Yamaha YZF-R1P Service Manual
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Yamaha YZF-R1P Service Manual

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Summary of Contents for Yamaha YZF-R1P

  • Page 3 YZF-R1P YZF-R1PC SERVICE MANUAL LIT-11616-15-47 5PW-28197-10...
  • Page 5 EAS00000 YZF-R1P/YZF-R1PC SERVICE MANUAL ©2001 by Yamaha Motor Corporation, U.S.A. First edition, December 2001 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-11616-15-47...
  • Page 6 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 7 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 8: General Information

    EAS00008 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information CHAS 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system COOL 8 Electrical system...

  • Page 10: 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 11 CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ..............1-1 VEHICLE IDENTIFICATION NUMBER ............1-1 MODEL LABEL ..................1-1 FEATURES .....................1-2 OUTLINE OF FI SYSTEM ................1-2 FI SYSTEM ....................1-3 COMPONENTS ..................1-5 FUEL INJECTION SYSTEM ..............1-16 THREE-WAY CATALYTIC CONVERTER SYSTEM ......1-19 INSTRUMENT FUNCTION ..............1-20 IMPORTANT INFORMATION ...............1-23 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-23 REPLACEMENT PARTS ................1-23 GASKETS, OIL SEALS AND O-RINGS ..........1-23...
  • Page 12 TIGHTENING TORQUES ................2-17 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-17 ENGINE TIGHTENING TORQUES ............2-18 CHASSIS TIGHTENING TORQUES ............2-21 LUBRICATION POINTS AND LUBRICANT TYPES ........2-23 ENGINE ....................2-23 CHASSIS ....................2-24 COOLING SYSTEM DIAGRAMS ..............2-25 ENGINE OIL LUBRICATION CHART ............2-29 LUBRICATION DIAGRAMS .................2-30 CABLE ROUTING ..................2-35 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION .....................3-1...
  • Page 13 ENGINE ......................3-9 ADJUSTING THE VALVE CLEARANCE ..........3-9 SYNCHRONIZING THE THROTTLE BODIES ........3-14 ADJUSTING THE ENGINE IDLING SPEED ..........3-16 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-17 CHECKING THE SPARK PLUGS ............3-19 MEASURING THE COMPRESSION PRESSURE .........3-20 CHECKING THE ENGINE OIL LEVEL ...........3-23 CHANGING THE ENGINE OIL ...............3-24 ADJUSTING THE CLUTCH CABLE FREE PLAY ........3-26 REPLACING THE AIR FILTER ELEMENT ..........3-28...
  • Page 14 CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS ............4-1 FRONT WHEEL ..................4-2 REMOVING THE FRONT WHEEL ............4-3 CHECKING THE FRONT WHEEL ............4-3 CHECKING THE BRAKE DISCS .............4-5 INSTALLING THE FRONT WHEEL ............4-6 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-7 REAR WHEEL AND BRAKE DISC ..............4-9 REAR WHEEL ..................4-10 REMOVING THE REAR WHEEL ............4-12 CHECKING THE REAR WHEEL ............4-13...
  • Page 15 HANDLEBARS .....................4-56 REMOVING THE HANDLEBARS ............4-58 CHECKING THE HANDLEBARS ............4-58 INSTALLING THE HANDLEBARS ............4-58 STEERING HEAD ..................4-61 REMOVING THE LOWER BRACKET ............4-63 CHECKING THE STEERING HEAD ............4-63 INSTALLING THE STEERING HEAD ............4-64 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 ................4-66...
  • Page 16 CYLINDER HEAD ..................5-19 REMOVING THE CYLINDER HEAD ............5-20 CHECKING THE CYLINDER HEAD ............5-20 INSTALLING THE CYLINDER HEAD ............5-21 VALVES AND VALVE SPRINGS ..............5-22 REMOVING THE VALVES ..............5-24 CHECKING THE VALVES AND VALVE GUIDES ........5-25 CHECKING THE VALVE SEATS ............5-27 CHECKING THE VALVE SPRINGS ............5-28 CHECKING THE VALVE LIFTERS ............5-29 INSTALLING THE VALVES ..............5-29 GENERATOR ....................5-32...
  • Page 17 OIL PAN AND OIL PUMP ................5-51 OIL PUMP ....................5-53 REMOVING THE OIL PAN ..............5-54 CHECKING THE OIL PUMP ..............5-54 CHECKING THE RELIEF VALVE ............5-55 CHECKING THE OIL DELIVERY PIPES ..........5-55 CHECKING THE OIL STRAINER ............5-55 ASSEMBLING THE OIL PUMP ..............5-56 INSTALLING THE OIL PUMP ..............5-56 INSTALLING THE OIL STRAINER ............5-57 INSTALLING THE OIL PAN ..............5-57...
  • Page 18 CHAPTER 6 COOLING SYSTEM RADIATOR .....................6-1 CHECKING THE RADIATOR ..............6-3 INSTALLING THE RADIATOR ..............6-4 OIL COOLER ....................6-5 CHECKING THE OIL COOLER ..............6-6 INSTALLING THE OIL COOLER ..............6-6 THERMOSTAT ....................6-7 CHECKING THE THERMOSTAT ............6-10 ASSEMBLING THE THERMOSTAT ASSEMBLY ........6-11 INSTALLING THE THERMOSTAT ASSEMBLY ........6-11 WATER PUMP ....................6-12 DISASSEMBLING THE WATER PUMP ..........6-14 CHECKING THE WATER PUMP ............6-14...
  • Page 19 AIR INDUCTION SYSTEM ................7-37 AIR INDUCTION ..................7-37 AIR CUT-OFF VALVE ................7-37 AIR INDUCTION SYSTEM DIAGRAMS ..........7-38 CHECKING THE AIR INDUCTION SYSTEM .........7-39 CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS ...............8-1 CHECKING SWITCH CONTINUITY ...............8-3 CHECKING THE SWITCHES .................8-4 CHECKING THE BULBS AND BULB SOCKETS .........8-5 TYPES OF BULBS ...................8-5 CHECKING THE CONDITION OF THE BULBS ........8-6 CHECKING THE CONDITION OF THE BULB SOCKETS .......8-7...

  • Page 20: Troubleshooting

    COOLING SYSTEM ..................8-41 CIRCUIT DIAGRAM ................8-41 TROUBLESHOOTING ................8-42 FUEL PUMP SYSTEM ..................8-45 CIRCUIT DIAGRAM ................8-45 FUEL PUMP SYSTEM ................8-46 TROUBLESHOOTING ................8-47 CHECKING THE FUEL PUMP ...............8-49 CHAPTER 9 TROUBLESHOOTING STARTING FAILURES ...................9-1 ENGINE ....................9-1 FUEL SYSTEM ..................9-1 ELECTRICAL SYSTEMS .................9-2 INCORRECT ENGINE IDLING SPEED ............9-2 ENGINE ....................9-2 FUEL SYSTEM ..................9-2...
  • Page 21 FAULTY FRONT FORK LEGS ...............9-5 LEAKING OIL ...................9-5 MALFUNCTION ..................9-5 UNSTABLE HANDLING .................9-5 FAULTY LIGHTING OR SIGNALING SYSTEM ..........9-6 HEADLIGHT DOES NOT COME ON ............9-6 HEADLIGHT BULB BURNT OUT .............9-6 TAIL/BRAKE LIGHT DOES NOT COME ON ...........9-6 TAIL/BRAKE LIGHT BULB BURNT OUT ..........9-6 TURN SIGNAL DOES NOT COME ON ............9-6 TURN SIGNAL BLINKS SLOWLY ............9-6 TURN SIGNAL REMAINS LIT ..............9-6...

  • Page 22: General Information

    MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.

  • Page 23: Features

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

  • Page 24: Fi System

    FEATURES INFO FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 284 kPa (2.84 kg/cm , 40.4 psi) higher than the intake manifold pressure.
  • Page 25 FEATURES INFO Fuel control block The fuel control block consists of the following main components: Component Function Control block Total FI system control Throttle body Air volume control Pressure regulator Fuel pressure detection Sensor block Intake air pressure sensor Intake air pressure detection Atmospheric pressure sensor Atmospheric pressure detection Coolant temperature sensor...

  • Page 26: Components

    FEATURES INFO COMPONENTS ECU (Electronic Control Unit) The ECU is mounted underneath the seat. The main functions of the ECU are ignition control, fuel control, self-diagnosis, and load control. • ECU’s internal construction and functions The main components and functions of the ECU can be broadly divided into the following four items: A.
  • Page 27 FEATURES INFO • Ignition control The ignition control function of the ECU controls the ignition timing and the duration of ignition energizing. The ignition timing control uses the signals from the throttle position sensor (to detect the angle of the throttle), and the crankshaft position sensor and speed sensor (to detect the speed of the engine).
  • Page 28 FEATURES INFO Fuel pump The fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps it to the injector. A filter that is provided in the fuel pump prevents any debris in the fuel tank from entering the fuel system downstream of the pump.
  • Page 29 FEATURES INFO Pressure regulator It regulates the fuel pressure that is applied to the injectors that are provided in the cylinders in order to maintain a constant pressure difference with the pressure in the intake manifold. The fuel that is delivered by the fuel pump fills the fuel chamber through the fuel inlet of the regulator and exerts pressure on the diaphragm in the direction for opening the valve.
  • Page 30 FEATURES INFO Fuel injector Upon receiving injection signals from the ECU, the fuel injector injects fuel. In the normal state, the core is pressed downward by the force of the spring, as illustrated. The plunger that is integrated with the bottom of the core keeps the fuel passage closed. When the current flows to the coil in accordance with the signal from the ECU, the core is drawn upward, allowing the flange that is integrated with the plunger to move to the spacer.
  • Page 31 FEATURES INFO Crankshaft position sensor The crankshaft position sensor uses the signals of the pickup coil that is mounted on the right side of the crankshaft. When the rotation of the pickup rotor that is attached to the crankshaft causes the projections on the rotor to pass by the pickup coil, an electromotive force is generated in the coil.
  • Page 32 FEATURES INFO Cylinder identification sensor The cylinder identification sensor is mounted on the middle of exhaust side head cover. When the exhaust camshaft rotates, the sensor generates a signal and sends it to the ECU. Based on this sig- nal and the signal from the crankshaft position sensor, the ECU then actuates the injector of the cyl- inder that is currently in order to supply fuel.
  • Page 33 FEATURES INFO Throttle position sensor The throttle position sensor measures the intake air volume by detecting the position of the throttle valve. It detects the mechanical angle of the throttle valve through the positional relationship between the moving contact that moves in unison with the throttle shaft and the resistor board. In actual operation, the ECU supplies 5 V power to both ends of the resistor board and the voltage that is output by the throttle position sensor is used to determine the angle of the throttle valve.
  • Page 34 FEATURES INFO Intake air pressure sensor and atmospheric pressure sensor • Intake air pressure sensor The intake air pressure sensor is used for measuring the intake air volume. The intake air volume of every intake stroke is proportionate to the intake air pressure. Therefore, the intake air volume can be measured by measuring the intake air pressure.
  • Page 35 FEATURES INFO Coolant temperature sensor The signals from the coolant temperature sensor are used primarily for making fuel volume compen- sations during starting and warm-up. The coolant temperature sensor converts the temperature of the coolant into electrical signals and sends them to the ECU. This sensor uses a semi-conductor thermistor that has a large resistance at low temperatures and a small resistance at high temperatures.
  • Page 36 FEATURES INFO Lean angle cut-off switch The lean angle cut-off switch stops the supply of fuel to the engine in case the motorcycle overturns. When the motorcycle is in the normal state, the cut-off switch outputs a constant voltage of approxi- mately 1.0 V (low level).

