, align the “T” mark a with the stationary pointer b on the gen- erator rotor.
Page 265 CAMSHAFT 5. Install: S timing chain guide (exhaust side) NOTE: S When installing the timing chain guide, be sure to keep the timing chain as tight as possible on the exhaust side. S Make sure the match marks a are parallel with the edge of the cylinder head.
Page 266 CAMSHAFT CAUTION: S Lubricate the camshaft cap botls with the engine oil. S The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. S Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing.
Page 267 CAMSHAFT 10. Turn: S crankshaft (several full turns counterclockwise) 11. Check: S “T” mark a Make sure the “T” mark on the generator ro- tor is aligned with the stationary pointer b on the generator rotor cover. S camshaft punch mark c Make sure the punch marks on the cam- shafts are aligned with the embossed marks d on the camshaft cap.
Page 268: Cylinder Head
CYLINDER HEAD EAS00221 CYLINDER HEAD 10 Nm (1.0 mSkg) Initial 18 Nm (1.8 mSkg) 18 Nm (1.8 mSkg) Final 150_ 55 Nm (5.5 mSkg) 55 Nm (5.5 mSkg) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Exhaust pipe, Muffler Refer to “EXHAUST PIPES”...
Page 269: Removing The Cylinder Head
CYLINDER HEAD EAS00223 REMOVING THE CYLINDER HEAD 1. Remove: S cylinder head bolts S cylinder head nuts NOTE: S Loosen the nuts in the proper sequence as shown. S Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
Page 270: Installing The Cylinder Head
CYLINDER HEAD EAS00233 INSTALLING THE CYLINDER HEAD 1. Install: S gasket S dowel pins 2 2. Install: S cylinder head NOTE: Pass the timing chain through the timing chain cavity. 3. Tighten: S cylinder head nuts 1 X 6 Initial 18 Nm (1.8 mSkg) 18 Nm (1.8 mSkg) Final...
Page 271: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Valve lifter Valve pad Valve cotter Upper valve spring seat Valve spring Valve spring seat Valve stem seal Exhaust valve Intake valve (center)
Page 272: Removing The Valves
VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
Page 273: Checking The Valves And Valve Guides
VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 Valve spring compressor attachment 90890-04108 4. Remove: S upper valve spring seat 1 S valve spring 2 S valve stem seal 3 S lower valve spring seat 4 S valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
Page 274 VALVES AND VALVE SPRINGS a. Remove the valve guide with the valve guide remover 1 . b. Install the new valve guide with the valve guide installer 2 and valve guide remover c. After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valve-guide clearance.
Page 275: Checking The Valve Seats
VALVES AND VALVE SPRINGS EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: S carbon deposits (from the valve face and valve seat) 2. Check: S valve seat Pitting/wear ! Replace the cylinder head. 3.
Page 276 VALVES AND VALVE SPRINGS a. Apply a coarse lapping compound a to the valve face. CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Apply molybdenum disulfide oil onto the valve stem.
Page 277: Checking The Valve Springs
VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: S valve spring free length a Out of specification ! Replace the valve spring. Valve spring free length Intake and exhaust valve spring 37.3 mm <Limit>:35.4 mm 2.
Page 278 VALVES AND VALVE SPRINGS EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters. 1. Check: S valve lifter Damage/scratches ! Replace the valve lift- ers and cylinder head. EAS00247 INSTALLING THE VALVES The following procedure applies to all of the valves and related components.
Page 279 VALVES AND VALVE SPRINGS NOTE: S Make sure each valve is installed in its original place. Refer to the following embossed marks. Right and left intake valve(s): “3LD:” Middle intake valve(s): “3LD.” Exhaust valve(s): “5PS:” S Install the valve spring with the larger pitch a facing up.
Page 280 VALVES AND VALVE SPRINGS 6. Lubricate: S valve pad Recommended lubricant Molybdenum disulfide oil S valve lifter (with the recommended lubricant) Recommended lubricant Engien oil 7. Install: S valve pad S valve lifter NOTE: S The valve lifter must move smoothly when ro- tated with a finger.
Page 281: Cylinder And Pistons
CYLINDER AND PISTONS EAS00252 CYLINDER AND PISTONS Order Job/Part Q’ty Remarks Removing the cylinder and pistons Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”. Cylinder Cylinder gascket Circlip Piston pin piston Piston ring set Dowel pin For installation, reverse the removal procedure.
Page 282: Removing The Cylinder And Pistons
CYLINDER AND PISTONS EAS00254 REMOVING THE CYLINDER AND PISTONS The following procedure applies to all of the cyl- inders and pistons. 1. Remove: S piston pin clip 1 S piston pin 2 S piston 3 CAUTION: Do not use a hammer to drive the piston pin out.
Page 283: Checking The Cylinder And Pistons
CYLINDER AND PISTONS EA262 CHECKING THE CYLINDER AND PISTONS The following procedure applies to all of the cyl- inders and pistons. 1. Check: S piston wall S cylinder wall Vertical scratches ! Replace the cylinder, and replace the piston and piston rings as a set.
Page 284 CYLINDER AND PISTONS Piston-to-cylinder clearance 0.025 X 0.050 mm <Limit>: 0.11 mm f. If out of specification, replace the cylinder, and the piston and piston rings as a set. 5-35...
Page 285: Checking The Piston Rings
CYLINDER AND PISTONS EAS00264 CHECKING THE PISTON RINGS 1. Measure: S piston ring side clearance Out of specification ! Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings.
Page 286: Checking The Piston Pins
CYLINDER AND PISTONS EAS00266 CHECKING THE PISTON PINS The following procedure applies to all of the pis- ton pins. 1. Check: S piston pin Blue discoloration/grooves ! Replace the piston pin and then check the lubrication sys- tem. 2. Measure: S piston pin outside diameter a Out of specification ! Replace the piston pin.
Page 287: Installing The Pistons And Cylinder
CYLINDER AND PISTONS EAS00272 INSTALLING THE PISTONS AND CYLINDER The following procedure applies to all of the pis- tons and cylinders. 1. Install: S top ring S 2nd ring S lower oil ring rail S upper oil ring rail S oil ring expander NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.
Page 288 CYLINDER AND PISTONS 5. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A Intake side 6. Install: S cylinder NOTE: S While compressing the piston rings with one hand, install the cylinder with the other hand.
Page 289: Clutch
CLUTCH EAS00273 CLUTCH CLUTCH COVER 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Engine oil Drain Refer to “CHANGING THE ENGINE OIL” in chapter 3. Clutch cable Clutch cable stay Clutch cover NOTE: Loosen the bolts in a crisscross pattern.
Page 290: Pull Lever Shaft
CLUTCH EB405010 PULL LEVER SHAFT Order Job/Part Q’ty Remarks Removing the pull lever shaft Remove the parts in the order listed. Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing Washer For installation, reverse the removal procedure. 5-41...
