Page 2 EAS00010 YZF-R1S/YZF-R1SC SERVICE MANUAL 2003 by Yamaha Motor Corporation, U.S.A. First edition, December 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-17-55...
Page 3: Important Manual Information
If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
Page 4: 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 5: 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 6: 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 7 CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ......VEHICLE IDENTIFICATION NUMBER ......MODEL LABEL .
Page 8 LUBRICATION DIAGRAMS ........2-30 CABLE ROUTING .
Page 9 CHASSIS ........... . 3-42 ADJUSTING THE FRONT BRAKE .
Page 10 FRONT AND REAR BRAKES ........4-15 FRONT BRAKE PADS .
Page 11 REAR SHOCK ABSORBER ASSEMBLY ......4-65 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER ......... . . 4-66 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER...
Page 12 STARTER CLUTCH AND GENERATOR ......5-35 STATOR COIL ASSEMBLY ....... . . 5-35 STARTER CLUTCH .
Page 13 CRANKCASE ..........5-72 DISASSEMBLING THE CRANKCASE .
Page 14 CHECKING THE WATER PUMP ......6-14 ASSEMBLING THE WATER PUMP ......6-15 CHAPTER 7 FUEL INJECTION SYSTEM...
Page 15: Troubleshooting
CHECKING THE CONDITION OF THE BULB SOCKETS ..CHECKING THE LEDs ........IGNITION SYSTEM .
Page 16 ELECTRICAL SYSTEMS ........INCORRECT ENGINE IDLING SPEED .
Page 17: Gen Info
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 1 is affixed to the frame. This information will be needed to order spare parts.
Page 18: Features
FEATURES INFO EAS00019 FEATURES INSTRUMENT FUNCTIONS Multi-function display The multi-function meter unit is equipped with the following: S a speedometer (which shows the riding speed) S a tachometer (witch shows engine speed) S an odometer (which shows the total distance traveled) 1 Clock S two tripmeters (which show the distance...
Page 19 FEATURES INFO Odometer, tripmeter, and stopwatch modes Push the “SELECT” button to switch the display between the odometer mode “ODO”, the trip- meter modes “TRIP A” and “TRIP B” and the stopwatch mode in the following order: TRIP A ! TRIP B ! ODO ! Stopwatch ! TRIP A If the fuel level warning light comes on, the odometer display will automatically change to...
Page 20 FEATURES INFO Self-diagnosis devices The model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the engine trouble warning light will come on, and then the right display will indicate a two-digit error code (e.g.,11,12,13). Display brightness and shift timing indicator light control mode This mode cycles through five control functions, allowing you to make the following settings in the order listed below.
Page 21 FEATURES INFO To set the shift timing indicator light activation function NOTE: The shift timing indicator light activation function can be set between 7000 r/min and 15000 r/m. From 7000 r/min to 12000 r/min, the indicator light can be set in increments of 500 r/min. From 12000 r/min to 15000 r/min, the indicator light can be set in increments of 200 r/min.
Page 22: 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 23: 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 24: 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 25: 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 26 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Fork spring compressor 90890-01441 YM-01441 This tool is used to disassemble or assemble the front fork legs. Fork seal driver 90890-01442 YM-01442 This tool is used to install the front fork’s oil seal and dust seal.
Page 27 Ignition checker 90890-06754 YM-34487 This tool is used to check the ignition sys- tem components. Yamaha bond No. 1215 90890-85505 ACC-1109-0501 This bond is used to seal two mating sur- faces (e.g., crankcase mating surfaces). Digital circuit tester 90890-03174 This tool is used to check the electrical sys- tem.
Page 28 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Valve lapper 90890-04101 This tool is needed to remove and install the valve lifter. Fuel pressure adapter 90890-03176 YM-03176 This tool is needed to measure fuel pres- sure. Pressure gauge 90890-03153 YU-03153 This tool is used to measure fuel pressure.
Page 29: Spec
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5VY4 (USA), 5VY5 (CAL) Dimensions Overall length 2,065 mm (8.13 in) Overall width 720 mm (28.3 in) Overall height 1,105 mm (43.5 in) Seat height 835 mm (32.9 in) Wheelbase 1,395 mm (54.9 in) Minimum ground clearance...
Page 30: Engine Specifications
SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC Displacement 998 cm (60.90 cu.in) Cylinder arrangement Forward-inclined parallel 4-cylinder Bore stroke 77.0 53.6 mm (3.03 2.11 in) Compression ratio 12.4 : 1 1,150 X 1,250 r/min Engine idling speed Vacuum pressure at engine idling 22 kPa (165 mmHg, 6.5 inHg)
Page 31 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Paper 80 X 120 kPa (0.8 X 1.2 kg/cm Bypass valve opening pressure 0.8 X 1.2 bar, 11.6 X 17.4 psi) Oil pump Oil pump type Trochoid 0.01 X 0.10 mm Inner-rotor-to-outer-rotor-tip 0.18 mm (0.0004 X 0.0039 in)
Page 32 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) 22.500 X 22.521 mm (0.8858 X 0.8867 in) Camshaft cap inside diameter 22.459 X 22.472 mm (0.8842 X 0.8847 in) Camshaft journal diameter 0.028 X 0.062 mm (0.0011 X 0.0024 in) Camshaft-journal-to-camshaft- cap clearance Intake camshaft lobe dimensions...
Page 33 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links RH2020 /122 Tensioning system Automatic Valves, valve seats, valve guides Valve clearance (cold) 0.11 X 0.20 mm (0.0043 X 0.0079 in) Intake 0.21 X 0.25 mm (0.0083 X 0.0098 in) Exhaust Valve dimensions Head Diameter...
Page 34 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Free length Intake 39.3 mm (1.55 in) 37.3 mm (1.47 in) Exhaust 39.3 mm (1.55 in) 37.3 mm (1.47 in) Installed length (valve closed) Intake 32.7 mm (1.29 in) Exhaust 32.8 mm (1.29 in) Compressed spring force (installed) 145.9 X 167.9 N (14.88 X 17.12 kg,...
Page 35 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston 0.010 X 0.035 mm (0.0004 X 0.0014 in) Piston-to-cylinder clearance 0.120 mm (0.0047 in) 76.975 X 76.990 mm (3.0305 X 3.0311 in) Diameter D Height H 5 mm (0.20 in) Piston pin bore (in the piston) 17.002 X 17.013 mm Diameter 17.043 mm...
Page 36 SPEC ENGINE SPECIFICATIONS Item Standard Limit Connecting rods 0.034 X 0.058 mm (0.0013 X 0.0023 in) Crankshaft-pin-to-big-end-bearing 0.09 mm clearance (0.0035 in) Bearing color code 1 = Blue 2 = Black 3 = Brown 4 = Green Crankshaft 55.20 X 56.60 mm (2.17 X 2.23 in) Width A 298.8 X 300.7 mm (11.76 X 11.84 in) Width B...
Page 37 SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch Clutch type Wet, multiple disc Clutch release method Outer pull, rack and pinion pull Clutch release method operation Cable operation Operation Left-hand operation 10 X 15 mm (0.39 X 0.59 in) Clutch cable free play (at the end of the clutch lever) Friction plates Color code...
Page 38 SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Transmission type Constant mesh, 6-speed Primary reduction system Spur gear Primary reduction ratio 65/43 (1.512) Secondary reduction system Chain drive Secondary reduction ratio 45/17 (2.647) Operation Left-foot operation Gear ratios 1st gear 38/15 (2.533) 2nd gear 33/16 (2.063) 3rd gear...
Page 39: Chassis Specifications
SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond Caster angle Trail 97 mm (3.82 in) Front wheel Wheel type Cast wheel Size 17 M/C MT3.50 Material Aluminum Wheel travel 120 mm (4.72 in) Wheel runout Max. radial wheel runout 1 mm (0.04 in) Max.
Page 40 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front brakes Brake type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 2.3 X 11.5 mm (0.09 X 0.45 in) Brake lever free play Brake discs Diameter thickness 4.5 mm (12.60 0.18 in) Min.
Page 41 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Suspension type Telescopic fork Front fork type Coil spring/oil damper Front fork travel 120 mm (4.72 in) Spring Free length 236.5 mm (9.31 in) 231.8 mm (9.13 in) Spacer length 100 mm (3.937 in) Installed length 222.5 mm (8.76 in) Spring rate (K1)
Page 42 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Angular bearing Lock to lock angle (left) Lock to lock angle (right) Rear suspension Suspension type Swingarm (link suspension) Rear shock absorber assembly Coil spring/gas-oil damper type Rear shock absorber assembly 65 mm (2.56 in) travel Spring...
Page 43: Electrical Specifications
SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V Ignition system Ignition system type DC. T.C.I. Ignition timing 5_ BTDC at 1,050 r/min 336 X 504 Ω at 20_C (68_F)/Gy-B Crankshaft position sensor resistance/color T.C.I. unit model (manufacturer) F8T822 (MITSUBISHI) (USA) F8T823 (MITSUBISHI) (CAL) Ignition coils...
Page 44 Coolant temparture indicator light Engine trouble warning light Shift timing indicator light Electric starting system System type Constant mesh Starter motor Model (manufacturer) 5VY (YAMAHA) Power output 0.9 kW Brushes Overall length 10.8 mm (0.43 in) 3.6 mm (0.14 in) 5.28 X 7.92 N (538 X 808 g,...
Page 45 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuses (amperage quantity) Main fuse 50 A Fuel injection system fuse 15 A Headlight fuse 25 A Signaling system fuse 10 A Ignition fuse 15 A Radiator fan motor fuse 15 A Backup fuse (odometer and clock) 10 A Reserve fuse 25 A, 15 A, 10 A...
Page 46: Conversion Table
CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed in SPECIFICATIONS SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.
Page 47: Tightening Torques
SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Item Fastener Fastener Q’ty Q ty Remarks Remarks size mSkg ftSlb Spark plugs — Cylinder head See NOTE 1 Bolt Camshaft caps Bolt Cylinder head cover Bolt Cylinder head (exhaust pipe) Stud bolt Air indication system cap Bolt...
Page 48 SPEC TIGHTENING TORQUES Tightening torque Thread Item Item Fastener Fastener Q’ty Q ty Remarks Remarks size mSkg ftSlb Exhaust pipe and cylinder head Catalyst pipe assembly and Bolt muffler Exhaust pipe and exhaust valve Bolt pipe assembly Exhaust valve pipe and housing Bolt Pulley and shaft arm EXUP pulley bracket...
Page 49 SPEC TIGHTENING TORQUES Tightening torque Thread Item Item Fastener Fastener Q’ty Q ty Remarks Remarks size mSkg ftSlb Main axle bearing housing Bolt Shift fork shaft stopper Bolt Stopper screw Screw Left thread Shift rod lock nut (rear) Shift rod lock nut (front) Shift rod joint Bolt Shift arm...
Page 50 SPEC TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence. 2-22...
Page 51: Chassis Tightening Torques
SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Thread Item Item Remarks Remarks size mSkg ftSlb Upper bracket and outer tube Upper bracket and steering stem nut 11.3 Handlebar and outer tube Handlebar and upper bracket Steering shaft and ring nut See NOTE 1 Outer tube and under bracket Main switch and upper bracket...
Page 52 SPEC TIGHTENING TORQUES Tightening Thread Item Item Remarks Remarks size mSkg ftSlb Battery box and frame Atmospheric pressure sensor and battery box — 0.07 Lean angle cut-off switch and battery box — Foot rest bracket (front) and frame Foot rest bracket (rear) and frame Rear brake master cylinder and foot rest bracket Rear brake hose union bolt Sidestand bracket and frame...
Page 53: Lubrication Points And Lubricant Types
Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Yamaha bond Cylinder head cover mating surface No.1215 Yamaha bond Crankcase mating surface No.1215 Yamaha bond Clutch cover (crankcase mating surface) No.1215...
Page 54: Chassis
SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Throttle grip inner surface Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Engine mount bolts (rear upper and lower) Relay arm, connecting rod and rear shock absorber collar Pivot shaft Swingarm pivot bearing...
Page 55: Cooling System Diagrams
SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS Radiator fan Radiator Water pump 2-27...
Page 56 SPEC COOLING SYSTEM DIAGRAMS Thermostat Radiator cap Radiator Oil cooler 2-28...
Page 57: Engine Oil Lubrication Chart
SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART 2-29...
Page 58: Lubrication Diagrams
SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS Intake camshaft Exhaust camshaft Oil filter cartridge Oil level switch 2-30...
Page 59 SPEC LUBRICATION DIAGRAMS Intake camshaft Exhaust camshaft Crankshaft Oil cooler Oil pipe Oil strainer Oil pump Relief valve 2-31...
Page 60 SPEC LUBRICATION DIAGRAMS Oil cooler Oil filter cartridge Oil level switch Oil strainer Oil pump Oil pipe 2-32...
Page 61 SPEC LUBRICATION DIAGRAMS Main axle Oil delivery pipe Drive axle 2-33...
Page 62 SPEC LUBRICATION DIAGRAMS Cylinder head Crankshaft 2-34...
Page 63: Cable Routing
SPEC CABLE ROUTING EAS00035 CABLE ROUTING Ground lead A Insert to the rib of the head light. G Clamp the head light lead by Meter lead (Either location of the right and wrapping and insert it to the in- Stay 1 left relays is acceptable.) take air grill hole.
Page 64 SPEC CABLE ROUTING L Clamp the head light lead to the stay 1 at the positioning white tape section. There should be no slack when clamping. Point the tip of the clamp (excessive part) to the front side of the vehicle. Fasten the head light lead with a clamp.
Page 65 SPEC CABLE ROUTING Right handlebar switch lead A Route the clutch cable so as to F Clamp the leads inside the front Clutch cable get along the front side of the fork of the vehicle. Point the exit Main switch lead main switch after passing it of the horn lead to the left front Left handlebar switch lead...
Page 66 SPEC CABLE ROUTING H Clamp the assembly of the clamp and guide wire to the front fork outer tube. Cut the tip of the clamp leaving 2 to 4 mm (0.08 X 0.16 in). Point the binding part to the external part of the vehicle. Clamp it to the outer tube.
Page 67 SPEC CABLE ROUTING Wire harness Throttle body lead E Clamp the clamp upper end Crankshaft position sensor lead along the line of lower end of the Heat protector A Clamp it after passing between hose clamp assembly. Point the Right handlebar switch lead the frame and radiator stay.
Page 68 SPEC CABLE ROUTING I The coupler for the air induction L Pass the rear brake light switch P To the air filter solenoid lead and camshaft sen- lead between the swingarm Q Route the fuel tank drain hose sor lead should be connected bracket and coolant reservoir over the canister stay and be- above the ignition coil sub wire...
Page 69 SPEC CABLE ROUTING Heat protector A Clamp the leads so that they are C Fold back the clamp and secure Main switch lead positioned inner of the vehicle it after passing the lead through Left handlebar switch lead than the washer position after the clamp.
Page 70 SPEC CABLE ROUTING G Route the lead by the inside of M There should be no exposure of R Arrange so as not for each hose the water hose and water pipe. bared conductors due to the dis- to cross in the part between “BB” H Route the lead by the inside of placement of the tube.
Page 71 SPEC CABLE ROUTING Heat protector Battery negative lead Throttle body side cap Crankshaft position sensor lead Starter motor lead Mud guard Neutral switch lead A.C.magneto lead Turn signal light lead Ground lead Oil level switch lead License plate light lead Coolant reservoir tank Sidestand switch lead Rear fender rib...