  • Page 37: Fuel Injection System

    FEATURES INFO FUEL INJECTION SYSTEM Operation and control The fuel injection timing, injection duration, ignition timing, and the coil energizing duration are con- trolled by the ECU. To determine the basic injection timing, the ECU calculates the intake air volume through the signals from the intake air pressure sensor, throttle position sensor, cylinder identifica- tion sensor, and crankshaft position sensor.
  • Page 38 FEATURES INFO Determining the final injection duration The intake air volume determines the basic injection duration. However, at a given intake air vol- ume, the volume of fuel that is required varies by the engine operating conditions such as accelera- tion or deceleration, or by weather conditions.
  • Page 39 FEATURES INFO Reactive injection duration: A lag is created between the time the ECU outputs a fuel injection signal to the injector and the time the injector actually opens. Therefore, the ECU calculates this lag in advance before sending the actuation signal to the injector.

  • Page 40: Three-Way Catalytic Converter System

    FEATURES INFO THREE-WAY CATALYTIC CONVERTER SYSTEM System outline This is a highly efficient exhaust gas cleaning system that effects air-fuel control through a joint effort by the FI system and the three-way catalytic converter system. By effecting comprehensive control of the air-fuel ratio in this manner, this system reduces the CO, HC, and NOx in the exhaust gases.

  • Page 41: Instrument Function

    FEATURES INFO INSTRUMENT FUNCTION Multi-function display The multi-function display is equipped with the following: • a speedometer (which shows the riding speed) • an odometer (which shows the total dis- tance traveled) • two tripmeters (which show the distance traveled since they were last set to zero) 1 Multi-function display •...
  • Page 42 FEATURES INFO Display brightness and engine speed indi- cator light control mode This mode cycles through five control func- tions, allowing you to make the following set- tings in the order listed below. 1. Display brightness: This function allows you to adjust the brightness of the multi-function display to suit the outside lighting condi- tions.
  • Page 43 FEATURES INFO To set the engine speed indicator light activation function NOTE: The indicator light activation function can be set between 7,000 and 12,000 r/min in increments of 500 r/min. 1. Push the “RESET” button to select the desired engine speed for activating the indicator light. 2.

  • Page 44: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 45: 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 manu-...

  • Page 46: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...

  • Page 47: 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 inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 48 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Oil filter wrench YU-38411 This tool is needed to loosen or tighten the oil filter cartridge. Rod holder YM-01434 This tool is used to support the damper adjusting rod. Rod puller Rod puller YM-01437 These tools are used to pull up the front fork damper rod.
  • Page 49 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Middle driven shaft bearing driver Middle driven shaft Mechanical seal installer bearing driver YM-4058-1 Mechanical seal installer These tools are used to install the water YM-33221 pump seal. Universal clutch holder YM-91042 This tool is used to hold the clutch boss when removing or installing the clutch boss nut.
  • Page 50 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Pocket tester YM-03112 This instrument is needed for checking the engine oil temperature. Mity vac YB-35956 This tool used to measure the vacuum pressure. Piston ring compressor YM-8037 This tool is used to compress the piston rings when installing the piston into the cylinder.

  • Page 51: Spec

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5PW4 USA ---- 5PW5 California ---- 5PW6 Canada ---- Dimensions Overall length 2,040 mm (80.3 in) ---- Overall width 705 mm (27.8 in) ---- Overall height 1,105 mm (43.5 in) ---- Seat height 820 mm (32.3 in)

  • Page 52: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC ---- Displacement 998 cm (60.9 cu.in) ---- Cylinder arrangement Forward-inclined parallel 4-cylinder ---- Bore × stroke 74 × 58 mm (2.91 × 2.28 in) ---- Compression ratio 11.8 : 1 ---- Engine idling speed...
  • Page 53 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Cartridge (paper) ---- Bypass valve opening pressure 80 ~ 120 kPa ---- (0.8 ~ 1.2 kg/cm , 11.6 ~ 17.4 psi) Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip 0.01 ~ 0.10 mm (0.0004 ~ 0.0039 in) 0.18 mm clearance...
  • Page 54 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) ---- Camshaft cap inside diameter 24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in) ---- Camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) ---- Camshaft-journal-to-camshaft- 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) ---- cap clearance Intake camshaft lobe dimensions...
  • Page 55 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links RH2015/130 ---- Tensioning system Automatic ---- Valves, valve seats, valve guides Valve clearance (cold) Intake 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) ---- Exhaust 0.21 ~ 0.27 mm (0.0083 ~ 0.0106 in) ---- Valve dimensions Head Diameter...
  • Page 56 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve stem runout ---- 0.01 mm (0.0004 in) Valve seat width Intake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) ---- Exhaust 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) ---- Valve springs Free length Intake 38.9 mm (1.53 in) 37.0 mm...
  • Page 57 SPEC ENGINE SPECIFICATIONS Item Standard Limit Cylinders Cylinder arrangement Forward-inclined, parallel 4-cylinder ---- Bore × stroke 74 × 58 mm (2.91 × 2.28 in) ---- Compression ratio 11.8 : 1 ---- Bore 74.00 ~ 74.01 mm (2.9134 ~ 2.9138 in) ---- Max.
  • Page 58 SPEC ENGINE SPECIFICATIONS Item Standard Limit 2nd ring Ring type Taper ---- Dimensions (B × T) 0.8 × 2.8 mm (0.03 × 0.11 in) ---- End gap (installed) 0.43 ~ 0.58 mm (0.017 ~ 0.023 in) 0.93 mm (0.037 in) Ring side clearance 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) 0.115 mm...
  • Page 59 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 ---- Clutch cable free play (at the end 10 ~ 15 mm (0.4 ~ 0.6 in) ---- of the clutch lever)
  • Page 60 SPEC ENGINE SPECIFICATIONS Item Standard Limit Air filter type Wet element ---- Fuel pump Pump type Electrical ---- Model (manufacturer) 5PW (DENSO) ---- Output pressure 94 kPa (2.94 kg/cm 42.6 psi) ---- Throttle position sensor Resistance 4.85 ~ 5.15 kΩ at 20 °C (68 °F) ---- Output voltage (at idle) Adjusted by tachometer...

  • Page 61: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond ---- Caster angle 24° ---- Trail 103 mm (4.06 in) ---- Front wheel Wheel type Cast wheel ---- 17 M/C × MT3.50 Size ---- Material Aluminum ---- Wheel travel 120 mm (4.72 in) ---- Wheel runout...
  • Page 62 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front brakes Brake type Dual disc brake ---- Operation Right hand operation ---- Recommended fluid DOT 4 ---- Brake lever free play 2.3 ~ 11.5 mm (0.09 ~ 0.45 in) ---- Brake discs Diameter × thickness 298 ×...
  • Page 63 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 251 mm (9.88 in) 246 mm (9.69 in) Spacer length 74 mm (2.91 in) ---- Installed length...
  • Page 64 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension Suspension type Swingarm (link suspension) ---- Rear shock absorber assembly type Coil spring/gas-oil damper ---- Rear shock absorber assembly travel 65 mm (2.56 in) ---- Spring Free length 176.5 mm (6.95 in) ---- Installed length 162.5 mm (6.4 in)

  • Page 65: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 5° BTDC at 1,050 r/min ---- 248 ~ 372 Ω at 20 °C (68 °F)/Gy-B Crankshaft position sensor ---- resistance/color...
  • Page 66 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Electric starting system System type Constant mesh ---- Starter motor Model (manufacturer) 5JJ (YAMAHA) ---- Power output 0.9 kW ---- Brushes Overall length 10.8 mm (0.43 in) 3.65 mm (0.14 in) Spring force 5.28 ~ 7.92 N ---- (528 ~ 792 g, 19.01 ~ 28.51 oz)

  • Page 67: Conversion Table

    SPEC CONVERSION TABLE/TIGHTENING TORQUES EAS00028 TIGHTENING TORQUES CONVERSION TABLE EAS00029 All specification data in this manual are listed GENERAL TIGHTENING TORQUE in SI and METRIC UNITS. SPECIFICATIONS Use this table to convert METRIC unit data to This chart specifies tightening torques for stan- IMPERIAL unit data.
  • Page 68 SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening Thread torque Item Fastener Q’ty Remarks size m·kg ft·lb Spark plugs — 20 + 121° 2.0 + 121° 14 + 121° Cylinder head (50) (5.0) (36) 20 + 105° 2.0 + 105° 14 + 105° Cylinder head (50) (5.0)
  • Page 69 SPEC TIGHTENING TORQUES Tightening Thread torque Item Fastener Q’ty Remarks size m·kg ft·lb Exhaust pipe and exhaust valve Bolt Exhaust valve and housing Bolt EXUP pulley and arm shaft Bolt Exhaust joint Bolt Exhaust valve pipe Bolt Air induction system pipe Clamp —...
  • Page 70 SPEC TIGHTENING TORQUES Tightening Thread torque Item Fastener Q’ty Remarks size m·kg ft·lb EXUP servo motor cover Screw Intake air temperature sensor — Cylinder identification sensor Bolt Atmospheric pressure sensor Screw Speed sensor Bolt Stator coil clamp Bolt NOTE: 1. First, tighten the bolt to approximately 20 Nm (2.0 m • kg, 14 ft • lb) with a torque wrench. 2.
  • Page 71 SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Thread Item Remarks size m·kg ft·lb Upper bracket and front fork Steering stem nut 11.5 Handlebar and front fork Handlebar and upper bracket Lower ring nut See NOTE Lower bracket pinch bolt Main switch and handle crown Brake fluid reservoir cap stopper 0.12 Front brake hose union bolts...
  • Page 72 SPEC TIGHTENING TORQUES Tightening Thread Item Remarks size m·kg ft·lb Coolant reservoir and radiator Tail cowling and frame Battery box and frame Taillight and battery box ECU and battery box Passenger seat lock and battery box Atmospheric pressure sensor and battery box 0.07 Lean angle cut-off switch sensor and battery box Rider footrest bracket and frame...

  • Page 73: 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...

  • Page 74: Chassis

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Sidestand pivoting point and metal-to-metal moving parts Throttle grip inner surface...

  • Page 75: Cooling System Diagrams

    SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Radiator fan 2 Radiator 3 Water pump 2 - 25...
  • Page 76 SPEC COOLING SYSTEM DIAGRAMS 1 Thermostat 2 Radiator cap 3 Coolant reservoir 4 Radiator 5 Oil cooler 6 Water jacket joint 2 - 26...
  • Page 77 SPEC COOLING SYSTEM DIAGRAMS 1 Water pump 2 Radiator cap 3 Thermostat 4 Thermostat housing 2 - 27...
  • Page 78 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator 2 - 28...

  • Page 79: Engine Oil Lubrication Chart

    SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART Exhaust camshaft Intake camshaft Piston cooler Main gallery Oil filter Main axle Mission cooler Oil pump cooler Relief valve Drive axle Strainer 2 - 29...

  • Page 80: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Oil filter cartridge 4 Oil level switch 2 - 30...
  • Page 81 SPEC LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Oil pipe 6 Oil strainer 7 Oil pump 2 - 31...
  • Page 82 SPEC LUBRICATION DIAGRAMS 1 Oil cooler 2 Oil filter cartridge 3 Oil level switch 4 Oil strainer 5 Oil pump 6 Oil pipe 2 - 32...
  • Page 83 SPEC LUBRICATION DIAGRAMS 1 Main axle 2 Oil delivery pipe 3 Drive axle 2 - 33...
  • Page 84 SPEC LUBRICATION DIAGRAMS 1 Cylinder head 2 Crankshaft 2 - 34...