Page 291 CLUTCH EAS00274 CLUTCH 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Clutch spring Pressure plate Pull rod Friction plate 1 Clutch plate Friction plate 2 Lock washer Clutch boss Thrust plate Bearing...
Page 292 CLUTCH 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) Order Job/Part Q’ty Remarks Thrust plate 1 Thrust plate 2 For installation, reverse the removal procedure. 5-43...
Page 293: Removing The Clutch
CLUTCH EAS00275 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: S clutch boss nut 1 NOTE: While holding the clutch boss 3 with the univer- sal clutch holder 4 , loosen the clutch boss nut. Universal clutch holder 90890-04086 3.
Page 294 CLUTCH 3. Measure: S assembly width a Out of specification ! Adjust. Assembly width 42.5 X 43.7 mm a. Assembly width adjusted by clutch plate 1 and 2 . b. Select the clutch plate from the following table. Clutch plate 1 Part No.
Page 295: Checking The Clutch Plates
CLUTCH EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: S clutch plate Damage ! Replace the clutch plates as a set. 2. Measure: S clutch plate warpage (with a surface plate and thickness gauge 1 ) Out of specification ! Replace the clutch plates as a set.
Page 296: Checking The Clutch Housing
CLUTCH EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: S clutch housing dogs Damage/pitting/wear ! Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause er- ratic clutch operation. 2. Check: S bearing Damage/wear ! Replace the bearing and clutch housing.
Page 297: Checking The Pull Lever Shaft And Pull Rod
CLUTCH EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: S pull lever shaft 1 S pull rod 2 Damage/wear ! Replace the pull rod and pull lever shaft pinion gear as a set. 2. Check: S pull rod bearing Damage/wear ! Replace.
Page 298: Installing The Clutch
CLUTCH EAS00299 INSTALLING THE CLUTCH 1. Install: S clutch boss 1 S lock washer S clutch boss nut 3 2. Tighten: S clutch boss nut 70 Nm (7.0 mSkg) NOTE: While holding the clutch boss with the universal clutch holder 4 , tighten the clutch boss nut. Universal clutch holder 90890-04086 3.
Page 299 CLUTCH 8. Install: S clutch springs S clutch spring bolts 8 Nm (0.8 mSkg) NOTE: Tighten the clutch spring bolts in stages and in a crisscross pattern. 9. Install: S dowel pins S gasket S clutch cover 10 Nm (1.0 mSkg) NOTE: S When installing the clutch cover, push the pull lever and check that the punch mark a on the...
Page 300: Generator Rotor Cover
SHIFT SHAFT EAS00326 SHIFT SHAFT GENERATOR ROTOR COVER 20 Nm (2.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the generator rotor cover Remove the parts in the order listed. Drive sprocket cover Shift arm Cover 1...
Page 301: Shift Shaft And Stopper Lever
SHIFT SHAFT EAS00327 SHIFT SHAFT AND STOPPER LEVER 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the shift shaft and stopper Remove the parts in the order listed. lever Clutch Refer to “CLUTCH”. Shift arm Refer to “GENERATOR ROTOR COVER”.
Page 302 SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 S shift shaft pawl 2 Bends/damage/wear ! Replace. S shift lever spring 3 Damage/wear ! Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: S stopper lever 1 Bends/damage ! Replace.
Page 303: Starter Clutch And Generator
STARTER CLUTCH AND GENERATOR EAS00341 STARTER CLUTCH AND GENERATOR STATOR COIL ASSEMBLY 4 Nm (0.4 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the stator coil assembly Remove the parts in the order listed. Engine oil Drain Generator rotor cover...
Page 304: Starter Clutch And Generator Rotor
STARTER CLUTCH AND GENERATOR EAS00343 STARTER CLUTCH AND GENERATOR ROTOR 10 Nm (1.0 mSkg) 130 Nm (13.0 mSkg) Order Job/Part Q’ty Remarks Removing the starter clutch and Remove the parts in the order listed. generator rotor Generator rotor Idle gear shaft Starter motor idle gear Starter clutch Washer...
Page 305: Removing The Generator
STARTER CLUTCH AND GENERATOR EAS00347 REMOVING THE GENERATOR 1. Remove: S generator rotor bolt 1 S washer NOTE: S While holding the generator rotor 2 with the sheave holder 3 , loosen the generator rotor bolt. S Do not allow the sheave holder to touch the projection on the generator rotor.
Page 306: Removing The Starter Clutch
STARTER CLUTCH AND GENERATOR REMOVING THE STARTER CLUTCH 1. Remove: S starter clutch bolt 1 NOTE: S While holding the generator rotor with the sheave holder, remove the starter clutch bolt. S Do not allow the sheave holder to touch the projection on the generator rotor.
Page 307: Checking The Generator Shaft
STARTER CLUTCH AND GENERATOR a. Install the starter clutch gear 1 onto the starter clutch 2 and hold the starter clutch. b. When turning the starter clutch gear clock- wise A , the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced.
Page 308: Installing The Starter Clutch
STARTER CLUTCH AND GENERATOR EAS00352 INSTALLING THE STARTER CLUTCH 1. Install: S starter clutch 10 Nm (1.0 mSkg) NOTE: S While holding the generator rotor 1 with the sheave holder, tighten the starter clutch bolt. S Do not allow the sheave holder to touch the projection on the generator rotor.
Page 309: Oil Pan And Oil Pump
OIL PAN AND OIL PUMP EAS00357 OIL PAN AND OIL PUMP OIL PUMP COVER AND OIL PUMP DRIVEN GEAR 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the oil pump cover and oil Remove the parts in the order listed. pump driven gear Engine oil Drain.
Page 310: Oil Pump
OIL PAN AND OIL PUMP EAS00359 OIL PUMP 6 Nm (0.6 mSkg) 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Removing the oil pump Remove the parts in the order listed. Scavenge pump Gascket Dowel pin Feed pump Gascket For installation, reverse the removal procedure.
Page 311 OIL PAN AND OIL PUMP EAS00360 Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. Oil pump cover Oil pump housing Inner rotor Outer rotor Rotor shaft Dowel pin Stay For assembly, reverse the disassembly procedure.
Page 312: Oil Hose And Oil Tank
OIL PAN AND OIL PUMP EAS00358 OIL HOSE AND OIL TANK Order Job/Part Q’ty Remarks Removing the oil hose and oil tank Remove the parts in the order listed. Oil hose 1 O-ring Oil tank Union bolt Oil pipe Oil hose 2 Oil level switch coupler Disconnect.
Page 313: Oil Pan
OIL PAN AND OIL PUMP EAS00356 OIL PAN 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the oil pan Remove the parts in the order listed. Engine oil Drain. Oil hose Refer to “OIL HOSE”.