Page 72 SPEC CABLE ROUTING A Pass the wire harness through G Point the tip of the clamp (exces- K Pass the water hose lower side the clamp inserted to the radiator sive part) to the inside of the ve- of the thermostat, and between stay.
Page 73 SPEC CABLE ROUTING P Pass the lead through inside of U Make sure to position the cou- W Point the tip of the clamp (sur- the battery band. pler at the downmost position of plus section) to the rear side of Q Press on the tip of the clamp af- leads.
Page 74 SPEC CABLE ROUTING Z Point the tip of the clamp (exces- DD Fasten the wire harness, HH Insert the wire harness wrap- sive part) to the down side of the A.C.magneto lead, ping clamp to the hole of the vehicle. Fasten the wire har- throttle body lead with a frame.
Page 75 SPEC CABLE ROUTING MM Route each lead lower than PP Route the leads in random or- the frame plate. Leads should der. be routed in random order. Clamp can be inserted in any direction. NN Route each lead higher than the frame plate, pass it to the inside of the vehicle from the hole.
Page 76 SPEC CABLE ROUTING Fuel tank A Install the lip of O-ring facing up- a Fuel piping connector attach- O-ring ward. ment directions. (fuel pump side) Fuel tank drain hose B Install the part pointing the white 1. Insert the connector until the Fuel tank breather hose paint part of the hose to the left click sound is heard and check...
Page 77 SPEC CABLE ROUTING for CAL A Point the clip grip to the down F Point the clip grip to the upper Clip side of the vehicle. side of the vehicle. Clamp B Insert the hose so that its tip of G Install the part pointing the yel- Rivet the nipple does not protrude.
Page 78: Chk Adj
INTRODUCTION/PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM/GENERAL MAINTENANCE AND LUBRICATION CHART EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work.
Page 79: Air Filter
(See page 3-22) Lubricate the throttle grip housing and cable. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.
Page 80: Seats
SEATS EAS00039 SEATS 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Removing the seats Remove the parts in the order listed. Rider seat Passenger seat For installation, reverse the removal procedure.
Page 81: Fuel Tank
FUEL TANK EAS00040 FUEL TANK 10 Nm (1.0 mSkg, 7.2 ftSlb) 4 Nm (0.4 mSkg, 2.9 ftSlb) 4 Nm (0.4 mSkg, 2.9 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Rider sear Refer to “SEATS”.
Page 82: Removing The Fuel Tank
FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: S fuel hose connector cover S fuel return hose S fuel hose S fuel sender coupler S fuel pump coupler S fuel tank breather hose S fuel tank over flow hose...
Page 83: Installing The Fuel Pump
FUEL TANK INSTALLING THE FUEL PUMP 1. Install: S fuel pump 4 Nm (0.4 mSkg, 2.9 ftSlb) 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 84: Cowlings
COWLINGS COWLINGS FRONT COWLING AND SIDE COWLINGS 7 Nm (0.7 mSkg, 5.1 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Removing the front cowling and Remove the parts in the order listed. side cowlings Rider seat Refer to “SEATS”.
Page 85: Rear Cowling
COWLINGS REAR COWLING 10 Nm (1.0 mSkg, 7.2 ftSlb) 4 Nm (0.4 mSkg, 2.9 ftSlb) Order Job/Part Q’ty Remarks Removing the rear cowling Remove the parts in the order listed. Rider seat and passenger seat Refer to “SEATS”. Muffler Refer to “EXHAUST PIPE” in chapter 5. Rear cowling (upper) Tail/brake light lead coupler Disconnect.
Page 86: Removal
COWLINGS REMOVAL 1. Remove: S rear cowling S side cowlings NOTE: To remove the quick fastener, push its center with a screwdriver, then pull the fastener out. INSTALLATION 1. Install: S side cowlings S rear cowling NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cowling and push the pin a in with a screwdriver.
Page 87: Air Filter Case
AIR FILTER CASE AIR FILTER CASE 2 Nm (0.2 mSkg, 1.4 ftSlb) 3.4 Nm (0.34 mSkg, 2.5 ftSlb) Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Rider sear Refer to “SEATS”. Fuel tank Refer to “FUEL TANK”.
Page 88: 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 89 ADJUSTING THE VALVE CLEARANCE 4. Measure: S valve clearance Out of specification ! Adjust. Valve clearance (cold) Intake valve 0.11 X 0.20 mm (0.0043 X 0.0079 in) Exhaust valve 0.21 X 0.25 mm (0.0083 X 0.0098 in) a. Turn the crankshaft counterclockwise. b.
Page 90 ADJUSTING THE VALVE CLEARANCE 5. Remove: S camshafts NOTE: S Refer to “DISASSEMBLING THE ENGINE – CAMSHAFT AND CYLINDER HEAD” in chap- ter 5. S When removing the timing chain and cam- shafts, fasten the timing chain with a wire to re- trieve it if it falls into the crankcase.
Page 91 ADJUSTING THE VALVE CLEARANCE c. Round off the original valve pad number ac- cording to the following table. Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm (0.058 in)) Rounded value = 150 d.
Page 92 ADJUSTING THE VALVE CLEARANCE NOTE: S Refer to “ASSEMBLING AND ADJUSTING THE ENGINE – CYLINDER HEAD AND CAM- SHAFT” in chapter 5. S Lubricate the camshaft bearings, camshaft lobes and camshaft journals. S First, install the exhaust camshaft. S Align the camshaft marks with the camshaft cap marks.
Page 93 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 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.08 X 0.10...
Page 94: Synchronizing The Throttle Bodies
ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE THROTTLE BODIES 7. Install: S all removed parts NOTE: For installation, reverse the removal procedure. SYNCHRONIZING THE THROTTLE BODIES NOTE: Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition tim- ing should be checked.
Page 95 SYNCHRONIZING THE THROTTLE BODIES 5. Install: S fuel tank Refer to “FUEL TANK”. 6. Start the engine and let it warm up for several minutes. 7. Measure: S engine idling speed Out of specification ! Adjust. Refer to “ADJUSTING THE ENGINE IDLING SPEED”.
Page 96: Adjusting The Exhaust Gas Volume
SYNCHRONIZING THE THROTTLE BODIES/ ADJUSTING THE EXHAUST GAS VOLUME 9. Measure: S engine idling speed Out of specification ! Adjust. Make sure that the vacuum pressure is within specification. 10. Stop the engine and remove the measuring equipment. 11. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”.
Page 97 ADJUSTING THE EXHAUST GAS VOLUME 3. Using the “SELECT” button, select either the Co adjustment mode 1 (which appears as “Co”) or the diagnosis mode (which appears as “dIAG”). 4. After “Co” appears as a result of pressing the “SELECT” button, simultaneously press the “SELECT”...
Page 98: Adjusting The Engine Idling Speed
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, and the engine should have ad- equate compression. 1. Start the engine and let it warm up for several minutes.
Page 99: Adjusting The Throttle Cable Free Play
ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00056 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted proper- 1. Check: S throttle cable free play a Out of specification ! Adjust. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm (0.12 X 0.20 in)
Page 100: Checking The Spark Plugs
CHECKING THE SPARK PLUGS EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: S side cowlings S bottom cowlings Refer to “COWLINGS”. 2. Remove: S radiator upper bolts S radiator lower bolt Refer to “RADIATOR”...
Page 101: Measuring The Compression Pressure
CHECKING THE SPARK PLUGS/ MEASURING THE COMPRESSION PRESSURE 8. Install: S spark plugs 13 Nm (1.3 mSkg, 9.4 ftSlb) S ignition coils NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 9. Install: S radiator upper bolts S radiator lower bolt Refer to “RADIATOR”...
Page 102 MEASURING THE COMPRESSION PRESSURE 4. Install: S compression gauge 1 S adapter Compression gauge 90890-03081, YU-33223 Adapter 90890-04136 5. Measure: S compression pressure Out of specification ! Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 1,290 kPa (12.90 kg/cm 12.90 bar, 183.48 psi) Standard 1,480 kPa (14.80 kg/cm...
Page 103: Checking The Engine Oil Level
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and mea- sure again. Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis...
Page 104 CHECKING THE ENGINE OIL LEVEL Recommended oil AT 5_C (40_F) or higher A Yamalube 4 (20W40) or SAE 20W40 type SE motor AT 15_C (60_F) or lower B Yamalube 4 (10W30) or SAE 10W30 type SE motor NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
Page 105: Changing The Engine Oil
CHANGING THE ENGINE OIL EAS00074 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 bottom cowlings Refer to “COWLINGS”.
Page 106: Measuring The Engine Oil Pressure
CHANGING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE Oil filter cartridge 17 Nm (1.7 mSkg, 12 ftSlb) 8. Replace: S engine oil drain bolt gasket 9. Install: S engine oil drain bolt (along with the new gasket) 43 Nm (4.3 mSkg, 31 ftSlb) 10.
Page 107 MEASURING THE ENGINE OIL PRESSURE 4. Remove: S oil gallery bolt 1 WARNING The engine, muffler and engine oil are ex- tremely hot. 5. Install: S oil pressure gauge 1 S adapter 2 Pressure gauge 90890-03153, YU-03153 Oil pressure adapter 90890-03139 6.
Page 108: Adjusting The Clutch Cable Free Play
MEASURING THE ENGINE OIL PRESSURE/ ADJUSTING THE CLUTCH CABLE FREE PLAY Engine oil pressure Possible causes Below Faulty oil pump specification Clogged oil filter Leaking oil passage Broken or damaged oil seal Above Leaking oil specification passage Faulty oil filter Oil viscosity too high 7.
Page 109: Replacing The Air Filter Element
ADJUSTING THE CLUTCH CABLE FREE PLAY/ REPLACING THE AIR FILTER ELEMENT Engine side a. Loosen the locknut 1 . b. Turn the adjusting nut 2 in direction a or b until the specified clutch cable free play is ob- tained. Clutch cable free play is Direction increased.
Page 110: Checking The Fuel And Breather Hoses
REPLACING THE AIR FILTER ELEMENT/ CHECKING THE FUEL AND BREATHER HOSES 4. Install: S air filter case cover CAUTION: Never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine.
Page 111: Checking The Crankcase Breather Hose
CHECKING THE FUEL AND BREATHER HOSES/ CHECKING THE CRANKCASE BREATHER HOSE 3. Install: S fuel tank Refer to “FUEL TANK”. S rider seat Refer to “SEATS”. CAUTION: To install the fuel tank, check that the breath- er hose is not folded or pinched by the fuel tank.
Page 112: Checking The Exhaust System
CHECKING THE EXHAUST SYSTEM EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipes and gaskets. WARNING Do not touch the muffler bracket until the ex- haust system has cooled. 1. Check: S exhaust pipe 1 S exhaust valve pipe 2 S muffler 3 Cracks/damage ! Replace.
Page 113: Adjusting The Exup Cables
ADJUSTING THE EXUP CABLES EAS00101 ADJUSTING THE EXUP CABLES 1. Remove: S bottom cowlings Refer to “COWLINGS”. 2. Remove: S EXUP valve pulley cover 1 3. Check: S EXUP system operation a. Turn the main switch ON. b. Check that the EXUP valve operates properly. 4.
Page 114: Checking The Coolant Level
ADJUSTING THE EXUP CABLES/ CHECKING THE COOLANT LEVEL 7. Install: S bottom cowlings Refer to “COWLINGS”. 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.
Page 115: Checking The Cooling System
CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Remove: S bottom cowlings S side cowlings Refer to “COWLINGS”. 2. Check: S radiator 1 S radiator inlet hose 2 S radiator outlet hose 3 S oil cooler 4 S oil cooler inlet hose 5 S oil cooler outlet hose 6 S water jacket joint 7 S water jacket joint inlet hose 8...
Page 116: Changing The Coolant
CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove: S bottom cowlings S side cowlings Refer to “COWLINGS”. S rider seat Refer to “SEATS”. 2. Remove: S coolant reservoir tank S coolant reservoir hose 3. Disconnect: S coolant reservoir cap 1 4.
Page 117 CHANGING THE COOLANT 7. Drain: S coolant (water pump inlet pipe and outlet pipe) 8. Check: S copper washers 1 9. Install: S coolant drain bolts 2 (with copper washers) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10. Install: S coolant reservoir tank 11.
Page 118 CHANGING THE COOLANT CAUTION: S Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. S Use only distilled water. However, if dis- tilled water is not available, soft water may be used.
Page 119: Chassis
ADJUSTING THE FRONT BRAKE EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) NOTE: While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the de- sired position.
Page 120: Adjusting The Rear Brake
ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Adjust: S brake pedal position a. Loosen the locknut 1 . b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is ob- tained.
Page 121: Checking The Brake Fluid Level
CHECKING THE BRAKE FLUID LEVEL 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. 2. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.
Page 122: Adjusting The Rear Brake Light Switch
ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT AND REAR BRAKE PADS 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 123: Checking The Front And Rear Brake Hoses
CHECKING THE FRONT AND REAR BRAKE PADS/ CHECKING THE FRONT AND REAR BRAKE HOSES 2. Check: S front brake pad S rear brake pad Brake pad wear limit a , b Wear limit reached ! Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES”...
Page 124: Bleeding The Hydraulic Brake System
BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00135 BLEEDING THE HYDRAULIC BRAKE SYSTEM 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 125: Adjusting The Shift Pedal
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL NOTE: Loosening the bleed screw will release the pres- sure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. h. Tighten the bleed screw and then release the brake lever or brake pedal.
Page 126: 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 127: Lubricating The Drive Chain
ADJUSTING THE DRIVE CHAIN SLACK/ LUBRICATING THE DRIVE CHAIN Direction Drive chain is tightened. Direction Drive chain is loosened. NOTE: To maintain the proper wheel alignment, adjust both sides evenly. d. Tighten both locknuts to specification. Locknut 16 Nm (1.6 mSkg, 12 ftSlb) e.
Page 128: Checking And Adjusting The Steering Head
CHECKING AND ADJUSTING THE STEERING HEAD EAS00146 CHECKING AND ADJUSTING THE STEERING 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 129 CHECKING AND ADJUSTING THE STEERING HEAD c. Loosen the lower ring nut 4 completely, then tighten it to specification. WARNING Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 18 Nm (1.8 mSkg, 13 ftSlb) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions.
Page 130: Checking The Front Fork
CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK Steering head tension 200 X 500 g e. Repeat the above procedure on the opposite handlebar. f. If the steering head tension is out of specifi- cation (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut.
Page 131: Adjusting The Front Fork Legs
ADJUSTING THE FRONT FORK LEGS EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING S Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. S Securely support the motorcycle so that there is no danger of it falling over.
Page 132 ADJUSTING THE FRONT FORK LEGS 1. Adjust: S rebound damping a. Turn the adjusting screw 1 in direction a or Rebound damping is Direction increased (suspension is harder). Rebound damping is Direction decreased (suspension is softer). Adjusting positions Minimum: 26 clicks in direction b * Standard: 10 clicks in direction b * Maximum: 1 clicks in direction b * * with the adjusting screw fully...