  • Page 85: Cable Routing

    SPEC CABLE ROUTING EAS00035 CABLE ROUTING 1 Headlight drain plug Ì Secure the junction of head- Ð Insert the headlight relay to the light lead (including the head- rib of the headlight body. (No È Make sure to securely insert light leads and position lamp special roder is specified for the coupler and boot.
  • Page 86 SPEC CABLE ROUTING 1 Handlebar switch (left) C AI system lead 2 Main switch D Oil level switch lead 3 Throttle position sensor lead E Sidestand switch lead 4 Guide-air F Wire harness assembly 5 Handlebar switch (right) G Injector sub lead 6 Wiring section ! H Starter lead 7 AC magneto lead...
  • Page 87 SPEC CABLE ROUTING È Route the horn lead under the Ï To fuel pump Õ Fasten the wire harness, (–) Ð Insert the holding clamp of the rib of bracket horn positioning lead, AC magneto lead and the stepped part of protector wire harness to the frame.
  • Page 88 SPEC CABLE ROUTING Ú Route under the wire harness Á Route the starter motor lead Branch from the main har- to the assembling point !. through the clamp inserted to ness Û Insert the holding clamp of the Assembling point $ the box battery.
  • Page 89 SPEC CABLE ROUTING Pass the filter of throttle body Press the lead of the coupler Fasten the (+) lead junction through the hole of rubber for ALARM in under the cou- lead by hooking on the pawl baffle and release it under pler of ECU.
  • Page 90 SPEC CABLE ROUTING 1 Turn signal light lead È Route the clutch cable through Ð Pass the clutch cable behind 2 Radiator hose backward radiator the front fork. 3 Reservoir tank breather hose Ñ Pass the handlebar switch lead bracket and inside of coolant (L = 440) breather hose.
  • Page 91 SPEC CABLE ROUTING Ô To turn signal light Õ In this area, pass the handlebar switch (right) lead behind of the throttle cable. Ö Route the coolant temperature sensor lead between the engine and the radiator hose. × Route the clutch cable through the inside of radiator hose and fasten it with the clamp to the radiator. Ø...
  • Page 92 SPEC CABLE ROUTING 1 Ignition coil plate G Oil level gauge lead X To throttle body 2 Rubber baffle H AI system hose Y Rear brake switch lead 3 Assembling point ± I Sidestand switch lead Z AC magneto lead 4 Assembling point ! J Fuel return hose 5 To wiring section ±...
  • Page 93 SPEC CABLE ROUTING Ê Clamp the air cleaner drain Ì Clamp the oil level gauge, side Ñ Pass the fuel tank breather hose, fuel tank breather hose, stand switch lead and radiator hose and fuel tank drain hose drain hose, AI system hose, AI hose.
  • Page 94 SPEC CABLE ROUTING Õ Point the tip of the band to the Ú Pay attention to the inserting À Position the clamp between the inner side. direction of the relay. clamp of oil level switch lead Ö Routing position of each hose Û...
  • Page 95 SPEC CABLE ROUTING for California 1 Canister 2 Roll over valve assembly 3 Hose (fuel tank breather – canister) 4 Hose (canister – roll over valve) 5 Hose (roll over valve – throttle body) È To throttle body É To atomosphere 2 - 45...

  • Page 96: Chk Adj

    √ hose for damage. (See page 7-39.) • Replace any damaged parts if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS...
  • Page 97 (See page 2-21.) • Correct if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.

  • Page 98: Seats

    SEATS EAS00039 SEATS 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the seats Remove the parts in the order listed. Passenger seat Rider seat For installation, reverse the removal procedure. 3 - 3...

  • Page 99: Fuel Tank

    FUEL TANK EAS00040 FUEL TANK 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed.

  • Page 100: 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: • fuel return hose • fuel hose CAUTION: Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remain- ing in it.

  • Page 101: Installing The Fuel Pump

    FUEL TANK INSTALLING THE FUEL PUMP 1. Install: • fuel pump 4 Nm (0.4 m · kg, 2.9 ft · lb) NOTE: • Do not damage the installation surfaces of the fuel tank when installing the fuel pump. • Always use a new fuel pump gasket. •...

  • Page 102: Cowlings

    COWLINGS EAS00042 COWLINGS Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed. Rider and passenger seats Refer to “SEATS”. Tail cowling Bottom cowling Front cowling inner panel (left) Front cowling inner panel (right) Left side cowling Right side cowling Windshield Rear view mirror...

  • Page 103: Air Filter Case

    AIR FILTER CASE EAS00043 AIR FILTER CASE 10 Nm (1.0 m kg, 7.2 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS”...

  • Page 104: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 105 ADJUSTING THE VALVE CLEARANCE 4. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) Exhaust valve 0.21 ~ 0.27 mm (0.0083 ~ 0.0106 in) M MMM M MMM M MMM M MMM M MMM...
  • Page 106 ADJUSTING THE VALVE CLEARANCE 5. Remove: • camshaft NOTE: • Refer “DISASSEMBLING ENGINE—CAMSHAFT CYLINDER HEAD” in chapter 5. • When removing the timing chain and cam- shafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase. 6.
  • Page 107 ADJUSTING THE VALVE CLEARANCE c. Round off the original valve pad number according to the following table. Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm) Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clear- ance in the valve pad selection table.
  • Page 108 ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLE INTAKE INSTALLED PAD NUMBER Measured clearance 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 0.00 ~ 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 ~ 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...

  • Page 109: Synchronizing The Throttle Bodies

    ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE THROTTLE BODIES NOTE: • Refer to “ASSEMBLING AND ADJUSTING THE ENGINE—CYLINDER HEAD AND CAMSHAFT” in chapter 5. • Lubricate the camshaft bearings, camshaft lobes and camshaft journals. • First, install the exhaust camshaft. • Align the camshaft marks with the camshaft cap marks.
  • Page 110 SYNCHRONIZING THE THROTTLE BODIES 4. Install: • carburetor syncronizer 1 (onto the synchronizing hose) • digital tachometer (near the spark plug) Carburetor synchronizer YU-08030 5. Install: • fuel tank Refer to “FUEL TANK”. 6. Start the engine and let it warm up for sev- eral minutes.

  • Page 111: Adjusting The Engine Idling Speed

    SYNCHRONIZING THE THROTTLE BODIES/ ADJUSTING THE ENGINE IDLING SPEED NOTE: The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (10 mmHg, 0.39 inHg). L LLL L LLL L LLL L LLL L LLL 9. Measure: •...

  • Page 112: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 2. Install: • digital tachometer (onto the spark plug lead of cylinder #1) 3. Check: • engine idling speed Out of specification → Adjust. Engine idling speed 1,000 ~ 1,100 r/min 4.
  • Page 113 ADJUSTING THE THROTTLE CABLE FREE PLAY 2. Remove: • rider seat Refer to “SEATS”. • fuel tank Refer to “FUEL TANK”. • air filter case Refer to “AIR FILTER CASE”. 3. Adjust: • throttle cable free play M MMM M MMM M MMM M MMM M MMM...

  • Page 114: Checking The Spark Plugs

    ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS Throttle cable free play Direction a is increased. Throttle cable free play Direction b is decreased. d. Tighten the locknut. WARNING After adjusting the throttle cable free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change.

  • Page 115: Measuring The Compression Pressure

    CHECKING THE SPARK PLUGS/ MEASURING THE COMPRESSION PRESSURE 4. Check: • electrode 1 Damage/wear → Replace the spark plug. • insulator 2 Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • spark plug (with a spark plug cleaner or wire brush) 6.
  • Page 116 MEASURING THE COMPRESSION PRESSURE 1. Measure: • valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE”. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Remove: • rider seat Refer to “SEATS”.
  • Page 117 MEASURING THE COMPRESSION PRESSURE Compression pressure (at sea level) Minimum 1,350 kPa (13.5 kg/cm , 192 psi) Standard 1,450 kPa (14.5 kg/cm , 206 psi) Maximum 1,500 kPa (15.0 kg/cm , 213 psi) M MMM M MMM M MMM M MMM M MMM a.

  • Page 118: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL 7. Install: • spark plug 13 Nm (1.3 m · kg, 9.4 ft · lb) • ignition coil 8. Install: • rubber baffle • ignition coil plates • air filter case Refer to “AIR FILTER CASE”.

  • Page 119: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
  • Page 120 CHANGING THE ENGINE OIL c. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 m · kg, 12 ft · lb) L LLL L LLL L LLL L LLL L LLL 6.

  • Page 121: Adjusting The Clutch Cable Free Play

    CHANGING THE ENGINE OIL/ ADJUSTING THE CLUTCH CABLE FREE PLAY 13.Check: • engine oil pressure M MMM M MMM M MMM M MMM M MMM a. Slightly loosen the oil gallery bolt 1. b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt.
  • Page 122 ADJUSTING THE CLUTCH CABLE FREE PLAY 2. Adjust: • clutch cable free play M MMM M MMM M MMM M MMM M MMM Handlebar side a. Turn the adjusting dial 1 in direction a or b until the specified clutch cable free play is obtained.

  • Page 123: Replacing The Air Filter Element

    REPLACING THE AIR FILTER ELEMENT EAS00086 REPLACING THE AIR FILTER ELEMENT 1. Remove: • rider seat Refer to “SEATS”. • fuel tank Refer to “FUEL TANK”. 2. Remove: • air filter case cover 1 3. Check: • air filter element 1 Damage →...

  • Page 124: Checking The Fuel And Breather Hoses

    CHECKING THE FUEL AND BREATHER HOSES/ CHECKING THE CRANKCASE BREATHER HOSE EAS00096 CHECKING THE FUEL AND BREATHER HOSES The following procedure applies to all of the fuel and breather hoses. 1. Remove: • rider seat Refer to “SEATS”. • fuel tank Refer to “FUEL TANK”.

  • Page 125: Checking The Exhaust System

    CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM 3. Install: • fuel tank Refer to “FUEL TANK”. • rider seat Refer to “SEATS”. EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1.

  • Page 126: Adjusting The Exup Cables

    ADJUSTING THE EXUP CABLES EAS00101 ADJUSTING THE EXUP CABLES 1. Remove: • bottom cowling Refer to “COWLINGS”. 2. Remove: • EXUP valve pulley cover 1 3. Check: • EXUP system operation M MMM M MMM M MMM M MMM M MMM a.

  • Page 127: Checking The Coolant Level

    ADJUSTING THE EXUP CABLES/ CHECKING THE COOLANT LEVEL 7. Install: • bottom cowling Refer to “COWLINGS”. EAS00102 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2.

  • Page 128: Checking The Cooling System

    CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Remove: • bottom cowling • side cowlings Refer to “COWLINGS”. 2. Check: • radiator 1 • radiator inlet hose 2 • radiator outlet hose 3 • oil cooler 4 • oil cooler inlet hose 5 •...

  • Page 129: Changing The Coolant

    CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove: • side cowling • bottom cowling Refer to “COWLINGS”. 2. Disconnect: • coolant reservoir hose 1 3. Drain: • coolant (from the coolant reservoir) 4. Remove: • radiator cap 1 WARNING A hot radiator is under pressure.
  • Page 130 CHANGING THE COOLANT 10.Fill: • cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 2.45 L (2.16 Imp qt, 2.59 US qt) Coolant reservoir capacity 0.24 L (0.21 Imp qt, 0.25 US qt)
  • Page 131 CHANGING THE COOLANT 11.Install: • radiator cap 12.Fill: • coolant reservoir (with the recommended coolant to the maxi- mum level mark a) 13.Install: • coolant reservoir cap 14.Start the engine, warm it up for several min- utes, and then stop it. 15.Check: •...

  • Page 132: Chassis

    ADJUSTING THE FRONT BRAKE EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: • 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 desired position.

  • Page 133: Adjusting The Rear Brake

    ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Check: • brake pedal position (distance a from the top of the brake pedal to the bottom of the rider footrest bracket) Out of specification → Adjust. Brake pedal position (from the top of the brake pedal to the bot- tom of the rider footrest bracket) 38 ~ 42 mm (1.50 ~ 1.65 in)

  • Page 134: Checking The Brake Fluid Level

    ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL 3. Adjust: • rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. •...

  • Page 135: Checking The Front And Rear Brake Pads

    CHECKING THE FRONT AND REAR BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00122 È CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pad •...