Page 314: Checking The Oil Pump
OIL PAN AND OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: S oil pump driven gear 1 S oil pump housing 2 S oil pump housing cover 3 Cracks/damage/wear ! Replace the de- fective part(s). 2. Measure: S inner-rotor-to-outer-rotor-tip clearance a S outer-rotor-to-oil-pump-housing clearance S oil-pump-housing-to-inner-rotor-and-outer-...
Page 315: Checking The Relief Valve
OIL PAN AND OIL PUMP EAS00365 CHECKING THE RELIEF VALVE 1. Check: S relief valve body 1 S relief valve 2 S spring 3 EAS00367 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes. 1.
Page 316: Assembling The Oil Pump
OIL PAN AND OIL PUMP EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: S inner rotor S outer rotor S oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: S oil pump shaft 1 (to the oil pump cover 2 ) S pin 3 S inner rotor 4 S outer rotor 5...
Page 317: Installing The Oil Strainer
OIL PAN AND OIL PUMP EAS00378 INSTALLING THE OIL STRAINER 1. Install: S collar S O-ring S oil strainer 1 10 Nm (1.0 mSkg) NOTE: The mark a on the oil strainer housing must point towards the front of the engine. EAS00380 INSTALLING THE OIL PAN 1.
Page 318: Crankshaft
CRANKSHAFT CRANKSHAFT BALANCER SHAFT 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the balancer shaft Remove the parts in the order listed. Engine Refer to “ENGINE”. Oil tank Refer to “OIL TANK”.
Page 319 CRANKSHAFT 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Rear balancer weight Front balancer holder Dowel pin Front balancer shaft/O-ring Front balancer weight Water pump drive gear For installation, reverse the removal procedure.
Page 320: Crankshaft Assembly
CRANKSHAFT EAS00381 CRANKSHAFT ASSEMBLY Initial 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) Final 12 Nm (1.2 mSkg) 24 Nm (2.4 mSkg) Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Balancer weight Refer to “BALANCER”. Water pump Refer to “WATER PUMP”...
Page 321: Connecting Rod
CRANKSHAFT EAS00382 CONNECTING ROD 62 Nm (6.2 mSkg) Order Job/Part Q’ty Remarks Removing the connecting rod Remove the parts in the order listed. Connecting rod bolt Connecting rod Connecting rod cap Connecting rod bearing For installation, reverse the removal procedure. 5-72...
Page 322: Disassembling The Crankcase
CRANKSHAFT EAS00384 DISASSEMBLING THE CRANKCASE 1. Remove: S cover plate S timing chain guide (intake) 2. Remove: S crankcase bolts NOTE: S Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
Page 323: Removing The Crankshaft Assembly
CRANKSHAFT EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: S crankshaft assembly 1 S crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. EAS00391 REMOVING THE CONNECTING RODS The following procedure applies to all of the...
Page 324: Checking The Crankshaft And Connecting Rods
CRANKSHAFT EAS00395 CHECKING THE CRANKSHAFT AND CONNECTING RODS 1. Measure: S crankshaft runout Out of specification ! Replace the crank- shaft. Crankshaft runout Less than 0.03 mm 2. Check: S crankshaft journal surfaces S crankshaft pin surfaces S bearing surfaces Scratches/wear ! Replace the crankshaft.
Page 325 CRANKSHAFT NOTE:  Do not put the Plastigauge over the oil hole in the crankshaft journal. e. Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase halves. NOTE: S Align the projections of the crankshaft journal lower bearings with the notches in the lower crankcase.
Page 326 CRANKSHAFT 4. Select: S Crankshaft journal bearings (J1 X J3) NOTE: S The numbers A stamped into the crankshaft web and the numbers 1 stamped into the low- er crankcase are used to determine the re- placement crankshaft journal bearing sizes. S “J1 X J3”...
Page 327 CRANKSHAFT a. Clean the big end bearings, crankshaft pins, and the inside of the connecting rods halves. b. Install the big end upper bearing into the con- necting rod and the big end lower bearing into the connecting rod cap. NOTE: Align the projections a on the big end bearings with the notches b in the connecting rod and...
Page 328: Checking The Crankcase
CRANKSHAFT g. Measure the compressed Plastigauge width a on the crankshaft pin. crankshaft-pin-to-big-end-bearing clearance is out of specification, select re- placement big end bearings. 6. Select: S big end bearings (P1 X P2) NOTE: S The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes.
Page 329: Checking The Circlips And Washers
CRANKSHAFT EAS00402 CHECKING THE CIRCLIPS AND WASHERS 1. Check: S circlips Bends/damage/looseness ! Replace. S washers Bends/damage ! Replace. EAS00404 INSTALLING THE CONNECTING RODS 1. Lubricate: S bolt threads S nut seats (with the recommended lubricant) Recommended lubricant Molybdenum disulfide grease 2.
Page 330 CRANKSHAFT 4. Align: S bolt heads (with the connecting rod caps) 5. Tighten: S connecting rod nuts Connecting rod nuts 62 Nm (6.2 mSkg) CAUTION: S When tightening the connecting rod nuts, be sure to use an F-type torque wrench. S Without pausing, tighten the connecting rod nuts to the specified torque.
Page 331: Installing The Crankshaft
CRANKSHAFT EAS00407 INSTALLING THE CRANKSHAFT 1. Install: S crankshaft journal upper bearings (into the upper crankcase) NOTE: S Align the projections a on the crankshaft jour- nal upper bearings 1 with the notches b in the upper crankcase. S Be sure to install each crankshaft journal up- per bearing in its original place.
Page 332: Assembling The Crankcase
Recommended lubricant Engine oil 2. Apply: S sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings.
Page 333 CRANKSHAFT 6. Install: S crankcase bolts (M10) initial 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) final CAUTION: S Use an angle torgue gauge 1 and tighten at the correct angle. S If an angle torgue gauge is not available, do not tighten at an angle because accurate tightening cannot be expected.
Page 334 CRANKSHAFT EAS00411 INSTALLING THE BALANCER SHAFT 1. Install: S front balancer shaft weight 1 S front balancer shaft 2 S O-ring S plate (balancer shaft) a. Turn the crankshaft until the keyway a on the crankshaft is aligned with the mark b on the crankcase.
Page 335 CRANKSHAFT a. Turn the crankshaft until the keyway a on the crankshaft is aligned with the mark b on the crankcase. b. While holding the crankshaft, install the rear balancer shaft weight and align the mark c on the rear balancer shaft gear with the mark d on the crankcase.
Page 336: Transmission
TRANSMISSION EAS00419 TRANSMISSION TRANSMISSION, SHIFT DRUM ASSEMBLY, AND SHIFT FORKS 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum assembly, and shift forks Engine Refer to “ENGINE”. Cover plate Collar Oil seal...
Page 337 TRANSMISSION 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Shift drum Bearing housing Drive axle assembly For installation, reverse the removal pro- cedure. 5-88...