Page 133: 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 134 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 1. Adjust: S rebound damping a. Turn the adjusting screw 1 in direction a or Rebound damping is Direction increased (suspension is harder). Rebound damping is Direction decreased (suspension is softer). Adjusting positions Minimum: 20 clicks in direction b * Standard: 17 clicks in direction b * Maximum: 1 clicks in direction b * * with the adjusting screw fully...
Page 135: Checking The Tires
CHECKING THE TIRES EAS00162 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 136 WARNING After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee con-...
Page 137: Checking The Wheels
CHECKING THE TIRES/CHECKING THE WHEELS Front tire Manufacturer Size Model DUNLOP 120/70ZR 17 D218FL M/C (58W) MICHELIN 120/70ZR 17 Pilot M/C (58W) POWER C Rear tire Manufacturer Size Model DUNLOP 190/50ZR 17 D218L M/C (73W) MICHELIN 190/50ZR 17 Pilot M/C (73W) POWER G WARNING New tires have a relatively low grip on the...
Page 138: Checking And Lubricating The Cables
CHECKING AND LUBRICATING THE CABLES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION EAS00170 CHECKING AND LUBRICATING THE 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 139: 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 140 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 141 CHECKING AND CHARGING THE BATTERY 5. Charge: S battery (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. CAUTION: S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause bat- tery overheating and battery plate damage.
Page 142 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (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 143 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 144: 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 145 CHECKING THE FUSES Pocket tester 90890-03112, YU-3112 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 146: 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 bulb cover 1 S headlight coupler 2 A high beam B low beam 2. Remove: S headlight bulb holder 1 A high beam B low beam 3.
Page 147: Adjusting The Headlight Beams
REPLACING THE HEADLIGHT BULBS/ ADJUSTING THE HEADLIGHT BEAMS CAUTION: Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
Page 148: Chas
CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 6 Nm (0.6 mSkg, 4.3 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 2 Nm (0.2 mSkg, 1.4 ftSlb) 91 Nm (9.1 mSkg, 66 ftSlb) 20 Nm (2.0 mSkg, 13 ftSlb) 2 Nm (0.2 mSkg, 1.4 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb)
Page 149 CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 Order Job/Part Q’ty Remarks Disassembling the front wheel Disassemble the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly procedure.
Page 150: 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 151 CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: S radial wheel runout 1 S lateral wheel runout 2 Over the specified limits ! Replace. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) 4.
Page 152: Checking The Brake Discs
CHAS FRONT WHEEL AND BRAKE DISCS EAS00533 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 153: Installing The Front Wheel
CHAS FRONT WHEEL AND BRAKE DISCS Brake disc bolt Front : 18 Nm (1.8 mSkg, 13 ftSlb) Rear : 30 Nm (3.0 mSkg, 22 ftSlb)  LOCTITE d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification.
Page 154: Adjusting The Front Wheel Static Balance
CHAS FRONT WHEEL AND BRAKE DISCS 6. Install: S brake caliper (left and right) 35 Nm (3.5 mSkg, 25 ftSlb) NOTE: Make sure that there is enough space between the brake pads before installing the brake cali- pers onto the brake discs. WARNING Make sure the brake hose is routed properly.
Page 155 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 156: Rear Wheel And Brake Disc
CHAS REAR WHEEL AND BRAKE DISC EAS00551 REAR WHEEL AND BRAKE DISC REAR WHEEL 22 Nm (2.2 mSkg, 16 ftSlb) 27 Nm (2.7 mSkg, 20 ftSlb) 150 Nm (15 mSkg, 108 ftSlb) Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed.
Page 157: Rear Brake Disc And Rear Wheel Sprocket
CHAS REAR WHEEL AND BRAKE DISC EAS00560 REAR BRAKE DISC AND REAR WHEEL SPROCKET 30 Nm (3.0 mSkg, 22 ftSlb) 100 Nm (10 mSkg, 72 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake disc and Remove the parts in the order listed. rear wheel sprocket Rear brake disc Rear wheel sprocket...
Page 158 CHAS REAR WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed. Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly procedure. 4-11...
Page 159: Removing The Rear Wheel
CHAS REAR WHEEL AND BRAKE DISC 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 160: Checking The Rear Wheel
CHAS REAR WHEEL AND BRAKE DISC EAS00565 CHECKING THE REAR WHEEL 1. Check: S wheel axle S rear wheel S wheel bearings S oil seals Refer “CHECKING FRONT WHEEL”. 2. Check: S tire S rear wheel Damage/wear ! Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS”...
Page 161: Installing The Rear Wheel
CHAS REAR WHEEL AND BRAKE DISC 2. Replace: S rear wheel sprocket a. Remove the self-locking nuts and the rear wheel sprocket. b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. c.
Page 162: Front And Rear Brakes
CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 5 Nm (0.5 mSkg, 3.6 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed.
Page 163: Rear Brake Pads
CHAS FRONT AND REAR BRAKES REAR BRAKE PADS 5 Nm (0.5 mSkg, 3.6 ftSlb) 27 Nm (2.7 mSkg, 20 ftSlb) 22 Nm (2.2 mSkg, 16 ftSlb) 3 Nm (0.3 mSkg, 2.2 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake pads...
Page 164 CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: WARNING 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 165: Replacing The Front Brake Pads
CHAS FRONT AND REAR BRAKES EAS00582 REPLACING THE FRONT BRAKE PADS The following procedure applies to both brake calipers. NOTE: When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1.
Page 166 CHAS FRONT AND REAR BRAKES 5. Install: S brake pad shims (onto the brake pads) S brake pads S brake pad spring NOTE: Always install new brake pads, brake pad shims, and a brake pad spring as a set. a. Connect a clear plastic hose 1 tightly to the bleed screw 2 .
Page 167: Replacing The Rear Brake Pads
CHAS FRONT AND REAR BRAKES 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 screw plug 1 S brake pad pin 2 S brake caliper 3 S brake pad spring 2.
Page 168 CHAS FRONT AND REAR BRAKES a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger.
Page 169: Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 3.8 Nm (0.38 mSkg, 2.7 ftSlb) 1.2 Nm (0.12 mSkg, 0.9 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed.
Page 170 CHAS FRONT AND REAR BRAKES 3.8 Nm (0.38 mSkg, 2.7 ftSlb) 1.2 Nm (0.12 mSkg, 0.9 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Copper washer Brake hose Brake master cylinder bracket Brake master cylinder Front brake light switch For installation, reverse the removal...
Page 171 CHAS FRONT AND REAR BRAKES EAS00585 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. master cylinder Brake master cylinder kit Bleed screw Brake master cylinder body For assembly, reverse the disassembly procedure.
Page 172: Cylinder
CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 18 Nm (1.8 mSkg, 13 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder Brake fluid Drain.
Page 173: Disassembling The Rear Brake Master
CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the rear brake master Disassemble the parts in the order listed. cylinder Brake master cylinder kit Hose joint Bush Brake master cylinder body For assembly, reverse the disassembly procedure. 4-26...
Page 174 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 light switch connector 1 (from the brake light switch) 2.
Page 175: Checking The Front And Rear Brake Master
CHAS FRONT AND REAR BRAKES EAS00593 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders. 1. Check: S brake master cylinder Damage/scratches/wear ! Replace. S brake fluid delivery passages (brake master cylinder body) Obstruction ! Blow out with compressed air.
Page 176: Assembling And Installing The Front Brake
CHAS FRONT AND REAR BRAKES EAS00607 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 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.
Page 177 CHAS FRONT AND REAR BRAKES NOTE: S While holding the brake hose, tighten the union bolt. S Turn the handlebars to the left and right to make sure the brake hose does not touch oth- er parts (e.g., wire harness, cables, leads). Correct if necessary.
Page 178: Assembling The Rear Brake Master Cylinder
CHAS FRONT AND REAR BRAKES 6. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system.
Page 179 CHAS FRONT AND REAR BRAKES WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake perfor- mance.
Page 180: Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 6 Nm (0.6 mSkg, 4.3 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. NOTE: The following procedure applies to both of the front brake calipers.
Page 181 CHAS FRONT AND REAR BRAKES EAS00615 5 Nm (0.5 mSkg, 3.6 ftSlb) Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. calipers NOTE: The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring...
Page 182: Rear Brake Caliper
CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 mSkg, 22 ftSlb) 27 Nm (2.7 mSkg, 20 ftSlb) 22 Nm (2.2 mSkg, 16 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain.
Page 183 CHAS FRONT AND REAR BRAKES EAS00617 5 Nm (0.5 mSkg, 3.6 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 3 Nm (0.3 mSkg, 2.2 ftSlb) Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Disassemble the parts in the order listed. Screw plug Brake pad pin Brake pad...
Page 184: 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 union bolt 1 S copper washers 2 S brake hose 3 NOTE:...
Page 185 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 union bolt 1 S copper washers 2 S brake hose 3 S brake caliper 4 NOTE: Put the end of the brake hose into a container...
Page 186 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 Brake fluid Every two years and whenever the brake is disas- sembled 1.
Page 187 CHAS FRONT AND REAR BRAKES EAS00640 ASSEMBLING AND INSTALLING THE 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 188 CHAS FRONT AND REAR BRAKES 3. 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 189: Assembling And Installing The Rear
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 190 CHAS FRONT AND REAR BRAKES 2. 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 191: Front Fork
CHAS FRONT FORK EAS00647 FRONT FORK FRONT FORK LEGS 17 Nm (1.7 mSkg, 12 ftSlb) 26 Nm (2.6 mSkg, 19 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job/Part Q’ty Remarks...
Page 192 CHAS FRONT FORK EAS00648 23 Nm (2.3 mSkg, 17 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Disassembling the front fork legs Disassemble the parts in the order listed. NOTE: The following the procedure applies to both of the front fork legs.
Page 193 CHAS FRONT FORK 23 Nm (2.3 mSkg, 17 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Washer Damper rod assembly bolt Copper washer Damper rod assembly Inner tube Outer tube For assembly, reverse the disassembly procedure.
Page 194: Removing The Front Fork Legs
CHAS FRONT FORK EAS00649 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 195: Disassembling The Front Fork Legs
CHAS FRONT FORK EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: S cap bolt 1 (from the damper adjusting rod) S spacer 2 S nut 3 a. Press down on the spacer with the fork spring compressor 4 .
Page 196: Checking The Front Fork Legs
CHAS FRONT FORK 4. Remove: S damper rod assembly bolt S damper rod assembly NOTE: While holding the damper rod assembly with the damper rod holder 1 , loosen the damper rod assembly bolt. Damper rod holder 90890-01423, YM-01423 EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
Page 197: Assembling The Front Fork Legs
CHAS FRONT FORK CAUTION: S The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material. S When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork.
Page 198 CHAS FRONT FORK WARNING Always use new copper washer. CAUTION: Allow the damper rod assembly to slide slowly down the inner tube 1 until it pro- trudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2.
Page 199 CHAS FRONT FORK CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: S Before installing the oil seal, lubricate its lips with lithium-soap-based grease. S Lubricate the outer surface of the inner tube with fork oil. S Before installing the oil seal, cover the top of the front fork leg with a plastic bag to protect the oil seal during installation.
Page 200 CHAS FRONT FORK 8. Install: S rod puller 1 S rod puller attachment 2 (onto the damper rod 3 ) Rod puller 90890-01437, YM-01437 Rod puller attachment 90890-01436, YM-01436 9. Fill: S front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.53 L (0.47 Imp qt, 0.56 US qt)
Page 201 CHAS FRONT FORK d. Press down on the spacer with the fork spring compressor 1 . e. Pull up the rod puller and install the rod hold- er 2 between the nut 3 and the spacer 4 . NOTE: Use the side of the rod holder that is marked “B”. Fork spring compressor 90890-01441, YM-01441 Rod holder...
Page 202: 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 203: Handlebars
CHAS HANDLEBARS EAS00665 HANDLEBARS 13 Nm (1.3 mSkg, 9.4 ftSlb) 3.8 Nm (0.38 mSkg, 2.7 ftSlb) 26 Nm (2.6 mSkg, 19 ftSlb) 113 Nm (11.3 mSkg, 82 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 3.8 Nm (0.38 mSkg, 2.7 ftSlb)
Page 204 CHAS HANDLEBARS 13 Nm (1.3 mSkg, 9.4 ftSlb) 3.8 Nm (0.38 mSkg, 2.7 ftSlb) 26 Nm (2.6 mSkg, 19 ftSlb) 113 Nm (11.3 mSkg, 82 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 3.8 Nm (0.38 mSkg, 2.7 ftSlb) 3.8 Nm (0.38 mSkg, 2.7 ftSlb)
Page 205: Removing The Handlebars
CHAS HANDLEBARS EAS00667 REMOVING THE HANDLEBARS 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 handlebar grip 1 NOTE: Blow compressed air between the left handle- bar and the handlebar grip, and gradually push the grip off the handlebar.
Page 206 CHAS HANDLEBARS 2. Install: S right handlebar switch 1 NOTE: Align the projection a on the right handlebar switch with the hole b in the right handlebar. 3. Install: S brake master cylinder holder 1 CAUTION: S Install the brake master cylinder holder with the “UP”...
Page 207: Checking The Steering Damper
CHAS HANDLEBARS 6. Install: S left handlebar switch 1 NOTE: Align the projection a on the left handlebar switch with the hole b in the left handlebar. 7. Install: S handlebar grip a. Apply a thin coat of rubber adhesive onto the end of the left handlebar.
Page 208: Steering Head
CHAS STEERING HEAD EAS00676 STEERING HEAD UNDER BRACKET 38 Nm (0.38 mSkg, 2.75 ftSlb) 113 Nm (11.3 mSkg, 82 ftSlb) 52 Nm (5.2 mSkg, 38 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order...
Page 209 CHAS STEERING HEAD 38 Nm (0.38 mSkg, 2.75 ftSlb) 113 Nm (11.3 mSkg, 82 ftSlb) 52 Nm (5.2 mSkg, 38 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part...
Page 210: Removing The Under Bracket
CHAS STEERING HEAD EAS00677 REMOVING THE UNDER 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 ring nut 1 (with the steering nut wrench 2 ) Steering nut wrench 90890–01403, YU-33975 WARNING...
Page 211: Installing The Steering Head