  • Page 136: Checking The Front And Rear Brake Hoses

    CHECKING THE FRONT AND REAR BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00131 CHECKING THE FRONT AND REAR BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: • brake hose Cracks/damage/wear → Replace. 2.
  • Page 137 BLEEDING THE HYDRAULIC BRAKE SYSTEM 1. Bleed: È • hydraulic brake system M MMM M MMM M MMM M MMM M MMM a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the brake fluid reservoir diaphragm. c.

  • Page 138: Adjusting The Shift Pedal

    ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK EAS00136 ADJUSTING THE SHIFT PEDAL 1. Check: • shift pedal position (distance a from the bottom of the rider footrest bracket to the top of the shift pedal) Out of specification→ Adjust. Shift pedal position (below the top of the rider footrest) 38 ~ 43 mm (1.50 ~ 1.69 in)
  • Page 139 ADJUSTING THE DRIVE CHAIN SLACK 3. Check: • drive chain slack a Out of specification → Adjust. Drive chain slack 40 ~ 50 mm (1.57 ~ 1.97 in) 4. Adjust: • drive chain slack M MMM M MMM M MMM M MMM M MMM a.

  • Page 140: Lubricating The Drive Chain

    LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas.
  • Page 141 CHECKING AND ADJUSTING THE STEERING HEAD 3. Remove: • upper bracket Refer to “HANDLEBARS” and “STTERLING HEAD” in chapter 4. 4. Adjust: • steering head M MMM M MMM M MMM M MMM M MMM a. Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3.
  • Page 142 CHECKING AND ADJUSTING THE STEERING HEAD e. Install the rubber washer 3. f. Install the upper ring nut 2. g. Finger tighten the upper ring nut 2, then align the slots of both ring nuts. If neces- sary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned.

  • Page 143: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK g. Reinstall the upper bracket and measure the steering head tension again as described above. h. Repeat the above procedure until the steer- ing head tension is within specification. i. Grasp the bottom of the front fork legs and gently rock the front fork.

  • Page 144: 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 • Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. •...
  • Page 145 ADJUSTING THE FRONT FORK LEGS Rebound damping CAUTION: Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • rebound damping M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw 1 in direction a or b.
  • Page 146 ADJUSTING THE FRONT FORK LEGS/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Compression damping Direction a is increased (suspen- sion is harder). Compression damping Direction b is decreased (suspen- sion is softer). Adjusting positions Minimum: 20 clicks in direction b * Standard: 13 clicks in direction b * Maximum: 1 click in direction b * * with the adjusting screw fully turned-in direction a...

  • Page 147: Adjusting The Rear Shock Absorber Assembly

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Spring preload is Direction a increased (suspension is harder). Spring preload is Direction b decreased (suspension is softer). Adjusting positions Minimum: 1 Standard: 4 Maximum: 9 L LLL L LLL L LLL L LLL L LLL Rebound damping CAUTION:...
  • Page 148 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRES 1. Adjust: • compression damping M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw 1 in direction a or b. Compression damping Direction a is increased (suspen- sion is harder).

  • Page 149: Checking The Tires

    CHECKING THE TIRES Basic weight For USA, Canada (with oil and 193 kg (426 lb) a full fuel For California tank) 194 kg (428 lb) For USA, Canada Maximum 202 kg (445 lb) load* For California 201 kg (443 lb) Cold tire Front Rear...
  • Page 150 No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motor- cycle. 3 - 55...

  • Page 151: Checking The Wheels

    CHECKING THE TIRES/ CHECKING THE WHEELS Front tire Manufacturer Size Model 120/70ZR DUNLOP D208FL 17M/C (58W) 120/70ZR Pilot MICHELIN 17M/C (58W) SPORT E Rear tire Manufacturer Size Model 190/50ZR DUNLOP D208L 17M/C (73W) 190/50ZR Pilot MICHELIN 17M/C (73W) SPORT WARNING New tires have a relatively low grip on the road surface until they have been slightly worn.

  • Page 152: 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 inner and outer cables. WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement.

  • Page 153: 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 poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 154 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 155 CHECKING AND CHARGING THE BATTERY 5. Charge: Charging Ambient temperature 20 °C • battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. • Never remove the MF battery sealing caps.
  • Page 156 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger NOTE: Voltage should be measured 30 minutes after the machine is Charger AMP meter Measure the open-circuit stopped. voltage prior to charging. NOTE: Set the charging voltage at Connect a charger and 16 ~ 17 V.
  • Page 157 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Measure the open-circuit Voltage should be measured 30 voltage prior to charging. minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.

  • Page 158: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: • battery terminals Dirt →...
  • Page 159 CHECKING THE FUSES 3. Replace: • blown fuse M MMM M MMM M MMM M MMM M MMM 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 160: 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: • headlight coupler 1 2. Remove: • headlight bulb cover 2 3. Remove: • headlight bulb holder 1 4. Remove: •...

  • Page 161: Adjusting The Headlight Beam

    ADJUSTING THE HEADLIGHT BEAM EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • headlight beam (vertically) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw 1 in direction a or b. Direction a Headlight beam is raised. Headlight beam is low- Direction b ered.

  • Page 162: Chas

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. discs NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Brake hose holder (left and right) Brake caliper (left and right) Wheel axle pinch bolt...

  • Page 163: Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 FRONT WHEEL Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly procedure.

  • Page 164: 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 165 CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: • radial wheel runout 1 • 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 166: 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: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc.

  • Page 167: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS Brake disc bolt 18 Nm (1.8 m · kg, 13 ft · lb) ® LOCTITE d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification.

  • Page 168: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISCS 8. Tighten wheel axle pinch bolt 1, and then pinch bolt 2 to the specified torque. Wheel axle pinch bolt 18 Nm (1.8 m · kg, 13 ft · lb) 9. Tap the outer side of the right fork leg with a rubber mallet to align it with the end of the wheel axle.
  • Page 169 CHAS FRONT WHEEL AND BRAKE DISCS M MMM M MMM M MMM M MMM M MMM a. Spin the front wheel. b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. c. Turn the front wheel 90° so that the “X ”...

  • Page 170: Rear Wheel And Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC EAS00551 REAR WHEEL AND BRAKE DISC 27 Nm (2.7 m kg, 20 ft • • 150 Nm (15.0 m kg, 108 ft • • Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 171: Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EAS00560 REAR WHEEL Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Spacer Bearing Spacer Oil seal Circlip Bearing For installation, reverse the disassembly procedure. 4 - 10...
  • Page 172 CHAS REAR WHEEL AND BRAKE DISC 18 Nm (1.8 m kg, 13 ft • • 100 Nm (10 m kg, 72 ft • • Order Job/Part Q’ty Remarks Remove the brake disc and rear Remove the parts in the order listed. wheel sprocket Brake disc Rear wheel sprocket...

  • Page 173: 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 174: Checking The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC 5. Remove: • left collar 1 • rear wheel drive hub 2 • rear wheel drive hub damper • right collar EAS00565 CHECKING THE REAR WHEEL 1. Check: • wheel axle • rear wheel •...

  • Page 175: Checking And Replacing The Rear Wheel Sprocket

    CHAS REAR WHEEL AND BRAKE DISC EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: • rear wheel sprocket More than 1/4 tooth a wear → Replace the rear wheel sprocket. Bent teeth → Replace the rear wheel sprocket. b Correct 1 Drive chain roller 2 Rear wheel sprocket...

  • Page 176: Adjusting The Rear Wheel Static Balance

    CHAS REAR WHEEL AND BRAKE DISC 2. Adjust: • drive chain slack Drive chain slack 40 ~ 50 mm (1.57 ~ 1.97 in) Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. 3. Tighten: • wheel axle nut 150 Nm (15 m · kg, 108 ft · lb) •...

  • Page 177: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 6 Nm (0.6 m kg, 4.3 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty...

  • Page 178: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES REAR BRAKE PADS 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 20 ft • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Brake caliper Brake pad Brake pad shim...

  • Page 179: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: WARNING • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 180 CHAS FRONT AND REAR BRAKES 2. Remove: • brake pad clips 1 • brake pad pins 2 • brake pad spring 3 3. Remove: • brake pads 1 (along with the brake pad shims) 4. Measure: • brake pad wear limit Out of specification →...
  • Page 181 CHAS FRONT AND REAR BRAKES M MMM M MMM M MMM M MMM M MMM 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 182: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00583 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. Remove: • brake caliper 1 2. Remove: •...
  • Page 183 CHAS FRONT AND REAR BRAKES M MMM M MMM M MMM M MMM M MMM 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 184: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 30 Nm (3.0 m kg, 22 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain.
  • Page 185 CHAS FRONT AND REAR BRAKES 30 Nm (3.0 m kg, 22 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Part Q’ty Remarks Brake hose Brake master cylinder bracket Brake master cylinder Front brake switch For installation, reverse the removal procedure.
  • Page 186 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 4 - 25...

  • Page 187: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 3 Nm (0.3 m kg, 2.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed.
  • Page 188 CHAS FRONT AND REAR BRAKES EAS00587 16 Nm (1.6 m kg, 12 ft • • Order Job/Part Q’ty Remarks Disassembling the rear brake Remove the parts in the order listed. master cylinder Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure.

  • Page 189: Disassembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: • brake switch coupler 1 (from the brake switch) 2.

  • Page 190: Checking The Front And Rear Brake Master Cylinders

    CHAS FRONT AND REAR BRAKES EAS00593 È CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders. 1. Check: • brake master cylinder Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction →...

  • Page 191: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00607 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components.
  • Page 192 CHAS FRONT AND REAR BRAKES 3. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 193: Assembling The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00610 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: • copper washers • brake hose • union bolt 30 Nm (3.0 m · kg, 22 ft · lb) CAUTION: When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection a on the brake master cylinder.
  • Page 194 CHAS FRONT AND REAR BRAKES 3. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.

  • Page 195: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 6 Nm (0.6 m kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft 40 Nm (4.0 m kg, 29 ft • • • • Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed.
  • Page 196 CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. calipers The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring...

  • Page 197: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 m kg, 22 ft • • 27 Nm (2.7 m kg, 20 ft • • Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain.
  • Page 198 CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Disassembling the rear brake Remove the parts in the order listed. caliper Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly procedure.

  • Page 199: 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: • union bolt 1 •...

  • Page 200: Disassembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00627 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.

  • Page 201: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Every two years and whenever the Brake fluid brake is disassem- bled 1.

  • Page 202: Assembling And Installing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00640 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. •...
  • Page 203 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 204: Assembling And Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort.
  • Page 205 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 206: Front Fork

    CHAS FRONT FORK EAS00647 FRONT FORK 13 Nm (1.3 m kg, 9.4 ft • • 23 Nm (2.3 m kg, 17 ft • • 26 Nm (2.6 m kg, 19 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 207 CHAS FRONT FORK EAS00648 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed. Cap bolt O-ring Spacer Spring seat Fork spring Damper adjusting rod Outer tube Dust seal Oil seal clip...
  • Page 208 CHAS FRONT FORK 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty Remarks Damper rod assembly bolt Copper washer Damper rod assembly Inner tube For assembly, reverse the disassembly procedure. 4 - 47...

  • Page 209: 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 210 CHAS FRONT FORK Fork spring compressor YM-01441 Rod holder YM-01434 NOTE: Use the side of the rod holder that is marked “B”. c. Loosen the nut. d. Remove the cap bolt. e. Remove the rod holder and fork spring com- pressor.

  • Page 211: Checking The Front Fork Legs

    CHAS FRONT FORK EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 Bends/damage/scratches → Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.

  • Page 212: Assembling The Front Fork Legs

    CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Make sure the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor han- dling and a loss of stability.
  • Page 213 CHAS FRONT FORK 4. Install: • dust seal 1 • oil seal clip 2 • oil seal 3 • washer 4 CAUTION: Make sure the numbered side of the oil seal faces out side. NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease.
  • Page 214 CHAS FRONT FORK 8. Install: • rod puller 1 (onto the damper rod 2) Rod puller YM-01437 9. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.543 L (0.478 Imp qt, 0.574 US qt) Recommended oil Suspension oil “01”...
  • Page 215 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 holder 2 between the nut 3 and the spacer 4. NOTE: Use the side of the rod holder that is marked “B”.