Page 338 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle Disassemble the parts in the order listed. assembly. 2nd pinion gear Lock washer Lock washer retainer 6th pinion gear Collar Washer Circlip 3rd/4th pinion gear 5th pinion gear Main axle For assembly, reverse the disassembly procedure.
Page 339 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle Disassemble the parts in the order listed. assembly. Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Lock washer Lock washer retainer 4th wheel gear 5-90...
Page 340 TRANSMISSION Order Job/Part Q’ty Remarks 6th wheel gear 2nd wheel gear Drive axle For assembly, reverse the disassembly procedure. 5-91...
Page 341: Removing The Transmission
TRANSMISSION EAS00420 REMOVING THE TRANSMISSION 1. Remove: S drive axle assembly S bearing housing 1  (with the Torx wrench) NOTE: Remove the bearing housing with the slide hammer bolt 2 and weight 3 . Slide hammer bolt 90890-01083 Weight 90890-01084 2.
Page 342: Checking The Shift Drum Assembly
TRANSMISSION 3. Check: S shift fork movement (along the shift fork guide bar) Rough movement ! Replace the shift forks and shift fork guide bar as a set. EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: S shift drum grooves Damage/scratches/wear ! Replace the shift drum assembly.
Page 343: Installing The Transmission
TRANSMISSION 3. Check: S transmission gears Blue discoloration/pitting/wear ! Replace the defective gear(s). S transmission gear dogs Cracks/damage/rounded edges ! Replace the defective gear(s). 4. Check: S transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect ! Reassemble the transmission axle assemblies.
Page 344 TRANSMISSION 3. Install: S shift drum assembly 1 S shift fork “C” 2 S shift fork “L” 3 S shift fork “R” 4 S shift fork guide bars 5 NOTE: S The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”, “C”, “L”.
Page 346: Cool
COOL...
Page 347 COOL CHAPTER 6 COOLING SYSTEM RADIATOR ........... . CHECKING THE RADIATOR .
Page 348 COOL...
Page 349: Cooling System
COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 7 Nm (0.7 mSkg) 7 Nm (0.7 mSkg) 7 Nm (0.7 mSkg) 5 Nm (0.5 mSkg) Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Side cowlings Refer to “FRONT COWLING”. Coolant Drain.
Page 350: Checking The Radiator
COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: S radiator fins Obstruction ! Clean. Apply compressed air to the rear of the radia- tor. Damage ! Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.
Page 351: Installing The Radiator
COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: S cooling system Leaks ! Repair or replace any faulty part. a.
Page 352: Thermostat
COOL THERMOSTAT EAS00460 THERMOSTAT THERMOSTAT ASSEMBLY 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the thermostat assembly Remove the parts in the order listed. Fuel tank Refer to “FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE” in chapter 3. Coolant Drain.
Page 353 COOL THERMOSTAT EAS00461 10 Nm (1.0 mSkg) 18 Nm (1.8 mSkg) Order Job/Part Q’ty Remarks Disassembling the thermostat Disassembly the parts in the order listed. assembly Thermo unit Thermostat cover O-ring Thermostat Thermostat housing For assembly, reverse the disassembly procedure.
Page 354: Checking The Thermostat
COOL THERMOSTAT EAS00463 CHECKING THE THERMOSTAT 1. Check: S thermostat 1 Does not open at 82 X 95_C ! Replace. a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d.
Page 355: Assembling The Thermostat Assembly
COOL THERMOSTAT EAS00464 ASSEMBLING THERMOSTAT SEMBLY 1. Install: S thermostat housing 1 S thermostat 2 S O-ring S thermostat housing cover NOTE: Install the thermostat with its breather hole a facing up. 2. Install: S thermo unit 1 18 Nm (18 mSkg) CAUTION: Use extreme care when handling the thermo unit.
Page 356: Water Pump
COOL WATER PUMP EAS00468 WATER PUMP 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil.
Page 357 COOL WATER PUMP EAS00469 Order Job/Part Q’ty Remarks Disassembling the water pump Disassembly the parts in the order listed. Water pump cover Circlip Impeller Water pump seal Bearing Oil seal Water pump housing Rubber damper holder Rubber damper O-ring For assembly, reverse the disassembly procedure.
Page 358 COOL WATER PUMP EAS00470 DISASSEMBLING THE WATER PUMP 1. Remove: S impeller S water pump seal 1 NOTE: Remove the water pump seal from the inside of the water pump housing. 2 Water pump housing 2. Remove: S bearing 1 S oil seal 2 NOTE: Remove the bearing and oil seal from the inside...
Page 359 NOTE: S Install the water pump seal with the special tools. S Before installing the water pump seal, apply Yamaha bond No.1215 2 to the water pump housing 3 . Mechanical seal installer 4 90890-04078 Middle driven shaft bearing...
Page 360: Installing The Water Pump
COOL WATER PUMP 4. Measure: S impeller shaft tilt Out of specification ! Repeat steps (3) and (4). CAUTION: Make sure the rubber damper and rubber damper holder are flush with the impeller. Impeller shaft tilt limit 0.15 mm 1 Straightedge 2 Impeller 5.
Page 362 CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM ........CIRCUIT DIAGRAM .
Page 364: Fuel Injection System
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM Ignition coil Crankshaft position sensor Fast idle plunger Air filter case Coolant temperature sensor Adjustable air intake duct Intake temperature sensor Spark plug Intake Solenoid Fuel delivery hose Cylinder identification sensor Fuel tank Pressure regulator Fuel pump...
Page 365: Circuit Diagram
FUEL INJECTION SYSTEM EAS00814 CIRCUIT DIAGRAM Main fuse Battery Fuel injection system fuse Main switch Cylinder identification sensor Fuel injection system relay Speed sensor Intake air pressure sensor Atmospheric pressure sensor Intake air temperature sensor Coolant temperature sensor Lean angle cut-off switch sensor Injector #1 Injector #2...
Page 366: Ecu's Self-Diagnostic Function
FUEL INJECTION SYSTEM ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control 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.
Page 367: Substitute Characteristics Operation Control (Fail-Safe Action)
FUEL INJECTION SYSTEM SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the motorcycle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with substitute characteristic op- eration instructions that are appropriate for the type of the malfunction.
Page 368: Troubleshooting Chart
FUEL INJECTION SYSTEM TROUBLE SHOOTING CHART “Engine runs irregularly.” or “Engine trouble warning light is illuminated.” * Engine trouble warning light may not be illuminated even if the engine runs irregularly. When the engine trouble warning light is not illumi- When the engine trouble warning light is illumi- nated nated...
Page 369: Diagnostic Monitoring Mode
FUEL INJECTION SYSTEM DIAGNOSTIC MONITORING MODE It is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the Normal mode to the Diagnostic monitoring mode. Switching the mode to the Diagnostic monitoring mode Turn OFF the main switch.
Page 370 FUEL INJECTION SYSTEM Diagnostic monitoring code table Fault Diagnostic Symptom Probable cause of malfunction Code No. monitoring code No. S Open or short circuit in wiring sub lead. No normal signals are received S Open or short circuit in wiring harness. from the cylinder identification S Defective cylinder identification sensor.
