Yamaha YZF-R1(B) 2012 Service Manual
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Yamaha YZF-R1(B) 2012 Service Manual

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Table Of Contents
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Table of Contents

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2012
SERVICE MANUAL
YZF-R1(B)
1KB-28197-E0

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Summary of Contents for Yamaha YZF-R1(B) 2012

  • Page 1 2012 SERVICE MANUAL YZF-R1(B) 1KB-28197-E0...
  • Page 2 EAS20040 YZF-R1(B) SERVICE MANUAL ©2011 by Yamaha Motor Co., Ltd. First edition, July 2011 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3 EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 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 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: Table Of Contents

    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 OUTLINE OF THE TCS (Traction Control System) ........1-8 INSTRUMENT FUNCTIONS ..............1-12 IMPORTANT INFORMATION ..............1-20 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-20 REPLACEMENT PARTS...............1-20...

  • 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: Outline Of The Fi System

    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 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 a certain level. Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing 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) 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 • Improved power band By using a dual intake funnel system, YCC-I optimizes the effectiveness of the fuel injection sys- tem to deliver an incredibly precise air/fuel mixture to the combustion chamber. This degree of intake volume control gives both improved low to mid-range power, as well as improved power in the higher rpm 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. Rear speed sensor 21.Base map 5. D-mode switch 22.Air funnel position (Calculation value) 6.

  • Page 17: Outline Of The Tcs (Traction Control System)

    FEATURES EAS1KB8101 OUTLINE OF THE TCS (Traction Control System) The traction control system controls excessive spinning (slipping) of the rear wheel when accelerat- ing. The ECU monitors the front and rear wheel speeds using the signals from the front and rear speed sensors, and detects rear wheel slipping according to the difference between the wheel speeds.
  • Page 18 FEATURES TCS (Traction control system) block diagram The signals from the front and rear speed sensors are sent to the ECU, and the ECU calculates the amount of slip according to the difference between the detected front and rear wheel speeds. If the amount of slip exceeds the preset value, the ECU controls the ignition timing, fuel cut-off, and throttle valve opening of the YCC-T system so that the amount of slip is less than the preset value.
  • Page 19 FEATURES There are six traction control system modes and an off mode. Display Mode 1 Mode 2 Mode 3 Mode 4 Mode 5 Mode 6 • “TCS” mode 1 provides for the least traction control system assist. • “TCS” modes 2 through 6 provide for more traction control system assist. Mode 6 provides the most traction control system assist.
  • Page 20 FEATURES 2. Traction control system mode display 1. Traction control system switch Resetting The traction control system may be disabled in the following conditions: • Either the front wheel or rear wheel comes off the ground while riding • Excessive rear wheel spinning If the traction control system has been disabled, both the traction control system indicator/warning light and the engine trouble warning light come on.

  • Page 21: Instrument Functions

    FEATURES EAS1KB8102 • A fuel consumption display (instantaneous INSTRUMENT FUNCTIONS and average consumption functions) • A traction control system mode display Multi-function meter unit (which shows the selected traction control system mode) • A self-diagnosis device • A display brightness and shift timing indicator light control mode •...
  • Page 22 FEATURES Clock and stopwatch modes Split time history 1. Clock/stopwatch 1. Coolant temperature display/air intake tem- 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.
  • Page 23 FEATURES • To reset all the recorded times for the the distance traveled from that point. In that selected split time history, push the “RESET” case, push the “SELECT” button to switch the button for at least one second. display between the various tripmeter, odome- ter, instantaneous fuel consumption and aver- 4.
  • Page 24 FEATURES Transmission gear display If traveling at speeds under 10 km/h (6.0 mi/h), “_ _._” is displayed. Average fuel consumption mode 1. Neutral indicator light “ ” 2. Transmission gear display This display shows the selected gear. The neutral position is indicated by “ ” and by the neutral indicator light.
  • Page 25 FEATURES Traction control system mode display When the coolant temperature display is selected, “C” is displayed for one second, and then the coolant temperature is displayed. ECA14B1016 Do not continue to operate the engine if it is overheating. Air intake temperature display 1.
  • Page 26 FEATURES 1. Use the code re-registering key to start the b. Shift timing indicator light activity: engine. This function allows you to choose whether or not the indicator light should be activated and whether it should flash Make sure there are no other immobilizer keys or stay on when activated.
  • Page 27 FEATURES 2. Push the “SELECT” button to confirm the 2. Push the “SELECT” button to confirm the selected indicator light activity. The control selected indicator light brightness level. mode changes to the shift timing indicator The display returns to the odometer or light activation function.
  • Page 28 FEATURES Using this switch changes the drive mode to “STD”, “A”, or “B” in the following order: STD → A → B → STD The throttle grip must be completely closed in order to change the drive mode. • The mode is set to “STD” by default. The “STD”...