  • Page 216: 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: • 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 217 CHAS HANDLEBARS EAS00665 HANDLEBARS 9 Nm (0.9 m kg, 6.5 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 26 Nm (2.6 m kg, 19 ft • • 115 Nm (11.5 m kg, 83 ft • • 13 Nm (1.3 m kg, 9.4 ft •...
  • Page 218 CHAS HANDLEBARS 9 Nm (0.9 m kg, 6.5 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 26 Nm (2.6 m kg, 19 ft • • 115 Nm (11.5 m kg, 83 ft • • 13 Nm (1.3 m kg, 9.4 ft •...

  • Page 219: 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: • handlebar grip NOTE: Blow compressed air between the left handle- bar and the handlebar grip, and gradually push the grip off the handlebar.
  • Page 220 CHAS HANDLEBARS 2. Install: • right handlebar switch 1 NOTE: Align the projection a on the right handlebar switch with the hole b in the right handlebar. 3. Install: • brake master cylinder holder 1 CAUTION: • Install the brake master cylinder holder with the “UP”...
  • Page 221 CHAS HANDLEBARS 6. Install: • left handlebar switch 1 NOTE: Align the projection a on the left handlebar switch with the hole b in the left handlebar. 7. Install: • handlebar grip M MMM M MMM M MMM M MMM M MMM a.

  • Page 222: Steering Head

    CHAS STEERING HEAD EAS00676 STEERING HEAD 115 Nm (11.5 m kg, 83 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 26 Nm (2.6 m kg, 19 ft • • 1st 50 Nm (5.0 m kg, 36 ft •...
  • Page 223 CHAS STEERING HEAD 115 Nm (11.5 m kg, 83 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 26 Nm (2.6 m kg, 19 ft • • 1st 50 Nm (5.0 m kg, 36 ft • • 2nd 9 Nm (0.9 m kg, 6.5 ft •...

  • Page 224: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • ring nut 1 (with the steering nut wrench 2) Steering nut wrench YU-33975 WARNING...

  • Page 225: 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: •...

  • Page 226: Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 45 Nm (4.5 m kg, 33 ft • • 45 Nm (4.5 m kg, 33 ft • • 45 Nm (4.5 m kg, 33 ft • • Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed.

  • Page 227: Handling The Rear Shock Absorber

    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 understand the following information.

  • Page 228: 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 229: Checking The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. •...

  • Page 230: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00700 SWINGARM AND DRIVE CHAIN 7 Nm (0.7 m kg, 5.1 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 105 Nm (10.5 m kg, 76 ft •...
  • Page 231 CHAS SWINGARM AND DRIVE CHAIN 7 Nm (0.7 m kg, 5.1 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 105 Nm (10.5 m kg, 76 ft • •...

  • Page 232: 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 233: 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 234: Checking The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN 3. Wash: • pivot shaft • dust covers • spacer • washers • bearings Recommended cleaning solvent Kerosene 4. Check: • dust covers 1 • spacer 2 Damage/wear → Replace. • bearings 3 Damage/pitting → Replace. 5.
  • Page 235 CHAS SWINGARM AND DRIVE CHAIN 2. Check: • drive chain Stiffness → Clean and lubricate or replace. 3. Clean: • drive chain M MMM M MMM M MMM M MMM M MMM a. Wipe the drive chain with a clean cloth. b.

  • Page 236: Installing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN 6. Check: • drive sprocket • rear wheel sprocket More than 1/4 tooth a wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. b Correct 1 Drive chain roller 2 Drive chain sprocket...

  • Page 237: Eng

    ENGINE EAS00188 OVERHAULING THE ENGINE ENGINE DRIVE SPROCKET 10 Nm (1.0 m kg, 7.2 ft • • 85 Nm (8.5 m kg, 61 ft • • Order Job/Part Q’ty Remarks Removing the drive sprocket Remove the parts in the order listed. Locknut Shift rod Drive sprocket cover...

  • Page 238: Exhaust Pipe

    ENGINE EAS00189 EXHAUST PIPE 38 Nm (3.8 m kg, 27 ft • • 20 Nm (2.0 m kg, 14 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 239 ENGINE 38 Nm (3.8 m kg, 27 ft • • 20 Nm (2.0 m kg, 14 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft •...

  • Page 240: Leads And Hoses

    ENGINE LEADS AND HOSES 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Air filter case Refer to “AIR FILTER CASE”...

  • Page 241: Engine

    ENGINE 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Clutch cable Crankcase breather hose Starter motor lead Disconnect. Ground lead Disconnect. Starter motor Stator coil assembly coupler Disconnect.
  • Page 242 ENGINE EAS00191 ENGINE 50 Nm (5.0 m kg, 36 ft • • 45 Nm (4.5 m kg, 33 ft • • 24 Nm (2.4 m kg, 17 ft • • 45 Nm (4.5 m kg, 33 ft • • 50 Nm (5.0 m kg, 36 ft •...

  • Page 243: Installing The Engine

    ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: • engine mounting adjust bolts 1 • rear mounting bolts 2 • self-locking nuts 3 • left front mounting bolt 4 • right front mounting bolt 5 • pinch bolt 6 NOTE: • Lubricate the rear mounting bolt threads with lithium soap base grease.

  • Page 244: Camshaft

    CAMSHAFT EAS00194 CAMSHAFT CYLINDER HEAD COVERS 13 Nm (1.3 m kg, 9.4 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the cylinder head covers Remove the parts in the order listed.

  • Page 245: Camshafts

    CAMSHAFT EAS00196 CAMSHAFTS 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 246 CAMSHAFT 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 247: Removing The Camshafts

    CAMSHAFT EAS00198 REMOVING THE CAMSHAFTS 1. Align: • TDC mark on the pickup coil rotor (with the crankcase mating surface) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the pickup coil rotor with the crankcase mating surface b.

  • Page 248: Checking The Camshafts

    CAMSHAFT 6. Remove: • timing chain guide (exhaust side) 1 • camshaft caps • dowel pins CAUTION: To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 7.
  • Page 249 CAMSHAFT 3. Measure: • camshaft runout Out of specification → Replace. Camshaft runout limit 0.03 mm (0.0012 in) 4. Measure: • camshaft-journal-to-camshaft-cap clear- ance Out of specification → Measure the cam- shaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) M MMM M MMM...

  • Page 250: Checking The Timing Chain, Camshaft Sprockets, And Timing Chain Guides

    CAMSHAFT 5. Measure: • camshaft journal diameter a Out of specification → Replace the cam- shaft. Within specification → Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING...

  • Page 251: Checking The Timing Chain Tensioner

    CAMSHAFT EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage → Replace. 2. Check: • one-way cam operation Rough movement → Replace the timing chain tensioner housing. 3. Check: • cap bolt • copper washer • spring •...
  • Page 252 CAMSHAFT CAUTION: The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. 4. Install: • intake camshaft sprocket • exhaust camshaft sprocket M MMM M MMM M MMM M MMM M MMM a.
  • Page 253 CAMSHAFT 6. Install: • timing chain tensioner M MMM M MMM M MMM M MMM M MMM a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1. b.
  • Page 254 CAMSHAFT 9. Tighten: • camshaft sprocket bolts 24 Nm (2.4 m · kg, 17 ft · lb) CAUTION: Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine.

  • Page 255: Cylinder Head

    CYLINDER HEAD EAS00221 CYLINDER HEAD 1st 20 Nm (2.0 m kg, 14 ft 1st 20 Nm (2.0 m kg, 14 ft • • • • 2nd 140˚ or 65 Nm (6.5 m kg, 47 ft 2nd 105˚ or 50 Nm (5.0 m kg, 36 ft •...

  • Page 256: Removing The Cylinder Head

    CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remove: • cylinder head nuts • cylinder head bolts NOTE: • Loosen the nuts in the proper sequence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.

  • Page 257: Installing The Cylinder Head

    CYLINDER HEAD EAS00233 INSTALLING THE CYLINDER HEAD 1. Install: • gasket • dowel pins 2 2. Install: • cylinder head NOTE: Pass the timing chain through the timing chain cavity. 3. Tighten: • cylinder head nuts 1 ~ 6 20 Nm (2.0 m · kg, 14 ft · lb) 105°...
  • Page 258 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 259 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 260: 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 261: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 4. Remove: • upper spring seat 1 • valve spring 2 • valve stem seal 3 • lower spring seat 4 • valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 È...
  • Page 262 VALVES AND VALVE SPRINGS Valve guide remover Intake (4.0 mm, 0.16 in) 90890-04111 Exhaust (4.5 mm, 0.18 in) YM-4116 Valve guide installer Intake (4.0 mm, 0.16 in) 90890-04112 Exhaust (4.5 mm, 0.18 in) YM-4117 Valve guide reamer Intake (4.0 mm, 0.16 in) 90890-04113 Exhaust (4.5 mm, 0.18 in) YM-4118...

  • Page 263: 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: • carbon deposits (from the valve face and valve seat) 2. Check: • valve seat Pitting/wear → Replace the cylinder head. 3.

  • Page 264: Checking The Valve Springs

    VALVES AND VALVE SPRINGS M MMM M MMM M MMM M MMM M MMM 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.

  • Page 265: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 2. Measure: • compressed valve spring force a Out of specification → Replace the valve spring. b Installed length Compressed valve spring force (installed) Intake valve spring 82 ~ 96 N (8.2 ~ 9.6 kg, 18.43 ~ 21.58 lb) at 34.5 mm (1.36 in) Exhaust valve spring 110 ~ 126 N...
  • Page 266 VALVES AND VALVE SPRINGS 2. Lubricate: • valve stem 1 • valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: • valve 1 • lower spring seat 2 • valve stem seal 3 • valve spring 4 •...
  • Page 267 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: • valve pad 1 •...

  • Page 268: Generator

    GENERATOR GENERATOR 14 Nm (1.4 m kg, 10 ft • • 65 Nm (6.5 m kg, 47 ft Ib) + 60˚ • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Removing the stator coil assembly Remove the parts in the order listed.

  • Page 269: Removing The Generator

    GENERATOR REMOVING THE GENERATOR 1. Remove: • generator rotor cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: •...
  • Page 270 GENERATOR CAUTION: • Clean the tapered portion of the crank- shaft and the generator rotor hub with lacquer thinner. • Lubricate the generator rotor bolt threads with engine oil. 3. Tighten: • generator rotor bolt 1 65 Nm (6.5 m · kg, 47 ft · lb) + 60° NOTE: While holding the generator rotor 2 with the rotor holding tool 3, tighten the generator...
  • Page 271 GENERATOR WARNING When the bolt are 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. CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle.

  • Page 272: Pickup Coil

    PICKUP COIL PICKUP COIL 60 Nm (6.0 m kg, 43 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 15 Nm (1.5 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty...
  • Page 273 PICKUP COIL 60 Nm (6.0 m kg, 43 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 15 Nm (1.5 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Crankshaft position sensor coupler...

  • Page 274: Removing The Pickup Coil Rotor

    PICKUP COIL REMOVING THE PICKUP COIL ROTOR 1. Remove: • clutch cable holder 1 • pickup coil lead holder 2 • pickup coil rotor cover 3 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 275 PICKUP COIL 2. Tighten: • pickup coil rotor bolt 1 60 Nm (6.0 m · kg, 43 ft · lb) NOTE: While holding the generator rotor 2 with the rotor holding tool 3, tighten the pickup coil rotor bolt. Rotor holding tool YU-01235 3.

  • Page 276: Clutch

    CLUTCH CLUTCH CLUTCH COVER 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Bottom cowling and right side cowling Refer to “COWLINGS”...