Page 371 FUEL INJECTION SYSTEM Fault Diagnostic Symptom Probable cause of malfunction Code No. monitoring code No. S Open or short circuit in wiring harness. Open circuit is detected in the S Malfunction in ignition coil. primary wire of the ignition coil S Malfunction in ECU.
Page 372 FUEL INJECTION SYSTEM Sensor operation table Diagnostic monitoring Item Meter display Checking method code No. Throttle angle S Check with throttle fully closed. Fully closed position 15-17 S Check with throttle fully open. Fully opened position 97-100 Atmospheric pressure — Compare the actually measured atmospheric pressure with the meter display value.
Page 373 FUEL INJECTION SYSTEM Actuator operation table Diagnostic monitoring Item Actuation Checking method code No. Ignition coil #1 Actuates the ignition coils #1 for five times Check the spark five times. every second. S Connect an ignition checker. Illuminates the engine trouble warning light Ignition coil #2 Actuates the ignition coils #2 for five times Check the spark five times.
Page 374: Troubleshooting Details
FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section dscribes the measures per fault code number displayd on the meter. Carry out check and maintenance on items or components that could be a cause of malfunction in accordance with the or- der. When the check and maintenance of malfunctioned part is completed, restore the meter display ac- cording to the “Restore method”.
Page 375 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft position sensor. Diagnostic monitoring code No. Order Item / components Check or maintenance job Restore method Installed state of crankshaft position Check the installed area for looseness or Reinstated by sensor pinching.
Page 376 FUEL INJECTION SYSTEM Intake air pressure sensor-pipe system malfunction Fault code No. Symptom (clogged or deteched hose). Diagnostic monitoring Intake air pressure sensor code No. Order Item / components Check or maintenance job Restore method Intake air pressure sensor hose Repair or replace the sensor hose.
Page 377 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor-open or short circuit defected. Diagnostic monitoring Throttle position sensor code No. Order Item / components Check or maintenance job Restore method Installed state of throttle position Check the installed area for looseness or Reinstated by sensor.
Page 378 FUEL INJECTION SYSTEM Open circuit is detected in the input line from the sidestand switch to the Fault code No. Symptom ECU. Diagnostic monitoring Sidestand switch code No. Order Item / components Check or maintenance job Restore method Connected state of connector Check the coupler for any pins that may If the transmission...
Page 379 FUEL INJECTION SYSTEM A. Intake air pressure sensor-open or short circuit detected. Fault code No. Symptom B. Defective values are detected due to the internal malfunction of the intake air pressure sensor or the Atmospheric pressure sensor. Diagnostic monitoring Intake air pressure sensor code No.
Page 380 FUEL INJECTION SYSTEM Open or short sircuit is detected from the coolant temperature sensor. Fault code No. Symptom Diagnostic monitoring Coolant temperature sensor code No. Order Item / components Check or maintenance job Restore method Installed state of coolant temperature Check the installed area for looseness or Reinstated by sensor...
Page 381 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit detected from the atmospheric pressure sensor. Diagnostic monitoring Atmospheric pressure sensor code No. Order Item / components Check or maintenance job Restore method Installed state of atmospheric pressure Check the installed area for looseness or Reinstated by sensor pinching.
Page 382 FUEL INJECTION SYSTEM Fault code No. Symptom The motorcycle has overturned. Diagnostic monitoring Lean angle cut-off switch code No. Order Item / components Check or maintenance job Restore method The motorcycle has overturned. Raise the motorcycle upright. Reinstated by turning the Installed state of the lean angle cut-off Check the installed area for looseness or main switch...
Page 383 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the ignition coil (#2). Diagnostic monitoring Ignition coil (#2) code No. Order Item / components Check or maintenance job Restore method Connected state of connector Check the coupler for any pins that may have Reinstated by Ignition coil primary side pulled out.
Page 384 FUEL INJECTION SYSTEM A. No normal signal are received from the speed sensor. Fault code No. Symptom B. Open or short circuit is detected in the neutral switch. Diagnostic monitoring Speed sensor code No. Neutral switch Order Item / components Check or maintenance job Restore method...
Page 385 FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage. Diagnostic monitoring Fuel injection system relay code No. Order Item / components Check or maintenance job Restore method Connected state of connector Check the coupler for any pins that may have Reinstated by Fuel injection system relay coupler pulled out.
Page 386 FUEL INJECTION SYSTEM Er-1 Fault code No. Symptom No signals are received from the ECU. Diagnostic monitoring code No. Order Item / components Check or maintenance job Restore method Connected state of connector Check the coupler for any pins that may have Reinstated Main wiring harness ECU coupler pulled out.
Page 387 FUEL INJECTION SYSTEM Er-4 Fault code No. Symptom Non-registered data has been received from the meter. Diagnostic monitoring code No. Order Item / components Check or maintenance job Restore method Connected state of connector Check the coupler for any pins that may have Reinstated Main wiring harness ECU coupler pulled out.
Page 388: Throttle Body Assembly
FUEL INJECTION SYSTEM THROTTLE BODY ASSEMBLY 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the throttle body assembly Remove the parts in the order listed. Seat Refer to “SEAT”, “FUEL TANK”, Fuel tank “AIR FILTER CASE” in chapter 3. Air filter case Coolant Drain.
Page 389 FUEL INJECTION SYSTEM 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Fuel hose Disconnect. Vacuum hose Disconnect. Throttle body assembly Throttle body joint For installation, reverse the removal procedure. 7-26...
Page 390 FUEL INJECTION SYSTEM Order Job/Part Q’ty Remarks Disassembling the throttle body Disassemble the parts in the order listed. Throttle position sensor Fast idle plunger Pressur regulator Intake air pressure sensor Fuel injection pipe Fuel distributor Injector Throttle body Sub-wire harness CAUTION The throttle bodies should not be disassembled unnecessarily.
Page 391: Checking The Injector
FUEL INJECTION SYSTEM CAUTION: The throttle bodies should not be disas- sembled unnecessarily. CHECKING THE INJECTOR 1. Check: S injector Damage ! Replace. CHECKING THE THROTTLE BODY 1. Check: S throttle body Cracks/damage ! Replace the throttle bo- dies. 2. Check: S fuel passages Obstruction ! Clean.
Page 392: Checking The Fuel Pump And Pressure Regulator Operation
FUEL INJECTION SYSTEM CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: S pressure regulator operation a. Remove the fuel tank. Refer to “FUEL TANK” in chapter 3. b. Disconnect the vacuum hose 1 from the pressure regulator. c. Connect the vacuum/pressure pump gauge set 2 onto the vacuum hose from the pres- sure regulator.
