Yamaha YZFR1Y(C) 2009 Service Manual
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Yamaha YZFR1Y(C) 2009 Service Manual

Motorcycle
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Table of Contents

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2009
SERVICE MANUAL
YZFR1Y(C)
LIT-11616-22-78
14B-28197-10

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Summary of Contents for Yamaha YZFR1Y(C) 2009

  • Page 1 2009 SERVICE MANUAL YZFR1Y(C) LIT-11616-22-78 14B-28197-10...
  • Page 2 EAS20050 YZFR1Y(C) SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, December 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Cor- poration, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-22-78...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 4: How To Use This Manual

    EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...

  • Page 5: Symbols

    EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine Gear oil mounted Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    MODEL LABEL ..................1-1 FEATURES ....................1-2 OUTLINE OF THE FI SYSTEM ..............1-2 FI SYSTEM .....................1-3 YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake) ..........1-4 INSTRUMENT FUNCTIONS ..............1-8 IMPORTANT INFORMATION ..............1-15 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-15 REPLACEMENT PARTS...............1-15 GASKETS, OIL SEALS AND O-RINGS..........1-15 LOCK WASHERS/PLATES AND COTTER PINS .........1-15...

  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the seat rail reinforcement under the passenger seat. This information will be needed to order spare parts.

  • Page 11: Features

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

  • Page 12: Fi System

    FEATURES EAS14B1017 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm², 47.0 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus- ing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 13: Ycc-T (Yamaha Chip Controlled Throttle) Ycc-I (Yamaha Chip Controlled Intake)

    YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake) Mechanism characteristics Yamaha developed the YCC-T and YCC-I system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a faster, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
  • Page 14 FEATURES Aims and advantages of using YCC-I system • Improvement of the engine power characteristics The high power design in all ranges is now provided by having both two features of the short intake function to ensure the power at the high speed revolution of engine, and the long intake function to ensure the power in the practical use range.
  • Page 15 FEATURES YCC-T/YCC-I system outline 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. ECU (engine control unit) 5. ETV main CPU (32 bit) 6. FI CPU (32 bit) 7. Throttle servo motor driver 8. Throttle servo motor driver operation sens- ing/shut off circuit 9.
  • Page 16 FEATURES YCC-T/YCC-I control outline 17.ECU (engine control unit) 1. Accelerator position sensor 18.Base map 2. Throttle position sensor 19.Idle speed control 3. Crankshaft position sensor 20.Calculated throttle valve opening angle 4. Speed sensor 21.Base map 5. D-mode switch 22.Air funnel position (Calculation value) 6.

  • Page 17: Instrument Functions

    FEATURES EAS14B4002 • A throttle opening position display INSTRUMENT FUNCTIONS • A fuel consumption display (instantaneous and average consumption functions) Multi-function meter unit • A self-diagnosis device • A display brightness, shift timing indicator light and throttle opening position display control mode •...
  • Page 18 FEATURES Clock and stopwatch modes Split-time history 1. Coolant temperature display/air intake tem- 1. Clock/stopwatch perature display To set the clock 2. Stopwatch 1. Push the “SELECT” button and “RESET” The split-time history displays up to 20 stored button together for at least two seconds. split times.
  • Page 19 FEATURES Odometer, tripmeter, instantaneous fuel Instantaneous fuel consumption mode consumption and average fuel consump- tion modes 1. Instantaneous fuel consumption The instantaneous fuel consumption display 1. Odometer/tripmeter/fuel reserve tripmeter/ can be set to either “km/L”, “L/100 km” or instantaneous fuel consumption/average fuel consumption “MPG”.
  • Page 20 FEATURES This display shows the average fuel consump- Throttle opening position display tion since it was last reset. • When the display is set to “AV_ _._ km/L”, the average distance that can be traveled on 1.0 L of fuel is shown. •...
  • Page 21 If the display indicates any error codes, note Air intake temperature display the code number, and then have a Yamaha dealer check the vehicle. ECA14B1017 If the display indicates an error code, the vehicle should be checked as soon as pos- sible in order to avoid engine damage.
  • Page 22 FEATURES This mode allows you to make changes to six To set the shift timing indicator light activity settings by performing the following steps. function 1. Turn the key to “OFF”. 1. Push the “RESET” button to select one of 2.
  • Page 23 FEATURES function, otherwise the shift timing indicator light remains deactivated. Before using D-mode, make sure you under- stand its operation along with the operation of 1. Push the “RESET” button to select the the drive mode switch “MODE”. desired engine speed for deactivating the indicator light.

  • Page 24: Important Information

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

  • Page 25: Bearings And Oil Seals

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

  • Page 26: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead • Coupler • If there is no continuity, clean the terminals. •...

  • Page 27: Handling The Electronic Parts

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

  • Page 28: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-21, 4-73 90890-01403 Exhaust flange nut wrench YU-A9472 Damper rod holder 4-64, 4-66 90890-01506 YM-01506 Oil filter wrench 3-27 90890-01426 YU-38411 Rod holder 4-63, 4-69 90890-01434 Damper rod holder double ended YM-01434 Rod puller 4-67, 4-69...
  • Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller attachment (M10) 4-67, 4-69 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Fork spring compressor 4-63, 4-69 90890-01441 YM-01441 Fork seal driver 4-66, 4-67 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Vacuum gauge 90890-03094...
  • Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 Valve spring compressor 5-30, 5-36 90890-04019 YM-04019 Valve spring compressor attachment 5-30, 5-36 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Middle driven shaft bearing driver 6-14 90890-04058 Bearing driver 40 mm...
  • Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover (ø5) 5-32 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide remover (ø4.5) 5-32 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide installer (ø5) 5-32 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide installer (ø4.5) 5-32...
  • Page 33 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pivot shaft wrench adapter 5-10 90890-01476 Valve lapper 90890-04101 Valve lapping tool YM-A8998 Oil pressure adapter H 3-29 90890-03139 Pressure gauge 3-29, 7-18 90890-03153 YU-03153 Fuel pressure adapter 7-18 90890-03176 YM-03176 Fuel injector pressure adapter 7-18 90890-03210 YU-03210...
  • Page 34 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder (22 mm) 4-82, 4-83 90890-01365 Drive chain cut & rivet tool 4-85, 4-86 90890-01550 Piston installing tool 5-81 90890-04161 YM-04161 Rotor puller 5-38 2K7-85555-00 Sheave holder 5-38, 5-41, 5- 90890-01701 42, 5-44 Primary clutch holder...
  • Page 35 Test harness-speed sensor (3P) 8-121, 8-125 90890-03208 YU-03208 Test harness-lean angle sensor (6P) 8-117 90890-03209 YU-03209 Test harness S-pressure sensor 5S7 (3P) 8-124, 8-126 90890-03211 YU-03211 Yamaha bond No. 1215 5-24, 5-39, 5- (Three bond No. 1215®) 45, 5-73 90890-85505 1-26...
  • Page 36 SPECIAL TOOLS 1-27...

  • Page 37: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-9 ELECTRICAL SPECIFICATIONS...............2-12 TIGHTENING TORQUES................2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-15 ENGINE TIGHTENING TORQUES ............2-16 CHASSIS TIGHTENING TORQUES ............2-20 LUBRICATION POINTS AND LUBRICANT TYPES ........2-24 ENGINE ....................2-24 CHASSIS ....................2-26 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-27 ENGINE OIL LUBRICATION CHART ...........2-27 LUBRICATION DIAGRAMS ..............2-29 COOLING SYSTEM DIAGRAMS ...............2-45...

  • Page 38: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 14B4/14B7 (USA) 14B5/14B8 (California) Dimensions Overall length 2070 mm (81.5 in) Overall width 715 mm (28.1 in) Overall height 1130 mm (44.5 in) Seat height 835 mm (32.9 in) Wheelbase 1415 mm (55.7 in) Ground clearance 135 mm (5.31 in) Minimum turning radius...

  • Page 39: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 998.0 cm³ Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 78.0 × 52.2 mm (3.07 × 2.06 in) Compression ratio 12.70 : 1 Standard compression pressure (at sea level) 1480 kPa/350 r/min (14.8 kgf/cm²/350 r/min, 210.5 psi/350 r/min) Minimum–Maximum...
  • Page 40 ENGINE SPECIFICATIONS 85 °C (185.0 °F) Valve full open temperature Valve lift (full open) More than 8 mm (0.31 in) Radiator core Width 383.0 mm (15.08 in) Height 250.6 mm (9.87 in) Depth 24.0 mm (0.94 in) Water pump Water pump type Single suction centrifugal pump 65/43 ×...
  • Page 41 ENGINE SPECIFICATIONS Valve, valve seat, valve guide Valve clearance (cold) Intake 0.11–0.20 mm (0.0043–0.0079 in) Exhaust 0.21–0.25 mm (0.0083–0.0098 in) Valve dimensions Valve head diameter A (intake) 30.90–31.10 mm (1.2165–1.2244 in) Valve head diameter A (exhaust) 24.90–25.10 mm (0.9803–0.9882 in) Valve face width B (intake) 1.200–2.475 mm (0.0472–0.0974 in) Valve face width B (exhaust)
  • Page 42 ENGINE SPECIFICATIONS Valve spring Inner spring Free length (intake) 39.33 mm (1.55 in) Limit 37.36 mm (1.47 in) Free length (exhaust) 37.96 mm (1.49 in) Limit 36.06 mm (1.42 in) Installed length (intake) 34.50 mm (1.36 in) Installed length (exhaust) 33.00 mm (1.30 in) Spring rate K1 (intake) 41.57 N/mm (4.24 kgf/mm, 237.36 lbf/in)
  • Page 43 ENGINE SPECIFICATIONS End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Limit 0.50 mm (0.0197 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring Ring type Taper Dimensions (B × T) 0.80 × 2.75 mm (0.03 × 0.11 in) End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Limit...
  • Page 44 ENGINE SPECIFICATIONS Clutch Clutch type Wet, multiple-disc Clutch release method Outer pull, rack and pinion pull Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.82 mm (0.111 in) Plate quantity 9 pcs Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in) Plate quantity...
  • Page 45 ENGINE SPECIFICATIONS Accelerator position sensor resistance 1.2–2.8 kΩ Output voltage (at idle) 0.63–0.73 V Fuel injection sensor 248–372 Ω at 20 °C (68 °F) Crankshaft position sensor resistance Cylinder identification sensor output voltage (ON) Less than 0.8 V Cylinder identification sensor output voltage (OFF) More than 4.8 V Atmospheric pressure sensor output voltage...

  • Page 46: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 24.0° Trail 102.0 mm (4.02 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 47 CHASSIS SPECIFICATIONS Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.8 mm (0.03 in) Master cylinder inside diameter 16.00 mm (0.63 in) 24.05 mm × 3 (0.95 in × 3) Caliper cylinder inside diameter Recommended fluid DOT 4 Rear brake Type Single disc brake...
  • Page 48 CHASSIS SPECIFICATIONS Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 60.0 mm (2.36 in) Spring free length 159.5 mm (6.28 in) Installed length 147.5 mm (5.81 in) Spring rate K1 98.10 N/mm (10.00 kgf/mm, 560.15 lb/in) Spring stroke K1 0.0–60.0 mm (0.00–2.36 in) Optional spring available...

  • Page 49: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system TCI (digital) Ignition timing (B.T.D.C.) 5.0°/1200 r/min Engine control unit Model/manufacturer TBDF66/DENSO Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 0.85–1.15 Ω Primary coil resistance Secondary coil resistance 8.50–11.50 kΩ...
  • Page 50 ELECTRICAL SPECIFICATIONS Coolant temperature warning light Engine trouble warning light Steering damper warning light Shift timing indicator light Electric starting system System type Constant mesh Starter motor Power output 0.90 kW Armature coil 0.0090–0.0110 Ω at 20 °C (68 °F) Commutator resistance Above 1 MΩ...
  • Page 51 ELECTRICAL SPECIFICATIONS Signaling system fuse 7.5 A Ignition fuse 15.0 A 15.0 A × 2 Radiator fan fuse Fuel injection system fuse 15.0 A Steering damper fuse 7.5 A Backup fuse 7.5 A ETV (Electronic Throttle Valve) fuse 7.5 A Spare fuse 20.0 A 15.0 A ×...

  • Page 52: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.

  • Page 53: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plugs 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Cylinder head nut See TIP. Cylinder head nut See TIP. Cylinder head bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head cover bolt...
  • Page 54 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Throttle body and throttle body 3 Nm (0.3 m·kgf, 2.2 ft·lbf) joint clamp Throttle position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Accelerator position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Intake funnel joint bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Air filter case screw...
  • Page 55 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Pickup rotor cover 2 bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Crankcase breather case bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Oil baffle plate bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
  • Page 56 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Speed sensor bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head nut Use new nuts and washers. 1. Apply engine oil to bolt thread and mating surface. 2. Tighten the bolt to 10 Nm (1.0 m·kgf, 7.2 ft·lbf). 3.

  • Page 57: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front side) 70 Nm (7.0 m·kgf, 50 ft·lbf) Engine mounting nut (rear side) 51 Nm (5.1 m·kgf, 37 ft·lbf) Engine mount adjusting bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Clutch cable locknut (engine side) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Clutch lever holder bolt...
  • Page 58 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Handlebar end grip bolt 4 Nm (0.4 m·kgf, 2.9 ft·lbf) Front brake hose joint bracket bolt 11 Nm (1.1 m·kgf, 8.0 ft·lbf) Coolant reservoir bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Air chamber bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Left lower cowling bracket bolt...
  • Page 59 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front wheel axle pinch bolt 21 Nm (2.1 m·kgf, 15 ft·lbf) See TIP. Rider footrest bolt 28 Nm (2.8 m·kgf, 20 ft·lbf) Passenger footrest bolt 28 Nm (2.8 m·kgf, 20 ft·lbf) Rear frame lower reinforcement 13 Nm (1.3 m·kgf, 9.4 ft·lbf) and passenger footrest bolt...
  • Page 60 TIGHTENING TORQUES At this stage, it can be accepted if the end face of the axle becomes partially concave to the end face of the fork. 4. In the order from the pinch bolt “4” → pinch bolt “3” → pinch bolt “4”, tighten each bolt to 21 Nm (2.1 m·kgf, 15 ft·lbf) without performing temporary tightening.

  • Page 61: Lubrication Points And Lubricant Types

    Oil/water pump assembly drive sprocket collar and washer Transmission gears (wheel and pinion) Main axle and drive axle Shift forks and shift fork guide bars Three bond Cylinder head cover mating surface No.1541C® Yamaha bond Cylinder head cover semicircular No.1215 (Three bond No.1215®) 2-24...
  • Page 62 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond Crankcase mating surface No.1215 (Three bond No.1215®) Yamaha bond Crankcase cover (lead grommet) No.1215 (Three bond No.1215®) 2-25...