  • Page 277: 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 - 41...

  • Page 278: Clutch

    CLUTCH EAS00274 CLUTCH 12 Nm (1.2 m kg, 8.7 ft • • 105 Nm (10.5 m kg, 76 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Clutch spring plate retainer Clutch spring plate Clutch spring plate seat...
  • Page 279 CLUTCH 12 Nm (1.2 m kg, 8.7 ft • • 105 Nm (10.5 m kg, 76 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Part Q’ty Remarks Thrust washer Clutch housing Bearing Starter clutch gear Bearing Starter clutch assembly Circlip...

  • Page 280: Removing The Clutch

    CLUTCH EAS00277 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: • clutch boss nut 1 NOTE: While holding the clutch boss 2 with the uni- versal clutch holder 3, loosen the clutch boss nut. Universal clutch holder YM-91042 3.

  • Page 281: Checking The Clutch Plates

    CLUTCH EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: • clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge Out of specification →...

  • Page 282: Checking The Pressure Plate

    CLUTCH EAS00286 CHECKING THE PRESSURE PLATE 1. Check: • pressure plate 1 Cracks/damage → Replace. • bearing 2 Damage/wear → Replace. EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: • pull lever shaft pinion gear teeth 1 •...

  • Page 283: Installing The Clutch

    CLUTCH 2. Check: • starter clutch operation M MMM M MMM M MMM M MMM M MMM a. Install the starter clutch drive gear onto the starter clutch and hold the starter clutch. b. When turning the starter clutch drive gear clockwise È, the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and...
  • Page 284 CLUTCH 5. Install: • friction plates • clutch plates NOTE: First, install a friction plate and then alternate between a clutch plate and a friction plate. 6. Install: • pressure plate 1 • clutch spring plate seat 2 • clutch spring plate 3 •...

  • Page 285: Shift Shaft

    SHIFT SHAFT EAS00327 SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER 22 Nm (2.2 m kg, 16 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Removing the shift shaft and stop- Remove the parts in the order listed. per lever Drive sprocket cover Refer to “ENGINE”.

  • Page 286: Checking The Shift Shaft

    SHIFT SHAFT CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 Bends/damage/wear → Replace. • shift shaft spring 2 Damage/wear → Replace. CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.

  • Page 287: Oil Pan And Oil Pump

    OIL PAN AND OIL PUMP EAS00356 OIL PAN AND OIL PUMP 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 288 OIL PAN AND OIL PUMP 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...

  • Page 289: Oil Pump

    OIL PAN AND OIL PUMP EAS00360 OIL PUMP 10 Nm (1.0 m kg, 7.2 ft • • 15 Nm (1.5 m kg, 11 ft • • Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. Oil/water pump assembly driven sprocket Washer...

  • Page 290: Removing The Oil Pan

    OIL PAN AND OIL PUMP EAS00362 REMOVING THE OIL PAN 1. Remove: • oil level switch 1 • oil pan 2 • gasket • dowel pins 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 291: Checking The Relief Valve

    OIL PAN AND OIL PUMP 3. Check: • oil pump operation Rough movement → Repeat steps (1) and (2) or replace the defective part(s). EAS00365 CHECKING THE RELIEF VALVE 1. Check: • relief valve body 1 • relief valve 2 •...

  • Page 292: Assembling The Oil Pump

    OIL PAN AND OIL PUMP EAS00374 ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: • pin 1 • inner rotor 2 • outer rotor 3 •...

  • Page 293: Installing The Oil Strainer

    OIL PAN AND OIL PUMP EAS00378 INSTALLING THE OIL STRAINER 1. Install: • oil strainer housing 1 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: The arrow mark a on the oil strainer housing must point towards the front of the engine. EAS00380 INSTALLING THE OIL PAN 1.

  • Page 294: Crankcase

    CRANKCASE EAS00381 CRANKCASE 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Cylinder head Refer to “CYLINDER HEAD”.
  • Page 295 CRANKCASE 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Washer Oil/water pump assembly drive sprocket Washer Plate Lower crankcase Dowel pin For installation, reverse the removal procedure.

  • Page 296: Disassembling The Crankcase

    CRANKCASE EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside down. 2. Remove: • crankcase bolts 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 297: Checking The Crankcase

    CRANKCASE EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase Cracks/damage → Replace. • oil delivery passages Obstruction → Blow out with compressed air.

  • Page 298: Assembling The Crankcase

    CRANKCASE EAS00414 ASSEMBLING THE CRANKCASE 1. Lubricate: • crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: • sealant (onto the crankcase mating surfaces) ® Quick Gasket ACC-11001-05-01 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.
  • Page 299 CRANKCASE 6. Install: • lower crankcase 1 (onto the upper crankcase 2) CAUTION: Before tightening the crankcase bolts, make sure the transmission gears shift cor- rectly when the shift drum assembly is turned by hand. 7. Install: • crankcase bolts NOTE: •...

  • Page 300: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS00382 CONNECTING RODS AND PISTONS 20 Nm (2.0 m kg, 14 ft Ib) + 120˚ • • Order Job/Part Q’ty Remarks Removing the connecting rods and Remove the parts in the order listed. pistons Crankcase Separate. Refer to “CRANKCASE”. Connecting rod cap Big end lower bearing Piston pin clip...

  • Page 301: 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: • connecting rod 1 • big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.

  • Page 302: Removing The Crankshaft Assembly

    CONNECTING RODS AND PISTONS 3. Remove: • top ring • 2nd ring • oil ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY...
  • Page 303 CONNECTING RODS AND PISTONS 74.00 ~ 74.01 mm Cylinder bore “C” (2.9134 ~ 2.9138 in) 74.06 mm Wear limit (2.9157 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.002 in) “C” = maximum of D “T”...

  • Page 304: Checking The Piston Rings

    CONNECTING RODS AND PISTONS EAS00263 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 305: Checking The Piston Pins

    CONNECTING RODS AND PISTONS CHECKING THE PISTON PINS The following procedure applies to all of the piston pins. 1. Check: • piston pin Blue discoloration/grooves → Replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter a Out of specification →...
  • Page 306 CONNECTING RODS AND PISTONS M MMM M MMM M MMM M MMM M MMM The following procedure applies to all of the connecting rods. 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 orig-...
  • Page 307 CONNECTING RODS AND PISTONS e. Tighten the connecting rod nuts. Connecting rod nut 20 Nm (2.0 m · kg, 14 ft · lb) + 120° f. Replace the connecting rod bolts and nuts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method.

  • Page 308: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS 2. Select: • big end bearings (P1 ~ P4) NOTE: • The numbers È 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 2. Install: • piston 1 (onto the respective connecting rod 2) • piston pin 3 • piston pin clip NOTE: • Apply engine oil onto the piston pin. • Make sure that the “Y” mark a on the con- necting rod faces left when the arrow mark b on the piston is pointing up.
  • Page 310 CONNECTING RODS AND PISTONS 6. Install: • big end bearings • connecting rod assembly (into the cylinder and onto the crankshaft pin). • connecting rod cap (onto the connecting rod) NOTE: • Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps.
  • Page 311 CONNECTING RODS AND PISTONS e. Tighten the nut further to reach the speci- fied angle (120°). WARNING When the nut is tightened more than the specified angle, do not loosen the nut and then retighten it. Replace the bolt with a new one and per- form the procedure again.

  • Page 312: Crankshaft

    CRANKSHAFT CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Connecting rod caps Refer to “CONNECTING RODS AND PISTONS”. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing For installation, reverse the removal procedure.

  • Page 313: Checking The Crankshaft

    CRANKSHAFT EAS00395 CHECKING THE CRANKSHAFT 1. Measure: • crankshaft runout Out of specification → Replace the crank- shaft. Crankshaft runout Less than 0.03 mm (0.0012 in) 2. Check: • crankshaft journal surfaces • crankshaft pin surfaces • bearing surfaces Scratches/wear → Replace the crankshaft. CHECKING THE CRANKSHAFT JOURNAL BEARINGS 1.
  • Page 314 CRANKSHAFT c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crank- case. NOTE: Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the upper crankcase. ® d. Put a piece of Plastigauge 2 on each crankshaft journal.
  • Page 315 CRANKSHAFT g. Remove the lower crankcase and the crank- shaft journal lower bearings. ® h. Measure the compressed Plastigauge width c on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. L LLL L LLL L LLL...

  • Page 316: Installing The Crankshaft

    CRANKSHAFT EAS00407 INSTALLING THE CRANKSHAFT 1. Install: • crankshaft journal upper bearings 1 (into the upper crankcase) NOTE: • Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase. • Be sure to install each crankshaft journal upper bearing in its original place.

  • Page 317: Transmission

    TRANSMISSION EAS00419 TRANSMISSION 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum assembly, and shift forks Crankcase Separate.
  • Page 318 TRANSMISSION 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Shift drum assembly Shift fork “C” Main axle assembly For installation, reverse the removal procedure. 5 - 82...
  • Page 319 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle Disassembly the parts in the order listed. assembly 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Toothed spacer Toothed washer Circlip 3rd/4th pinion gears 5th pinion gear Collar 5 - 83...
  • Page 320 TRANSMISSION Order Job/Part Q’ty Remarks Main axle/1st pinion gear Bearing Main axle bearing housing For assembly, reverse the disassembly procedure. 5 - 84...
  • Page 321 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle Disassembly the parts in the order listed. assembly Washer 1st wheel gear Spacer 5th wheel gear Circlip Washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 5 - 85...
  • Page 322 TRANSMISSION Order Job/Part Q’ty Remarks 4th wheel gear 6th wheel gear 2nd wheel gear Spacer Drive axle Bearing Spacer For assembly, reverse the disassembly procedure. 5 - 86...

  • Page 323: Removing The Transmission

    TRANSMISSION EAS00420 REMOVING THE TRANSMISSION 1. Remove: • main axle assembly 1 ® (with the Torx wrench T30) M MMM M MMM M MMM M MMM M MMM a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing.

  • Page 324: Checking The Shift Drum Assembly

    TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • shift drum grooves Damage/scratches/wear → Replace the shift drum assembly. • shift drum segment 1 Damage/wear → Replace the shift drum assembly. • shift drum bearing 2 Damage/pitting → Replace the shift drum assembly.

  • Page 325: Installing The Transmission

    TRANSMISSION 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 5. Check: • transmission gear movement Rough movement → Replace the defective part(s). 6. Check: • circlips Bends/damage/looseness → Replace. EAS00428 INSTALLING THE TRANSMISSION 1.

  • Page 326: Cool

    COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Air filter case and rubber cover Refer to “AIR FILTER CASE”...
  • Page 327 COOL RADIATOR Order Job/Part Q’ty Remarks Radiator inlet hose Radiator outlet hose Water pump breather hose Radiator Radiator fan Water pump inlet pipe For installation, reverse the removal procedure. 6 - 2...

  • Page 328: Checking The Radiator

    COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.

  • Page 329: Installing The Radiator

    COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part. 3.

  • Page 330: Oil Cooler

    COOL OIL COOLER EAS00457 OIL COOLER 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 35 Nm (3.5 m kg, 25 ft •...

  • Page 331: Checking The Oil Cooler

    COOL OIL COOLER EAS00458 CHECKING THE OIL COOLER 1. Check: • oil cooler Cracks/damage → Replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose Cracks/damage/wear → Replace. EAS00459 INSTALLING THE OIL COOLER 1. Clean: • mating surfaces of the oil cooler and the crankcase (with a cloth dampened with lacquer thin- ner)

  • Page 332: Thermostat

    COOL THERMOSTAT EAS00460 THERMOSTAT 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the thermostat assembly Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS”...
  • Page 333 COOL THERMOSTAT 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Thermostat assembly Thermostat assembly inlet pipe (left) For installation, reverse the removal procedure. 6 - 8...
  • Page 334 COOL THERMOSTAT EAS00461 ‘ 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Disassembling the thermostat Remove the parts in the order listed. housing Thermostat housing cover Thermostat Thermostat housing For assembly, reverse the disassembly...