Page 393: Checking The Throttle Body Joints
FUEL INJECTION SYSTEM EAS00095 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints. 1. Remove: S fuel tank Refer to “FUEL TANK” in chapter 3. S air filter case Refer to “AIR FILTER CASE” in chapter 3. 2.
Page 394: Air Induction System
AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system bums unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.
Page 395: Air Induction System Diagrams
AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS Air cut-off valve Reed valve Exhaust port Air filter case 7-32...
Page 396: Air Cut-Off Valve And Reed Valve
AIR INDUCTION SYSTEM AIR CUT-OFF VALVE AND REED VALVE 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the air cut-off valve and Remove the parts in teh order listed. reed valve Seat Refer to “SEAT, FUEL TANK, Fuel tank AIR FILTER CASE”...
Page 397: Checking The Air Induction System
AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: S hoses Loose connection ! Connect properly. Cracks/damage ! Replace. S pipes Cracks/damage ! Replace. 2. Check: S steel reed S steel reed stopper S reed valve seat Cracks/damage ! Replace the reed valve. 3.
Page 398: Elec
ELEC...
Page 399 ELEC CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS ........CHECKING SWITCH CONTINUITY .
Page 400 ELEC FUEL INJECTION SYSTEM ........8-49 CIRCUIT DIAGRAM .
Page 401 ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS Wire harness Radiator fan motor Ignition coil Horn Front brake light switch Clutch switch Starter relay Fuse box Battery Neutral switch Sidestand switch Rear brake light switch Oil level switch...
Page 402 ELEC ELECTRICAL COMPONENTS Coolant temperature sensor Atomospheric pressure sensor Intake air tempreture sensor Intake air pressure sensor Lean angle cut-off switch Turn signal relay Fuel injection system relay Radiator fan motor relay Starting circuit cut-off relay Speed sensor sensor Crankshaft position sensor Cylinder identification sensor...
Page 403: Checking Switch Continuity
ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots a .
Page 404 ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.
Page 405: Checking The Bulbs And Bulb Sockets
ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING BULBS BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear ! Repair or replace the bulb, bulb socket or both. Improperly connected ! Properly connect.
Page 406 ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: S Be sure to hold the socket firmly when re- moving the bulb.
Page 407 ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: S bulb socket (for continuity) (with the pocket tester) No continuity ! Replace. Pocket tester 90890-03132 NOTE: Check each bulb socket for continuity in the...
Page 408 ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE LEDs The following procedures applies to all of the LEDs. 1. Check: S LED (for proper operation) Improper operation ! Replace. a. Disconnect the meter assembly coupler (me- ter assembly side). b.
Page 409: Circuit Diagram
ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM Crankshaft position sensor Main fuse Battery Main switch Starting circuit cut-off relay Sidestand switch Lean angle cut-off switch Ignition coil Spark plug Throttle position sensor Engine stop switch Ignition fuse...
Page 410: Troubleshooting
ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING AND CHARGING spark or intermittent spark). THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1.
Page 411 ELEC IGNITION SYSTEM EAS00743 4. Ignition spark gap The following procedure applies to all of the spark plugs. S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker as shown. Spark plug cap S Set the main switch to “ON”. S Measure the ignition spark gap Spark plug cap resistance S Crank the engine by pushing the starter...
Page 412 ELEC IGNITION SYSTEM EAS00750 Negative tester probe ! 8. Engine stop switch spark plug lead S Check the engine stop switch for continuity. Positive tester probe ! spark plug lead Refer to “CHECKING THE SWITCHES”. S Is the engine stop switch OK? Replace the right handlebar switch.
Page 413 ELEC IGNITION SYSTEM EAS00748 EAS00753 11. Starting circuit cut-off relay 10. Crankshaft position sensor rasistance S Disconnect the crankshaft position sensor S Disconnect the starting circuit cut-off relay coupler from the wire harness. coupler from the wire harness. S Connect the pocket tester (Ω S Connect the pocket tester (Ω...
Page 414 ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main fuse Battery Starter relay Starter motor Main switch Diode Starting circuit cut-off relay Sidestand switch Neutral switch Engine stop switch Start switch Clutch switch Ignition fuse 8-14...
Page 415 ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: S The transmission is in neutral (the neutral switch is closed).
Page 416 ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. S Check the condition of the battery. Check: Refer to “CHECKING AND CHARGING 1. main and ignition fuses THE BATTERY” in chapter 3. 2. Battery 3.
Page 417 ELEC ELECTRIC STARTING SYSTEM EAS00759 Tester positive probe ! 4. Starting circuit cut-off relay sky blue S Disconnect the starting circuit cut-off relay Tester negative probe ! from the wire harness. black/yellow S Connect the pocket tester (Ω 1) and bat- Tester positive probe ! tery (12 V) to the starting circuit cut-off relay sky blue...
Page 418 ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00750 6. Starter relay 8. Engine stop switch S Disconnect the starter relay from the cou- S Check the engine stop switch for continuity. pler. Refer to “CHECKING THE SWITCHES”. S Connect the pocket tester (Ω S Is the engine stop switch OK? 1) and bat- tery (12 V) to the starter relay terminals as...
Page 419 ELEC ELECTRIC STARTING SYSTEM EAS00764 12. Start switch S Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the start switch OK? Replace the right handlebar switch. EAS00766 13. Wiring S Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”.
Page 420: Starter Motor
ELEC STARTER MOTOR EAS00767 STARTER MOTOR 10Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Exhaust pipe Starter motor lead Disconnect. Starter motor O-ring For installation, reverse the removal procedure. 8-20...
Page 421 ELEC STARTER MOTOR EAS00768 10Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the starter motor Disassemble the parts in the order listed. Front bracket Washer kit Rear bracket Washer kit Brush holder Brush Armature coil O-ring Starter motor yoke Seal Bearing For assembly, reverse the disassembly procedure.
Page 422 ELEC STARTER MOTOR EAS00770 CHECKING THE STARTER MOTOR 1. Check: S commutator Dirt ! Clean with 600 grit sandpaper. 2. Measure: S commutator diameter a Out of specification ! Replace the starter motor. Commutator diameter limit 27 mm 3. Measure: S mica undercut a Out of specification ! Scrape the mica to the proper measurement with a hacksaw blade...
Page 423 ELEC STARTER MOTOR Armature coil Resistance 0.03 X 0.04 Ω at 20_C b. If any resistance is out of specification, re- place the starter motor. 5. Measure: S brush length a . Out of specification ! Replace the brushes as a set. Brush length wear limit 5 mm 6.
Page 424 ELEC STARTER MOTOR EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: S brush holder 1 NOTE: Align the tab a on the brush holder with the slot b in the starter motor yoke. 2. Install: S armature coil 1 S washers 2 S starter motor front cover 3 S starter motor rear cover 4 NOTE:...
Page 425 ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM 2 Generator 3 Rectifier/ regulator 4 Main fuse 5 Battery 8-25...