  • Page 29: 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 30: 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 31: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 5. Check: CHECKING THE CONNECTIONS • Continuity Check the leads, couplers, and connectors for (with the pocket tester) stains, rust, moisture, etc. Pocket tester 1. Disconnect: 90890-03112 • Lead Analog pocket tester • Coupler YU-03112-C • Connector 2.

  • Page 32: 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 33: 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 34 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-23, 4-74 90890-01403 Exhaust flange nut wrench YU-A9472 Damper rod holder 4-65, 4-67 90890-01506 YM-01506 Oil filter wrench 3-29 90890-01426 YU-38411 Rod holder 4-64, 4-69 90890-01434 Damper rod holder double ended YM-01434 Rod puller 4-68, 4-69...
  • Page 35 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller attachment (M10) 4-68, 4-69 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Fork spring compressor 4-64, 4-69 90890-01441 YM-01441 Fork seal driver 4-67, 4-68 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Vacuum gauge 3-10...
  • Page 36 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Thickness gauge 3-7, 3-8, 4-24 90890-03180 Feeler gauge set YU-26900-9 Valve spring compressor 5-29, 5-35 90890-04019 YM-04019 Valve spring compressor attachment 5-29, 5-35 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Middle driven shaft bearing driver 6-14 90890-04058 Bearing driver 40 mm...
  • Page 37 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover (ø5) 5-31 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide remover (ø4.5) 5-31 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide installer (ø5) 5-31 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide installer (ø4.5) 5-31...

  • Page 38: Table Of Contents

    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 3-30 90890-03139 Pressure gauge 3-30, 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 39 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder (22 mm) 4-83, 4-84 90890-01365 Drive chain cut & rivet tool 4-86, 4-87 90890-01550 YM-01550 Piston installing tool 5-82 90890-04161 YM-04161 Rotor puller 5-37 2K7-85555-00 Sheave holder 5-37, 5-40, 5- 90890-01701 41, 5-43 Primary clutch holder...
  • Page 40 Test harness-speed sensor (3P) 8-141, 8-146 90890-03208 YU-03208 Test harness-lean angle sensor (6P) 8-138 90890-03209 YU-03209 Test harness S-pressure sensor (3P) 8-145, 8-146 90890-03207 YU-03207 Yamaha bond No. 1215 5-23, 5-38, 5- (Three bond No. 1215®) 44, 5-72 90890-85505 1-31...
  • Page 41 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 42: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 1KB8, 1KBJ (AUT, BEL, CHE, CZE, DEU, DNK, ESP, FIN, GBR, GRC, HUN, IRL, ITA, NLD, NOR, POL, PRT, SVN, SWE, ZAF) 1KB9, 1KBK (BEL, FRA) 1KBH, 1KBP (AUS) Dimensions Overall length 2070 mm (81.5 in) Overall width 715 mm (28.1 in) Overall height...

  • Page 43: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 998.0 cm³ Cylinder arrangement Inline 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 44 ENGINE SPECIFICATIONS Thermostat 71 °C (159.8 °F) Valve opening temperature 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...
  • Page 45 ENGINE SPECIFICATIONS Timing chain Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.11–0.20 mm (0.0043–0.0079 in) Exhaust 0.23–0.27 mm (0.0091–0.0106 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)
  • Page 46 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 47 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 48 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) Warpage limit...
  • Page 49 ENGINE SPECIFICATIONS Throttle position sensor Throttle position sensor resistance 1.2–2.8 kΩ 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) More than 4.8 V Cylinder identification sensor output voltage...