  • Page 63: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Throttle grip inner surface and throttle cable end Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Clutch cable end Engine mounting bolts (rear upper and lower side) Relay arm, connecting arm and rear shock absorber spacer...

  • Page 64: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-27...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Sub gallery 6. Oil filter cartridge 7. Main gallery 8. Mission shower 9. Drive axle 10.Main axle 11.Shift fork (upper) 12.Crankshaft 13.Oil nozzle 14.Balancer shaft 15.Timing chain tensioner 16.Intake camshaft...

  • Page 66: Lubrication Diagrams

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

  • Page 82: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-45...
  • Page 83 COOLING SYSTEM DIAGRAMS 1. Oil/water pump assembly 2. Radiator 3. Radiator fan 4. Thermostat 5. Oil cooler 2-46...
  • Page 84 COOLING SYSTEM DIAGRAMS 2-47...
  • Page 85 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Radiator fan 4. Oil cooler 2-48...

  • Page 86: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-49...
  • Page 87 CABLE ROUTING 1. Meter lead 2. Ground lead 3. Meter 4. Meter bracket 5. Right auxiliary light lead 6. Headlight sub-wire harness 7. Headlight lead 8. Intake air temperature sensor 9. Left auxiliary light lead 10.Right air intake air duct cover 11.Turn signal relay 12.Headlight relay 13.Left air intake air duct cover...
  • Page 88 CABLE ROUTING 2-51...
  • Page 89 CABLE ROUTING S. Cut off the excess end of the plastic band 1. Clutch cable leaving 2–4 mm (0.08–0.16 in). Connect it 2. Main switch lead at the position shown in the illustration. 3. Left handlebar switch lead 4. Steering damper lead 5.
  • Page 90 CABLE ROUTING 2-53...
  • Page 91 CABLE ROUTING 1. Headlight sub-wire harness 2. Right radiator fan motor lead 3. AC magneto lead 4. Crankshaft position sensor 5. Coolant reservoir hose 6. Throttle cable 7. Right handlebar switch lead 8. Clutch cable 9. Main harness 10.Rectifier/regulator 11.Rectifier/regulator bracket 12.Right handlebar switch lead 13.Oil cooler outlet hose A.
  • Page 92 CABLE ROUTING 2-55...
  • Page 93 CABLE ROUTING 1. Ignition coil lead 2. Crankshaft position sensor lead 3. Rear brake light switch lead 4. O sensor lead A. Route the rear brake light switch lead out- side of the O sensor lead and push it to the occluding surface of the clutch cover.
  • Page 94 CABLE ROUTING 2-57...
  • Page 95 CABLE ROUTING Q. Route the rear brake light switch lead 1. Union bolt between the top and bottom frame bosses 2. Washer for installing the right footrest assembly 3. Exhaust chamber cover and to inside of the frame. 4. Right footrest assembly 5.
  • Page 96 CABLE ROUTING 2-59...
  • Page 97 CABLE ROUTING 1. Left radiator fan motor lead 2. Radiator fan motor relay 3. ECU (engine control unit) 4. Radiator inlet pipe A. Insert the clamp winding the main harness into the ECU bracket hole. B. To the main harness branch lead, throttle body C.
  • Page 98 CABLE ROUTING 2-61...
  • Page 99 CABLE ROUTING 1. Oil level switch lead 2. Gear position sensor lead 3. Speed sensor lead 4. Sidestand switch lead 5. Fuel tank breather hose (Except for Califor- nia) 6. Fuel tank overflow hose 7. Coolant reservoir breather hose 8. Sidestand switch 9.
  • Page 100 CABLE ROUTING 2-63...
  • Page 101 CABLE ROUTING H. Route the starter motor lead and fuel pump 1. Right handlebar switch lead lead under the fuel tank breather hose and 2. Headlight sub-wire harness fuel tank overflow hose, behind the fuel 3. Right radiator fan motor lead hose and above the ground lead and bat- 4.
  • Page 102 CABLE ROUTING 2-65...
  • Page 103 CABLE ROUTING 1. Rear frame 2. Right upper tail cover bracket 3. License plate light lead 4. Right turn signal light lead 5. Left turn signal light lead 6. Battery box 2 7. Tail/brake light lead 8. Lean angle sensor lead 9.
  • Page 104 CABLE ROUTING 2-67...
  • Page 105 CABLE ROUTING S. Install the canister hose with the 90° bent 1. Fuel tank upper cover hose to the canister side and about parallel 2. Fuel tank breather hose to the rollover valve. 3. Fuel tank overflow hose T. To the throttle body 4.
  • Page 106 CABLE ROUTING 2-69...
  • Page 107 CABLE ROUTING 1. Upper air filter case 2. Fuel hose (secondary injector fuel rail side) 3. Fuel hose (primary injector fuel rail side) 4. Primary injector fuel rail 5. Sub-wire harness (secondary injector side) 6. Throttle cable (pull side) 7. Throttle cable (return side) 8.
  • Page 108 CABLE ROUTING 2-71...
  • Page 109 CABLE ROUTING 1. Cap case 2. Upper air filter case 3. Sub-wire harness 4. Cap case assembly 5. Grommet 6. Plastic locking tie 7. Fuel rail A. Sub-wire harness should not be pinched under the bearing surface of the bolt. B.
  • Page 110 CABLE ROUTING 2-73...

  • Page 111: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .....3-2 CHECKING THE FUEL LINE (Primary injector) ........3-4 CHECKING THE FUEL LINE (Secondary injector) ........3-4 CHECKING THE SPARK PLUGS............3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5 SYNCHRONIZING THE THROTTLE BODIES ........3-9 CHECKING THE THROTTLE BODY JOINTS ........3-10...
  • Page 112 CHECKING THE COOLING SYSTEM ..........3-29 CHANGING THE COOLANT ..............3-30 CHECKING THE FRONT BRAKE LIGHT SWITCH ......3-32 ADJUSTING THE REAR BRAKE LIGHT SWITCH ......3-32 CHECKING AND LUBRICATING THE CABLES ........3-32 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-32 LUBRICATING THE REAR SUSPENSION ..........3-33 CHECKING AND CHARGING THE BATTERY........3-33 CHECKING THE FUSES..............3-33 REPLACING THE HEADLIGHT BULBS..........3-33...

  • Page 114: Periodic Maintenance

    • Check the air cut-off valve, reed valve, and hose for dam- Air induction sys- √ √ age. • Replace any damaged parts if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

  • Page 115: General Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE EAS14B1034 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) 1 month 6 months 12 months 18 months 24 months...
  • Page 116 • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.

  • Page 117: Checking The Fuel Line (Primary Injector)

    PERIODIC MAINTENANCE EAS21030 4. Install: CHECKING THE FUEL LINE (Primary injec- • Fuel tank tor) Refer to “FUEL TANK” on page 7-1. The following procedure applies to all of the 5. Install: fuel, vacuum and breather hoses. • Rider seat 1.

  • Page 118: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE 2. Remove: • Fuel tank Refer to “FUEL TANK” on page 7-1. 3. Remove: • Air filter case Refer to “AIR FILTER CASE” on page 7- 4. Remove: • Radiator • Radiator fan Refer to “RADIATOR” on page 6-1. 11.
  • Page 119 PERIODIC MAINTENANCE • Fuel tank (At this time, make sure the intake cam- Refer to “FUEL TANK” on page 7-1. shaft sprocket punch mark “c” and cylinder • Air filter case head occluding surface “d”, and exhaust Refer to “AIR FILTER CASE” on page 7- camshaft sprocket punch mark “e”...
  • Page 120 PERIODIC MAINTENANCE d. Measure the valve clearance #1 with a h. Measure the valve clearance #2 and #4 thickness gauge “1”. with a thickness gauge. Thickness gauge Thickness gauge 90890-03180 90890-03180 Feeler gauge set Feeler gauge set YU-26900-9 YU-26900-9 • If the valve clearance is incorrect, record the measured reading.
  • Page 121 PERIODIC MAINTENANCE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Since valve pads of various sizes are origi- a. Remove the valve lifter “1” and the valve nally installed, the valve pad number must be pad “2” with a valve lapper “3”. rounded in order to reach the closest equiva- lent to the original.

  • Page 122: Synchronizing The Throttle Bodies

    PERIODIC MAINTENANCE Checking the throttle body synchronization 1. Stand the vehicle on a level surface. • Lubricate the valve pad with molybdenum disulfide oil. • Lubricate the valve lifter with engine oil. Place the vehicle on a suitable stand. • The valve lifter must turn smoothly when 2.

  • Page 123: Checking The Throttle Body Joints

    PERIODIC MAINTENANCE • Fuel tank Refer to “FUEL TANK” on page 7-1. 6. Check: • Throttle body synchronization ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed •...

  • Page 124: Checking The Crankcase Breather Hose

    PERIODIC MAINTENANCE EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Remove: • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: • Passenger seat 3. Install: Refer to “GENERAL CHASSIS” on page •...

  • Page 125: Checking The Air Induction System

    PERIODIC MAINTENANCE 4. Check: • Air filter element “1” • Air filter seal Damage → Replace. • Replace the air filter element every 40000 km (24000 mi) of operation. • The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 126: Adjusting The Clutch Cable Free Play

    PERIODIC MAINTENANCE EAS20870 b. Turn the adjusting bolt “2” in direction “a” or ADJUSTING THE CLUTCH CABLE FREE “b” until the specified clutch cable free play PLAY is obtained. 1. Check: • Clutch cable free play “a” Direction “a” Out of specification → Adjust. Clutch cable free play is increased.

  • Page 127: Adjusting The Front Disc Brake

    PERIODIC MAINTENANCE EAS21160 ADJUSTING THE FRONT DISC BRAKE 1. Adjust: • Brake lever position (distance “a” from the throttle grip to the brake lever) While pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in the desired position.

  • Page 128: Adjusting The Rear Disc Brake

    PERIODIC MAINTENANCE 2. Check: EWA13070 WARNING • Front brake pad Wear indicators “1” almost touch the After adjusting the brake pedal position, brake disc → Replace the brake pads as check that the end of the adjusting bolt “c” a set. is visible through the hole “d”.

  • Page 129: Bleeding The Hydraulic Brake System

    PERIODIC MAINTENANCE EAS21360 BLEEDING THE HYDRAULIC BRAKE SYS- EWA13100 WARNING Bleed the hydraulic brake system when- ever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. •...

  • Page 130: Checking The Front Brake Hoses

    PERIODIC MAINTENANCE the throttle grip or the brake pedal to fully EAS21290 CHECKING THE REAR BRAKE HOSE extend. 1. Check: h. Tighten the bleed screw and then release • Brake hose “1” Cracks/damage/wear → Replace. the brake lever or brake pedal. Repeat steps (e) to (h) until all of the air 2.
  • Page 131 PERIODIC MAINTENANCE Tire air pressure (measured on cold tires) Loading condition 0–90 kg (0–198 lb) Front 250 kPa (2.50 kgf/cm², 36 psi, 2.50 bar) Rear 290 kPa (2.90 kgf/cm², 42 psi, 2.90 bar) Loading condition EWA13180 90–189 kg (198–417 lb) WARNING Front •...

  • Page 132: Checking The Wheel Bearings

    The following procedure applies to all of the given if a tire combination other than one wheel bearings. approved by Yamaha is used on this vehi- 1. Check: cle. • Wheel bearings Refer to “CHECKING THE FRONT Front tire WHEEL”...

  • Page 133: Lubricating The Drive Chain

    PERIODIC MAINTENANCE Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Move the rear wheel several times and find the tightest position of drive chain. 3. Check: • Drive chain slack “a” Out of specification → Adjust. To maintain the proper wheel alignment, adjust both sides evenly.
  • Page 134 PERIODIC MAINTENANCE EWA13120 Steering nut wrench WARNING 90890-01403 Securely support the vehicle so that there Exhaust flange nut wrench is no danger of it falling over. YU-A9472 Place the vehicle on a suitable stand so that Lower ring nut (initial tightening the front wheel is elevated.

  • Page 135: Checking The Steering Damper

    PERIODIC MAINTENANCE EAS14B1092 CHECKING THE STEERING DAMPER Refer to “CHECKING THE STEERING DAMPER” on page 4-74. EAS14B1093 CHECKING THE CHASSIS FASTENERS Make sure that all nuts, bolts, and screws are properly tightened. Refer to “CHASSIS TIGHTENING TORQUES” on page 2-20. EAS21700 2.

  • Page 136: Lubricating The Sidestand

    PERIODIC MAINTENANCE EAS21720 Spring preload LUBRICATING THE SIDESTAND EWA14B1026 Lubricate the pivoting point and metal-to-metal WARNING moving parts of the sidestand. Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- Recommended lubricant dling and loss of stability. Lithium-soap-based grease ECA13570 EAS14B1095...

  • Page 137: Checking The Rear Shock Absorber Assembly

    PERIODIC MAINTENANCE Compression damping Spring preload adjusting posi- ECA13590 tions Minimum Never go beyond the maximum or minimum adjustment positions. Standard 1. Adjust: • Compression damping (left side) Maximum ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ or “b”.
  • Page 138 PERIODIC MAINTENANCE Spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ECA13590 a. Turn the adjusting screw “1” in direction “a” or “b”. Never go beyond the maximum or minimum Direction “a” adjustment positions. Rebound damping increased 1. Adjust: (suspension is harder). • Spring preload Direction “b” Rebound damping decreased...

  • Page 139: Checking The Connecting Arm And Relay Arm

    PERIODIC MAINTENANCE Minimum 4 turn(s) out* Standard 3 turn(s) out* Maximum 0 turn(s) out* * With the adjusting screw fully turned in ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS14B1097 CHECKING THE CONNECTING ARM AND RELAY ARM Refer to “CHECKING THE CONNECTING ARM AND RELAY ARM” on page 4-77. EAS20730 CHECKING THE ENGINE OIL LEVEL 1.

  • Page 140: Changing The Engine Oil

    PERIODIC MAINTENANCE ECA13360 • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of CD “a” or higher and do not use oils labeled “ENERGY CON- SERVING II”...

  • Page 141: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE ECA13390 12. Check: • Engine oil level Refer to “CHECKING THE ENGINE OIL Make sure the O-ring “3” is positioned cor- LEVEL” on page 3-26. rectly in the groove of the oil filter car- tridge. EAS20820 MEASURING THE ENGINE OIL PRESSURE 1.

  • Page 142: Checking The Coolant Level

    PERIODIC MAINTENANCE 2. Check: Pressure gauge • Coolant level 90890-03153 The coolant level should be between the YU-03153 maximum level mark “a” and minimum Oil pressure adapter H level mark “b”. 90890-03139 Below the minimum level mark → Add the recommended coolant to the proper level.