Page 426 ELEC CHARGING SYSTEM EAS00774 TROUBLESHOOTING The battery is not being charged. S Clean the battery Check: 1. main fuse terminals. S Recharge 2. battery 3. charging voltage place the battery. 4. stator assembly resistance 5. wiring connections (of the entire charging system) NOTE: EAS00775 S Before troubleshooting, remove the following...
Page 427 ELEC CHARGING SYSTEM EAS00776 4. Stator coil resistance S Remove the generator cover. S Connect the pocket tester (Ω 1) to the sta- tor coils as shown. Positive tester probe ! white Negative tester probe ! white Positive tester probe ! white Negative tester probe ! white S Measure the stator coil resistances.
Page 428 ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM Main fuse Battery Main switch High beam indicator light Meter light Light switch Pass switch Dimmer switch Headlight fuse Parking light fuse Auxiliary light Tail/ brake light switch Headlight 8-28...
Page 429 ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Any of the following fail to light: headlight, Refer to “CHECKING AND CHARGING high beam indicator light, taillight, auxilia- THE BATTERY” in chapter 3. ry light or meter light. Minimum open-circuit voltage Check: 12.8 V or more at 20_C...
Page 430 ELEC LIGHTING SYSTEM EAS00784 5. Dimmer switch S Check the dimmer switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the dimmer switch OK? The dimmer switch is faulty. Replace the left handlebar switch. EAS00786 6. Pass switch S Check the pass switch for continuity. Refer to “CHECKING THE SWITCHES”.
Page 431 ELEC LIGHTING SYSTEM EAS00788 CHECKING THE LIGHTING SYSTEM Meter assembly coupler (wire harness side) 1. The headlight and the high beam indicator S Set the main switch to “ON”. light fail to come on. S Set the light switch to “ ”.
Page 432 ELEC LIGHTING SYSTEM EAS00789 EAS00790 2. The meter light fails to come on. 3. The tail/brake light fails to come on. 1. Meter light bulb and socket 1. Tail/brake light bulb and socket S Check the meter light bulb and socket for S Check the tail/brake light bulb and socket for continuity.
Page 433 ELEC LIGHTING SYSTEM EAS00791 4. The auxiliary light fails to come on. 1. Auxiliary light bulb and socket S Check the auxiliary light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND SOCKETS” S Are the auxiliary light bulb and socket OK? Replace the auxiliary light bulb, socket or both.
Page 434 ELEC SIGNALING SYSTEM EAS00780 SIGNALING SYSTEM CIRCUIT DIAGRAM 8-34...
Page 435 ELEC SIGNALING SYSTEM EAS00793 Main fuse Battery Main switch Buck up fuse Starting circuit cut-off relay Neutral switch Fuel pump Oil level warning light Neutral indicator light Engine trouble warning light Left turn signal indicator light Right turn signal indicator light Oil level switch Front brake light switch Horn switch...
Page 436 ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Any of the following fail to light: turn sig- Refer to “CHECKING AND CHARGING nal light, brake light or an indicator light. THE BATTERY” in chapter 3. The horn fails to sound.
Page 437: Signaling System
ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNAL SYSTEM 1. The horn fails to sound. S Disconnect the black connector at the horn terminal. 1. Horn switch S Connect a jumper lead to the horn termi- S Check the horn switch for continuity. nal and ground the jumper lead.
Page 438 ELEC SIGNALING SYSTEM EAS00797 2. The tail/brake light fails to come on. 3. Voltage S Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket tail/brake light coupler (wire harness side) S Check the tail/brake light bulb and socket as shown.
Page 439 ELEC SIGNALING SYSTEM EAS00799 S Set the main switch to “ON”. 3. The turn signal light, turn signal indicator S Measure the voltage (DC 12 V) on light or both fail to blink. brown/green at the turn signal relay 1. Turn signal indicator light bulb and socket coupler (wire harness side).
Page 440 ELEC SIGNALING SYSTEM EAS00800 5. Voltage 4. The neutral indicator light fails to come on. S Connect the pocket tester (DC 20 V) to the 1. Neutral indicator light bulb and socket turn signal light coupler or meter assembly S Check the neutral indicator light bulb and coupler (wire harness side) as shown.
Page 441 ELEC SIGNALING SYSTEM EAS00753 4. Voltage 3. Starting circuit cut-off relay S Connect the pocket tester (DC 20 V) to the S Disconnect the starting circuit cut-off relay meter assembly coupler (wire harness side) from the wire harness. as shown. S Connect the pocket tester (Ω...
Page 442 ELEC SIGNALING SYSTEM 2. Engine oil level switch 4. Voltage S Drain the engine oil and remove the engine S Connect the pocket tester (DC 20 V) to the oil level switch from the oil tank. engine oil level switch coupler as shown. S Check the engine oil level switch for continu- Tester positive probe ! white ity.
Page 443 ELEC SIGNALING SYSTEM EAS00803 6. The fuel level gauge fails to operate. 1. Fuel sender S Drain the fuel from the fuel tank and remove the fuel pump assembly from the fuel tank. S Connect the pocket tester (Ω 1) to the fuel sender as shown.
Page 444 ELEC SIGNALING SYSTEM EAS00805 7. The clock fails to operate. 1. Voltage S Connect the pocket tester (DC V 20) to the meter assembly (wire harness side) as shown. Positive tester probe ! brown Negative tester probe ! black/white S Set the main switch to “ON”. S Measure the voltage (DC 12 V).
Page 445 ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM Main fuse Battery Main switch Coolant temperature sensor Ignition fuse Radiator fan motor fuse Radiator fan relay Radiator fan motor 8-45...
Page 446 ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The radiator fan motor fails to turn. Refer to “CHECKING AND CHARGING The water temperature gauge needle fails THE BATTERY” in chapter 3. to move when the engine is warm. Minimum open-circuit voltage Check: 12.8 V or more at 20_C...
Page 447 ELEC COOLING SYSTEM EAS00809 S Does the radiator fan motor relay have conti- 4. Radiator fan motor nuity between brown and blue? S Disconnect the radiator fan motor coupler from the wire harness. S Connect the battery (DC 12 V) as shown. Positive battery lead ! blue Replace the radiator Negative battery lead ! black...
Page 448 ELEC COOLING SYSTEM S Does the coolant temperature sensor oper- ate properly as described above? Replace the coolant temperature sensor. EAS00813 7. Wiring S Check the entire cooling system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the cooling system’s wiring properly con- nected and without defects? This circuit is OK.
Page 449 ELEC FUEL INJECTION SYSTEM EAS00814 FUEL INJECTION SYSTEM CIRCUIT DIAGRAM Main fuse Battery Fuel injection system fuse Main switch Cylinder identification sensor Fuel injection system relay Speed sensor Intake air pressure sensor Atmospheric pressure sensor Intake air temperature sensor Coolant temperature sensor Lean angle cut-off switch sensor Cylinder #1 –...