  • Page 50: 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 51 CHASSIS SPECIFICATIONS Front disc brake Disc outside diameter × thickness 310.0 × 5.0 mm (12.20 × 0.20 in) Brake disc thickness limit 4.5 mm (0.18 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (outer)
  • Page 52 CHASSIS SPECIFICATIONS Compression damping adjusting positions Minimum Standard Maximum 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 161.0 mm (6.34 in) Installed length 147.5 mm (5.81 in) Spring rate K1 93.20 N/mm (9.50 kgf/mm, 532.17 lb/in) Spring stroke K1...

  • Page 53: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 5.0°/1200 r/min Engine control unit Model/manufacturer TBDFE9/DENSO (1KB8, 1KBH, 1KBJ, 1KBP) TBDFF0/DENSO (1KB9, 1KBK) Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 0.85–1.15 Ω...
  • Page 54 ELECTRICAL SPECIFICATIONS Fuel level warning light Coolant temperature warning light Engine trouble warning light Immobilizer system indicator light Shift timing indicator light Traction control system indicator/warning light Electric starting system System type Constant mesh Starter motor Power output 0.90 kW Armature coil 0.0090–0.0110 Ω...
  • Page 55 ELECTRICAL SPECIFICATIONS Ignition fuse 15.0 A 10.0 A × 2 Radiator fan fuse Turn signal light fuse 7.5 A 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 56: 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 57 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 58 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) Secondary injector assembly bolt 4 Nm (0.4 m·kgf, 2.9 ft·lbf) Fuel rail screw...
  • Page 59 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Generator rotor cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Drive sprocket cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 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)
  • Page 60 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Starter motor bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Rear 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 nut thread, mating surface and washer. 2.
  • Page 61 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 62 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 63 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Bleed screw (master cylinder) 6 Nm (0.6 m·kgf, 4.3 ft·lbf) 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...
  • Page 64 TIGHTENING TORQUES If the end face of the axle is not parallel to the end face of the fork, align them so that one point of the axle circumference is positioned on the end face of the fork. At this stage, it can be accepted if the end face of the axle becomes partially concave to the end face of the fork.

  • Page 65: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Coolant hose insertion part Silicon fluid Bearings Camshaft lobes and journals (intake and exhaust) Valve stem seal (installed on valve guide) Silicon fluid Valve lifter outer surface (intake and exhaust) Valve stems and stem ends (intake and exhaust)
  • Page 66 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond Cylinder head cover semicircular No.1215 (Three bond No.1215®) 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 67 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 68: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-27...
  • Page 69 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 70 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-29...
  • Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil filter cartridge 5. Oil level switch 2-30...
  • Page 72 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 73 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 74 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 75 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 76 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
  • Page 77 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil/water pump assembly 2-36...
  • Page 78 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
  • Page 79 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil delivery pipe 2 3. Drive axle 2-38...
  • Page 80 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
  • Page 81 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 82 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-41...
  • Page 83 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Oil nozzle 5. Crankshaft 2-42...
  • Page 84 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-43...
  • Page 85 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Balancer shaft 2. Crankshaft 2-44...

  • Page 86: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-45...
  • Page 87 COOLING SYSTEM DIAGRAMS 1. Oil/water pump assembly 2. Radiator 3. Radiator fan 4. Thermostat 5. Oil cooler 2-46...
  • Page 88 COOLING SYSTEM DIAGRAMS 2-47...
  • Page 89 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Radiator fan 4. Oil cooler 2-48...