  • Page 335: Checking The Thermostat

    COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: • thermostat Does not open at 71 ~ 85 °C (160 ~ 185 °F) → Replace. M MMM M MMM M MMM M MMM M MMM a. Suspend the thermostat in a container filled with water.

  • Page 336: Assembling The Thermostat Assembly

    COOL THERMOSTAT EAS00464 ASSEMBLING THE THERMOSTAT ASSEMBLY 1. Install: • thermostat housing 1 • thermostat 2 • O-ring • thermostat housing cover 4 NOTE: Install the thermostat with its breather hole a facing up. 2. Install: • coolant temperature sensor 1 18 Nm (1.8 m ·...

  • Page 337: Water Pump

    COOL WATER PUMP EAS00468 WATER PUMP 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the impeller shaft Remove the parts in the order listed. NOTE: • The water pump and oil pump are com- bined into one unit (oil/water pump assembly).
  • Page 338 COOL WATER PUMP 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Water pump seal Oil seal Bearing For installation, reverse the removal procedure. 6 - 13...

  • Page 339: Disassembling The Water Pump

    COOL WATER PUMP EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: • 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: • oil seal 1 •...

  • Page 340: Assembling The Water Pump

    NOTE: • Install the water pump seal with the special tools. • 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 YM-33221 Middle driven shaft bearing driver 5 YM-4058-1 ®...
  • Page 341 COOL WATER PUMP 4. Measure: • 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 (0.0059 in) 1 Straightedge 2 Impeller 6 - 16...

  • Page 342: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Ignition coil 8 Intake air pressure C Coolant temperature I Atmospheric pressure 2 Air filter case sensor sensor sensor 3 Intake temperature 9 Throttle position sensor D Spark plug J Fuel injection system 0 Fuel injector E Cylinder identification sensor...

  • Page 343: Wiring Diagram

    FUEL INJECTION SYSTEM WIRING DIAGRAM 1 Main switch 5 Battery 6 Fuse (main) 7 Fuse (fuel injection system) 0 Starting circuit cut-off relay A Side stand switch C ECU D Ignition coil E Spark plug F Fuel injector H EXUP servo motor I Speed sensor J Lean angle cut-off switch K Cylinder identification sensor...

  • Page 344: Ecu's Self-Diagnostic Function

    FUEL INJECTION SYSTEM ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control sys- tem is operating normally. If this function detects a malfunction in the system, it immediately oper- ates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 345: Substitute Characteristics Operation Control (Fail-Safe Action)

    FUEL INJECTION SYSTEM SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the motorcycle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with substitute characteristic operation instructions that are appropriate for the type of the malfunction.

  • Page 346: Troubleshooring Chart

    FUEL INJECTION SYSTEM TROUBLESHOORING CHART “Engine runs irregularly.” or “Engine trouble warning light is illuminated.” * Engine trouble warning light may not be illuminated even if the engine runs irregularly. When the engine trouble warning light is illumi- When the engine trouble warning light is not illumi- nated nated Checking the self-diagnostic fault code number:...

  • Page 347: Diagnostic Mode

    FUEL INJECTION SYSTEM DIAGNOSTIC MODE • In this mode, diagnostic codes are input into the ECU in accordance with the number of times the start switch has been operated. • In accordance with the diagnostic codes, the ECU displays the values received from the sensors and actuates the actuators.
  • Page 348 FUEL INJECTION SYSTEM Diagnostic fault code table Fault Code of Symptom Probable cause of malfunction Code No. diagnostic mode No normal signals are received from • Open or short circuit in wiring sub lead. the cylinder identification sensor. • Open or short circuit in wiring harness. •...
  • Page 349 FUEL INJECTION SYSTEM Fault Code of Symptom Probable cause of malfunction Code No. diagnostic mode Open circuit is detected in the primary • Open or short circuit in wiring harness. lead of the ignition coil (#1). • Malfunction in ignition coil. •...
  • Page 350 FUEL INJECTION SYSTEM Diagnostic mode table Set the meter display from the regular mode to the diagnosis mode. For the setting method, refer to “DIAGNOSTIC MODE”. NOTE: • Check the intake temperature and coolant temperature as close as possible to the area in which the respective sensor is mounted.
  • Page 351 FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) Ignition coil #3 After 1 second has elapsed from the time the engine stop Check that spark is generated, switch has been turned from OFF to ON, it actuates ignition 5 times with the engine stop coil #3 for five times every second and illuminates the engine switch ON.
  • Page 352 FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) Headlight relay 1 After 1 second has elapsed from the time the engine stop Check the headlight relay oper- switch has been turned from OFF to ON, it actuates the head- ating sound 5 times with the light relay five times every 5 seconds and illuminates the engine stop switch ON.

  • Page 353: 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 according to the “Restore method”.
  • Page 354 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft position sensor. Used diagnostic code No.-- Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Installed condition of sensor Check the installed area for looseness or Reinstated by pinching.
  • Page 355 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) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective intake air pressure sensor Replace if defective.
  • Page 356 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) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Intake air pressure sensor hose detached, Repair or replace the sensor hose.
  • Page 357 FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor potention circuit - open or short circuit detected. Used diagnostic code 53 Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective EXUP servo motor potention circuit. Replace if defective. Reinstated by turn- 1.
  • Page 358 FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor is stuck. Used diagnostic code 53 Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective EXUP servo motor. Replace if defective. Reinstated by turn- 1. Disconnect the EXUP cables from the ing the main switch EXUP servomotor pulley.
  • Page 359 FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit is detected in the input line from the sidestand switch to the ECU. Used diagnostic code No. 20 (sidestand switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective sidestand switch Replace if defective.
  • Page 360 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) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Installed condition of sensor Check the installed area for looseness or Reinstated by turn- pinching.
  • Page 361 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) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective atmospheric pressure sensor. Replace if defective.
  • Page 362 FUEL INJECTION SYSTEM Fault code No. Symptom The motorcycle has overturned. Used diagnostic code No. 08 (lean angle cut-off switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective lean angle cut-off switch Replace if defective. Reinstated by turn- 1.
  • Page 363 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) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective ignition coil (test the primary and Replace if defective.
  • Page 364 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) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective ignition coil (test the primary and Replace if defective.
  • Page 365 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. Used diagnostic code No. 07 (speed sensor) No. 21 (neutral switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective speed sensor...
  • Page 366 FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09 (fuel system voltage) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Malfunction in ECU Fuel injection system relay is on. Reinstated by starting the engine Open or short circuit in the wiring harness.
  • Page 367 FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading or writing on EEP-ROM. Used diagnostic No. 60 (EEP-ROM improper cylinder indication) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Malfunction in ECU Execute diagnostic code 60 Reinstated by turn- * Check the faulty cylinder.
  • Page 368 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signal are received from the ECU. Used diagnostic code No. -- Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Open or short circuit in wiring harness and/or Repair or replace if there is an open or short Reinstated by turn- sub lead.
  • Page 369 FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Used diagnostic code No. -- Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Open or short circuit in wiring harness and/or Repair or replace if there is an open or short Reinstated by turn- sub lead.

  • Page 370: Throttle Bodies

    THROTTLE BODIES THROTTLE BODIES Order Job/Part Q’ty Remarks Removing the throttle bodies Remove the parts in the order listed. Seats/fuel tank/rubber sheet Refer to “SEATS” and “FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE” in chapter Coolant Drain.
  • Page 371 THROTTLE BODIES Order Job/Part Q’ty Remarks Throttle cable Disconnect. Plunger control unit hose Disconnect. Throttle body joint For installation, reverse the removal procedure. 7 - 30...
  • Page 372 THROTTLE BODIES Order Job/Part Q’ty Remarks Removing the injector Remove the parts in the order listed. Throttle position sensor coupler Disconnect. Intake air pressure sensor Disconnect. Cylinder #1-injector coupler Disconnect. Cylinder #2-injector coupler Disconnect. Cylinder #3-injector coupler Disconnect. Cylinder #4-injector coupler Disconnect.
  • Page 373 THROTTLE BODIES Order Job/Part Q’ty Remarks Intake air pressure sensor Fuel distributor Injector Throttle position sensor For installation, reverse the removal procedure. 7 - 32...

  • Page 374: Checking The Injector

    THROTTLE BODIES CAUTION: The throttle bodies should not be disas- sembled unnecessarily. CHECKING THE INJECTOR 1. Check: • injector Damage → Replace. CHECKING THE THROTTLE BODY 1. Check: • throttle body Cracks/damage → Replace the throttle bodies. 2. Check: • fuel passages Obstruction →...

  • Page 375: Checking The Pressure Regulator

    THROTTLE BODIES CHECKING THE PRESSURE REGULATOR 1. Check: • pressure regulator Damage → Replace. CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: • pressure regulator operation M MMM M MMM M MMM M MMM M MMM a. Remove the fuel tank. Refer to “SEATS”...

  • Page 376: 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. L LLL L LLL L LLL L LLL L LLL EAS00500 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor,...
  • Page 377 THROTTLE BODIES f. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range. The resistance does not change or it changes abruptly → Replace the throttle position sensor. The slot is worn or broken → Replace the throttle position sensor.

  • Page 378: Air Induction System

    AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INDUCTION The air induction system burns unburned exhaust gases by injecting fresh air (second- ary 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 379 AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS È To cylinder #1 1 Air cut-off valve É To cylinder #2 2 Reed valve Ê To cylinder #3 3 Air cleaner Ë To cylinder #4 7 - 38...

  • Page 380: Checking The Air Induction System

    AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection → Connect properly. Cracks/damage → Replace. • pipes Cracks/damage → Replace. 2. Check: • reed valve 1 • reed valve stopper • reed valve seat Cracks/damage →...
  • Page 381 AIR INDUCTION SYSTEM 5. Check • Al system solenoid M MMM M MMM M MMM M MMM M MMM a. Remove the AI system solenoid coupler from the wire harness. b. Connect the pocket tester (Ω × 1) to the AI system solenoid terminal as shown.

  • Page 382: Elec

    – ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 Fuse box 8 Neutral switch 2 Front brake switch 9 Rear brake switch 3 Clutch switch 0 Sidestand switch 4 Battery A Oil level switch 5 Starter relay B Radiator fan motor 6 Fuel injection system fuse C Horn 7 Main fuse...
  • Page 383 – ELEC ELECTRICAL COMPONENTS 1 Coolant temperature sensor 8 Turn signal relay 2 Intake air temperature sensor 9 Speed sensor 3 Intake air pressure sensor 0 Crankshaft position sensor 4 Lean angle cut-off switch A Cylinder identification sensor 5 Atmospheric pressure sensor B Radiator fan motor relay 6 ECU C Headlight relay 1...

  • Page 384: 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 incor- rect, check the wiring connections and if nec- essary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1.

  • Page 385: 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 ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading →...

  • Page 386: 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 con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.

  • Page 387: Checking The Condition Of The Bulbs

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 388: Checking The Condition Of The Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester YM-03112 NOTE:...

  • Page 389: Ignition System

    – ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM 1 Main switch 5 Battery 6 Fuse (main) 0 Starting circuit cut-off relay A Side stand switch C ECU D Ignition coil E Spark plug J Lean angle cut-off switch O Crankshaft position sensor R Neutral switch s Engine stop switch w Fuse (ignition)

  • Page 390: Troubleshooting

    – ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no • Check the condition of the battery. spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses Minimum open-circuit voltage 12.8 V or more at 20°C (68°F) 2.
  • Page 391 – ELEC IGNITION SYSTEM EAS00743 EAS00747 5. Ignition coil resistance 4. Ignition spark gap The following procedure applies to all of the The following procedure applies to all of the ignition coils. spark plugs. • Disconnect the ignition coil leads from the •...
  • Page 392 – ELEC IGNITION SYSTEM EAS00748 EAS00750 6. Crankshaft position sensor resistance 8. Engine stop switch • Disconnect the crankshaft position sensor • Check the engine stop switch for continu- coupler from the wire harness. ity. • Connect the pocket tester (Ω × 100) to the Refer to “CHECKING THE SWITCHES”.
  • Page 393 – ELEC IGNITION SYSTEM EAS00753 EAS00754 11.Starting circuit cut-off relay 12.Wiring • Disconnect the starting circuit cut-off relay • Check the entire ignition system’s wiring. coupler from the wire harness. Refer to “CIRCUIT DIAGRAM”. • Connect the pocket tester (Ω × 1) to the •...