  • Page 143: Changing The Coolant

    PERIODIC MAINTENANCE • Water pump inlet pipe “9” • Water pump outlet pipe “10” Cracks/damage → Replace. Refer to “RADIATOR” on page 6-1 and “OIL COOLER” on page 6-5. EWA13030 WARNING 3. Install: A hot radiator is under pressure. Therefore, •...
  • Page 144 PERIODIC MAINTENANCE • If coolant is swallowed, induce vomiting and get immediate medical attention. ECA13480 • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant.

  • Page 145: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE EAS14B1098 Replace damaged outer cable and inner CHECKING THE FRONT BRAKE LIGHT cables as soon as possible. SWITCH 1. Check: Refer to “ELECTRICAL COMPONENTS” on • Outer cable page 8-101. Damage → Replace. 2. Check: EAS21330 ADJUSTING THE REAR BRAKE LIGHT •...

  • Page 146: Lubricating The Rear Suspension

    PERIODIC MAINTENANCE Direction “a” Throttle cable free play is increased. Direction “b” Throttle cable free play is decreased. c. Tighten the locknut “1”. 2. Disconnect: • Headlight coupler “1” EWA14B1016 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 147: Adjusting The Headlight Beams

    PERIODIC MAINTENANCE the transparency of the glass, the life of the Direction “a” bulb and the luminous flux will be Headlight beam moves to the left. adversely affected. If the headlight bulb Direction “b” gets soiled, thoroughly clean it with a cloth Headlight beam moves to the right.
  • Page 148 PERIODIC MAINTENANCE 3-35...

  • Page 149: Chassis

    CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE QUICK FASTENER (SCREW TYPE).......4-11 INSTALLING THE QUICK FASTENER (SCREW TYPE)......4-11 REMOVING THE QUICK FASTENER (PUSH TYPE) ......4-11 INSTALLING THE QUICK FASTENER (PUSH TYPE) ......4-11 REMOVING THE QUICK FASTENER (PULL TYPE) ......4-11 INSTALLING THE QUICK FASTENER (PULL TYPE) ......4-12 INSTALLING THE PASSENGER SEAT LOCK CYLINDER ....4-12 REMOVING THE FRONT TURN SIGNAL/POSITION LIGHTS....4-12 INSTALLING THE FRONT TURN SIGNAL/POSITION LIGHTS ..4-12...
  • Page 150 CHECKING THE FRONT BRAKE CALIPERS ........4-38 ASSEMBLING THE FRONT BRAKE CALIPERS .........4-39 INSTALLING THE FRONT BRAKE CALIPERS........4-39 REMOVING THE FRONT BRAKE MASTER CYLINDER.....4-40 CHECKING THE FRONT BRAKE MASTER CYLINDER .....4-40 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER....4-41 INSTALLING THE FRONT BRAKE MASTER CYLINDER ....4-41 REAR BRAKE ....................4-43 INTRODUCTION ..................4-48 CHECKING THE REAR BRAKE DISC ..........4-48...
  • Page 151 SWINGARM ....................4-79 REMOVING THE SWINGARM .............4-81 CHECKING THE SWINGARM .............4-82 INSTALLING THE SWINGARM ............4-82 CHAIN DRIVE .....................4-84 REMOVING THE DRIVE CHAIN ............4-85 CHECKING THE DRIVE CHAIN ............4-85 CHECKING THE DRIVE SPROCKET ..........4-86 CHECKING THE REAR WHEEL SPROCKET ........4-86 CHECKING THE REAR WHEEL DRIVE HUB ........4-86 INSTALLING THE DRIVE CHAIN ............4-86...
  • Page 152 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats and battery Order Job/Parts to remove Q’ty Remarks Rider seat Passenger seat Battery negative lead Disconnect. Battery positive lead Disconnect. Tool band Tool Upper tail cover bracket Battery cover Battery Battery seat For installation, reverse the removal proce- dure.

  • Page 153: General Chassis

    GENERAL CHASSIS Removing the side cowlings Order Job/Parts to remove Q’ty Remarks Front cowling inner panel Side cowling Front turn signal/position light coupler Disconnect. Front turn signal/position light Lower cowling Side cowling inner panel For installation, reverse the removal proce- dure.
  • Page 154 GENERAL CHASSIS Removing the ECU and rectifier/regulator Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. ECU coupler Disconnect. Radiator fan motor relay coupler Disconnect. Radiator fan motor relay ECU bracket Rectifier/regulator coupler Disconnect. Stator coil lead coupler Disconnect.
  • Page 155 GENERAL CHASSIS Removing the Air ducts Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. ECU and rectifier/regulator Refer to “GENERAL CHASSIS” on page 4-1. Air chamber cover Air chamber Air chamber bracket Air intake air duct cover Rear intake air duct upper Rear intake air duct lower Front intake air duct...

  • Page 156: General Chassis

    GENERAL CHASSIS Removing the front cowling assembly Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. ECU and Rectifier/regulator Refer to “GENERAL CHASSIS” on page 4-1. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Intake air temperature sensor coupler Disconnect.
  • Page 157 GENERAL CHASSIS Removing the meter and headlight Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. ECU and Rectifier/regulator Refer to “GENERAL CHASSIS” on page 4-1. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Front cowling assembly Refer to “GENERAL CHASSIS”...
  • Page 158 GENERAL CHASSIS Removing the meter and headlight Order Job/Parts to remove Q’ty Remarks Windshield Intake air temperature sensor Headlight assembly Front cowling For installation, reverse the removal proce- dure.
  • Page 159 GENERAL CHASSIS Disassembling the headlight assembly Order Job/Parts to remove Q’ty Remarks Auxiliary light socket Auxiliary light bulb Headlight bulb cover Headlight bulb Headlight harness Headlight grille For installation, reverse the removal proce- dure.
  • Page 160 GENERAL CHASSIS Removing the rear fender Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. Upper tail cover bracket Refer to “GENERAL CHASSIS” on page 4-1. Upper tail cover Muffler Refer to “ENGINE REMOVAL”...
  • Page 161 GENERAL CHASSIS Disassembling the license plate/turn signal light assembly Order Job/Parts to remove Q’ty Remarks License plate/turn signal light stay License plate/turn signal light stay plate Cover Rear turn signal light License plate light Rear reflector Side reflector bracket Side reflector Mudguard For installation, reverse the removal proce- dure.
  • Page 162 GENERAL CHASSIS EAS14B1029 REMOVING THE QUICK FASTENER (SCREW TYPE) To remove the quick fastener, turn its center with a screwdriver counterclockwise, then pull the fastener out. EAS14B1032 INSTALLING THE QUICK FASTENER (PUSH TYPE) To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert EAS14B1030 the fastener into the cover and push the pin “a”...
  • Page 163 GENERAL CHASSIS EAS14B1038 REMOVING THE FRONT TURN SIGNAL/ POSITION LIGHTS EAS14B1104 1. Remove: INSTALLING THE QUICK FASTENER (PULL • Stay “1” TYPE) • Front turn signal/position light “2” To install the quick fastener, pull the pin, then Remove the stay “1” first and then remove the insert the fastener into the cover and push the front turn signal/position light “2”...
  • Page 164 GENERAL CHASSIS EAS14B1040 REMOVING THE LOWER COWLINGS 1. Remove: • Lower cowling “1” Slide the lower cowling to the forward and remove. EAS14B1043 INSTALLING THE SIDE COWLING INNER PANELS 1. Install: • Side cowling inner panel “1” Install the grommet “2” to the side cowling inner panel and insert them into the projection EAS14B1041 “a”...
  • Page 165 GENERAL CHASSIS EAS14B1045 INSTALLING THE AIR CHAMBER COVERS 1. Install: • Air chamber cover “1” Insert the air chamber cover tab “a” downward into the hole “b” of the air chamber “2”. EAS14B1048 INSTALLING THE AIR INTAKE DUCTS 1. Install: •...
  • Page 166 GENERAL CHASSIS EAS14B1051 INSTALLING THE MIRROR FITTING PLATES 1. Install: • Mirror fitting plate “1” (to meter bracket “2”) Face the mirror fitting plate concave “a” up and install it to the meter bracket. EAS14B1049 REMOVING THE WINDSHIELD 1. Remove: •...
  • Page 167 GENERAL CHASSIS 2. Install: • Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS14B1054 INSTALLING THE TAIL/BRAKE LIGHT 1. Install: • Tail/brake light “1” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS14B1002 Fit the tail/brake light tabs “a” into the holes “b” INSTALLING THE UPPER TAIL COVER of the lower tail cover “2”.
  • Page 168 GENERAL CHASSIS exhaust chamber cover “1” and then install it to the right rider footrest “2”. Exhaust chamber cover bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) e. Install the rider footrest bolts. Rider footrest bolt 28 Nm (2.8 m·kgf, 20 ft·lbf) c.

  • Page 169: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Reflector Reflector bracket Left brake hose holder Right brake hose holder Left front brake caliper Right front brake caliper Front wheel axle pinch bolt Loosen.
  • Page 170 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly pro- cedure. 4-19...
  • Page 171 FRONT WHEEL EAS21900 • Front wheel REMOVING THE FRONT WHEEL Damage/wear → Replace. 1. Stand the vehicle on a level surface. Refer to “CHECKING THE TIRES” on EWA13120 page 3-17 and “CHECKING THE WARNING WHEELS” on page 3-17. Securely support the vehicle so that there 3.
  • Page 172 FRONT WHEEL EAS21970 ADJUSTING THE FRONT WHEEL STATIC To prevent damaging the wheel, place a rag “2” BALANCE between the screwdriver and the wheel sur- face. • After replacing the tire, wheel or both, the front wheel static balance should be adjusted.
  • Page 173 FRONT WHEEL 3. Adjust: EAS22000 INSTALLING THE FRONT WHEEL • Front wheel static balance The following procedure applies to both of the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ brake discs. a. Install a balancing weight “1” onto the rim 1. Lubricate: exactly opposite the heavy spot “X”. •...
  • Page 174 FRONT WHEEL EWA13490 WARNING Make sure the brake cable is routed prop- erly. Make sure that there is enough space between the brake pads before installing the brake cali- pers on to the brake discs. 4-23...

  • Page 175: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Rear brake caliper Refer to “REAR BRAKE” on page 4-43. Locknut (left and right) Loosen. Adjusting bolt (left and right) Loosen. Rear wheel axle nut Washer Rear wheel axle Adjusting block (left)
  • Page 176 REAR WHEEL Removing the brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar Dust cover Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel For installation, reverse the removal proce- dure.
  • Page 177 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly pro- cedure. 4-26...
  • Page 178 REAR WHEEL EAS22040 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
  • Page 179 REAR WHEEL EAS22110 CHECKING THE REAR WHEEL DRIVE HUB Tighten the self-locking nuts in stages and in a 1. Check: crisscross pattern. • Rear wheel drive hub “1” Cracks/damage → Replace. • Rear wheel drive hub dampers “2” Damage/wear → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 180 REAR WHEEL 3. Tighten: • Rear wheel axle nut • Rear brake caliper bolts Rear wheel axle nut 150 Nm (15 m·kgf, 110 ft·lbf) Rear brake caliper bolt (front side) 27 Nm (2.7 m·kgf, 19 ft·lbf) Rear brake caliper bolt (rear side) 22 Nm (2.2 m·kgf, 16 ft·lbf) EWA13500...
  • Page 181 FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Reflector Reflector bracket Brake hose holder Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw...
  • Page 182 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-16. Stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Brake lever...

  • Page 183: Front Brake

    FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Bleed screw Brake master cylinder body For installation, reverse the removal proce- dure. 4-32...
  • Page 184 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-16. Reflector Reflector bracket Union bolt Washer Brake hose...
  • Page 185 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For installation, reverse the removal proce- dure.
  • Page 186 FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 187 FRONT BRAKE 1. Remove: • Brake hose holder “1” • When installing the brake disc, align the • Brake caliper “2” arrow “1” on the brake disc and arrow “2” on the wheel in the direction of wheel rotation. • Tighten the brake disc bolts in stages and in a crisscross pattern.
  • Page 188 FRONT BRAKE Brake lining thickness The arrow mark “a” on the brake pad springs (inner) must point in the direction of disc rotation. 4.5 mm (0.18 in) Limit 0.8 mm (0.03 in) Brake lining thickness (outer) 4.5 mm (0.18 in) Limit 0.8 mm (0.03 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 189 FRONT BRAKE Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • Union bolt “1” • Washers “2” • Brake hose “3” EWA14B1002 WARNING • Never try to pry out the brake caliper pis- tons.
  • Page 190 FRONT BRAKE • Brake caliper body “3” • Brake hose “2” Cracks/damage → Replace the brake • Union bolt “3” caliper assembly. • Brake hose holder • Brake fluid delivery passages Front brake caliper bolt (brake caliper body) 35 Nm (3.5 m·kgf, 25 ft·lbf) Obstruction →...
  • Page 191 FRONT BRAKE EWA13090 EAS22490 REMOVING THE FRONT BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. Other brake fluids may cause the rubber Before removing the front brake master cylin- seals to deteriorate, causing leakage and der, drain the brake fluid from the entire brake poor brake performance.
  • Page 192 FRONT BRAKE 2. Check: Front brake master cylinder • Brake fluid reservoir tank “1” holder bolt Cracks/damage → Replace. 13 Nm (1.3 m·kgf, 9.4 ft·lbf) • Brake fluid reservoir diaphragm “2” Damage/wear → Replace. • Brake fluid reservoir diaphragm holder “3” •...
  • Page 193 FRONT BRAKE a. 36° 6. Check: b. 3 mm (0.12 in) • Brake lever operation Soft or spongy feeling → Bleed the brake 3. Fill: system. • Brake fluid reservoir Refer to “BLEEDING THE HYDRAULIC (with the specified amount of the recom- BRAKE SYSTEM”...
  • Page 194 REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad Bleed screw Brake pad spring For installation, reverse the removal proce- dure.
  • Page 195 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-16. Footrest plate Brake fluid reservoir cap Rear brake fluid reservoir diaphragm holder Rear brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Union bolt...
  • Page 196 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Adjusting nut Brake master cylinder kit Hose joint O-ring Brake master cylinder body For installation, reverse the removal proce- dure. 4-45...

  • Page 197: Rear Brake

    REAR BRAKE Removing the rear brake calipers Order Job/Parts to remove Q’ty Remarks Union bolt Washer Brake hose Brake caliper For installation, reverse the removal proce- dure. 4-46...
  • Page 198 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Brake pad Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For installation, reverse the removal proce- dure.