  • Page 90: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-49...
  • Page 91 CABLE ROUTING 1. Meter assembly 2. Meter lead 3. Meter bracket 4. Right auxiliary light lead 5. Headlight sub-wire harness 6. Headlight lead 7. Intake air temperature sensor 8. Left auxiliary light lead 9. Right air intake air duct cover 10.Right front intake air duct 11.Turn signal relay 12.Headlight relay...
  • Page 92 CABLE ROUTING 2-51...
  • Page 93 CABLE ROUTING P. Fasten the front wheel sensor lead on the 1. Clutch cable white tape. Face the end of the plastic 2. Main switch lead band to rear and to inside of the vehicle, 3. Left handlebar switch lead and cut off the excess end leaving 5–10 4.
  • Page 94 CABLE ROUTING 2-53...
  • Page 95 CABLE ROUTING Q. Fasten the clutch cable in front of the oil 1. Hazard switch lead cooler outlet hose. 2. Right auxiliary light lead 3. Headlight sub-wire harness 4. Right radiator fan motor lead 5. AC magneto lead 6. Crankshaft position sensor 7.
  • Page 96 CABLE ROUTING 2-55...
  • Page 97 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 98 CABLE ROUTING 2-57...
  • Page 99 CABLE ROUTING P. When installing the exhaust chamber 1. Union bolt cover, route the rear brake light switch lead 2. Washer in front of the projection of the right footrest 3. Exhaust chamber cover assembly. 4. Right footrest assembly Q. Projection of the right footrest assembly 5.
  • Page 100 CABLE ROUTING 2-59...
  • Page 101 CABLE ROUTING 1. Immobilizer unit lead 2. Left radiator fan motor lead 3. Radiator fan motor relay 4. ECU (engine control unit) 5. ECU (engine control unit) bracket 6. Radiator inlet pipe 7. Cable guide A. To the handlebar switch B.
  • Page 102 CABLE ROUTING 2-61...
  • Page 103 CABLE ROUTING 1. Oil level switch lead 2. Gear position sensor lead 3. Rear speed sensor lead 4. Sidestand switch lead 5. Fuel tank overflow hose 6. Fuel tank breather hose 7. Coolant reservoir breather hose 8. Sidestand switch 9. AC magneto lead 10.Frame 11.Main harness holder 12.Main harness...
  • Page 104 CABLE ROUTING 2-63...
  • Page 105 CABLE ROUTING F. Route the coolant reservoir hose in front of 1. Right handlebar switch lead the crankcase breather hose and to the 2. Headlight sub-wire harness coolant reservoir tank. Route it as shown in 3. Right radiator fan motor lead the illustration and it should not touch the 4.
  • Page 106 CABLE ROUTING 2-65...
  • Page 107 CABLE ROUTING Z. After connecting the main harness coupler and immobilizer unit coupler, insert them into the stay 1. AA.Main harness side AB.Fasten the secondary injector sub-wire harness and throttle sub-wire harness at the protector. Face the end of the clamp downward.
  • Page 108 CABLE ROUTING 2-67...
  • Page 109 CABLE ROUTING N. Insert the fuse box until back of the tab of 1. Rear frame the battery box 2. 2. Battery box 1 O. Black 3. License plate light lead P. Green 4. Left turn signal light lead Q. Brown 5.
  • Page 110 CABLE ROUTING 2-69...
  • Page 111 CABLE ROUTING 1. Fuel tank upper cover 2. Fuel tank breather hose 3. Fuel tank overflow hose 4. Fuel tank 5. Fuel pump 6. Frame 7. Fuel hose connector cover 8. Clip 9. Fuel hose A. Install the lip on the fuel pump gasket upward.
  • Page 112 CABLE ROUTING 2-71...
  • Page 113 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. Secondary injector sub-wire harness 6. Throttle cable (pull side) 7. Throttle cable (return side) 8.
  • Page 114 CABLE ROUTING 2-73...
  • Page 115 CABLE ROUTING 1. Cap case 2. Upper air filter case 3. Sub-wire harness 4. Secondary injector holder 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 116 CABLE ROUTING 2-75...
  • Page 117 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 ........3-11...
  • Page 118 CHECKING THE COOLANT LEVEL ............3-31 CHECKING THE COOLING SYSTEM ..........3-31 CHANGING THE COOLANT ..............3-32 CHECKING THE FRONT BRAKE LIGHT SWITCH ......3-33 ADJUSTING THE REAR BRAKE LIGHT SWITCH ......3-33 CHECKING AND LUBRICATING THE CABLES ........3-34 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-34 LUBRICATING THE REAR SUSPENSION ..........3-34 CHECKING AND CHARGING THE BATTERY........3-34 CHECKING THE FUSES..............3-34...