  • Page 394: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 1 Main switch 5 Battery 6 Fuse (main) 8 Starter relay 9 Starter motor 0 Starting circuit cut-off relay A Side stand switch R Neutral switch e Clutch switch s Engine stop switch t Start switch w Fuse (ignition)

  • Page 395: 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: •...

  • Page 396: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses 2. battery Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F) 3.
  • Page 397 – ELEC ELECTRIC STARTING SYSTEM EAS00759 4. Starting circuit cut-off relay • Disconnect the starting circuit cut-off relay coupler from the wire harness. • Connect the pocket tester (Ω × 1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown.
  • Page 398 – ELEC ELECTRIC STARTING SYSTEM EAS00752 EAS00766 9. Sidestand switch 12.Wiring • Check the sidestand switch for continuity. • Check the entire starting system’s wiring. Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”. • Is the sidestand switch OK? •...

  • Page 399: Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM EAS00767 STARTER MOTOR 5 Nm (0.5 m kg, 3.6 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Rider seat Refer to “SEATS”...
  • Page 400 – ELEC ELECTRIC STARTING SYSTEM EAS00768 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Disassembling the starter motor Disassembly the parts in the order listed. Starter motor rear cover Bearing Starter motor yoke O-ring Armature assembly Brush Brush holder Starter motor front cover...

  • Page 401: Checking The Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM EAS00769 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600-grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 23.5 mm (0.93 in) 3.

  • Page 402: Assembling The Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Brush length wear limit 3.65 mm (0.14 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set.

  • Page 403: Charging System

    – ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM (GRAY) (BLACK) R/W L/W Br/L L/B L/Y Br/L (RED) L/Y L/B (RED) Br/L Br/L 2 AC magneto 3 Rectifier/regulator 5 Battery 6 Fuse (main) 8 - 22...

  • Page 404: 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. • Is the battery OK? Check: 1. main fuse 2. battery 3. charging voltage • Clean the battery 4.
  • Page 405 – ELEC CHARGING SYSTEM EAS00776 4. Stator coil resistance • Remove the generator cover. • Connect the pocket tester (Ω × 1) to the stator coils as shown. Positive tester probe → white 1 Negative tester probe → white 2 Positive tester probe →...

  • Page 406: Lighting System

    – ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 8 - 25...
  • Page 407 – ELEC LIGHTING SYSTEM 1 Main switch 5 Battery 6 Fuse (main) C ECU X Hi beam indicator light [ Meter light c Dimmer switch l Auxiliary light m Headlight n License light o Taillight u Headlight relay (on/off) v Headlight relay (dimmer) x Fuse (signal) y Fuse (headlight) 8 - 26...

  • Page 408: Troubleshooting

    – ELEC LIGHTING SYSTEM EAS00781 • Is the battery OK? TROUBLESHOOTING Any of the following fail to light: head- light, high beam indicator light, taillight, auxiliary light or meter light. • Clean the battery terminals. Check: • Recharge or 1. main, signal and headlight fuses replace the battery.
  • Page 409 – ELEC LIGHTING SYSTEM Low-beam 5. Headlight relay (on/off) Positive tester probe → black/blue 1 • Disconnect the headlight relay (on/off) Negative tester probe → black/green 2 from the coupler. • Connect the pocket tester (Ω × 1) and bat- tery (12 V) to the headlight relay (on/off) coupler as shown.

  • Page 410: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EAS00788 High beam indicator light CHECKING THE LIGHTING SYSTEM Positive tester probe → black/yellow 4 1. The headlight and the high beam indicator Negative tester probe → black/white 5 light fail to come on. Meter light coupler (wire harness side) 1.
  • Page 411 – ELEC LIGHTING SYSTEM EAS00789 EAS00790 2. The meter light fails to come on. 3. The tail/brake light fails to come on. 1. Meter light bulb and socket 1. Tail/brake light bulb and socket • Check the meter light bulb and socket for •...
  • Page 412 – ELEC LIGHTING SYSTEM EAS00791 EAS00792 4. The auxiliary light fails to come on. 5. The license plate light fails to come on. 1. Auxiliary light bulb and socket 1. License plate light bulb and socket • Check the auxiliary light bulb and socket •...

  • Page 413: Signaling System

    – ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 8 - 32...
  • Page 414 – ELEC SIGNALING SYSTEM 1 Main switch 4 Fuse (back up) 5 Battery 6 Fuse (main) 0 Starting circuit cut-off relay B Fuel pump C ECU I Speed sensor R Neutral switch S Fuel level warning light T Oil level warning light U Neutral indicator light W Coolant temperature indicator light Y Turn signal indicator light (L)

  • Page 415: Troubleshooting

    – ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to light: turn • Check the condition of the battery. signal light, brake light or an indicator Refer to “CHECKING AND CHARGING light. THE BATTERY” in chapter 3. •...
  • Page 416 – ELEC SIGNALING SYSTEM EAS00797 2. Voltage 2. The tail/brake light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket horn connector at the horn terminal as shown. • Check the tail/brake light bulb and socket Positive tester probe →...
  • Page 417 – ELEC SIGNALING SYSTEM • Set the main switch to “ON”. • Measure the voltage (DC 12 V) on brown 1 at the turn signal relay coupler (wire This circuit is OK. The wiring circuit harness side). from the main switch •...
  • Page 418 – ELEC SIGNALING SYSTEM Left turn signal light Positive tester probe → chocolate 1 Negative tester probe → ground Replace the neutral Right turn signal light Positive tester probe → dark green 2 indicator light bulb, Negative tester probe → ground socket or both.
  • Page 419 – ELEC SIGNALING SYSTEM EAS00802 3. Voltage 5. The oil level warning light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Oil level warning light bulb and socket meter assembly coupler (wire harness •...

  • Page 420: Fuel Sender Coupler

    – ELEC SIGNALING SYSTEM 2. Fuel sender 3. Voltage • Drain the fuel from the fuel tank and • Connect the pocket tester (DC 20 V) to the remove the fuel pump from the fuel tank. meter assembly coupler (wire harness •...
  • Page 421 – ELEC SIGNALING SYSTEM 2. Voltage 3. Speed sensor • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness speed sensor coupler (wire harness side) side) as shown.

  • Page 422: Cooling System

    – ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM 1 Main switch C ECU z Fuse (fan motor) 5 Battery Q Coolant temperature sensor { Fan motor relay 6 Fuse (main) w Fuse (ignition) | Fan motor 8 - 41...

  • Page 423: Troubleshooting

    – ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery • The radiator fan motor fails to turn. • Check the condition of the battery. • The coolant temperature meter (meter Refer to “CHECKING AND CHARGING assembly) fails to indicate when the THE BATTERY”...
  • Page 424 – ELEC COOLING SYSTEM EAS00809 5. Radiator fan motor relay 4. Radiator fan motor • Disconnect the radiator fan motor relay • Disconnect the radiator fan motor coupler from the wire harness. from the wire harness. • Connect the pocket tester (Ω × 1) and bat- •...
  • Page 425 – ELEC COOLING SYSTEM EAS00812 6. Coolant temperature sensor • Remove the coolant temperature sensor from the thermostat housing. • Connect the pocket tester (Ω × 1k) to the coolant temperature sensor 1 as shown. • Immerse the coolant temperature sensor in a container filled with coolant 2.

  • Page 426: Fuel Pump System

    – ELEC FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM 1 Main switch 5 Battery 6 Fuse (main) 7 Fuse (fuel injection) 0 Starting circuit cut-off relay B Fuel pump C ECU s Engine stop switch w Fuse (ignition) 8 - 45...
  • Page 427 – ELEC FUEL PUMP SYSTEM EAS00815 FUEL PUMP SYSTEM 1 Battery The ECU includes the control unit for the fuel 2 Main fuse pump. 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 ECU 7 Fuel injection system fuse 8 Fuel injection system relay 9 Fuel pump 8 - 46...

  • Page 428: Troubleshooting

    – ELEC FUEL PUMP SYSTEM EAS00816 EAS00739 TROUBLESHOOTING 2. Battery If the fuel pump fails to operate. • Check the condition of the battery Refer to “CHECKING THE BATTERY” in Check: chapter 3. 1. Main and fuel injection system fuses 2.

  • Page 429: Fuel Pump Coupler

    – ELEC FUEL PUMP SYSTEM EAS00759 EAS00817 5. Starting circuit cut-off relay 6. Fuel pump resistance • Disconnect the starting circuit cut-off relay • Disconnect the fuel pump coupler from the coupler from the wire harness. wire harness. • Connect the pocket tester (Ω × 1) and bat- •...

  • Page 430: 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 dan- ger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refueling. •...

  • Page 431: Starting Failures

    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 man- ual for checks, adjustments, and replacement of parts.

  • Page 432: Trbl Shtg

    STARTING FAILURES/ TRBL INCORRECT ENGINE IDLING SPEED SHTG ELECTRICAL SYSTEMS Battery Ignition system • Discharged battery • Faulty ECU • Faulty battery • Faulty crankshaft position sensor Fuse(s) • Broken generator rotor woodruff key • Blown, damaged or incorrect fuse Switches and wiring •...

  • Page 433: Poor Medium-And-High-Speed Performance

    POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL FAULTY GEAR SHIFTING/FAULTY CLUTCH SHTG EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES”. ENGINE FUEL SYSTEM Air filter Fuel pump • Clogged air filter element • Faulty fuel pump EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT JUMPS OUT OF GEAR Refer to “CLUTCH DRAGS”.

  • Page 434: Overheating

    OVERHEATING/OVERCOOLING/ TRBL POOR BRAKING PERFORMANCE SHTG EAS00855 OVERHEATING ENGINE FUEL SYSTEM Clogged coolant passages Throttle body(-ies) • Cylinder head(s) and piston(s) • Incorrect main jet setting • Heavy carbon buildup • Incorrect fuel level Engine oil • Damaged or loose throttle body joint •...

  • Page 435: Unstable Handling

    FAULTY FRONT FORK LEGS/ TRBL UNSTABLE HANDLING SHTG EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL MALFUNCTION • Bent, damaged or rusty inner tube • Bent or damaged inner tube • Cracked or damaged outer tube • Bent or damaged outer tube •...

  • Page 436: 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 • Wrong headlight bulb • Faulty turn signal switch • Too many electrical accessories • Faulty turn signal relay •...
  • Page 437 YZF-R1P/YZF-R1PC WIRING DIAGRAM 1 Main switch 2 AC magneto 3 Rectifier/regulator 4 Fuse (back up) 5 Battery 6 Fuse (main) 7 Fuse (fuel injection system) 8 Starter relay 9 Starter motor 0 Starting circuit cut-off relay A Sidestand switch B Fuel pump...
  • Page 438 YZF-R1P/YZF-R1PC WIRING DIAGRAM (GRAY) (GRAY) MAIN HARNESS WIRE SUB LEAD 1 MAIN HARNESS CORD TAIL LIGHT MAIN HARNESS CORD HEAD LIGHT MAIN HARNESS CORD HEAD LIGHT (BLACK) (GRAY) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (GRAY) (GRAY) MAIN HARNESS WIRE SUB LEAD 4...
  • Page 439 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.

This manual is also suitable for:

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