CHAS STEERING HEAD b. Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer. c. Install a new rubber seal and new bearing races. CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: S Always replace the bearings and bearing races as a set.
Page 212: Rear Shock Absorber Assembly
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 44 Nm (4.4 mSkg, 32 ftSlb) 92 Nm (9.2 mSkg, 67 ftSlb) 44 Nm (4.4 mSkg, 32 ftSlb) 44 Nm (4.4 mSkg, 32 ftSlb) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed.
Page 213: 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 214: Removing The Rear Shock Absorber Assembly
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING Becurely 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 215: Checking The Rear Shock Absorber Assembly
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 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. S spring Damage/wear ! Replace the rear shock ab- sorber assembly.
Page 216: Swingarm And Drive Chain
CHAS SWINGARM AND DRIVE CHAIN EAS00700 SWINGARM AND DRIVE CHAIN 7 Nm (0.7 mSkg, 5.1 ftSlb) 2 Nm (0.2 mSkg, 1.4 ftSlb) 28 Nm (2.8 mSkg, 20 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 105 Nm (10.5 mSkg, 76 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part...
Page 217 CHAS SWINGARM AND DRIVE CHAIN 7 Nm (0.7 mSkg, 5.1 ftSlb) 2 Nm (0.2 mSkg, 1.4 ftSlb) 28 Nm (2.8 mSkg, 20 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 105 Nm (10.5 mSkg, 76 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty...
Page 218: 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 219: Removing The Drive Chain
CHAS SWINGARM AND DRIVE CHAIN EAS00704 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 220: Checking The Drive Chain
CHAS SWINGARM AND DRIVE CHAIN 3. Wash: S pivot shaft S dust covers S spacer S washers S bearings Recommended cleaning solvent Kerosene 4. Check: S dust covers 1 S spacer 2 Damage/wear ! Replace. S bearings 3 Damage/pitting ! Replace. 5.
Page 221 CHAS SWINGARM AND DRIVE CHAIN 2. Check: S drive chain Stiffness ! Clean and lubricate or replace. 3. Clean: S drive chain a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosene and remove any remaining dirt.
Page 222: Installing The Swingarm
CHAS SWINGARM AND DRIVE CHAIN 6. Check: S drive sprocket S rear wheel sprocket More than 1/4 tooth a wear ! Replace the drive chain sprockets as a set. Bent teeth ! Replace the drive chain sprock- ets as a set. b Correct 1 Drive chain roller 2 Drive chain sprocket...
Page 223: Eng
ENGINE ENGINE ENGINE DRIVE SPROCKET 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5 ftSlb) 85 Nm (8.5 mSkg, 61 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the drive sprocket Remove the parts in the order listed. Bottom cowlings Refer to “COWLINGS”...
Page 224: Exhaust Pipe
ENGINE EXHAUST PIPE 23 Nm (2.3 mSkg, 17 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) Order Job/Part Q’ty...
Page 225 ENGINE 23 Nm (2.3 mSkg, 17 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) Order Job/Part Q’ty...
Page 226 ENGINE 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Disassembling the exhaust valve Disassemble the parts in the order listed. pipe Washer Pulley Collar Plate Spring Housing Gasket Shaft arm...
Page 227: Leads And Hoses
ENGINE LEADS AND HOSES Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect 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. Throttle body assembly Refer to “THROTTLE BODIES”...
Page 228 ENGINE Order Job/Part Q’ty Remarks CAUTION: First, disconnect the negative battery lead, and then the positive battery lead. For connecting, reverse the disconnec- tion procedure. Clutch cable Ground lead Stator coil assembly coupler Disconnect. Crankshaft position sensor lead coupler Disconnect. Oil level switch connector Disconnect.
Page 229 ENGINE ENGINE 45 Nm (4.5 mSkg, 33 ftSlb) 51 Nm (5.1 mSkg, 37 ftSlb) 51 Nm (5.1 mSkg, 37 ftSlb) 45 Nm (4.5 mSkg, 33 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 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 230 ENGINE 45 Nm (4.5 mSkg, 33 ftSlb) 51 Nm (5.1 mSkg, 37 ftSlb) 51 Nm (5.1 mSkg, 37 ftSlb) 45 Nm (4.5 mSkg, 33 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks NOTE: Engine mounting adjust bolt Engine Use the pivot shaft wrench and adapter to loosen the engine mounting adjust bolts.
Page 231: Installing The Engine
ENGINE INSTALLING THE ENGINE 1. Install: S engine mounting adjust bolts (temporary tighten) 2. Install: S engine 3. Install: S lower engine mounting bolt 1 S upper engine mounting bolt 2 S self locking nuts NOTE: Lubricate the lower and upper engine mounting bolts threads with lithium-soap-based grease.
Page 232 ENGINE Pivot shaft wrench 90890-01471, YM-01471 Pivot shaft wrench adapter 90890-01476 7. Tighten: S upper self-locking nut 1 S lower self-locking nut 2 51 Nm (5.1 mSkg, 37 ftSlb) NOTE: First tighten the lower self-locking nut, and then tighten the upper self-locking nut. 8.
Page 233: Camshaft
CAMSHAFT EAS00194 CAMSHAFT CYLINDER HEAD COVER 13 Nm (1.3 mSkg, 9.4 ftSlb) 8 Nm (0.8 mSkg, 5.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Fuel tank Refer to “FUEL TANK”...
Page 234 CAMSHAFT 13 Nm (1.3 mSkg, 9.4 ftSlb) 8 Nm (0.8 mSkg, 5.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Timing chain guide (top side) Cylinder identification sensor O-ring For installation, reverse the removal procedure. 5-12...
Page 235: Camshafts
CAMSHAFT EAS00196 CAMSHAFTS 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed.
Page 236: Removing The Camshafts
CAMSHAFT EAS00198 REMOVING THE CAMSHAFTS 1. Remove: S pickup rotor cover Refer to “CRANKSHAFT POSITION SEN- SOR AND PICKUP ROTOR”. 2. Align: S “T” mark a on the pickup rotor (with the crankcase mating surface b ) a. Turn the crankshaft clockwise. b.
Page 237: Checking The Camshafts
CAMSHAFT 6. Remove: S intake camshaft 1 S exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 3 . 7. Remove: S camshaft sprockets EAS00204 CHECKING THE CAMSHAFTS 1. Check: S camshaft lobes Blue discoloration/pitting/scratches ! Re- place the camshaft.
Page 238 CAMSHAFT 3. Measure: S camshaft runout Out of specification ! Replace. Camshaft runout limit 0.03 mm (0.0012 in) 4. Measure: S camshaft-journal-to-camshaft-cap clear- ance Out of specification ! Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.028 X 0.062 mm (0.0011 X 0.0024 in) a.
Page 239: Checking The Timing Chain, Camshaft Sprockets, And Timing Chain Guides
CAMSHAFT EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: S timing chain 1 Damage/stiffness ! Replace the timing chain and camshaft sprockets as a set. 2.
Page 240 CAMSHAFT 3. Install: S timing chain tensioner spring S timing chain tension rod 1 NOTE: Prior to installing the timing chain tensioner rod, drain the engine oil from the timing chain ten- sioner housing. a. Install the timing chain tensioner spring and timing chain tensioner rod 1 .
Page 241: Installing The Camshafts
CAMSHAFT EAS00215 INSTALLING THE CAMSHAFTS 1. Align: S “T” mark a on the pickup rotor (with the crankcase mating surface b ) a. Turn the crankshaft clockwise. b. When piston #1 is at TDC, align the “T” mark a with the crankcase mating surface b . 2.
Page 242 CAMSHAFT 5. Install: S camshaft cap bolts 10 Nm (1.0 mSkg, 7.2 ftSlb) NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. CAUTION: S Lubricate the camshaft cap bolts with the engine oil.
Page 243 CAMSHAFT 8. Install: S O-ring S timing chain tensioner 1 S timing chain tensioner bolts 2 10 Nm (1.0 mSkg, 7.2 ftSlb) CAUTION: The “arrow” mark a on the timing chain ten- sioner should face up. WARNING Always use a new O-ring. 9.
Page 244: Cylinder Head
CYLINDER HEAD EAS00221 CYLINDER HEAD 19 Nm (1.9 mSkg, 14 ftSlb) 67 Nm (6.7 mSkg, 48 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed.
Page 245: Removing The Cylinder Head
CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remove: S intake camshaft S exhaust camshaft Refer to “REMOVING THE CAMSHAFTS”. 2. Remove: S cylinder head nuts S cylinder head bolts NOTE: S Loosen the nuts in the proper sequence as shown.
Page 246: Installing The Cylinder Head
CYLINDER HEAD EAS00233 INSTALLING THE CYLINDER HEAD 1. Check: S cylinder head bolts 1 8 Nm (0.8 mSkg, 5.8 ftSlb) NOTE: Retighten the cylinder head bolts to specifica- tion, before installing the cylinder head. 2. Install: S gasket S dowel pins 3.
Page 247 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 Cylinder head Refer to “CYLINDER HEAD”. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal...
Page 248 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal procedure.
Page 249: Valves And Valve Springs
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 250: Checking The Valves And Valve Guides
VALVES AND VALVE SPRINGS 4. Remove: S upper spring seat 1 S valve spring 2 S valve stem seal 3 S lower 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. EAS00239 CHECKING THE VALVES AND VALVE GUIDES...
Page 251 VALVES AND VALVE SPRINGS NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover Intake (4.0 mm, 0.16 in) 90890-04111 Exhaust (4.5 mm, 0.18 in) 90890-04116, YM-4116 Valve guide installer Intake (4.0 mm, 0.16 in) 90890-04112 Exhaust (4.5 mm, 0.18 in) 90890-04117, YM-4117 Valve guide reamer Intake (4.0 mm, 0.16 in)
Page 252: 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 253: Checking The Valve Springs
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 254: Checking The Valve Lifters
VALVES AND VALVE SPRINGS 2. Measure: S compressed valve spring force a Out of specification ! Replace the valve spring. b Installed length Compressed valve spring force (installed) Intake valve spring 145.9 X 167.9 N (14.88 X 17.12 kg, 32.80 X 37.74 lb) at 32.65 mm (1.285 in) Exhaust valve spring 164.1 X 188.9 N...
Page 255 VALVES AND VALVE SPRINGS 2. Lubricate: S valve stem 1 S valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: S valve 1 S lower spring seat 2 S valve stem seal 3 S valve spring 4 S upper spring seat 5 (into the cylinder head) NOTE:...
Page 256 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. CAUTION: Hitting the valve tip with excessive force could damage the valve. 6. Install: S valve pad 1 S valve lifter 2 NOTE: S Lubricate the valve lifter and valve pad with...
Page 257: Starter Clutch And Generator
STARTER CLUTCH AND GENERATOR STARTER CLUTCH AND GENERATOR STATOR COIL ASSEMBLY 10 Nm (1.0 mSkg, 7.2 ftSlb) 14 Nm (1.4 mSkg, 10 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 22 Nm (2.2 mSkg, 16 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb)
Page 258 STARTER CLUTCH AND GENERATOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 14 Nm (1.4 mSkg, 10 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 22 Nm (2.2 mSkg, 16 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 22 Nm (2.2 mSkg, 16 ftSlb)
Page 259: Starter Clutch
STARTER CLUTCH AND GENERATOR STARTER CLUTCH Order Job/Part Q’ty Remarks Removing the starter clutch Remove the parts in the order listed. Generator rotor Damper Driven gear Washer Starter clutch drive gear Collar Washer Spacer O-ring For installation, reverse the removal procedure.
Page 260: Removing The Generator
STARTER CLUTCH AND GENERATOR REMOVING THE GENERATOR 1. Remove: S rider seat S fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 2. Remove: S left side cowling S bottom cowlings Refer to “COWLINGS” in chapter 3. 3. Drain: S engine oil Refer to “CHANGING THE ENGINE OIL”...
Page 261: Checking The Damper
STARTER CLUTCH AND GENERATOR REMOVING THE STARTER CLUTCH 1. Remove: S spacer 1 S O-ring 2 S washer 3 2. Remove: S Starter clutch drive gear 1 S collar 2 S washer 3 3. Remove: S driven gear 1 S dampers 2 S generator rotor 3 CHECKING THE DAMPER 1.
Page 262: Checking The Starter Clutch
STARTER CLUTCH AND GENERATOR EAS00351 CHECKING THE STARTER CLUTCH 1. Check: S starter clutch rollers 1 Damage/wear ! Replace. 2. Check: S starter clutch idle gear 1 S starter clutch drive gear 2 Burrs/chips/roughness/wear ! Replace the defective part(s). 3. Check: S starter clutch gear’s contacting surfaces a Damage/pitting/wear ! Replace the starter clutch gear.
Page 263: Installing The Starter Clutch
STARTER CLUTCH AND GENERATOR INSTALLING THE STARTER CLUTCH 1. Install: S generator rotor 1 S damper 2 S driven gear 3 NOTE: S The hole side of the damper is installed to the generator side. S Lubricate the engine oil 4 . 2.
Page 264 STARTER CLUTCH AND GENERATOR 3. Install: S generator cover gasket S generator cover 1 (M6 bolts) 12 Nm (1.2 mSkg, 8.7 ftSlb) (M8 bolts) 22 Nm (2.2 mSkg, 16 ftSlb) NOTE: S First tighten the M8 bolts and then tighten the M6 bolts.
Page 265: Crankshaft Position Sensor
CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the crankshaft position Remove the parts in the order listed. sensor Rider seat Refer to “SEATS”...
Page 266: Removing The Crankshaft Position Sensor
CRANKSHAFT POSITION SENSOR REMOVING THE CRANKSHAFT POSITION SENSOR 1. Remove: S rider seat S fuel tank Refer to “SEATS” and “FUEL TANK” in chap- ter 3. 2. Remove: S right side cowling S bottom cowlings Refer to “COWLINGS” in chapter 3. 3.
Page 267 CRANKSHAFT POSITION SENSOR 5. Install: S rider seat S fuel tank Refer to “SEATS” and “FUEL TANK” in chap- ter 3. 5-45...
Page 268: Clutch
CLUTCH CLUTCH CLUTCH COVER 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Right side cowling Refer to “COWLINGS”...
Page 269: Pull Lever Shaft
CLUTCH 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 For installation, reverse the removal procedure. 5-47...
Page 270 CLUTCH CLUTCH 95 Nm (9.5 mSkg, 69 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Compression spring Pressure plate Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Wire clip Clutch plate 2...
Page 271 CLUTCH 95 Nm (9.5 mSkg, 69 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Clutch boss nut Washer Clutch boss Thrust plate Clutch housing Bearing For installation, reverse the removal procedure. 5-49...
Page 272: Removing The Clutch
CLUTCH EAS00276 REMOVING THE CLUTCH 1. Remove: S clutch cover 1 S gasket NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
Page 273 CLUTCH 6. Loosen: S clutch boss nut 1 NOTE: While holding the clutch boss 2 with the univer- sal clutch holder 3 , loosen the clutch boss nut. Universal clutch holder 90890-04086, YM-91042 7. Remove: S clutch boss nut S washer S clutch boss assembly S thrust plate 8.
Page 274: Checking The Friction Plates
CLUTCH EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates. 1. Check: S friction plate Damage/wear ! Replace the friction plates as a set. 2. Measure: S friction plate thickness Out of specification ! Replace the friction plates as a set.
Page 275: Checking The Clutch Springs
CLUTCH EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: S clutch spring Damage ! Replace the clutch springs as a set. 2. Measure: S clutch spring free length a Out of specification ! Replace the clutch springs as a set.
Page 276: Checking The Pressure Plate
CLUTCH EAS00286 CHECKING THE PRESSURE PLATE 1. Check: S pressure plate 1 Cracks/damage ! Replace. S bearing 2 Damage/wear ! Replace. EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: S pull lever shaft pinion gear teeth 1 S pull rod teeth 2 Damage/wear ! Replace the pull rod and pull lever shaft pinion gear as a set.
Page 277 CLUTCH 3. Install: S wire clip 1 4. Install: S clutch housing 1 NOTE: Align the projection of clutch housing a and hollow of the oil pump drive gear b . 5. Install: S thrust plate S clutch boss assembly 1 S washer S clutch boss nut 2 95 Nm(9.5 mSkg, 69 ftSlb)