  • Page 120: Periodic Maintenance

    UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 121: General Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE EAS14B1034 GENERAL MAINTENANCE AND LUBRICATION CHART ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) √ Air filter element •...
  • Page 122 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Rear suspension relay arm and con- √ √ √ √ •...
  • Page 123 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 124 PERIODIC MAINTENANCE 2. Remove: 10. Install: • Fuel tank • Spark plug Refer to “FUEL TANK” on page 7-1. Spark plug 3. Remove: 13 Nm (1.3 m·kgf, 9.4 ft·lbf) • Air filter case Refer to “AIR FILTER CASE” on page 7- Before installing the spark plug, clean the 4.
  • Page 125 PERIODIC MAINTENANCE • Air cut-off valve Refer to “AIR INDUCTION SYSTEM” on page 7-21. • Radiator • Radiator fan motor Refer to “RADIATOR” on page 6-1. 2. Remove: • Ignition coils • Spark plugs • Cylinder head cover • Cylinder head cover gasket Refer to “CAMSHAFTS”...
  • Page 126 PERIODIC MAINTENANCE b. Turn the crankshaft 105 degrees in clock- e. Measure the valve clearance #3 with a wise and align the pickup rotor T mark “a” thickness gauge. and crankcase mating surface “b”. Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 f.

  • Page 127: Valve Lapper

    PERIODIC MAINTENANCE b. Calculate the difference between the speci- Thickness gauge fied valve clearance and the measured 90890-03180 valve clearance. Feeler gauge set Example: YU-26900-9 Specified valve clearance = 0.11–0.20 mm (0.0043–0.0079 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Measured valve clearance = 0.23 mm 5.
  • Page 128 PERIODIC MAINTENANCE i. If the valve clearance is still out of specifi- Valve pad range No. 160–240 cation, repeat all of the valve clearance 1.60–2.40 mm adjustment steps until the specified clear- Valve pad thickness (0.0630–0.0945 in) ance is obtained. 17 thicknesses in ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 129 PERIODIC MAINTENANCE 4. Install: Adjusting the throttle body synchronization • Vacuum gauge “1” 1. Adjust: • Digital tachometer • Throttle body synchronization (Use goods on the market) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Start the engine, warm it up for several Vacuum gauge minutes, and then let it run at the specified 90890-03094 engine idling speed.
  • Page 130 PERIODIC MAINTENANCE 3. Adjust: ECA13450 • Throttle cable free play Refer to “ADJUSTING THE THROTTLE Make sure the crankcase breather hose is CABLE FREE PLAY” on page 3-34. routed correctly. Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 4. Install: •...
  • Page 131 PERIODIC MAINTENANCE 11. Install: • Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. 12. Install: • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS20600 ADJUSTING THE EXHAUST GAS VOLUME Be sure to set the CO density level to stan- dard, and then adjust the exhaust gas volume.
  • Page 132 PERIODIC MAINTENANCE 5. Press the “SELECT” and “RESET” buttons 10. Turn the main switch to “OFF” to cancel the to select a cylinder. CO adjustment mode. EAS14B1099 CHECKING THE AIR INDUCTION SYSTEM Refer to “CHECKING THE AIR INDUCTION SYSTEM” on page 7-25. EAS20961 REPLACING THE AIR FILTER ELEMENT 1.
  • Page 133 PERIODIC MAINTENANCE 2. Adjust: • Clutch cable free play 6. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Air filter case cover Refer to “AIR FILTER CASE” on page 7- Handlebar side a. Turn the adjusting bolt “1” in direction “a” or ECA14401 “b” until the specified clutch lever free play is obtained.
  • Page 134 PERIODIC MAINTENANCE c. Tighten the locknuts “1”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS14B1088 CHECKING THE BRAKE OPERATION 1. Check: • Brake operation Brake not working properly → Check the brake system. Refer to “FRONT BRAKE” on page 4-31 and “REAR BRAKE” on page 4-44. A.