  • Page 199: Rear Brake

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 4.5 mm (0.18 in) WARNING 5. Adjust: Disc brake components rarely require dis- • Brake disc deflection assembly. Therefore, always follow these Refer to “CHECKING THE FRONT preventive measures: BRAKE DISCS” on page 4-35. •...
  • Page 200 REAR BRAKE 3. Measure: c. Tighten the bleed screw. • Brake pad wear limit “a” Out of specification → Replace the brake Bleed screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) pads as a set. d. Install a new brake pad shim “3” onto each Brake lining thickness...
  • Page 201 REAR BRAKE EAS22590 • Never try to pry out the brake caliper pis- REMOVING THE REAR BRAKE CALIPER ton. Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • Union bolt “1” • Copper washers “2” •...
  • Page 202 REAR BRAKE • Brake hose “2” • Union bolt “3” Rear brake hose union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) EWA13530 WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” on page 2-49. EWA14B1005 ECA14170 WARNING...
  • Page 203 REAR BRAKE EWA13090 EAS22700 REMOVING THE REAR BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. 1. Remove: Other brake fluids may cause the rubber • Union bolt “1” seals to deteriorate, causing leakage and • Washers “2” poor brake performance.
  • Page 204 REAR BRAKE EWA13530 WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” on page 2-49. ECA14B1004 • When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection “a” as 3.
  • Page 205 REAR BRAKE reaction, leading to poor brake perfor- mance. • When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. ECA13540 Brake fluid may damage painted surfaces and plastic parts.
  • Page 206 HANDLEBARS EAS22850 HANDLEBARS Removing the handlebars Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. ECU and rectifier/regulator Refer to “GENERAL CHASSIS” on page 4-1. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Front cowling Refer to “GENERAL CHASSIS”...
  • Page 207 HANDLEBARS Removing the handlebars Order Job/Parts to remove Q’ty Remarks Throttle grip Right handlebar switch Handlebar pinch bolt Loosen. Handlebar bolt Loosen. Upper bracket pinch bolt Loosen. Steering stem nut Main switch coupler Disconnect. Clutch cable guide Upper bracket Left handlebar Right handlebar Grip end damper For installation, reverse the removal proce-...
  • Page 208 HANDLEBARS EAS22870 EWA13690 REMOVING THE HANDLEBAR WARNING 1. Stand the vehicle on a level surface. Do not attempt to straighten a bent handle- EWA13120 bar as this may dangerously weaken it. WARNING Securely support the vehicle so that there is no danger of it falling over. 2.
  • Page 209 HANDLEBARS ECA14260 • Install the brake master cylinder holder with the “UP” mark facing up. • First, tighten the upper bolt, and then the lower bolt. 6. Install: • Left handlebar switch “1” • Align the projection “a” on the left handlebar switch with the hole “b”...
  • Page 210 HANDLEBARS Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 9. Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-32. Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 4-59...
  • Page 211 FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies both of the front fork legs. Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Front wheel Refer to “FRONT WHEEL” on page 4-18. Front fender Upper bracket pinch bolt Loosen.
  • Page 212 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Washer Spacer Upper spring seat Fork spring Lower spring seat Outer tube Dust seal Oil seal clip Oil seal Washer...
  • Page 213 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Damper rod assembly Damper adjusting rod Damper adjusting valve Damper adjusting valve spring Inner tube For installation, reverse the removal proce- dure. 4-62...

  • Page 214: Front Fork

    FRONT FORK EAS14B1006 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA14B1008 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that 4.
  • Page 215 FRONT FORK Use the side of the rod holder that is marked “B”. 4. Remove: • Dust seal • Oil seal clip “1” (with a flat-head screwdriver) • Oil seal c. Hold the spring preload adjusting bolt “6” • Washer and loosen the nut “3”.
  • Page 216 FRONT FORK EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 4. Check: • Cap bolt O-ring “1” Damage/wear → Replace. • Cap bolt collar projections “2” Cracks/damage → Replace. 2. Measure: •...
  • Page 217 FRONT FORK • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil. • Before installing the oil seal, cover the top of the front fork leg with a plastic bag to protect the oil seal during installation.
  • Page 218 FRONT FORK Rod puller 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M10) 90890-01436 Universal damping rod bleeding tool set YM-A8703 7. Install: • Oil seal clip “1” Adjust the oil seal clip so that it fits into the outer tube’s groove.
  • Page 219 FRONT FORK ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 13. Before measuring the fork oil level, wait ten a. Remove the rod puller attachment. minutes until the oil has settled and the air b. Install the under spring seat. bubbles have dispersed. c. Install the fork spring. Be sure to bleed the front fork leg of any resid- Install the spring with the smaller pitch “a”...
  • Page 220 FRONT FORK m. Install the washer and cap bolt, and then Rod puller finger tighten the cap bolt. 90890-01437 n. Hold the nut and tighten the spring preload Universal damping rod bleeding adjusting bolt “2” into the cap bolt to specifi- tool set cation.
  • Page 221 FRONT FORK 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. EWA14B1012 WARNING Make sure the brake hoses are routed prop- erly. Make sure the outer tube is flush with the top of the upper bracket. 4.

  • Page 222: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Front fork legs Refer to “FRONT FORK” on page 4-60. Handlebars Refer to “HANDLEBARS”...
  • Page 223 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Lower ring nut Lower bracket Upper bearing cover Upper bearing inner race Upper bearing Lower bearing Lower bearing inner race Lower bearing dust seal Upper bearing outer race Lower bearing outer race For installation, reverse the removal proce- dure.
  • Page 224 STEERING HEAD EAS23110 3. Replace: REMOVING THE LOWER BRACKET • Bearings 1. Stand the vehicle on a level surface. • Bearing races EWA13120 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a. Remove the bearing races “1” from the Securely support the vehicle so that there steering head pipe with a long rod “2”...
  • Page 225 STEERING HEAD EAS23140 • Bearing INSTALLING THE STEERING HEAD Damage/pitting → Replace. 1. Lubricate: (It replace with the assembly.) • Upper bearing • Lower bearing • Bearing races Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” • Rubber washer “2” •...

  • Page 226: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK”...
  • Page 227 REAR SHOCK ABSORBER ASSEMBLY EAS14B1010 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that EWA14B1013 the rear wheel is elevated. WARNING This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Rear shock absorber assembly lower bolt the rear shock absorber, read and make “1”...
  • Page 228 REAR SHOCK ABSORBER ASSEMBLY • Spring Installed depth of bearing “a” Damage/wear → Replace the rear shock 4.0 mm (0.16 in) absorber assembly. Installed depth of oil seal “b” • Bearing 1.0 mm (0.04 in) Damage/wear → Replace. • Bolts Bends/damage/wear →...
  • Page 229 REAR SHOCK ABSORBER ASSEMBLY 3. Tighten: • Rear shock absorber assembly bracket Rear shock absorber assembly bracket nut 92 Nm (9.2 m·kgf, 66 ft·lbf) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 40 Nm (4.0 m·kgf, 29 ft·lbf) 4.
  • Page 230 SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-24. Refer to “REAR SHOCK ABSORBER Rear shock absorber assembly ASSEMBLY” on page 4-75. Drive chain guard Rear fender Left footrest Drive chain guide Brake hose holder Pivot shaft nut/washer...
  • Page 231 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Oil seal Circlip Bearing Bearing For installation, reverse the removal proce- dure. 4-80...
  • Page 232 SWINGARM EAS23350 REMOVING THE SWINGARM Swingarm side play (at the end 1. Stand the vehicle on a level surface. of the swingarm) EWA13120 1.0 mm (0.04 in) WARNING d. Check the swingarm vertical movement “B” Securely support the vehicle so that there by moving the swingarm up and down.
  • Page 233 SWINGARM Damper rod holder (22 mm) Recommended cleaning solvent 90890-01365 Kerosene 4. Check: • Dust cover “1” • Spacer “2” • Collar “3” • Bearings “4” Damage/wear → Replace. EAS23360 CHECKING THE SWINGARM 1. Check: • Swingarm Bends/cracks/damage → Replace. EAS14B1011 INSTALLING THE SWINGARM 1.
  • Page 234 SWINGARM Ring nut wrench 90890-01507 YM-01507 5. Dust cover 6. Collar 7. Swingarm 8. Pivot shaft A. Left side 5. Install: B. Right side • Pivot shaft nut “1” 3. Install: Pivot shaft nut • Pivot shaft “1” 105 Nm (10.5 m·kgf, 75 ft·lbf) Pivot shaft Lubricant the pivot shaft with lithium-soap- 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
  • Page 235 CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain Order Job/Parts to remove Q’ty Remarks Refer to “ADJUSTING THE DRIVE CHAIN Drive chain SLACK” on page 3-19. Locknut Shift rod Shift arm Shift pedal Drive sprocket cover Drive sprocket nut Washer Drive chain guide (drive sprocket side)
  • Page 236 CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
  • Page 237 CHAIN DRIVE use only kerosene to clean the drive EAS23460 CHECKING THE DRIVE SPROCKET chain. 1. Check: • Do not soak the drive chain in kerosene • Drive sprocket for more than ten minutes, otherwise the More than 1/4 tooth “a” wear → Replace O-rings can be damaged.
  • Page 238 CHAIN DRIVE • Stake the drive sprocket nut at cutouts, “a” in the drive axle. b. After riveting, make sure the length between the edges “b” of the connecting pin “2” is 5.7–6.0 mm (0.22–0.24 in). ECA14300 Never install a new drive chain onto worn drive chain sprockets;...

  • Page 239: Engine

    ENGINE ENGINE INSPECTION..................5-1 MEASURING THE COMPRESSION PRESSURE .........5-1 ENGINE REMOVAL ..................5-3 INSTALLING THE ENGINE ..............5-10 INSTALLING THE EXHAUST PIPE AND MUFFLER......5-11 CAMSHAFTS....................5-13 REMOVING THE CAMSHAFTS ............5-17 CHECKING THE CAMSHAFTS ............5-18 CHECKING THE TIMING CHAIN AND SPROCKET......5-19 CHECKING THE TIMING CHAIN GUIDES ..........5-20 CHECKING THE TIMING CHAIN TENSIONER ........5-20 INSTALLING THE CAMSHAFTS ............5-20 CYLINDER HEAD..................5-25...
  • Page 240 OIL PUMP ....................5-51 REMOVING THE OIL PAN ..............5-54 CHECKING THE SPROCKET AND CHAIN .........5-54 CHECKING THE OIL PUMP ..............5-54 CHECKING THE RELIEF VALVE ............5-55 CHECKING THE OIL DELIVERY PIPES..........5-55 CHECKING THE OIL STRAINER............5-55 ASSEMBLING THE OIL PUMP ............5-55 INSTALLING THE OIL/WATER PUMP ASSEMBLY......5-56 INSTALLING THE OIL PAN ..............5-57 CLUTCH......................5-59 REMOVING THE CLUTCH..............5-63...
  • Page 241 TRANSMISSION..................5-90 REMOVING THE TRANSMISSION ............5-95 CHECKING THE SHIFT FORKS ............5-95 CHECKING THE SHIFT DRUM ASSEMBLY........5-96 CHECKING THE TRANSMISSION ............5-96 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ......5-97 INSTALLING THE TRANSMISSION.............5-97...

  • Page 242: Engine Inspection

    ENGINE INSPECTION EAS14B1052 ENGINE INSPECTION EAS14B1053 MEASURING THE COMPRESSION PRES- SURE The following procedure applies to all of the cylinders. Insufficient compression pressure will result in a loss of performance. 6. Measure: 1. Measure: • Compression pressure • Valve clearance Out of specification →...
  • Page 243 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage → Replace. Same as without oil Piston, valves or cyl- inder head gasket possibly defective → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Install: •...

  • Page 244: Engine Removal

    ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the exhaust pipe and muffler Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. Upper tall cover Refer to “GENERAL CHASSIS” on page 4-1. Side cowling Refer to “GENERAL CHASSIS”...
  • Page 245 ENGINE REMOVAL Removing the exhaust pipe and muffler Order Job/Parts to remove Q’ty Remarks Left muffler Left muffler gasket Right muffler clamp Loosen. Right muffler Right muffler gasket Rear brake light switch coupler Disconnect. Right footrest assembly Exhaust chamber cover Rear brake light switch sensor lead coupler Disconnect.
  • Page 246 ENGINE REMOVAL Removing the exhaust pipe and muffler Order Job/Parts to remove Q’ty Remarks Exhaust chamber protector Exhaust chamber pipe protector clamp Loosen. Exhaust chamber pipe protector Exhaust chamber bracket Exhaust pipe Exhaust pipe gasket For installation, reverse the removal proce- dure.
  • Page 247 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Battery negative lead Refer to “GENERAL CHASSIS” on page 4-1. Battery positive lead Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Side cowling air duct Refer to “GENERAL CHASSIS”...
  • Page 248 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Speed sensor lead coupler Disconnect. Oil level switch lead coupler Disconnect. Gear position sensor coupler Disconnect. Engine ground lead Disconnect. Clutch cable Disconnect. For installation, reverse the removal proce- dure.
  • Page 249 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Left lower cowling bracket Right lower cowling bracket Left inner panel bracket Right inner panel bracket Sidestand assembly Sidestand switch Sidestand switch bracket Engine mounting bolt (front right side) Engine mount collar (front right side) Engine mount collar (front right side) Engine mounting bolt (front left side)
  • Page 250 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Engine mount bolt (rear upper side) Engine mount bolt (rear lower side) Engine Engine mount adjusting bolt For installation, reverse the removal proce- dure.

  • Page 251: Installing The Engine

    ENGINE REMOVAL EAS23720 5. Install: INSTALLING THE ENGINE • Engine mount collars (front right side) “1” ECA14B1021 • Engine mount collar (front right side) “2” • Engine mounting bolt (front right side) “3” Do not hold the radiator inlet hose when (temporary tighten) removing the engine and moving the engine by itself.

  • Page 252: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL Engine mounting bolt (front left side) 70 Nm (7.0 m·kgf, 50 ft·lbf) 7. Tighten: • Engine mounting nut (rear lower side) “1” • Engine mounting nut (rear upper side) “2” Engine mounting nut (rear 9. Tighten: lower side) •...
  • Page 253 ENGINE REMOVAL Installed depth of gasket “c” 3.5 mm (0.14 in) 5-12...

  • Page 254: Camshafts

    CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Radiator Refer to “RADIATOR”...
  • Page 255 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-14...
  • Page 256 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Pickup coil cover 2 Refer to “PICKUP ROTOR” on page 5-43. Generator cover Refer to “GENERATOR” on page 5-37. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft...
  • Page 257 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Pickup rotor Refer to “PICKUP ROTOR” on page 5-43. Timing chain Crankshaft sprocket Collar Woodruff key For installation, reverse the removal proce- dure. 5-16...