Page 450 ELEC FUEL INJECTION SYSTEM EAS00816 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. If the fuel injection system fails to operate. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuel injection system and ignition Minimum open-circuit voltage fuses 12.8 V or more at 20_C...
Page 451 ELEC FUEL INJECTION SYSTEM EAS00759 EAS00617 5. Fuel injection system relay 6. Fuel pump resistance S Disconnect the fuel injection system relay S Disconnect the fuel pump coupler from the from the wire harness. fuel pump. S Connect the pocket tester (Ω S Connect the pocket tester (Ω...
Page 452 ELEC FUEL INJECTION SYSTEM Crankshaft position sensor resis- 9. Speed sensor output voltage tance S Measure the speed sensor output voltage. 420 X 569 Ω at 20_C S Connect the pocket tester (DC 20 V) to the (between gray and black) speed sensor coupler terminal as shown.
Page 453 ELEC FUEL INJECTION SYSTEM EAS00811 10.Coolant temperature sensor S Remove the coolant temperature sensor from the thermostat assembly. S Connect the pocket tester (Ω 1) to the coolant temperature sensor as shown. S Immerse the coolant temperature sensor in a container filled with coolant NOTE: Make sure that the coolant temperature sen- sor terminals do not get wet.
Page 454 ELEC FUEL INJECTION SYSTEM 11. Intake air temperature sensor resistance 12.Intake air pressure sensor output voltage S Remove the intake air temperature sensor S Connect the pocket tester (DC 20 V) to the from the air filter case. intake air intake air pressure sensor coupler S Connect the pocket tester (Ω...
Page 455 ELEC FUEL INJECTION SYSTEM S Set the main switch to “ON”. 15.Intake solenoid S Measure the atmospheric pressure sensor S Remove the intake solenoid coupler from output voltage. the wire harness. S Connect the pocket tester (Ω 1) to the AI Atmospheric pressure sensor system solenoid terminal as shown.
Page 456: Checking The Fuel Pump
ELEC FUEL INJECTION SYSTEM EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: S Stop the engine before refueling. S Do not smoke, and keep away from open flames, sparks, or any other source of fire.
Page 457: Checking And Adjusting The Throttle Position Sensor
ELEC FUEL INJECTION SYSTEM EAS00502 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. 1. Check: S throttle position sensor (installed on the throttle body) a. Disconnect the throttle position sensor cou- pler from the throttle position sensor.
Page 458 ELEC FUEL INJECTION SYSTEM Throttle position sensor resistance (520 X 900 Ω) X (4.0 X 6.0 kΩ) at 20_C (yellow – black/blue) 2. Check: S throttle position sensor angle a. Connect the throttle position sensor coupler to the throttle position sensor. b.
Page 459 ELEC FUEL INJECTION SYSTEM d. Adjust the throttle position sensor angle so the measured output voltage is within the specified range. Throttle position sensor output voltage 0.53 X 0.83 V e. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws 4 .
Page 461: Trbl Shtg
TRBL SHTG...
Page 462 TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING FAILURES ......... ENGINE .
Page 463 TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM ....HEADLIGHT DOES NOT COME ON ......HEADLIGHT BULB BURNT OUT .
Page 464: Troubleshooting
TRBL STARTING FAILURES SHTG EAS00844 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
Page 465: Incorrect Engine Idling Speed
STARTING PROBLEMS/ TRBL INCORRECT ENGINE IDLING SPEED SHTG EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE ELECTRICAL SYSTEMS Cylinder(s) and cylinder head(s) Battery S Incorrect valve clearance S Discharged battery S Damaged valve train components S Faulty battery Air filter Spark plug(s) S Clogged air filter element S Incorrect spark plug gap S Incorrect spark plug heat range...
Page 466: Poor Medium-And-High-Speed Performance
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL FAULTY GEAR SHIFTING SHTG EAS00849 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES”. ENGINE FUEL SYSTEM Air filter Fuel pump S Clogged air filter element S Faulty fuel pump EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT JUMPS OUT OF GEAR Refer to “CLUTCH DRAGS”.
Page 467: Faulty Clutch
TRBL FAULTY CLUTCH/OVERHEATING SHTG EAS00852 FAULTY CLUTCH CLUTCH SLIPS CLUTCH DRAGS Clutch Clutch S Improperly assembled clutch S Air in hydraulic clutch system S Improperly assembled clutch master S Unevenly tensioned clutch springs S Warped pressure plate cylinder S Improperly assembled clutch release cylinder S Bent clutch plate S Incorrect clutch fluid level S Swollen friction plate...
Page 468: Overcooling
OVERCOOLING/POOR BRAKING PERFORMANCE/ TRBL FAULTY FRONT FORK LEGS SHTG EAS00856 OVERCOOLING COOLING SYSTEM Thermostat S Thermostat stays open EAS00857 POOR BRAKING PERFORMANCE S Worn brake pad S Worn brake disc S Air in hydraulic brake system S Leaking brake fluid S Faulty brake caliper kit S Faulty brake caliper seal S Loose union bolt...
Page 469: Unstable Handling
UNSTABLE HANDLING/ TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00862 UNSTABLE HANDLING Tire(s) S Uneven tire pressures (front and rear) Handlebar S Incorrect tire pressure S Bent or improperly installed handlebar S Uneven tire wear Steering head components S Improperly installed upper bracket Wheel(s) S Incorrect wheel balance S Improperly installed lower bracket...
Page 470 WIRING DIAGRAM (EUR) Crankshaft position sensor Auxiliary light Generator Rear brake light switch Rectifier/ regulator Tail/ brake light Main fuse Headlight Battery Rear turn signal light (left) Fuel injection system fuse Rear turn signal light (right) Starter relay Front turn signal light (left) Starter motor Front turn signal light (right) Main switch...
Page 471 WIRING DIAGRAM (OCE) Crankshaft position sensor Rear turn signal light (left) Generator Rear turn signal light (right) Rectifier/ regulator Front turn signal light (left) Main fuse Front turn signal light (right) Battery Radiator fan motor fuse Fuel injection system fuse Radiator fan relay Starter relay Radiator fan motor...
Page 474 TDM900 2002 WIRING DIAGRAM (EUR) Gy G/W L/B L/R Dg Lg Br Br/B Br/B B Y Ch G L B/L Br/W Br/W Br/B Gy/R Gy/G Br/W - - - Br/R Headlight Headlight Wire Wire Wire Wire FI system sub-wire FI system sub-wire FI system sub-wire Wire harness sub-wire...
Page 475 TDM900P 2002 WIRING DIAGRAM (OCE)

This manual is also suitable for:

2002 tdm900p Tdm 900 p 2002Tdm 900 2002

Yamaha 2002 TDM900 Service Manual

Table of Contents

Specifications Spec

Chk Adj

Chassis Chas

Eng

6 Cool

Air Induction System

Circuit Diagram

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha 2002 TDM900