Page 278 CLUTCH 6. Lubricate: S friction plates S clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 7. Install: S friction plate 2 S clutch plate 1 1 8. Install: S friction plate 1 1 NOTE: Install the last friction plate shifting half phase. 9.
Page 279 CLUTCH 11. Install: S clutch cover S clutch cover gasket NOTE: S Install the pull rod so that the teeth a face to- wards the rear of the motorcycle. Then, install the clutch cover. S Apply oil onto the bearing. S Apply molybdenum disulfide grease onto the pull rod.
Page 280: Shift Shaft
SHIFT SHAFT EAS00327 SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER 22 Nm (2.2 mSkg, 16 ftSlb) Order Job/Part Q’ty Remarks Removing the shift shaft and stopper Remove the parts in the order listed. lever Side cowlings Refer to “COWLINGS” in chapter 3. Bottom cowlings Clutch assembly Refer to “CLUTCH”.
Page 281 SHIFT SHAFT 22 Nm (2.2 mSkg, 16 ftSlb) Order Job/Part Q’ty Remarks Oil seal Bearing Bearing Stopper lever spring For installation, reverse the removal procedure. 5-59...
Page 282: Removing The Shift Shaft
SHIFT SHAFT REMOVING THE SHIFT SHAFT 1. Remove: S left and right side cowlings S bottom cowlings Refer to “COWLINGS” in chapter 3. 2. Remove: S clutch assembly Refer to “CLUTCH”. 3. Remove: S shift arm S shift rod Refer to “ENGINE”. 4.
Page 283: Checking The Shift Shaft
SHIFT SHAFT CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 Bends/damage/wear ! replace. S shift shaft spring 2 S collar 3 Damage/wear ! Replace. CHECKING THE STOPPER LEVER 1. Check: S stopper lever 1 Bends/damage ! Replace. Roller turns roughly ! Replace the stopper lever.
Page 284 SHIFT SHAFT 4. Install: S shift rod S shift arm Refer to “ENGINE”. 5. Install: S clutch assembly Refer to “CLUTCH”. 6. Install: S left and side cowling S bottom cowlings Refer to “COWLING” in chapter 3. 5-62...
Page 285: Oil Pan And Oil Pump
OIL PAN AND OIL PUMP EAS00356 OIL PAN AND OIL PUMP 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 43 Nm (4.3 mSkg, 31 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order...
Page 286 OIL PAN AND OIL PUMP 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 43 Nm (4.3 mSkg, 31 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part...
Page 287 OIL PAN AND OIL PUMP EAS00360 15 Nm (1.5 mSkg, 11 ftSlb) Order Job/Part Q’ty Remarks Disassembling the oil pump Disassemble the parts in the order listed. Oil/water pump driven sprocket Collar Oil pump housing Bearing Oil pump outer rotor Oil pump inner rotor For assembly, reverse the disassembly procedure.
Page 288: Removing The Oil Pan
OIL PAN AND OIL PUMP EAS00362 REMOVING THE OIL PAN 1. Remove: S oil level switch 1 S oil pan 2 S oil pan gasket S dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.
Page 289: 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 rotor housing 2 S oil pump cover 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 1 Inner rotor...
Page 290: Checking The Oil Delivery Pipe And Oil Pipe
OIL PAN AND OIL PUMP EAS00367 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 1. Check: S oil delivery pipe 1 S oil pipe 2 Damage ! Replace. Obstruction ! Wash and blow out with com- pressed air. EAS00368 CHECKING THE OIL STRAINER 1.
Page 291: Installing The Oil/Water Pump Assembly
OIL PAN AND OIL PUMP 2. Install: S pin 1 S inner rotor 2 S outer rotor 3 S oil pump housing 4 NOTE: When installing the inner rotor, align the pin 1 in the oil pump shaft with the groove a in the inner rotor 2 .
Page 292 OIL PAN AND OIL PUMP 2. Install: S washer S oil/water pump assembly drive chain 1 S oil/water pump assembly drive sprocket 2 S collar NOTE: Install the oil/water pump assembly drive chain 1 onto the oil/water pump assembly drive sprocket 2 .
Page 293: Installing The Oil Pan
OIL PAN AND OIL PUMP EAS00380 INSTALLING THE OIL PAN 1. Install: S dowel pins S gasket S oil pan 1 12 Nm (1.2 mSkg, 8.7 ftSlb) S oil level switch 2 10 Nm (1.0 mSkg, 7.2 ftSlb) S engine oil drain bolt 3 43Nm (4.3 mSkg, 31 ftSlb) WARNING Always use new copper washers.
Page 294: Crankcase
CRANKCASE CRANKCASE 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) +60_ 24 Nm (2.4 mSkg, 17 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty...
Page 295 CRANKCASE 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) +60_ 24 Nm (2.4 mSkg, 17 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty...
Page 296: Disassembling The Crankcase
CRANKCASE EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside down. 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. S Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration).
Page 297: Checking The Crankcase
(with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: S sealant Yamaha bond No. 1215 90890-85505, ACC-1109-05-01 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 (0.08 X 0.12 in) of the crankshaft journal bear-...
Page 298 CRANKCASE 3. Install: S dowel pin 4. Set the shift drum assembly and transmis- sion gears in the neutral position. 5. Install: S lower crankcase 1 (onto the upper crankcase 2 ) CAUTION: Before tightening the crankcase bolts, make sure that the transmission gears shift cor- rectly when the shift drum assembly is turned by hand.
Page 299: Connecting Rods And Pistons
CONNECTING RODS AND PISTONS EAS00252 CONNECTING RODS AND PISTONS 20 Nm (2.0 mSkg, 14 ftSlb) +150_ 8 Nm (0.8 mSkg, 5.8 ftSlb) Order Job/Part Q’ty Remarks Removing the connecting rods and Remove the parts in the order listed. pistons Lower crankcase Refer to “CRANKCASE”.
Page 300: Removing The Connecting Rods And Pistons
CONNECTING RODS AND PISTONS EAS00393 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: S connecting rod cap 1 S big end bearings NOTE: S Identify the position of each big end bearing so that it can be reinstalled in its original place.
Page 301: Removing The Crankshaft Assembly
CONNECTING RODS AND PISTONS EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: S crankshaft assembly S crankshaft journal upper bearings (from the upper crankcase) Refer to “CRANKSHAFT”. NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place.
Page 302: Checking The Piston Rings
CONNECTING RODS AND PISTONS 77.00 X 77.01 mm Cylinder bore “C” (3.0315 X 3.0319 in) Wear limit 77.06 mm (3.03 in) Taper limit “T” 0.005 mm (0.0002 in) Out of round “R” 0.005 mm (0.0002 in) “C” = maximum of D “T”...
Page 303: Checking The Piston Pins
CONNECTING RODS AND PISTONS Piston ring side clearance Top ring 0.030 X 0.065 mm (0.0012 X 0.0026 in) <Limit>: 0.115 mm (0.0045 in) 2nd ring 0.020 X 0.055 mm (0.0008 X 0.002 in) <Limit>: 0.115 mm (0.0045 in) 2. Install: S piston ring (into the cylinder) NOTE:...
Page 304: Checking The Big End Bearings
CONNECTING RODS AND PISTONS 2. Measure: S piston pin outside diameter a Out of specification ! Replace the piston pin. Piston pin outside diameter 16.991 X 17.000 mm (0.6689 X 0.6693 in) <Limit>: 16.971 mm (0.6682 in) 3. Measure: S piston pin bore inside diameter b Out of specification ! Replace the piston.
Page 305 CONNECTING RODS AND PISTONS CAUTION: Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clear- ance and prevent engine damage, the big end bearings must be installed in their origi- nal positions. a. Clean the big end bearings, crankshaft pins, and the inside of the connecting rods halves.
Page 306 CONNECTING RODS AND PISTONS e. Tighten the connecting rod bolts. NOTE: Install by carrying out the following procedures in order to assemble in the most suitable condi- tion. Connecting rod bolt 29.4 Nm (3.0 mSkg, 21 ftSlb) NOTE: S First, tighten the bolts to 15 Nm (1.5 mSkg, 11 ftSlb).
Page 307 CONNECTING RODS AND PISTONS l. Clean the connecting rod bolts. m. Tighten the connecting rod bolts. n. Put a mark 1 on the corner of the connecting rod bolt 2 and the connecting rod 3 . o. Tighten the bolt further to reach the specified angle (150_).
Page 308: Installing The Connecting Rod And Piston
CONNECTING RODS AND PISTONS  r. Measure the compressed Plastigauge width on the crankshaft pin. crankshaft-pin-to-big-end-bearing clearance is out of specification, select re- placement big end bearings. 2. Select: S big end bearings (P1 X P4) 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 309 CONNECTING RODS AND PISTONS NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers a face up. 2. Install: S piston 1 (onto the respective connecting rod 2 ) S piston pin 3 S piston pin clip NOTE: S Apply engine oil onto the piston pin.
Page 310 CONNECTING RODS AND PISTONS 6. Check: S cylinder stud bolts 1 8 Nm (0.8 mSkg, 5.8 ftSlb) 7. Install: S cylinder gasket 2 8. Install: S big end bearings (onto the connecting rods and connecting rod caps) NOTE: S Align the projection a on the big end bearings with the notches b in the connecting rods and connecting rod caps.
Page 311 CONNECTING RODS AND PISTONS b. Clean the connecting rod bolts. c. After installing the big end bearing, assemble the connecting rod and connecting rod cap once using a single unit of the connecting rod. d. Tighten the connecting rod bolt while check- ing that the sections shown a and b are flush with each other by touching the surface.
Page 312 CONNECTING RODS AND PISTONS 11. Install: S cylinder assembly 1 S connecting rod caps 2 NOTE: S Make sure that the “Y” marks a on the con- necting rods face towards the left side of the crankshaft. S Make sure that the characters on both the con- necting rod and connecting rod cap are aligned.
Page 313 CONNECTING RODS AND PISTONS WARNING S When the bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and per- form the procedure again. S If they are not flush with each other, remove the connecting rod bolt and big end bear- ing and restart from step “9”.
Page 314: Crankshaft
CRANKSHAFT EAS00381 CRANKSHAFT 60 Nm (6.0 mSkg, 43 ftSlb) Order Job/Part Q’ty Remarks Removing the crankshaft Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Connecting rod and connecting rod Refer to “CONNECTING RODS AND caps PISTONS”. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing...
Page 315: Checking The Crankshaft
CRANKSHAFT EAS00395 CHECKING THE CRANKSHAFT 1. Measure: S crankshaft runout Out of specification ! Replace the crank- shaft. Crankshaft runout Less than 0.03 mm (0.0012 in) 2. Check: S crankshaft journal surfaces S crankshaft pin surfaces S bearing surfaces Scratches/wear ! Replace the crankshaft. CHECKING THE CRANKSHAFT DRIVE SPROCKET 1.
Page 316 CRANKSHAFT a. Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. b. Place the upper crankcase upside down on a bench. c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crank- case.
Page 317 CRANKSHAFT * Following the tightening order, loosen the bolt one by one and then retighten it to the specific torque. NOTE: Lubricate the crankcase bolt threads with en- gine oil. Refer to “CRANKCASE”. g. Remove the lower crankcase and the crank- shaft journal lower bearings.
Page 318: Installing The Crankshaft
CRANKSHAFT EAS00407 INSTALLING THE CRANKSHAFT 1. Install: S crankshaft journal upper bearings 1 (into the upper crankcase) 2. Lubricate: S crankshaft journal upper bearings (with the recommended lubricant) Recommended lubricant Engine oil NOTE: S Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the upper crankcase.
Page 319: Transmission
TRANSMISSION EAS00419 TRANSMISSION TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the part in the order listed.
Page 320 TRANSMISSION 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Main axle retainer Main axle assembly Oil pipe O-ring Oil baffle plate For installation, reverse the removal procedure.
Page 321 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle Disassemble the parts in the order listed. assembly 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Main axle 5-99...
Page 322 TRANSMISSION Order Job/Part Q’ty Remarks Bearing housing Bearing For installation, reverse the removal procedure. 5-100...
Page 323 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 Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip...
Page 324 TRANSMISSION Order Job/Part Q’ty Remarks 6th wheel gear Circlip Washer Collar 2nd wheel gear Collar Oil seal Bearing Drive axle For installation, reverse the removal procedure. 5-102...
Page 325: Removing The Transmission
TRANSMISSION REMOVING THE TRANSMISSION 1. Remove: S drive axle assembly 1 S shift drum retainers 2 S shift fork guide bars S shift fork “L” and “R” S shift drum assembly S shift fork “C” 2. Remove: S bearing housing 1 S main axle assembly 2 a.
Page 326: Checking The Shift Drum Assembly
TRANSMISSION 2. Check: S shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends ! Replace. WARNING Do not attempt to straighten a bent shift fork guide bar. 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.
Page 327: Installing The Transmission
TRANSMISSION 2. Measure: S drive axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the drive axle. Drive axle runout limit 0.08 mm (0.0032 in) 3. Check: S transmission gears Blue discoloration/pitting/wear ! Replace the defective gear(s).
Page 328 TRANSMISSION 3. Install: S shift fork “L” 1 and “R” 2 S drive axle assembly 3 S shift fork guide bar S shift fork guide bar retainer 4 10 Nm (1.0 mSkg, 7.2 ftSlb)  LOCTITE NOTE: S Install shift fork “L” into the groove in the 6th wheel gear and shift fork “R”...
Page 329: Cool
COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 5 Nm (0.5 mSkg, 3.6 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Rider seat Refer to “SEATS”...
Page 330 COOL RADIATOR 5 Nm (0.5 mSkg, 3.6 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Radiator inlet pipe Oil cooler outlet hose Water pump breather hose Radiator outlet hose Water pump inlet pipe O-ring...
Page 331: 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 332: 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. 3.
Page 333: Oil Cooler
COOL OIL COOLER EAS00457 OIL COOLER 10 Nm (1.0 mSkg, 7.2 ftSlb) 63 Nm (6.3 mSkg, 46 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the oil cooler Remove the parts in the order listed. Engine oil Drain.
Page 334 COOL OIL COOLER 10 Nm (1.0 mSkg, 7.2 ftSlb) 63 Nm (6.3 mSkg, 46 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Water jacket joint Stay O-ring For installation, reverse the removal procedure.
Page 335: Checking The Oil Cooler
COOL OIL COOLER EAS00458 CHECKING THE OIL COOLER 1. Check: S oil cooler Cracks/damage ! Replace. 2. Check: S oil cooler inlet hose S oil cooler outlet hose Cracks/damage/wear ! Replace. EAS00459 INSTALLING THE OIL COOLER 1. Clean: S mating surfaces of the oil cooler and the crankcase (with a cloth dampened with lacquer thinner) 2.
Page 336: Thermostat
COOL THERMOSTAT EAS00460 THERMOSTAT Order Job/Part Q’ty Remarks Removing the thermostat assembly Remove the parts in the order listed. Rider seat Refer to “SEATS” in chapter 3. Fuel tank Refer to “FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE” in chapter 3. Coolant Drain.
Page 337 COOL THERMOSTAT 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Disassembling the thermostat Disassemble the parts in the order listed. housing Thermostat housing cover Thermostat Thermostat housing O-ring For assembly, reverse the disassembly procedure.
Page 338: Checking The Thermostat
COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: S thermostat Does not open at 71 X 85_C (160 X 185_F) ! 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 339: Assembling The Thermostat Assembly