  • Page 258: Removing The Camshafts

    CAMSHAFTS EAS23810 3. Remove: REMOVING THE CAMSHAFTS • Timing chain tensioner “1” 1. Remove: • Gasket • Pickup rotor cover 2 Refer to “PICKUP ROTOR” on page 5-43. • Generator cover Refer to “GENERATOR” on page 5-37. 2. Align: • “K” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ECA14B1034 When turning the crankshaft with a tool,...

  • Page 259: Checking The Camshafts

    CAMSHAFTS Camshaft lobe dimension limit Use the camshaft wrench “2” and loosen the Intake A camshaft sprocket bolt. 37.350–37.450 mm (1.4705– 1.4744 in) Camshaft wrench Limit 90890-04143 37.250 mm (1.4665 in) YM-04143 Intake B 28.034–28.134 mm (1.1037– 1.1076 in) Limit 27.934 mm (1.0998 in) Exhaust A 36.450–36.550 mm (1.4350–...

  • Page 260: Checking The Timing Chain And Sprocket

    CAMSHAFTS 4. Measure: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Camshaft-journal-to-camshaft-cap clear- 5. Measure: ance • Camshaft journal diameter “a” Out of specification → Measure the cam- Out of specification → Replace the cam- shaft journal diameter. shaft. Within specification → Replace the cylin- Camshaft-journal-to-camshaft- der head and the camshaft caps as a set.

  • Page 261: Checking The Timing Chain Guides

    CAMSHAFTS a. 1/4 tooth b. Correct b. Keep pressing the timing chain tensioner rod, mount clip “3” into groove “4”, and lock 1. Timing chain the timing chain tensioner rod. 2. Camshaft sprocket or crankshaft sprocket c. Push the timing chain tensioner rod in EAS23950 direction “c”.
  • Page 262 CAMSHAFTS b. When position #1 is at BTDC 105°, align the “K” mark “a” with the crankcase mating surface “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • Intake camshaft sprocket “1” • Exhaust camshaft sprocket “2” Camshaft sprocket bolt 24 Nm (2.4 m·kgf, 17 ft·lbf) Camshaft wrench 90890-04143 YM-04143...
  • Page 263 CAMSHAFTS • When installing the camshaft cap, face the hole with the screw thread “b” on the cam- shaft cap to the left side of the engine. 6. Install: • Exhaust camshaft “1” • Intake camshafts “2” • Hang the timing chain on the sprocket from A.
  • Page 264 When turning the crankshaft with a tool, der head cover gasket. remove all the spark plugs. • Apply bond Yamaha bond No.1215 (Three 11. Check: bond No.1215® “2” onto the mating surfaces • “K” mark “a”...
  • Page 265 CAMSHAFTS • Tighten the cylinder head cover bolts stages and in a crisscross pattern. Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 5-24...

  • Page 266: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-3. Intake camshaft Refer to “CAMSHAFTS” on page 5-13. Exhaust camshaft Refer to “CAMSHAFTS” on page 5-13. Coolant temperature sensor Cylinder head Cylinder head gasket Dowel pin...

  • Page 267: Removing The Cylinder Head

    CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD Warpage limit 1. Remove: 0.10 mm (0.0039 in) • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAM- SHAFTS” on page 5-17. 2. Remove: • Cylinder head nuts • Cylinder head bolts •...
  • Page 268 CYLINDER HEAD 2. Install: • Cylinder head gasket “2” • Dowel pins 5. Install: • Exhaust camshaft • Intake camshaft Refer to “INSTALLING THE CAM- 3. Install: SHAFTS” on page 5-20. • Cylinder head • Washers • Cylinder head nuts •...
  • Page 269 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-25. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve Intake valve stem seal...
  • Page 270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve Exhaust valve stem seal Exhaust valve lower spring seat Exhaust valve guide For installation, reverse the removal proce- dure.

  • Page 271: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 3. Remove: REMOVING THE VALVES • Valve cotters The following procedure applies to all of the valves and related components. Remove the valve cotters by compressing the valve spring with the valve spring compressor Before removing the internal parts of the cylin- “1”...

  • Page 272: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS EAS24290 CHECKING THE VALVES AND VALVE To ease valve guide removal and installation, GUIDES and to maintain the correct fit, heat the cylinder The following procedure applies to all of the head to 100 °C (212 °F) in an oven. valves and valve guides.

  • Page 273: Checking The Valve Seats

    VALVES AND VALVE SPRINGS Valve guide remover (ø4.5) 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide remover (ø5) 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø4.5) 90890-04117 Valve guide installer (4.5 mm) 6. Measure: YM-04117 • Valve stem runout Valve guide installer (ø5) Out of specification →...
  • Page 274 VALVES AND VALVE SPRINGS Valve seat width After replacing the cylinder head or replacing Valve seat width C (intake) the valves and valve guides, the valve seat and 0.90–1.10 mm (0.0354–0.0433 valve face should be lapped. Limit ECA14B1031 1.60 mm (0.06 in) Valve seat width C (exhaust) This model uses titanium intake valves.

  • Page 275: Checking The Valve Springs

    VALVES AND VALVE SPRINGS 1. Measure: • Valve spring free length “a” Out of specification → Replace the valve spring. Valve spring free length Free length (intake) 39.33 mm (1.55 in) Limit 37.36 mm (1.47 in) Free length (exhaust) e. Apply a fine lapping compound to the valve 37.96 mm (1.49 in) face and repeat the above steps.

  • Page 276: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 3. Measure: • Valve spring tilt “a” Out of specification → Replace the valve spring. Spring tilt limit Spring tilt (intake) 2.5°/1.7 mm (0.067 in) Spring tilt (exhaust) 2.5°/1.7 mm (0.067 in) 2. Lubricate: • Valve stem “1” •...
  • Page 277 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. ECA13800 Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad •...

  • Page 278: Generator

    GENERATOR EAS24480 GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Stator coil lead coupler Refer to “GENERAL CHASSIS”...

  • Page 279: Removing The Generator

    GENERATOR EAS24490 4. Remove: REMOVING THE GENERATOR • Stator coil lead holder “1” 1. Remove: • Stator coil assembly “2” • Generator cover • Generator cover gasket • Dowel pins 2. Remove: • Generator rotor bolt “1” • Washer While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt.
  • Page 280 GENERATOR 4. Apply: • Sealant (onto the stator coil lead grommet “1”) Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 5-39...

  • Page 281: Starter Clutch

    STARTER CLUTCH EAS24550 STARTER CLUTCH Removing the starter clutch Order Job/Parts to remove Q’ty Remarks Clutch housing assembly Refer to “CLUTCH” on page 5-59. Starter clutch gear Bearing Starter clutch holder Starter clutch Starter idle gear For installation, reverse the removal proce- dure.

  • Page 282: Removing The Starter Clutch

    STARTER CLUTCH EAS24560 REMOVING THE STARTER CLUTCH 1. Remove: • Starter clutch bolt “1” • While holding the clutch housing assembly “2” with the sheave holder “3”, remove the starter clutch bolt. • Fix the flat surface of the clutch housing assembly with the sheave holder.
  • Page 283 STARTER CLUTCH • Fix the flat surface of the clutch housing assembly with the sheave holder. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 5-42...

  • Page 284: Pickup Rotor

    PICKUP ROTOR EAS14B1058 PICKUP ROTOR Removing the pickup rotor Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Generator cover Refer to “GENERATOR” on page 5-37. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Timing check bolt Pickup rotor cover 1 O-ring...

  • Page 285: Removing The Pickup Rotor

    PICKUP ROTOR EAS14B1059 REMOVING THE PICKUP ROTOR 1. Remove: • Pickup rotor bolt “1” • Washer • Pickup rotor While holding the generator rotor “2” with the sheave holder “3”, loosen the pickup rotor bolt. Sheave holder 2. Tighten: 90890-01701 •...
  • Page 286 PICKUP ROTOR Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 5-45...

  • Page 287: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Battery negative lead Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Refer to “THROTTLE BODIES”...
  • Page 288 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Front cover Lock washer Washer Starter motor yoke Armature assembly Gasket Brush holder O-ring Rear cover For installation, reverse the removal proce- dure. 5-47...

  • Page 289: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ CHECKING THE STARTER MOTOR a. Measure the armature assembly resis- 1. Check: tances with the pocket tester. • Commutator Dirt → Clean with 600 grit sandpaper. Pocket tester 2. Measure: 90890-03112 • Commutator diameter “a” Analog pocket tester Out of specification →...

  • Page 290: Assembling The Starter Motor

    ELECTRIC STARTER Brush spring force Align the tab “a” on the brush holder “2” with 5.28–7.92 (538–808 the tab “b” in the rear cover. 19.01–28.51 oz) 7. Check: 3. Install: • Gear teeth • Washer Damage/wear → Replace the gear. •...
  • Page 291 ELECTRIC STARTER 5-50...

  • Page 292: Oil Pump

    OIL PUMP EAS24921 OIL PUMP Removing the oil pan and oil/water pump assembly Order Job/Parts to remove Q’ty Remarks Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Lower cowling Refer to “GENERAL CHASSIS” on page 4-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”...
  • Page 293 OIL PUMP Removing the oil pan and oil/water pump assembly Order Job/Parts to remove Q’ty Remarks Dowel pin Drain pipe Oil strainer Oil pipe Oil delivery pipe 1 Relief valve assembly Oil/water pump assembly drive chain guide Collar Oil/water pump assembly drive sprocket Washer Oil/water pump assembly drive chain Dowel pin...
  • Page 294 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil/water pump driven sprocket Circlip Oil pump housing Bearing Dowel pin Oil pump outer rotor Oil pump inner rotor For installation, reverse the removal proce- dure. 5-53...

  • Page 295: Removing The Oil Pan

    OIL PUMP EAS24930 EAS24960 REMOVING THE OIL PAN CHECKING THE OIL PUMP 1. Remove: 1. Check: • Oil level switch “1” • Oil pump driven gear “1” Cracks/damage/wear → Replace. • Oil level switch lead holder “2” • Oil pan “3” •...

  • Page 296: Checking The Relief Valve

    OIL PUMP EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes. 1. Check: • Oil delivery pipe 1 “1” • Oil pipe “2” Damage → Replace. Obstruction → Wash and blow out with compressed air.

  • Page 297: Installing The Oil/Water Pump Assembly

    OIL PUMP 4. Check: Recommended lubricant • Oil pump operation Engine oil Refer to “CHECKING THE OIL PUMP” on page 5-54. 2. Install: • Pin “1” EAS25030 INSTALLING THE OIL/WATER PUMP • Inner rotor “2” ASSEMBLY • Outer rotor “3” 1.

  • Page 298: Installing The Oil Pan

    OIL PUMP 5. Install: • Relief valve assembly “1” • O-ring Relief valve assembly bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® • Oil strainer “2” • O-ring Oil strainer bolt 3. Install: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Oil/water pump assembly drive chain LOCTITE®...
  • Page 299 OIL PUMP Engine oil drain bolt 43 Nm (4.3 m·kgf, 31 ft·lbf) Tighten the oil pan bolts in stages and in a crisscross pattern. 5-58...

  • Page 300: Clutch

    CLUTCH EAS25061 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Pull lever cover Clutch cable Disconnect. Clutch cover Clutch cover gasket Dowel pin Oil filler cap For installation, reverse the removal proce- dure. 5-59...
  • Page 301 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing For installation, reverse the removal proce- dure. 5-60...
  • Page 302 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Compression spring Pressure plate 1 Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Clutch plate 2 Clutch plate 3 Friction plate 1 Clutch boss nut Spring Clutch boss Pressure plate 2 Conical spring washer...
  • Page 303 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Thrust washer Clutch housing assembly Bearing Washer For installation, reverse the removal proce- dure. 5-62...

  • Page 304: Removing The Clutch

    CLUTCH EAS25080 4. Remove: REMOVING THE CLUTCH • Clutch plate 1 “1” 1. Remove: • Friction plate 2 • Pull lever cover “1” • Clutch plate 2 • Clutch cover “2” • Clutch plate 3 • Gasket Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.

  • Page 305: Checking The Friction Plates

    CLUTCH • Pressure plate 2 1. Check: • Conical spring washer • Clutch plate Damage → Replace the clutch plates as • Thrust washer • Clutch housing assembly a set. 2. Measure: EAS25100 • Clutch plate warpage CHECKING THE FRICTION PLATES (with a surface plate and thickness gauge The following procedure applies to all of the “1”)

  • Page 306: Checking The Clutch Springs

    CLUTCH ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Clutch spring free length a. Assembly width adjusted by clutch plate “1” 43.80 mm (1.72 in) and “2”. Limit b. Select the clutch plate from the following 41.61 mm (1.64 in) table. Clutch plate “1” Part No. Thickness 4B1-16324-00 1.6 mm (0.063 in) 5VY-16325-00...

  • Page 307: Checking The Pressure Plate

    CLUTCH EAS25220 EAS25170 CHECKING THE PULL LEVER SHAFT AND CHECKING THE PRESSURE PLATE PULL ROD 1. Check: 1. Check: • Pressure plate 1 “1” • Pull lever shaft pinion gear teeth “1” • Pressure plate 2 “2” Cracks/damage → Replace. •...
  • Page 308 CLUTCH • Stake the clutch boss nut at a cutout “a” in the main axle. Universal clutch holder 90890-04086 YM-91042 2. Install: • Pressure plate 2 “1” • Clutch boss “2” Fit the groove “a” of the pressure plate 2 to the projection “b”...
  • Page 309 CLUTCH • Tighten the clutch cover bolts in stages and in a crisscross pattern. 6. Install: • Bearing (into the pressure plate 1) • Pull rod • Pressure plate 1 7. Install: • Clutch springs • Clutch spring bolts “1” Clutch spring bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the clutch spring bolts in stages and in...

  • Page 310: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Shift arm Refer to “CHAIN DRIVE” on page 4-84. Clutch assembly Refer to “CLUTCH” on page 5-59. Circlip Washer Shift shaft Washer Circlip Washer Stopper lever...

  • Page 311: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear → Replace. • Shift shaft spring “2” • Collar Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stop- per lever.

  • Page 312: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-3. Cylinder head Refer to “CYLINDER HEAD” on page 5-25. Refer to “ELECTRIC STARTER” on page 5- Starter motor Stator coil assembly Refer to “GENERATOR”...
  • Page 313 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Crankcase breather cover Crankcase breather cover gasket Crankcase breather case Crankcase breather case gasket Lower crankcase Dowel pin Crankcase baffle plate For installation, reverse the removal proce- dure. 5-72...