  • Page 135 PERIODIC MAINTENANCE EAS21160 EAS21250 ADJUSTING THE FRONT DISC BRAKE CHECKING THE FRONT BRAKE PADS 1. Adjust: The following procedure applies to all of the • Brake lever position brake pads. (distance “a” from the throttle grip to the 1. Operate the brake. brake lever) 2.
  • Page 136 PERIODIC MAINTENANCE b. Turn the adjusting bolt “2” in direction “a” or 2. Check: “b” until the specified brake pedal position • Rear brake pad is obtained. Wear indicators “1” almost touch the brake disc → Replace the brake pads as Direction “a”...
  • Page 137 PERIODIC MAINTENANCE Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. h. Tighten the bleed screw and then release the brake lever or brake pedal. i.
  • Page 138 PERIODIC MAINTENANCE 4. Check: EAS21650 CHECKING THE TIRES • Brake hose The following procedure applies to both of the Brake fluid leakage → Replace the dam- tires. aged hose. 1. Check: Refer to “FRONT BRAKE” on page 4-31. • Tire pressure Out of specification →...
  • Page 139 290 kPa (2.90 kgf/cm², 42 psi) concerning handling characteristics can be High-speed riding given if a tire combination other than one Front approved by Yamaha is used on this vehi- 250 kPa (2.50 kgf/cm², 36 psi) cle. Rear 290 kPa (2.90 kgf/cm², 42 psi)
  • Page 140 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. EAS14B1089 CHECKING THE WHEEL BEARINGS The following procedure applies to all of the...
  • Page 141 PERIODIC MAINTENANCE EAS21500 CHECKING AND ADJUSTING THE STEER- ING HEAD 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 front wheel is elevated.
  • Page 142 PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Steering nut wrench 5. Install: 90890-01403 • Upper bracket Exhaust flange nut wrench Refer to “HANDLEBARS” on page 4-56. YU-A9472 EAS14B1092 Lower ring nut (initial tightening CHECKING THE STEERING DAMPER torque) Refer to “CHECKING THE STEERING 52 Nm (5.2 m·kgf, 37 ft·lbf) DAMPER”...
  • Page 143 PERIODIC MAINTENANCE EAS21380 EAS14B1094 ADJUSTING THE SHIFT PEDAL CHECKING THE SIDESTAND 1. Stand the vehicle on a level surface. EWA13120 The shift pedal position is determined by the WARNING installed shift rod length “a”. Securely support the vehicle so that there 1.
  • Page 144 PERIODIC MAINTENANCE EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. EWA14B1029 WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload EWA14B1026 WARNING ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Always adjust both front fork legs evenly.
  • Page 145 PERIODIC MAINTENANCE EAS14B1096 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY Refer to “CHECKING THE REAR SHOCK ABSORBER ASSEMBLY” on page 4-77. EAS21610 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 146 PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. Turn the adjusting bolt “1” in direction “a” or “b”. Rebound damping Direction “a” ECA13590 Compression damping increased (suspension is harder). Never go beyond the maximum or minimum Direction “b” adjustment positions. Compression damping decreased 1. Adjust: (suspension is softer).
  • Page 147 PERIODIC MAINTENANCE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting bolt “1” in direction “a” or “b”. Direction “a” Compression damping increased (suspension is harder). Direction “b” Compression damping decreased (suspension is softer). Minimum 20 click(s) out* Recommended brand Standard YAMALUBE 9 click(s) out* Type Maximum SAE 10W-40, 10W-50, 15W-40,...
  • Page 148 PERIODIC MAINTENANCE EAS20790 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • Lower cowlings Refer to “GENERAL CHASSIS” on page 4-1.