COOL THERMOSTAT EAS00464 ASSEMBLING THE THERMOSTAT ASSEMBLY 1. Install: S thermostat housing 1 S thermostat 2 S O-ring S thermostat housing cover 4 10 Nm (1.0 mSkg, 7.2 ftSlb) NOTE: Install the thermostat with its breather hole a facing up. EAS00466 INSTALLING THE THERMOSTAT ASSEMBLY...
Page 340: Water Pump
COOL WATER PUMP EAS00468 WATER PUMP IMPELLER SHAFT 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the impeller shaft Remove the parts in the order listed. NOTE: S The water pump and oil pump are com- bined into one unit (oil/water pump as- sembly).
Page 341 COOL WATER PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Water pump seal Oil seal Bearing O-ring For installation, reverse the removal procedure. 6-13...
Page 342: Disassembling The Water Pump
COOL WATER PUMP EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: S water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing. 2 Water pump housing 2. Remove: S oil seal 1 S bearing 2 NOTE: Tap out the bearing and oil seal from the outside...
Page 343 NOTE: S Install the water pump seal with the special tools. S Before installing the water pump seal, apply Yamaha bond No.1215 or Quick Gasket 2 to the water pump housing 3 . Mechanical seal installer 4 90890-04078, YM-33221 Middle driven shaft bearing...
Page 344 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 (0.006 in) 1 Straightedge 2 Impeller 6-16...
Page 345: Fuel Injection System
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM Ignition coil Intake air presure sen- Coolant temperature Atmospheric pressure Air filter case sensor sensor Intake temperature Throttle position sen- Spark plug Fuel injection system sensor Cylinder identification relay Fuel delivery hose Fuel injector sensor Engine trouble warning...
Page 346: Wiring Diagram
FUEL INJECTION SYSTEM WIRING DIAGRAM...
Page 347 FUEL INJECTION SYSTEM Main switch Fuse (main) Fuse (backup) Battery Fuse (fuel injection) Starting circuit cut-off relay Neutral switch Sidestand switch Fuel pump E.C.U. Ignition coil #1 Ignition coil #2 Ignition coil #3 Ignition coil #4 Spark plug Injector #1 Injector #2 Injector #3 Injector #4...
Page 348: Ecu's Self-Diagnostic Function
FUEL INJECTION SYSTEM EAS00899 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 349: 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 vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
Page 350 FUEL INJECTION SYSTEM Fault Able / unable Able / unable Item Symptom Fail-safe action Code No. to start to drive Vehicle system power Power supply to the FI system is not Able Able supply (Monitor voltage) normal. S Turn the sub-throttle servo motor Sub-throttle servo motor sub-throttle servo motor potention- potention (open or short...
Page 351: Troubleshooting Chart
FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. * Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light does not come The engine trouble warning light comes on.
Page 352: Diagnostic Mode
FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without con- necting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Setting the diagnostic mode 1.
Page 353 FUEL INJECTION SYSTEM 7. Verify the operation of the sensor or actuator. S Sensor operation The data representing the operating condi- tions of the sensor appears on the trip LCD. S Actuator operation Set the engine stop switch to “ON” to operate the actuator.
Page 354 FUEL INJECTION SYSTEM Diagnostic fault code table Fault Diagnostic Symptom Probable cause of malfunction code No. code S Open or short circuit in wiring sub lead. No normal signals are received from S Open or short circuit in wiring harness. the cylinder identification sensor.
Page 355 FUEL INJECTION SYSTEM Fault Diagnostic Symptom Probable cause of malfunction code No. code S Open or short circuit in wiring harness. Open circuit is detected in the primary S Malfunction in ignition coil. lead of the ignition coil (#2). S Malfunction in ECU. S Malfunction in a component of ignition cut-off circuit system.
Page 356 FUEL INJECTION SYSTEM Diagnostic mode table Switch the meter display from the regular mode to the diagnosis mode. To switch the display, refer to “DIAGNOSTIC MODE”. NOTE: S Check the intake air temperature and coolant temperature as close as possible to the intake air tem- perature sensor and the coolant temperature sensor respectively.
Page 357 FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) Ignition coil #3 After the engine stop switch has been turned from OFF to Check that spark is generated, ON, it actuates ignition coil #3 for five times every second 5 times with the engine stop and illuminates the engine trouble warning light.
Page 358 FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) Headlight relay 1 After the engine stop switch has been turned from OFF to Check the headlight relay ON, it actuates the headlight relay five times every operating sound 5 times with the 5 seconds and illuminates the engine trouble warning light.
Page 359: Troubleshooting Details
FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Carry out check and maintenance on items or components that could be a cause of malfunction in accordance with the order. When the check and maintenance of malfunctioned part is completed, restore the meter display ac- cording to the “Restore method”.
Page 360 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft position sensor. Used diagnostic code No. – – Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Installed condition of sensor Check the installed area for looseness or Reinstated by pinching.
Page 361 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor – open or short circuit detected. Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by Inspect the coupler for any pins that...
Page 362 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor – hose system malfunction (clogged or detached hose). Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and probable Operation item and countermeasuer Reinstatement cause method Reinstated by Intake air pressure sensor hose detached,...
Page 363 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor – open or shrt circuit detected. Used diagnostic code No. 01 (throttle position sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Installed condition of throttle position Check the installed area for looseness or Reinstated by sensor.
Page 364 FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor potention circuit – open or short circuit detected. Used diagnostic code 53 Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Connected condition of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that securely.
Page 365 FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor is stuck. Used diagnostic code 53 Order Inspection operation item and probable Operation item and countermeasure Reinstatement couse method Reinstated by Connected condition of connector If there is a malfunction repair it and Inspect the coupler for any pins that connect it securely.
Page 366 FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit in the input line of ECU No.15 terminal is detected. Used diagnostic code No. 20 (sidestand switch) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method If the Connected condition of connector Execute the diagnostic mode (Code No.20).
Page 367 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit is detected from the coolant temperature sensor. Used diagnostic code No. 06 (coolant temperature sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Connected condition of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that...
Page 368 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit detected from the intake temperature sensor. Used diagnostic code No. 05 (intake temperature sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by Inspect the coupler for any pins that...
Page 369 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit detected from the atmospheric pressure sensor. Used diagnostic code No. 02 (atmospheric pressure sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Connected condition of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that...
Page 370 FUEL INJECTION SYSTEM Fault code No. Symptom The motorcycle has overturned. Used diagnostic code No. 08 (lean angle cut-off switch) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by The motorcycle has overturned. Raise the motorcycle upright. turning the Installed condition of the lean angle Check the installed area for looseness or...
Page 371 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the ignition coil (#1). Used diagnostic code No. 30 (ignition coil #1) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of connector...
Page 372 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the ignition coil (#4). Used diagnostic code No. 33 (ignition coil #4) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Connected state of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that...
Page 373 FUEL INJECTION SYSTEM Fault code No. Symptom 1 No normal signals are received from the speed sensor. 2 Open or short circuit is detected in the neutral switch. No. 07 (speed sensor) ! A1 X A4 Used diagnostic code No. 21 (neutral switch) ! B1 X B4 Order Inspection operation item and probable Operation item and countermeasure...
Page 374 FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09 (fuel system voltage) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Connected condition of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that securely.
Page 375 FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading or writing on EEP-ROM (CO adjustment value). Used diagnostic No. 60 (EEP-ROM improper cylinder indication) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Malfunction in ECU Execute diagnostic code 60 Reinstated by...
Page 376 FUEL INJECTION SYSTEM Fault code No. Symptom Sub-throttle position sensor – open or short circuit detected. Used diagnostic code 56 Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Installed condition of sub-throttle position Check the installed area for looseness or pinch- sensor.
Page 377 FUEL INJECTION SYSTEM Fault code No. Symptom Sub-throttle servo motor is stuck. Used diagnostic code 56 Order Inspection operation item and probable Operation item and countermeasure Reinstatement couse method Reinstated by Connected condition of connector If there is a malfunction repair it and Inspect the coupler for any pins that connect it securely.
Page 378 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signal are received from the ECU. Er-2 Symptom No signal are received from the ECU within the specified duration. Er-3 Symptom Data from the ECU cannot be received correctly. Er-4 Symptom Non-registered data has been received from the meter.
Page 379: Throttle Bodies
THROTTLE BODIES THROTTLE BODIES Order Job/Part Q’ty Remarks Removing the throttle bodies Remove the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Fuel tank Refer to “FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE” in chapter 3. Sub-wire harness coupler Disconnect.
Page 380 THROTTLE BODIES Order Job/Part Q’ty Remarks NOTE: Throttle body joint To install the throttle body joint, make sure to install it to the cylinder with the same figures corresponding to the fig- ures stated on the throttle body joint. Heat protector Fuel hose For installation, reverse the removal procedure.
Page 381: Injectors
THROTTLE BODIES INJECTORS Order Job/Part Q’ty Remarks Removing the injectors Remove the parts in the order listed. Throttle position sensor coupler Disconnect. Sub-throttle position sensor coupler Disconnect. Sub-throttle motor assembly coupler Disconnect. Intake air pressure sensor coupler Disconnect. Cylinder #1-injector coupler Disconnect.
Page 382 THROTTLE BODIES Order Job/Part Q’ty Remarks Idle adjust screw wire Cotter pin Washer Link Sub-throttle servo motor assembly Throttle position sensor Fuel pressure regulator Throttle body assembly For installation, reverse the removal procedure. 7-38...
Page 383: Checking The Injectors
THROTTLE BODIES EAS00911 CAUTION: The throttle bodies should not be disas- sembled. EAS00912 CHECKING THE INJECTORS 1. Check: S injectors Damage ! Replace. EAS00913 CHECKING THE THROTTLE BODIES 1. Check: S throttle bodies Cracks/damage ! Replace the throttle bo- dies as a set. 2.
Page 384: Checking The Pressure Regulator
THROTTLE BODIES CHECKING THE PRESSURE REGULATOR 1. Check: S pressure regulator Damage ! Replace. 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.
Page 385: Checking And Adjusting The Throttle Position Sensor
THROTTLE BODIES Increase the vacuum pressure ! Fuel pressure is decreased Decrease the vacuum pressure ! Fuel pressure is increased Faulty ! Replace the pressure regulator. EAS00916 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed.
Page 386 THROTTLE BODIES f. While slowly opening the throttle, check that the throttle position sensor resistance is with- in the specified range. The resistance does not change or it changes abruptly ! Replace the throttle position sensor. The slot is worn or broken ! Replace the throttle position sensor.
Page 387: Checking And Adjusting The Sub-Throttle Position Sensor
THROTTLE BODIES CHECKING AND ADJUSTING THE SUB-THROTTLE POSITION SENSOR 1. Check: S sub-throttle position sensor a. Disconnect the sub-throttle position sensor coupler. b. Remove the sub-throttle position sensor from the sub-throttle servo motor. c. Connect the pocket tester (Ω 1k) to the sub-throttle position sensor.
Page 388 THROTTLE BODIES 2. Adjust: S sub-throttle position sensor full open angle a. Turn the nut 1 of the worm shaft of the sub- throttle counterclockwise until it contacts with the full open stopper. b. When the dimension of a sections of the throttle bodies #3 and #4 is measured with a micrometer caliper, adjust with the adjuster 2 of the output shaft section of the sub-...
Page 389: Checking And Adjusting The Thermo Wax
THROTTLE BODIES b. After performing the step a, move the sub- throttle position sensor to adjust to be in a range from 0.97 to 1.07 V Sub-throttle position sensor voltage 0.97 X 1.07 V (green/yellow – blue) NOTE: S After setting up the sub-throttle position sen- sor, check that the sub-throttle position sensor output voltage is 0.4 V or more with the nut of worm shaft turned to the full close side until it...
Page 390: Air Induction System
AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns 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 391 AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut-off valve A To cylinder #1 and #2 2 Plate B To cylinder #3 and #4 3 Reed valve assembly 4 Reed valve cap 5 To air filter case 7-47...
Page 392: 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 reed valve 1 S reed valve stopper S reed valve seat Cracks/damage ! Replace the reed valve.
Page 393 AIR INDUCTION SYSTEM 5. Check: S Air induction system solenoid a. Remove the Air induction system solenoid coupler from the wire harness. b. Connect the pocket tester (Ω 1) to the Air induction system solenoid terminal as shown. Tester positive probe ! orange 1 Tester negative probe ! green 2 c.
Page 394: Elec
ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS Main switch Oil level switch Front brake light switch Radiator fan motor Starter relay Horn Battery Ignition coil Fuse box Rear brake light switch Neutral switch Sidestand switch...