  • Page 314: Disassembling The Crankcase

    • Sealant order (refer to the numbers in the illustration). (onto the crankcase mating surfaces) • The numbers embossed on the crankcase Yamaha bond No.1215 indicate the crankcase tightening sequence. (Three Bond No.1215®) 90890-85505 Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.
  • Page 315 CRANKCASE * Following the tightening order, loosen the bolt one by one and then retighten it to the specific torque. Tighten the bolts in the tightening sequence cast on the crankcase. 6. Install: • Crankcase bolts • Lubricate the bolts “1”–“18” thread, mating surfaces and washers with engine oil.
  • Page 316 CONNECTING RODS AND PISTONS EAS14B1024 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-71. Connecting rod cap Big end lower bearing Big end upper bearing Connecting rod Piston pin clip Piston pin...

  • Page 317: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS26030 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: • Connecting rod cap “1” • Connecting rod • Big end bearings • Identify the position of each big end bear- ing so that it can be reinstalled in its origi- nal place.

  • Page 318: Checking The Piston Rings

    CONNECTING RODS AND PISTONS 2. Measure: • Piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cylinder. Then, find the average of the mea- surements.

  • Page 319: Checking The Piston Pin

    CONNECTING RODS AND PISTONS Piston ring side clearance Piston ring end gap Top ring Top ring 0.030–0.065 (0.0012– 0.15–0.25 mm (0.0059–0.0098 0.0026 in) Limit Limit 0.115 mm (0.0045 in) 0.50 mm (0.0197 in) 2nd ring 2nd ring 0.020–0.055 (0.0008– 0.30–0.45 mm (0.0118–0.0177 0.0022 in) Limit Limit...

  • Page 320: Checking The Connecting Rods

    CONNECTING RODS AND PISTONS a. Clean the big end bearings, crankshaft pins, and the inside of the connecting rods halves. b. Install the big end upper bearing into the connecting rod and the big end lower bear- ing into the connecting rod cap. Align the projections “a”...

  • Page 321: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS “P ” (connecting rod) - “P ” (crankshaft) = 5 - 2 = 3 (brown) Bearing color code 1.Blue 2.Black 3.Brown 4.Green e. Tighten the connecting rod bolts. Refer to “INSTALLING THE CONNECTING ROD AND PISTON” on page 5-80. f.
  • Page 322 CONNECTING RODS AND PISTONS 3. Lubricate: • Piston Be sure to install the piston rings so that the • Piston rings manufacturer’s marks or numbers “a” face up. • Cylinder (with the recommended lubricant) Recommended lubricant Engine oil 4. Offset: •...
  • Page 323 CONNECTING RODS AND PISTONS ECA14B1040 If the projection “a” of the piston installing tool damages, you cannot use it. Please handle with care. Fit the projection “a” of the piston installing tool “3” and blunt-edged part “b” of the cylinder, fix the position of the piston installing tool, and then push the piston down to the cylinder.
  • Page 324 CONNECTING RODS AND PISTONS c. Tighten the connecting rod bolts further to reach the specified angle 145°–155°. Connecting rod bolt (final) Specified angle 145°–155° EWA13400 WARNING If the connecting rod bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it.

  • Page 325: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-71. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS” on page 5-76. Balancer shaft Balancer shaft journal lower bearing Balancer shaft journal upper bearing Crankshaft Crankshaft journal lower bearing...

  • Page 326: Removing The Crankshaft And Balancer Shaft

    CRANKSHAFT EAS25980 REMOVING THE CRANKSHAFT AND BAL- ANCER SHAFT 1. Remove: • Balancer shaft “1” • Balancer shaft journal bearings • Crankshaft assembly “2” • Crankshaft journal bearings Identify the position of each balancer shaft journal bearings and crankshaft journal bear- ings so that it can be reinstalled in its original 2.
  • Page 327 CRANKSHAFT g. Remove the lower crankcase and the crankshaft journal lower bearings. h. Measure the compressed Plastigauge® width “a” on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specifica- tion, select replacement crankshaft journal bearings. d. Put a piece of Plastigauge® “1” on each crankshaft journal.

  • Page 328: Checking The Balancer Shaft

    CRANKSHAFT ECA14B1020 Do not interchange the balancer shaft jour- nal bearings. To obtain the correct balancer shaft-journal-to-balancer shaft-journal- bearing clearance and prevent engine dam- age, the balancer shaft journal bearings must be installed in their original positions. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the balancer shaft journal bearings, balancer shaft journals, and bearing por- tions of the crankcase.

  • Page 329: Installing The Crankshaft

    CRANKSHAFT • If J –J are the same, use the same size for all of the bearings. • Align the projections “a” of the balancer shaft journal lower bearings with the notches “b” in For example, if the crankcase J and bal- the lower crankcase.

  • Page 330: Installing The Balancer Assembly

    CRANKSHAFT • Align the projections “a” on the crankshaft journal bearings “1” with the notches “b” in the crankcases. • Be sure to install each crankshaft journal bearing in its original place. EAS14B1028 INSTALLING THE BALANCER ASSEMBLY 1. Install: • Balancer journal upper bearings (into the upper crankcase) •...

  • Page 331: Transmission

    TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Lower crankcase Refer to “CRANKCASE” on page 5-71. Drive axle assembly Oil seal Circlip Bearing Circlip Shift drum retainer Spring Shift fork guide bar Shift fork-L Shift fork-R Shift drum assembly...
  • Page 332 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks O-ring Oil baffle plate Bearing For installation, reverse the removal proce- dure. 5-91...
  • Page 333 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd/4th pinion gear Circlip Washer 5th pinion gear Collar Main axle Bearing housing Bearing For installation, reverse the removal proce- dure.
  • Page 334 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear 5-93...
  • Page 335 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip Washer 2nd wheel gear Collar Collar Oil seal Circlip Bearing Drive axle For installation, reverse the removal proce- dure. 5-94...

  • Page 336: Removing The Transmission

    TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainers “2” • Shift fork guide bars • Shift fork “L” and “R” • Shift drum assembly • Shift fork “C” EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks.

  • Page 337: Checking The Shift Drum Assembly

    TRANSMISSION 3. Check: • Shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift forks and shift fork guide bar as a set. 2. Measure: • Drive axle runout (with a centering device and dial gauge “1”) Out of specification →...

  • Page 338: Assembling The Main Axle And Drive Axle

    TRANSMISSION 5. Check: marks “e” with the alignment mark “d” on the • Transmission gear movement retainer. Rough movement → Replace the defec- tive part(s). 6. Check: • Circlips Bends/damage/looseness → Replace. EAS29020 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1.
  • Page 339 TRANSMISSION • Install shift fork-R into the groove “a” in the 5th wheel gear and shift fork-L into the groove “b” in the 6th wheel gear on the drive axle. • Install the shift drum retainer with its “OUT” mark “c” facing outward. •...
  • Page 340 TRANSMISSION 5-99...

  • Page 341: Cooling System

    COOLING SYSTEM RADIATOR ....................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR ..............6-3 OIL COOLER ....................6-5 CHECKING THE OIL COOLER..............6-7 INSTALLING THE OIL COOLER ............6-7 THERMOSTAT ....................6-8 CHECKING THE THERMOSTAT............6-10 ASSEMBLING THE THERMOSTAT ASSEMBLY .........6-10 INSTALLING THE THERMOSTAT ASSEMBLY ........6-11 WATER PUMP ....................6-12 DISASSEMBLING THE WATER PUMP..........6-13 CHECKING THE WATER PUMP ............6-13 ASSEMBLING THE WATER PUMP............6-13...
  • Page 342 RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-30. Refer to “GENERAL CHASSIS” on page 4-1. Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Rectifier/regulator Refer to “GENERAL CHASSIS” on page 4-1. Radiator cap Coolant reservoir hose Disconnect.
  • Page 343 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Radiator bracket Radiator fan Thermostat bypass hose 2 Disconnect. Thermostat bypass hose 3 Radiator inlet pipe Radiator inlet hose For installation, reverse the removal proce- dure.
  • Page 344 RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. Straighten any flattened fins with a thin, flat- head screwdriver. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.
  • Page 345 RADIATOR b. Apply 137.3 kPa (1.37 kgf/cm , 19.9 psi) of pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3.

  • Page 346: Oil Cooler

    OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-30. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-27. Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Lower cowling Refer to “GENERAL CHASSIS”...
  • Page 347 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Water jacket joint O-ring Water pump outlet pipe O-ring O-ring For installation, reverse the removal proce- dure.
  • Page 348 OIL COOLER EAS26420 • Crankcase CHECKING THE OIL COOLER (with the specified amount of the recom- 1. Check: mended engine oil) • Oil cooler Refer to “CHANGING THE ENGINE OIL” Cracks/damage → Replace. on page 3-27. 2. Check: 4. Check: •...
  • Page 349 THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-30. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Refer to “THROTTLE BODIES”...
  • Page 350 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Thermostat bypass hose 2 Water pump bypass hose Joint Thermostat bypass hose 1 Engine outlet pipe O-ring For installation, reverse the removal proce- dure.
  • Page 351 THERMOSTAT EAS26450 CHECKING THE THERMOSTAT If the accuracy of the thermostat is in doubt, 1. Check: replace it. A faulty thermostat could cause seri- • Thermostat “1” ous overheating or overcooling. Does not open at 71–85 °C (159.8–185.0 °F) → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 352 THERMOSTAT EAS26480 INSTALLING THE THERMOSTAT ASSEM- 1. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-30. 2. Check: • Cooling system Leaks → Repair or replace any faulty part.

  • Page 353: Water Pump

    WATER PUMP EAS26500 WATER PUMP Disassembling the water pump Order Job/Parts to removes Q’ty Remarks Oil/water pump assembly Refer to “OIL PUMP” on page 5-51. Oil pump rotor Refer to “OIL PUMP” on page 5-51. Water pump cover O-ring Impeller shaft (along with the impeller) Water pump seal Oil seal O-ring...

  • Page 354: Water Pump

    WATER PUMP EAS26520 DISASSEMBLING THE WATER PUMP 1. Remove: • Water pump seal “1” Remove the water pump seal from the inside of the water pump housing “2”. EAS26540 CHECKING THE WATER PUMP 1. Check: • Water pump housing cover “1” •...
  • Page 355 WATER PUMP Before installing the rubber damper, apply tap water or coolant onto its outer surface. 2. Install: • Water pump seal “1” ECA14080 Never lubricate the water pump seal sur- face with oil or grease. 4. Measure: • Impeller shaft tilt Out of specification →...
  • Page 356 WATER PUMP 6-15...

  • Page 357: Fuel System

    FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK SIDE COVERS ........7-3 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP...............7-3 CHECKING THE FUEL PUMP BODY ............7-3 CHECKING THE FUEL PUMP OPERATION .........7-3 INSTALLING THE FUEL PUMP..............7-3 INSTALLING THE FUEL TANK...............7-4 INSTALLING THE FUEL TANK SIDE COVERS ........7-4 AIR FILTER CASE ..................7-5 CHECKING THE SECONDARY INJECTORS...

  • Page 358: Fuel Tank

    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank and fuel pump Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank side cover Fuel tank upper cover Except for California Fuel tank breather hose Disconnect.

  • Page 359: Fuel Tank

    FUEL TANK Removing the fuel tank and fuel pump Order Job/Parts to remove Q’ty Remarks Fuel pump Fuel pump gasket For installation, reverse the removal proce- dure.
  • Page 360 FUEL TANK EAS14B1078 REMOVING THE FUEL TANK SIDE COVERS The following procedure applies to both of the fuel tank side covers. 1. Remove: • Fuel tank side cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the screw on the fuel tank side cover. b.
  • Page 361 FUEL TANK • Do not damage the installation surfaces of Install the fuel hose securely onto the fuel the fuel tank when installing the fuel pump. pump until a distinct “click” is heard. • Always use a new fuel pump gasket. •...

  • Page 362: Air Filter Case

    AIR FILTER CASE EAS14B1062 AIR FILTER CASE Removing the air filter case and secondary injectors Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Crankcase breather hose Disconnect. Sub-wire harness coupler Disconnect. Fuel hose (secondary injector fuel rail side) Disconnect.
  • Page 363 AIR FILTER CASE Removing the air filter case and secondary injectors Order Job/Parts to remove Q’ty Remarks Intake funnel servo motor rod assembly Intake funnel assembly Intake funnel servo motor For installation, reverse the removal proce- dure.
  • Page 364 AIR FILTER CASE EAS14B4003 EAS14B4004 CHECKING THE SECONDARY INJECTORS REMOVING THE SECONDARY INJECTORS (BEFORE REMOVING) EWA14B4001 WARNING 1. Check: • Injectors • Check the injectors in a well-ventilated Use the diagnostic code number “D:40– area free of combustible materials. Make D:43”.
  • Page 365 AIR FILTER CASE 4. Remove: EAS14B1077 REMOVING THE INTAKE FUNNEL ASSEM- • Sub-wire harness • Secondary injectors 1. Remove: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Intake funnel servo motor rod assembly a. Remove the fuel rail screws “1” as shown. • Intake funnel assembly ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 366 AIR FILTER CASE EAS14B1066 b. Set the engine stop switch to “ ”. CHECKING THE INTAKE FUNNEL c. Check that the intake funnel operate 1. Check: smoothly strokes from the upper position to • Intake funnel servo motor rod assembly the lower seating position.
  • Page 367 AIR FILTER CASE Secondary injector assembly bolt 4 Nm (0.4 m·kgf, 2.9 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS14B1069 6. Check the injector pressure after the injec- INSTALLING THE FUEL HOSE (PRIMARY tors are installed to the upper air filter case. INJECTOR JOINT SIDE AND SECONDARY Refer to “CHECKING THE INJECTOR INJECTOR JOINT SIDE) PRESSURE”...