  • Page 149: Oil Pressure Adapter H

    PERIODIC MAINTENANCE 3. Remove: Engine oil quantity • Main gallery bolt “1” Total amount 4.58 L (4.84 US qt, 4.03 Imp.qt) Without filter cartridge replacement 3.73 L (3.94 US qt, 3.28 Imp.qt) With oil filter cartridge replace- ment 3.93 L (4.15 US qt, 3.46 Imp.qt) 9.
  • Page 150 PERIODIC MAINTENANCE 4. Check: Engine oil pressure Possible causes • Coolant level • Leaking oil passage • Faulty oil filter Above specification Before checking the coolant level, wait a few • Oil viscosity too minutes until it settles. high 6. Install: EAS21120 •...
  • Page 151 PERIODIC MAINTENANCE EAS21130 The following procedure applies to all of the CHANGING THE COOLANT coolant drain bolts and copper washers. 1. Remove: 5. Remove: • Lower cowlings • Coolant drain bolt (engine) “1” • Side cowlings (along with the copper washer) Refer to “GENERAL CHASSIS”...
  • Page 152 PERIODIC MAINTENANCE • If coolant splashes on your clothes, 15. Install: quickly wash it away with water and then • Side cowlings with soap and water. • Lower cowlings • If coolant is swallowed, induce vomiting Refer to “GENERAL CHASSIS” on page and get immediate medical attention.
  • Page 153 PERIODIC MAINTENANCE EAS21690 2. Adjust: CHECKING AND LUBRICATING THE • Throttle cable free play CABLES ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ The following procedure applies to all of the a. Loosen the locknut “1”. inner and outer cables. b. Turn the adjusting nut “2” in direction “a” or EWA13270 “b”...
  • Page 154 PERIODIC MAINTENANCE EAS21790 4. Install: REPLACING THE HEADLIGHT BULBS • Headlight bulb The following procedure applies to both of the Secure the new headlight bulb with the headlight bulbs. headlight bulb holder. 1. Remove: ECA13690 • Headlight bulb cover “1” Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the...
  • Page 155 PERIODIC MAINTENANCE Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. Right headlight Direction “a” Headlight beam moves to the left. Direction “b” Headlight beam moves to the right. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-36...
  • Page 156 PERIODIC MAINTENANCE 3-37...
  • Page 157 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE QUICK FASTENER (SCREW TYPE).......4-10 INSTALLING THE QUICK FASTENER (SCREW TYPE)......4-10 REMOVING THE QUICK FASTENER (PUSH TYPE) ......4-10 INSTALLING THE QUICK FASTENER (PUSH TYPE) ......4-10 REMOVING THE QUICK FASTENER (PULL TYPE) ......4-10 INSTALLING THE QUICK FASTENER (PULL TYPE) ......4-11 INSTALLING THE PASSENGER SEAT LOCK CYLINDER ....4-11 REMOVING THE FRONT TURN SIGNAL LIGHTS......4-11 INSTALLING THE FRONT TURN SIGNAL LIGHTS......4-11...
  • Page 158 FRONT BRAKE ..................4-31 INTRODUCTION ..................4-36 CHECKING THE FRONT BRAKE DISCS ..........4-36 REPLACING THE FRONT BRAKE PADS ..........4-37 REMOVING THE FRONT BRAKE CALIPERS ........4-39 DISASSEMBLING THE FRONT BRAKE CALIPERS ......4-39 CHECKING THE FRONT BRAKE CALIPERS ........4-40 ASSEMBLING THE FRONT BRAKE CALIPERS .........4-40 INSTALLING THE FRONT BRAKE CALIPERS........4-40 REMOVING THE FRONT BRAKE MASTER CYLINDER.....4-41 CHECKING THE FRONT BRAKE MASTER CYLINDER .....4-42...
  • Page 159 REAR SHOCK ABSORBER ASSEMBLY ..........4-76 HANDLING THE REAR SHOCK ABSORBER ........4-77 DISPOSING OF A REAR SHOCK ABSORBER........4-77 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-77 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....4-77 CHECKING THE CONNECTING ARM AND RELAY ARM ....4-78 INSTALLING THE RELAY ARM............4-78 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ....4-78 SWINGARM ....................4-80 REMOVING THE SWINGARM .............4-82...
  • Page 160 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats and battery Order Job/Parts to remove Q’ty Remarks Fuel tank side cover Refer to “FUEL TANK” on page 7-1. Rider seat Passenger seat Battery negative lead Disconnect. Tool band Tool Battery cover Battery positive lead Disconnect.
  • Page 161 GENERAL CHASSIS Removing the side cowlings Order Job/Parts to remove Q’ty Remarks Front cowling inner panel Side cowling Front turn signal light coupler Disconnect. Front turn signal light Lower cowling Side cowling inner panel For installation, reverse the removal proce- dure.
  • Page 162 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 163 GENERAL CHASSIS Removing the air ducts Order Job/Parts to remove Q’ty Remarks Side cowling 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 For installation, reverse the removal proce- dure.