Page 395 ELEC ELECTRICAL COMPONENTS Coolant temperature sensor Radiator fan motor relay Intake air temperature sensor Turn signal relay Intake air pressure sensor Rectifier/ regulator Fuel pump Throttle position sensor Sub-throttle position sensor Lean angle cut-off switch Starting circuit cut-off relay Headlight relay (dimmer)
Page 396: 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.
Page 397: Checking The Switches
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 398: Checking The Bulbs And Bulb Sockets
ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND 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.
Page 399: Checking The Condition Of The Bulb Sockets
ELEC CHECKING THE BULBS AND BULB SOCKETS CAUTION: S Be sure to hold the socket firmly when re- moving the bulb. Never pull the lead, other- wise it may be pulled out of the terminal in the coupler. S Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adverse-...
Page 400: Checking The Leds
ELEC CHECKING THE BULBS AND BULB SOCKETS Pocket tester 90890-03112, YU-3112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. a. Install a good bulb into the bulb socket. b.
Page 401: Ignition System
ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM...
Page 402 ELEC IGNITION SYSTEM Main switch Fuse (main) Battery Starting circuit cut-off relay Neutral switch Sidestand switch E.C.U. Ignition coil #1 Ignition coil #2 Ignition coil #3 Ignition coil #4 Spark plug Crankshaft position sensor Cylinder identification sensor Lean angle cut-off switch Engine stop switch Clutch switch Fuse (ignition)
Page 403: 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 404 ELEC IGNITION SYSTEM EAS00743 Positive tester probe ! 4. Ignition spark gap ignition coil terminal Negative tester probe ! The following procedure applies to all of the ignition coil terminal spark plugs. S Disconnect the spark plug cap from the spark plug.
Page 405 ELEC IGNITION SYSTEM EAS00748 EAS00750 8. Engine stop switch 6. Crankshaft position sensor resistance S Check the engine stop switch for continuity. S Disconnect the crankshaft position sensor Refer to “CHECKING THE SWITCHES”. coupler from the wire harness. S Is the engine stop switch OK? S Connect the pocket tester (Ω...
Page 406 ELEC IGNITION SYSTEM EAS00753 12. Starting circuit cut-off relay (diode) 13. Lean angle cut-off switch S Disconnect the starting circuit cut-off relay S Check the lean angle cut-off switch. Refer to “FUEL INJECTION SYSTEM” in coupler from the wire harness. S Connect the pocket tester (Ω...
Page 407: Electric Starting System
ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Fuse (main) Battery Starter relay Starter motor Starting circuit cut-off relay Neutral switch Sidestand switch Engine stop switch Start switch Fuse (ignition) 8-14...
Page 408: Starting Circuit Cut-Off System Operation
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 409: Troubleshooting
ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses Minimum open-circuit voltage 2.
Page 410 ELEC ELECTRIC STARTING SYSTEM EAS00759 4. Starting circuit cut-off relay S Disconnect the starting circuit cut-off relay coupler from the wire harness. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown.
Page 411 ELEC ELECTRIC STARTING SYSTEM EAS00752 EAS00766 9. Sidestand switch 12. Wiring S Check the sidestand switch for continuity. S Check the entire starting system’s wiring. Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”. S Is the sidestand switch OK? S Is the starting system’s wiring properly con- nected and without defects? Replace the side-...
Page 412: Starter Motor
ELEC STARTER MOTOR EAS00767 STARTER MOTOR 5 Nm (0.5 mSkg, 3.6 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 5 Nm (0.5 mSkg, 3.6 ftSlb) Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Seat Refer to “SEAT”...
Page 413 ELEC STARTER MOTOR EAS00768 5 Nm (0.5 mSkg, 3.6 ftSlb) 5 Nm (0.5 mSkg, 3.6 ftSlb) 5 Nm (0.5 mSkg, 3.6 ftSlb) Order Job/Part Q’ty Remarks Disassembling the starter motor Disassemble the parts in the order listed. O-ring Front cover Lock washer Washer Starter motor yoke...
Page 414: Checking The Starter Motor
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 wear limit 24.5 mm (0.96 in) 3.
Page 415: Assembling The Starter Motor
ELEC STARTER MOTOR 5. Measure: S brush length a . Out of specification ! Replace the brushes as a set. Brush length wear limit 3.6 mm (0.14 in) 6. Measure: S brush spring force Out of specification ! Replace the brush springs as a set.
Page 416 ELEC STARTER MOTOR 3. Install: S starter motor yoke 1 S O-rings 2 S starter motor rear cover 3 S bolts 5 Nm (0.5 mSkg, 3.6 ftSlb) NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and rear covers.
Page 417: Charging System
ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Fuse (main) Battery 8-24...
Page 418: Troubleshooting
ELEC CHARGING SYSTEM EAS00774 Minimum open-circuit voltage TROUBLESHOOTING 12.8 V or more at 20_C (68_F) The battery is not being charged. S Is the battery OK? Check: 1. main fuse 2. battery S Clean the battery 3. charging voltage 4. stator coil lead terminals.
Page 419 ELEC CHARGING SYSTEM EAS00776 4. Stator coil lead 5. Stator coil resistance S Disconnect stator coil lead coupler. S Remove the generator cover. S Connect the pocket tester (Ω S Connect the pocket tester (Ω 1) to the sta- 1) to the sta- tor coil lead coupler as shown.
Page 420: Lighting System
ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 8-27...
Page 421 ELEC LIGHTING SYSTEM Main switch Fuse (main) Battery E.C.U. Hi beam indicator light Meter light Dimmer switch Front turn signal/position light (left) Front turn signal/position light (right) Headlight Auxiliary light License plate light Rear brake light switch Tail/brake light Headlight relay (on / off) Headlight relay (dimmer) Fuse (signal) Fuse (headlight)
Page 422: Troubleshooting
ELEC LIGHTING SYSTEM EAS00781 Minimum open-circuit voltage TROUBLESHOOTING 12.8 V or more at 20_C (68_F) Any of the following fail to light: headlight, S Is the battery OK? high beam indicator light, taillight, licence light or meter light. Check: S Clean the battery 1.
Page 423 ELEC LIGHTING SYSTEM 5. Headlight relay (on/off) S Disconnect the headlight relay (on/off) from the coupler. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the headlight relay (on/off) as shown. Positive battery lead ! red/yellow Negative battery lead ! yellow/black S Does the headlight relay (dimmer) have Positive tester probe ! red/yellow...
Page 424: Checking The Lighting System
ELEC LIGHTING SYSTEM EAS00788 Headlight CHECKING THE LIGHTING SYSTEM Positive tester probe ! black 1. The headlight and the high beam indicator Negative tester probe ! black/yellow light fail to come on. Headlight coupler (wire harness side) 1. Headlight bulb and socket High beam S Check the headlight bulb and socket for con- tinuity.
Page 425 ELEC LIGHTING SYSTEM EAS00792 EAS00790 2. The license plate light fails to come on. 3. The tail/brake light fails to come on. 1. Voltage 1. License plate light bulb and socket S Check the license plate light bulb and socket S Connect the pocket tester (DC 20 V) to the for continuity.
Page 426 ELEC LIGHTING SYSTEM EAS00791 5. The turn signal/position light fails to come on. 4. The auxiliary light fails to come on. 1. Turn signal/position light and socket 1. Auxiliary light and socket S Check the turn signal/position light bulb and S Check the auxiliary light bulb and socket for socket for continuity.
Page 427: Signaling System
ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 8-34...
Page 428 ELEC SIGNALING SYSTEM Main switch Fuse (main) Battery Starting circuit cut-off relay Neutral switch Fuel pump E.C.U. Speed sensor Fuel level warning light Oil level warning light Neutral indicator light Tachometer Shift timing indicator light Multi function meter Coolant temperature indicator light Turn signal indicator light (left) Turn signal indicator light (light) Turn signal relay...
Page 429: Troubleshooting
ELEC SIGNALING SYSTEM EAS00794 TROUBLESHOOTING S Any of the following fail to light: turn sig- nal light, brake light or an indicator light. S Clean the battery S The horn fails to sound. terminals. S Recharge or re- Check: place the battery. 1.
Page 430 ELEC SIGNALING SYSTEM EAS00797 2. Voltage 2. The tail/brake light fails to come on. S Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket horn connector at the horn terminal as S Check the tail/brake light bulb and socket for shown.
Page 431 ELEC SIGNALING SYSTEM S Turn the main switch to “ON”. S Measure the voltage (DC 12 V) on brown at the turn signal relay coupler (wire harness wiring circuit This circuit is OK. side). from the main switch S Is the voltage within specification? to the tail/brake light coupler is faulty and must be repaired.
Page 432 ELEC SIGNALING SYSTEM EAS00801 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 (LEDs) turn signal light connector or meter assem- S Check the neutral indicator light for continu- bly coupler (wire harness side) as shown.
Page 433 ELEC SIGNALING SYSTEM EAS00802 NOTE: 5. The oil level warning light fails to come on. When you switch the positive and negative tester probes, the readings in the above 1. Oil level warning light (LEDs) chart will be reversed. S Check the oil level warning light for continu- ity.
Page 434 ELEC SIGNALING SYSTEM EAS00803 3. Voltage 6. The fuel level warning light fails to come on. S Connect the pocket tester (DC 20 V) to the 1. Fuel sender meter assembly coupler (wire harness side) S Drain the fuel from the fuel tank and remove as shown.
Page 435 ELEC SIGNALING SYSTEM 2. Voltage 2. Speed sensor S Connect the pocket tester (DC 20 V) to the S Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) speed sensor coupler (wire harness side) as shown.
Page 436: Cooling System
ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM 8-43...
Page 437 ELEC COOLING SYSTEM Main switch Fuse (main) Battery E.C.U. Coolant temperature sensor Fuse (ignition) Radiator fan motor relay Fuse (radiator fan motor left) Fuse (radiator fan motor right) Radiator fan motor 2 Radiator fan motor 1 8-44...
Page 438: Troubleshooting
ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. S The radiator fan motor fails to turn. S The coolant temperature indicator light Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. fails to light when the engine is warm. Minimum open-circuit voltage Check: 12.8 V or more at 20_C (68_F)
Page 439 ELEC COOLING SYSTEM EAS00809 5. Radiator fan motor relay 4. Radiator fan motor S Disconnect the radiator fan motor coupler S Disconnect the radiator fan motor relay from the wire harness. form the wire harness. S Connect the battery (DC 12 V) as shown. S Connect the pocket tester (Ω...
Page 440 ELEC COOLING SYSTEM EAS00812 6. Coolant temperature sensor S Remove the coolant temperature sensor. S Connect the pocket tester (Ω 1k) to the coolant temperature sensor as shown. S Immerse the coolant temperature sensor in a container filled with coolant NOTE: Make sure the coolant temperature sensor terminals do not get wet.
Page 441: Fuel Pump System
ELEC FUEL PUMP SYSTEM EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM Main switch Fuse (main) Battery Fuse (fuel injection) Starting circuit cut-off relay Fuel pump E.C.U. Engine stop switch 8-48...
Page 442 ELEC FUEL PUMP SYSTEM EAS00815 FUEL PUMP SYSTEM Battery The ECU includes the control unit for the Fuse (main) fuel pump. Main switch Fuse (ignition) Engine stop switch Fuse (fuel injection) Starting circuit cut-off relay (fuel injection system relay) Fuel pump 8-49...
Page 443: Troubleshooting
ELEC FUEL PUMP SYSTEM EAS00816 EAS00739 TROUBLESHOOTING 2. Battery If the fuel pump fails to operate. S Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition and fuel injection fuses Minimum open-circuit voltage 2.
Page 444 ELEC FUEL PUMP SYSTEM EAS00759 EAS00817 5. Starting circuit cut-off relay (fuel injection 6. Fuel pump resistance system relay) S Disconnect the fuel pump coupler from the S Disconnect the starting circuit cut-off relay wire harness. S Connect the pocket tester (Ω coupler from the wire harness.
Page 445: Checking The Fuel Pump
ELEC FUEL PUMP 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 446: Self-Diagnosis
ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS The YZF-R1(S) features a self-diagnosing system for the following circuit(-s): S Fuel pump thermistor S Oil level switch If any of these circuits are defective, their respective condition codes will be displayed on the warning light when the main switch is turned “ON” (irrespective of whether the engine is running or not). Circuit Defect(-s) System response...
Page 447 ELEC SELF-DIAGNOSIS TROUBLESHOOTING 1. Wire harness The warning light starts to indicate the S Check the wire harness for continuity. self-diagnosis sequence. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? Check: 1. fuel pump thermistor 2. oil level switch NOTE: S Before troubleshooting, remove the following Repair or replace the...
Page 448 ELEC SELF-DIAGNOSIS 2. Oil level switch 2. Oil level switch CIRCUIT DIAGRAM S Check the oil level switch for continuity. Refer to “The oil level warning light fails to come on”. S Is the oil level switch OK? Sb/W Replace the multi- Replace the oil level function meter.
Page 449: 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 450: Trbl Shtg
STARTING FAILURES/INCORRECT ENGINE IDLING SPEED/ TRBL POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE SHTG Switches and wiring Starting system S Faulty main switch S Faulty starter motor S Faulty engine stop switch S Faulty starter relay S Broken or shorted wiring S Faulty starting circuit cut-off relay S Faulty neutral switch S Faulty starter clutch S Faulty start switch...
Page 451: Faulty Gear Shifting
TRBL FAULTY GEAR SHIFTING/FAULTY CLUTCH SHTG EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT JUMPS OUT OF GEAR Refer to “CLUTCH DRAGS”. Shift shaft S Incorrect shift pedal position SHIFT PEDAL DOES NOT MOVE S Improperly returned stopper lever Shift shaft S Improperly adjusted shift rod Shift forks S Bent shift shaft.
Page 452: Overheating
OVERHEATING/OVERCOOLING/ TRBL POOR BRAKING PERFORMANCE SHTG EAS00855 OVERHEATING ENGINE FUEL SYSTEM Clogged coolant passages Throttle body (-ies) S Cylinder head(s) and piston(s) S Damaged or loose throttle body joint S Heavy carbon buildup Air filter S Clogged air filter element Engine oil S Incorrect oil level CHASSIS...
Page 453: Faulty Front Fork Legs
TRBL FAULTY FRONT FORK LEGS/UNSTABLE HANDLING SHTG EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL MALFUNCTION S Bent, damaged or rusty inner tube S Bent or damaged inner tube S Cracked or damaged outer tube S Bent or damaged outer tube S Improperly installed oil seal S Damaged fork spring S Damaged oil seal lip...
Page 454: Faulty Lighting Or Signaling System
TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON TURN SIGNAL DOES NOT COME ON S Wrong headlight bulb S Faulty turn signal switch S Too many electrical accessories S Faulty turn signal relay S Hard charging S Burnt-out turn signal bulb S Incorrect connection...
Page 455 YZF-R1S/YZF-R1SC WIRING DIAGRAM Main switch Clutch switch A.C. magneto Turn signal switch Rectifier/ regulator Horn Fuse (main) Front turn signal / position light (left) Fuse (backup) Front turn signal / position light (right) Battery Rear turn signal light (left) Fuse (fuel injection)