  • Page 368: Throttle Bodies

    THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the canister Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Canister purge hose (throttle body-#2 to 3-way joint) Canister purge hose (throttle body-#1 to 3-way joint)
  • Page 369 THROTTLE BODIES Removing the throttle body assembly Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Throttle position sensor coupler Disconnect. Accelerator position sensor coupler Disconnect.
  • Page 370 THROTTLE BODIES Removing the throttle body assembly Order Job/Parts to remove Q’ty Remarks Crankshaft position sensor coupler Disconnect. Heat protector Throttle body joint For installation, reverse the removal proce- dure. 7-13...
  • Page 371 THROTTLE BODIES Removing the primary injectors Order Job/Parts to remove Q’ty Remarks Primary injector coupler #1 Disconnect. Primary injector coupler #2 Disconnect. Primary injector coupler #3 Disconnect. Primary injector coupler #4 Disconnect. Sub-wire harness Intake air pressure sensor hose Intake air pressure sensor Fuel rail Primary injector joint Primary injector...
  • Page 372 THROTTLE BODIES EAS14B4007 CHECKING THE PRIMARY INJECTORS (BEFORE REMOVING) 1. Check: • Injectors Use the diagnostic code number “D:36– D:39”. Refer to “DIAGNOSTIC MODE” on page 8-38. EAS14B4008 EAS14B4009 REMOVING THE PRIMARY INJECTORS CHECKING THE PRIMARY INJECTORS EWA14B4002 1. Check: WARNING •...
  • Page 373 THROTTLE BODIES Before cleaning the throttle bodies, check the • Do not apply cleaning solvent directly to following items: any plastic parts, sensors, or seals. • Valve clearance • Do not directly push the throttle valves to • Spark plugs open them.
  • Page 374 THROTTLE BODIES d. Apply a petroleum-based solvent to the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ throttle valves and the inside of the throttle 3. Adjust: bodies to remove any carbon deposits. • Throttle bodies synchronizing Out of specification → Replace the throt- tle bodies. • Do not allow any petroleum-based solvent to Refer to “SYNCHRONIZING THE enter the opening for the injectors.
  • Page 375 THROTTLE BODIES 5. Check the injector pressure after the injec- f. Close the valve on the injector pressure tors are installed to the throttle bodies. adapter. Refer to “CHECKING THE INJECTOR g. Check that the specified air pressure is PRESSURE” on page 7-18. held for about one seconds.
  • Page 376 THROTTLE BODIES d. Start the engine. “dIAG” appears on the odometer LCD. e. Measure the fuel pressure. f. Diagnostic code number “D:01” is selected. Fuel pressure g. Adjust the position of the throttle position 324.0 kPa (3.24 kgf/cm , 47.0 sensor angle so that 12–21 can appear in psi) the meter.
  • Page 377 THROTTLE BODIES ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Temporary tighten the accelerator position sensor. b. Check that the throttle valves are fully closed. c. Connect the throttle position sensor, accel- erator position sensor and throttle servo motor to the wire harness. d. Turn the main switch to “OFF”. e.

  • Page 378: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-21...
  • Page 379 AIR INDUCTION SYSTEM 1. Lower air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover) 7-22...
  • Page 380 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Side air filter case duct Atmospheric pressure sensor coupler Disconnect.
  • Page 381 AIR INDUCTION SYSTEM Removing the reed valves Order Job/Parts to remove Q’ty Remarks Reed valve cover Reed valve assembly Reed valve plate For installation, reverse the removal proce- dure. 7-24...
  • Page 382 AIR INDUCTION SYSTEM EAS27060 CHECKING THE AIR INDUCTION SYSTEM Air injection 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 neg- ative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.
  • Page 383 AIR INDUCTION SYSTEM 4. Check: A. Exhaust side • Air cut-off valve Cracks/damage → Replace. 3. Install: • Reed valve cover 5. Check: • Air induction system solenoid Reed valve cover bolt Refer to “CHECKING THE AIR INDUC- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) TION SYSTEM SOLENOID”...
  • Page 384 AIR INDUCTION SYSTEM 7-27...

  • Page 385: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM..................8-1 CIRCUIT DIAGRAM................8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION .....8-3 TROUBLESHOOTING ................8-5 ELECTRIC STARTING SYSTEM..............8-7 CIRCUIT DIAGRAM................8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-9 TROUBLESHOOTING ................8-11 CHARGING SYSTEM .................8-13 CIRCUIT DIAGRAM................8-13 TROUBLESHOOTING ................8-15 LIGHTING SYSTEM ...................8-17 CIRCUIT DIAGRAM................8-17 TROUBLESHOOTING ................8-19 SIGNALING SYSTEM.................8-21 CIRCUIT DIAGRAM................8-21 TROUBLESHOOTING ................8-23...
  • Page 386 CHECKING THE CRANKSHAFT POSITION SENSOR .....8-117 CHECKING THE LEAN ANGLE SENSOR .........8-117 CHECKING THE STARTER MOTOR OPERATION......8-118 CHECKING THE STATOR COIL............8-118 CHECKING THE RECTIFIER/REGULATOR ........8-119 CHECKING THE HORN ..............8-119 CHECKING THE OIL LEVEL SWITCH ..........8-120 CHECKING THE FUEL SENDER ............8-120 CHECKING THE SPEED SENSOR ...........8-121 CHECKING THE RADIATOR FAN MOTOR........8-121 CHECKING THE COOLANT TEMPERATURE SENSOR ....8-122...

  • Page 388: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 389 IGNITION SYSTEM 1. Main switch 4. Main fuse 7. Battery 8. Fuel injection system fuse 11.Relay unit 14.Sidestand switch 20.ECU (engine control unit) 21.Ignition coil #1 22.Ignition coil #2 23.Ignition coil #3 24.Ignition coil #4 25.Spark plug 40.Crankshaft position sensor 44.Cylinder identification sensor 45.Lean angle sensor 62.Right handlebar switch...
  • Page 390 IGNITION SYSTEM EAS14B1082 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
  • Page 391 IGNITION SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. ECU (engine control unit) 9. Sidestand switch 10.Relay unit (diode) 11.Gear position sensor 12.Battery negative lead 13.Engine ground...
  • Page 392 IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Air filter case duct 4. Side cowlings 1. Check the fuses. NG→...
  • Page 393 IGNITION SYSTEM 7. Check the cylinder identification NG→ sensor. Replace the cylinder identification Refer to “CHECKING THE CYLIN- sensor. DER IDENTIFICATION SENSOR” on page 8-125. OK↓ 8. Check the main switch. NG→ Refer to “CHECKING THE Replace the main switch. SWITCHES”...

  • Page 394: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 395 ELECTRIC STARTING SYSTEM 1. Main switch 4. Main fuse 7. Battery 9. Starter relay 10.Starter motor 11.Relay unit 12.Starting circuit cut-off relay 14.Sidestand switch 62.Right handlebar switch 65.Engine stop switch 66.Start switch 67.Gear position sensor 69.Left handlebar switch 72.Clutch switch 94.Ignition fuse 95.Engine ground 96.Battery negative lead...
  • Page 396 ELECTRIC STARTING SYSTEM EAS14B1036 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 397 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.
  • Page 398 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Heat protector 4. Side cowlings 1. Check the fuses. NG→ (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
  • Page 399 ELECTRIC STARTING SYSTEM 8. Check the main switch. NG→ Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-105. OK↓ 9. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-105. OK↓...

  • Page 400: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-13...
  • Page 401 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Main fuse 7. Battery 95.Engine ground 96.Battery negative lead 8-14...
  • Page 402 CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Right side cowling 1. Check the fuse. NG→ (Main) Replace the fuse. Refer to “CHECKING THE FUSES” on page 8-109. OK↓...
  • Page 403 CHARGING SYSTEM 8-16...

  • Page 404: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-17...
  • Page 405 LIGHTING SYSTEM 1. Main switch 4. Main fuse 7. Battery 8. Fuel injection system fuse 20.ECU (engine control unit) 46.Meter assembly 57.High beam indicator light 60.Meter light 69.Left handlebar switch 70.Dimmer switch 75.Front left turn signal/position light 76.Front right turn signal/position light 79.Headlight 80.Auxiliary light 81.Ground (cord headlight)
  • Page 406 LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight or license plate light. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Left side cowling 3. Air intake air duct covers 4.
  • Page 407 LIGHTING SYSTEM 7. Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-17. OK↓ Replace the ECU or meter assembly. 8-20...

  • Page 408: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21...
  • Page 409 SIGNALING SYSTEM 1. Main switch 4. Main fuse 7. Battery 8. Fuel injection system fuse 11.Relay unit 16.Fuel sender 20.ECU (engine control unit) 38.Speed sensor 41.Coolant temperature sensor 46.Meter assembly 47.Fuel level warning light 48.Oil level warning light 49.Neutral indicator light 50.Tachometer 51.Shift timing indicator light 52.Multi-function meter...
  • Page 410 SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3.
  • Page 411 SIGNALING SYSTEM 3. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-21. OK↓ This circuit is OK. The tail/brake light fails to come on. 1. Check the front brake light switch. NG→...
  • Page 412 SIGNALING SYSTEM 4. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-21. OK↓ Replace the meter assembly. The neutral indicator light fails to come on. 1. Check the gear position sensor. NG→...
  • Page 413 SIGNALING SYSTEM 2. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-21. OK↓ Replace the meter assembly. The coolant temperature warning light fails to come on. 1.
  • Page 414 SIGNALING SYSTEM 2. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-21. OK↓ Replace the meter assembly. 8-27...
  • Page 415 SIGNALING SYSTEM 8-28...
  • Page 416 COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-29...
  • Page 417 COOLING SYSTEM 1. Main switch 4. Main fuse 7. Battery 8. Fuel injection system fuse 20.ECU (engine control unit) 41.Coolant temperature sensor 86.Radiator fan motor relay 87.Right radiator fan motor fuse 88.Left radiator fan motor fuse 89.Right radiator fan motor 90.Left radiator fan motor 94.Ignition fuse 95.Engine ground...
  • Page 418 COOLING SYSTEM EAS27320 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings 1. Check the fuses. NG→ (Main, ignition, radiator fan motor and fuel injection system) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-109.
  • Page 419 COOLING SYSTEM 8-32...

  • Page 420: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-33...
  • Page 421 FUEL INJECTION SYSTEM 1. Main switch 4. Main fuse 6. ETV (Electronic Throttle Valve) fuse 7. Battery 8. Fuel injection system fuse 11.Relay unit 12.Starting circuit cut-off relay 13.Fuel pump relay 14.Sidestand switch 15.Fuel pump 17.Throttle position sensor 18.Accelerator position sensor 19.O sensor 20.ECU (engine control unit)
  • Page 422 FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 423 FUEL INJECTION SYSTEM ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.
  • Page 424 FUEL INJECTION SYSTEM EAS14B1115 The engine operation is not normal but the TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1. Check the operation of following sensors engine trouble warning light comes on. and actuators in the Diagnostic mode.
  • Page 425 FUEL INJECTION SYSTEM EAS14B1084 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.
  • Page 426 FUEL INJECTION SYSTEM Sensor operation table Diag- nostic Item Meter display Checking method code D:01 Throttle position sensor sig- nal 1 • Fully closed position 12–21 Check with throttle valves fully closed. • Fully opened position 96–106 Check with throttle valves fully open.
  • Page 427 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:14 Accelerator position sensor signal 1 • Fully closed position 12–22 Check with throttle grip fully closed. • Fully opened position 97–107 Check with throttle grip fully open. D:15 Accelerator position sensor signal 2 •...
  • Page 428 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:62 Malfunction history code erasure • No history — • History exists • Displays the total number To erase the history, set the of malfunctions, including engine stop switch from “ ”...
  • Page 429 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:33 Cylinder-#4 ignition coil Actuates the cylinder-#4 igni- Check the spark five times. tion coil five times at one-sec- • Connect an ignition ond intervals. checker. Illuminates the engine trouble warning light.
  • Page 430 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:43 Secondary injector #4 Actuates the secondary Check the operating sound injector #4 five times at one- of the secondary injector #4 second intervals. five times. Illuminates the engine trouble warning light.
  • Page 431 FUEL INJECTION SYSTEM EAS14B1085 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the meter display according to the reinstatement method.
  • Page 432 FUEL INJECTION SYSTEM Fault code No. Normal signals are not received from the cylinder identification sen- Symptom sor. Engine startup: Impossible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 433 FUEL INJECTION SYSTEM Fault code No. Normal signals are not received from the crankshaft position sen- Symptom sor. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 434 FUEL INJECTION SYSTEM If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code No. Symptom Open or short circuit of intake air pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:03...
  • Page 435 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:03 ing code No. Meter display Displays the intake air pressure. Set the engine stop switch to “ ”, and then push the start switch Checking method “...
  • Page 436 FUEL INJECTION SYSTEM If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code No. The intake air pressure sensor has failed (due to clogging of hose or Symptom sensor disconnection). Engine startup: Possible Fail-safe action Riding: Possible...
  • Page 437 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:01 ing code No. D:13 Throttle position sensor signal 1 Meter display •...
  • Page 438 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:01 ing code No. D:13 Throttle position sensor signal 1 Meter display •...
  • Page 439 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:01 ing code No. D:13 Throttle position sensor signal 1 Meter display •...
  • Page 440 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of ECU input line (Blue/Yellow lead) Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:20 ing code No. Sidestand switch Meter display • ON (stand retracted) • OFF (stand extended) Checking method Set on/off the sidestand switch.
  • Page 441 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of ECU input line (Blue/Yellow lead) Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:20 ing code No. Sidestand switch Meter display • ON (stand retracted) • OFF (stand extended) Checking method Set on/off the sidestand switch.
  • Page 442 FUEL INJECTION SYSTEM Fault code No. When the main switch is ON, there is a big difference in voltage Symptom value of the intake air pressure sensor and atmospheric pressure sensor Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:03 ing code No.
  • Page 443 FUEL INJECTION SYSTEM Fault code No. When the main switch is ON, there is a big difference in voltage Symptom value of the intake air pressure sensor and atmospheric pressure sensor Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:03 ing code No.
  • Page 444 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of coolant temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:06 ing code No. Meter display Displays the coolant temperature. Compare the actually measured coolant temperature with the meter Checking method display value.
  • Page 445 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:05 ing code No. Meter display Displays the intake air temperature. Compare the actually measured intake air temperature with the Checking method meter display value.
  • Page 446 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:05 ing code No. Meter display Displays the intake air temperature. Compare the actually measured intake air temperature with the Checking method meter display value.
  • Page 447 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of atmospheric pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:02 ing code No. Meter display Displays the atmospheric pressure. Compare the actually measured atmospheric pressure with the Checking method meter display value.
  • Page 448 FUEL INJECTION SYSTEM Fault code No. The O sensor does not operate. Symptom Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure sensor installation status...
  • Page 449 FUEL INJECTION SYSTEM Fault code No. The O sensor does not operate. Symptom Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure sensor malfunction...
  • Page 450 FUEL INJECTION SYSTEM Fault code No. Symptom Turnover of vehicle Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:08 ing code No. Lean angle sensor Meter display • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Checking method Remove the lean angle sensor and incline it more than 45 degrees. Item/components and Sensor inspection proce- Check or maintenance job...
  • Page 451 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #1 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:30 ing code No. Actuates the cylinder-#1 ignition coil five times at one-second inter- Meter display vals.
  • Page 452 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #2 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:31 ing code No. Actuates the cylinder-#2 ignition coil five times at one-second inter- Meter display vals.
  • Page 453 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #2 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:31 ing code No. Actuates the cylinder-#2 ignition coil five times at one-second inter- Meter display vals.
  • Page 454 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #3 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:32 ing code No. Actuates the cylinder-#3 ignition coil five times at one-second inter- Meter display vals.
  • Page 455 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #4 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:33 ing code No. Actuates the cylinder-#4 ignition coil five times at one-second inter- Meter display vals.
  • Page 456 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil #4 primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- D:33 ing code No. Actuates the cylinder-#4 ignition coil five times at one-second inter- Meter display vals.
  • Page 457 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of primary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:36 Diagnostic monitor- D:37 ing code No.
  • Page 458 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of primary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:36 Diagnostic monitor- D:37 ing code No.
  • Page 459 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of primary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:36 Diagnostic monitor- D:37 ing code No.
  • Page 460 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of secondary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:40 Diagnostic monitor- D:41 ing code No.
  • Page 461 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of secondary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:40 Diagnostic monitor- D:41 ing code No.
  • Page 462 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of secondary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:40 Diagnostic monitor- D:41 ing code No.
  • Page 463 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of secondary injector lead Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) D:40 Diagnostic monitor- D:41 ing code No.
  • Page 464 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of lean angle sensor lead Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:08 ing code No. Lean angle sensor Meter display • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Checking method Remove the lean angle sensor and incline more than 45 degrees.
  • Page 465 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of lean angle sensor lead Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- D:08 ing code No. Lean angle sensor Meter display • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Checking method Remove the lean angle sensor and incline more than 45 degrees.
  • Page 466 FUEL INJECTION SYSTEM Fault code No. Symptom A. Normal signals are not received from the speed sensor. B. Open or short circuit of gear position sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitoring D:07 (Speed sensor) code No. Meter display Vehicle speed pulses: 0–999 Make sure that the indication value increases when the rota-...
  • Page 467 FUEL INJECTION SYSTEM A. Speed sensor system malfunction Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection → Connect Connection of speed sensor Start the engine, and check (meter) coupler it securely, or repair/replace the connection of the coupler Check the connection of the the wire harness.
  • Page 468 FUEL INJECTION SYSTEM B. Gear position sensor system malfunction Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection → Recon- Connection of gear position Start the engine, and check sensor coupler nect or repair the coupler. the secure connection of the Check the connection of the coupler.
  • Page 469 FUEL INJECTION SYSTEM Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Shift drum (that detects the Check the gear shift drum Start the engine, and check neutral position) malfunction (that detects the neutral posi- the secure connection of the tion).
  • Page 470 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage supplied to the fuel injector and fuel pump Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:50 ing code No. Meter display Approximately 12.0 Set the engine stop switch to “ ”, and then compare with the actu- Checking method ally measured battery voltage.
  • Page 471 FUEL INJECTION SYSTEM Fault code No. Symptom An error is detected while reading or writing on EEP-ROM Engine startup: Under certain conditions Fail-safe action Riding: Under certain conditions Diagnostic monitor- D:60 ing code No. The in self diagnostic code 44 detected EEP-ROM errors are indi- cated.
  • Page 472 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage is supplied to the ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection →...
  • Page 473 FUEL INJECTION SYSTEM Fault code No. Symptom ECU memory malfunction Engine startup: Under certain conditions Fail-safe action Riding: Under certain conditions Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure ECU malfunction...
  • Page 474 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of accelerator position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:14 ing code No. D:15 Accelerator position sensor signal 1 Meter display •...
  • Page 475 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of accelerator position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:14 ing code No. D:15 Accelerator position sensor signal 1 Meter display •...
  • Page 476 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of accelerator position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D:14 ing code No. D:15 Accelerator position sensor signal 1 Meter display •...
  • Page 477 FUEL INJECTION SYSTEM Fault code No. Symptom Defect Found in YCC-T Drive Type Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause...
  • Page 478 FUEL INJECTION SYSTEM Fault code No. Symptom Defect Found in YCC-T Drive Type Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause...
  • Page 479 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of steering damper solenoid lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D:47 ing code No. Meter display The steering damper warning light lights up. The engine warning light flashes according to the ON/OFF switch- Checking method ing.
  • Page 480 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signal is received from the ECU. Engine startup: Impossible if ECU Failure Fail-safe action Riding: Impossible if ECU Failure Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job...
  • Page 481 FUEL INJECTION SYSTEM Fault code No. Er-2 Symptom No signal is sent from ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection →...
  • Page 482 FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Correct data cannot be received from the ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 483 FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom No registration data can be received from the meter unit. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...

  • Page 484: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-97...
  • Page 485 FUEL PUMP SYSTEM 1. Main switch 4. Main fuse 7. Battery 8. Fuel injection system fuse 11.Relay unit 13.Fuel pump relay 15.Fuel pump 20.ECU (engine control unit) 62.Right handlebar switch 65.Engine stop switch 94.Ignition fuse 95.Engine ground 96.Battery negative lead 8-98...
  • Page 486 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Passenger seat 4. Left side cowling 1. Check the fuses. NG→ (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 487 FUEL PUMP SYSTEM 7. Check the entire fuel pump sys- NG→ tem’s wiring. Properly connect or repair the fuel Refer to “CIRCUIT DIAGRAM” on pump system’s wiring. page 8-97. OK↓ Replace the ECU. 8-100...
  • Page 488 ELECTRICAL COMPONENTS EAS27972 ELECTRICAL COMPONENTS 8-101...
  • Page 489 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Ignition coil 5. Battery 6. Fuse box 7. Main fuse 8. Fuel injection system fuse 9. Starter relay 10.Rear brake light switch 11.Gear position sensor 12.Sidestand switch 13.O sensor 14.Speed sensor...
  • Page 490 ELECTRICAL COMPONENTS 8-103...
  • Page 491 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Headlight relay 3. Turn signal relay 4. Atmospheric pressure sensor 5. Intake air pressure sensor 6. Intake funnel servo motor 7. Fuel pump 8. Relay unit 9. Lean angle sensor 10.Coolant temperature sensor 11.Crankshaft position sensor 12.Throttle servo motor 13.Throttle position sensor...

  • Page 492: Electrical Components

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-105...
  • Page 493 ELECTRICAL COMPONENTS 1. Horn switch 2. Clutch switch 3. Main switch 4. Dimmer switch 5. Turn signal switch 6. Sidestand switch 7. Gear position sensor 8. Oil level switch 9. Front brake light switch 10.Engine stop switch 11.Start switch 12.Rear brake light switch 8-106...
  • Page 494 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
  • Page 495 ELECTRICAL COMPONENTS EAS27990 ECA14380 CHECKING THE BULBS AND BULB SOCK- • Be sure to hold the socket firmly when removing the bulb. Never pull the lead, Do not check any of the lights that use LEDs. otherwise it may be pulled out of the ter- minal in the coupler.
  • Page 496 ELECTRICAL COMPONENTS b. Install a new fuse of the correct amperage Pocket tester rating. 90890-03112 c. Set on the switches to verify if the electrical Analog pocket tester circuit is operational. YU-03112-C d. If the fuse immediately blows again, check the electrical circuit.
  • Page 497 ELECTRICAL COMPONENTS • Keep batteries away from fire, sparks or 2. Disconnect: open flames (e.g., welding equipment, • Battery leads lighted cigarettes). (from the battery terminals) • DO NOT SMOKE when charging or han- ECA13640 dling batteries. • KEEP BATTERIES AND ELECTROLYTE First, disconnect the battery negative lead OUT OF REACH OF CHILDREN.
  • Page 498 ELECTRICAL COMPONENTS • When charging a battery, be sure to remove it from the vehicle. (If charging has to be done with the battery mounted on the vehicle, disconnect the battery negative lead from the battery terminal.) • To reduce the chance of sparks, do not plug in the battery charger until the bat- tery charger leads are connected to the battery.
  • Page 499 ELECTRICAL COMPONENTS Voltage should be measured 30 minutes after Voltage should be measured 30 minutes after the engine is stopped. the engine is stopped. b. Connect a charged and ammeter to the b. Connect a charger and ammeter to the bat- battery and start charging.
  • Page 500 ELECTRICAL COMPONENTS 9. Lubricate: Relay unit (starting circuit cut-off relay) • Battery terminals Recommended lubricant Dielectric grease 10. Install: • Battery cover • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELAYS 1. Positive battery terminal Check each switch for continuity with the 2.
  • Page 501 ELECTRICAL COMPONENTS Headlight relay Turn signal relay input voltage DC 12 V ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the turn signal relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1. Positive battery terminal •...
  • Page 502 ELECTRICAL COMPONENTS Continuity Positive tester probe Sky blue “1” Negative tester probe Black/Yellow “2” No continuity Positive tester probe Black/Yellow “2” Negative tester probe Sky blue “1” Continuity b. Turn the main switch to “ON”. Positive tester probe c. Measure the turn signal relay output volt- Sky blue “1”...
  • Page 503 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Check: a. Disconnect the relay unit coupler from the • Secondary coil resistance Out of specification → Replace. wire harness. b. Connect the pocket tester (Ω × 1) to the Secondary coil resistance relay unit terminal as shown. 8.50–11.50 kΩ...

  • Page 504: Battery Box

    ELECTRICAL COMPONENTS b. Measure the crankshaft position sensor 2. Ignition coil resistance. b. Turn the main switch to “ON” and engine ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ stop switch to “ ”. c. Measure the ignition spark gap “a”. EAS28130 CHECKING THE LEAN ANGLE SENSOR d.
  • Page 505 ELECTRICAL COMPONENTS EAS28150 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.112–0.168 Ω at 20 °C (68 °F) c.
  • Page 506 ELECTRICAL COMPONENTS EAS28170 2. Check: CHECKING THE RECTIFIER/REGULATOR • Rectifier/regulator output voltage 1. Check: Out of specification → Replace the recti- • Rectifier/regulator input voltage fier/regulator. Out of specification → Correct the stator coil condition. Rectifier/regulator output volt- Refer to “CHECKING THE STATOR COIL”...
  • Page 507 ELECTRICAL COMPONENTS b. Connect the pocket tester (Ω × 1) to the Pocket tester horn terminals. 90890-03112 Pocket tester Analog pocket tester 90890-03112 YU-03112-C Analog pocket tester YU-03112-C Minimum level position “A” • Positive tester probe • Positive tester probe Connector (White) “1”...
  • Page 508 ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe Green/White “1” • Negative tester probe Black “2” c. Turn the main switch to “ON”. d. Elevate the rear wheel and slowly rotate it. e. Measure the voltage. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
  • Page 509 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 100) to the coolant temperature sensor as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Immerse the coolant temperature sensor “1” in a container filled with coolant “2”. Make sure the coolant temperature sensor ter- minals do not get wet.
  • Page 510 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Throttle position sensor resis- a. Connect the pocket tester (Ω × 1 k) to the tance accelerator position sensor terminal as 1.2–2.8 kΩ shown. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Pocket tester a. Connect the pocket tester (Ω × 1 k) to the 90890-03112 throttle position sensor terminal as shown.
  • Page 511 ELECTRICAL COMPONENTS b. Connect the pocket tester (Ω × 1) to the throttle servo motor coupler. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe Yellow/Red “1” c. Measure the air induction system solenoid • Negative tester probe resistance.
  • Page 512 ELECTRICAL COMPONENTS • Positive tester probe White/Black (wire harness color) • Negative tester probe Black/Blue (wire harness color) c. Turn the main switch to “ON”. d. Measure the atmospheric pressure sensor output voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28390 c. Turn the main switch to “ON”. CHECKING THE CYLINDER IDENTIFICA- d.
  • Page 513 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Digital circuit tester a. Connect the pocket tester (Ω × 100) to the 90890-03174 intake air temperature sensor terminal as Model 88 Multimeter with shown. tachometer YU-A1927 Pocket tester Test harness S-pressure sensor 90890-03112 5S7 (3P) Analog pocket tester 90890-03211 YU-03112-C YU-03211...
  • Page 514 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Result a. Disconnect the steering damper lead cou- Neutral position pler from wire harness. Continuity b. Connect the pocket tester (Ω × 1) to the Positive tester probe steering damper lead coupler. Sky blue “1” Pocket tester Negative tester probe 90890-03112 Sensor terminal “a”...
  • Page 515 ELECTRICAL COMPONENTS EAS14B1101 CHECKING THE FUEL INJECTORS 1. Remove: • Fuel tank Refer to “FUEL TANK” on page 7-1. • Air filter upper cover (for secondary injec- tor) Refer to “AIR FILTER CASE” on page 7- 2. Check: • Fuel injector resistance Out of specification →...
  • Page 516 ELECTRICAL COMPONENTS 8-129...

  • Page 517: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED ..........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING ..............9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ...................9-2 OVERHEATING ..................9-3 OVERCOOLING ..................9-3 POOR BRAKING PERFORMANCE ............9-3 FAULTY FRONT FORK LEGS ..............9-3 UNSTABLE HANDLING................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........9-4...
  • Page 518 TROUBLESHOOTING EAS28451 3. Throttle body(-ies) TROUBLESHOOTING • Deteriorated or contaminated fuel • Sucked-in air EAS28460 GENERAL INFORMATION Electrical system 1. Battery The following guide for troubleshooting does • Discharged battery not cover all the possible causes of trouble. It • Faulty battery should be helpful, however, as a guide to basic 2.
  • Page 519 TROUBLESHOOTING Fuel system Shift drum and shift forks 1. Throttle body(-ies) • Foreign object in a shift drum groove • Damaged or loose throttle body joint • Seized shift fork • Improperly synchronized throttle bodies • Bent shift fork guide bar •...
  • Page 520 TROUBLESHOOTING EAS28600 EAS28620 OVERHEATING POOR BRAKING PERFORMANCE • Worn brake pad Engine • Worn brake disc 1. Clogged coolant passages • Air in hydraulic brake system • Cylinder head and piston(s) • Leaking brake fluid • Heavy carbon buildup • Faulty brake caliper kit 2.
  • Page 521 TROUBLESHOOTING 4. Swingarm • Faulty turn signal switch • Worn bearing or bushing • Incorrect turn signal bulb • Bent or damaged swingarm Turn signal remains lit 5. Rear shock absorber assembly(-ies) • Faulty turn signal relay • Faulty rear shock absorber spring •...

  • Page 522: Battery Negative Lead

    EAS28740 56. Coolant temperature warning Violet WIRING DIAGRAM light White 57. High beam indicator light YZFR1Y(C) Yellow 58. Left turn signal indicator light Black/Green 1. Main switch 59. Right turn signal indicator light Black/Blue 2. AC magneto 60. Meter light Black/Red 3.
  • Page 524 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 525 WIRING DIAGRAM YZFR1Y(C)
  • Page 526 WIRING DIAGRAM YZFR1Y(C)

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