This manual is also suitable for:

Yzf-r1sc

Yamaha YZF-R1S Service Manual

Specifications

Periodic Checks and Adjustments

Chassis

Engine

Cooling System

Fuel Injection System

Electrical System

Troubleshooting

Chapter 1 General Information

Motorcycle Identification

Gen Info

Features

Important Information

Checking the Connections

Special Tools

Chapter 2 Specifications

Spec

General Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Conversion Table

General Tightening Torque Specifications

Tightening Torques

Lubrication Points and Lubricant Types

Cooling System Diagrams

Engine Oil Lubrication Chart

Lubrication Diagrams

Cable Routing

Chapter 3 Periodic Checks and Adjustments

Introduction

Periodic Maintenance Chart for the Emission Control System

General Maintenance and Lubrication Chart

Chk Adj

Seats

Fuel Tank

Cowlings

Air Filter Case

Engine

Chassis

Electrical System

Chapter 4 Chassis

Chas

Front Wheel and Brake Discs

Rear Wheel and Brake Disc Rear Wheel

Front and Rear Brakes

Front Fork

Handlebars

Steering Head

Rear Shock Absorber Assembly

Swingarm and Drive Chain

Chapter 5 Engine

Eng

Camshaft

Cylinder Head

Valves and Valve Springs

Starter Clutch and Generator

Crankshaft Position Sensor

Clutch

Shift Shaft

Oil Pan and Oil Pump

Crankcase

Connecting Rods and Pistons

Crankshaft

Transmission

Chapter 6 Cooling System

Cool

Radiator

Oil Cooler

Thermostat

Water Pump

Chapter 7 Fuel Injection System

Throttle Bodies

Quick Links

Troubleshooting

Related Manuals for Yamaha YZF-R1S

Summary of Contents for Yamaha YZF-R1S