  • Page 164: 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. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Intake air temperature sensor coupler Disconnect. Auxiliary light coupler Disconnect.
  • Page 165 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. Air duct Refer to “GENERAL CHASSIS” on page 4-1. Front cowling assembly Refer to “GENERAL CHASSIS” on page 4-1. Rear view mirror Meter bracket Meter coupler...
  • Page 166 GENERAL CHASSIS Removing the meter and headlight Order Job/Parts to remove Q’ty Remarks Windshield Windshield inner panel Intake air temperature sensor Headlight assembly Front cowling Headlight bulb cover Headlight bulb coupler Disconnect. Headlight bulb For installation, reverse the removal proce- dure.
  • Page 167 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. Muffler Refer to “ENGINE REMOVAL” on page 5-3. Passenger seat lock assembly Passenger seat lock cable Passenger seat lock key cylinder Upper tail cover...
  • Page 168 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 Mudguard For installation, reverse the removal proce- dure.
  • Page 169 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 170 GENERAL CHASSIS EAS14B1038 REMOVING THE FRONT TURN SIGNAL LIGHTS EAS14B1104 1. Remove: INSTALLING THE QUICK FASTENER (PULL • Stay “1” TYPE) • Front turn signal 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 light “2”...
  • Page 171 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 172 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 173 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 174 GENERAL CHASSIS d. Slide the upper tail cover forward and 2. Install: remove. • 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: •...
  • Page 175 GENERAL CHASSIS b. When adjusting the right rider footrest, change the position of the hole “a” of the exhaust chamber cover “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) •...

  • Page 176: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Front cowling assembly Refer to “GENERAL CHASSIS” on page 4-1. Front speed sensor coupler Disconnect. Left brake hose holder Front speed sensor Right brake hose holder Left front brake caliper Right front brake caliper...
  • Page 177 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal (left and right) Wheel bearing Spacer Wheel bearing For assembly, reverse the disassembly pro- cedure. 4-18...
  • Page 178 FRONT WHEEL EAS21900 EAS21920 REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL ECA1KB8401 1. Check: • Wheel axle Roll the wheel axle on a flat surface. • Keep any type of magnets (including Bends → Replace. magnetic pick-up tools, magnetic screw- drivers, etc.) away from the front speed sensor “1”...
  • Page 179 FRONT WHEEL Use a socket “4” that matches the diameter of the wheel bearing outer race. 5. Replace: • Wheel bearings • Oil seals ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ e. Install the spacer. a. Clean the outside of the front wheel hub. f. Install the new wheel bearing (right side). b.
  • Page 180 FRONT WHEEL • The front speed sensor cannot be disas- sembled. Do not attempt to disassemble it. If faulty, replace with a new one. 1. Check: • Front speed sensor “1” Cracks/bends/distortion → Replace. Iron powder/dust → Clean. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Adjust: •...
  • Page 181 FRONT WHEEL f. If the front speed sensor rotor deflection cannot be brought within specification, replace the front speed sensor rotor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE • After replacing the tire, wheel or both, the front wheel static balance should be f.
  • Page 182 FRONT WHEEL 4. Check: • Front wheel static balance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make sure it stays at each position shown. b. If the front wheel does not remain station- ary at all of the positions, rebalance it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 183 FRONT WHEEL 6. Lower the front wheel so that it is on the ground. • Before measuring the distance between the 7. Tighten: front speed sensor rotor and front speed • Front wheel axle bolt sensor, remove the brake caliper. •...

  • Page 184: 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 4-44. Locknut (left and right) Loosen. Adjusting bolt (left and right) Loosen. Rear wheel axle nut Washer Rear wheel axle Adjusting block (left)
  • Page 185 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 Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel For installation, reverse the removal proce- dure.
  • Page 186 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. 4-27...
  • Page 187 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 188 REAR WHEEL EAS1KB8402 EAS22110 ASSEMBLING THE REAR WHEEL CHECKING THE REAR WHEEL DRIVE HUB 1. Install: 1. Check: • Rear wheel drive hub “1” • Wheel bearings Cracks/damage → Replace. • Oil seal • Rear wheel drive hub dampers “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 189 REAR WHEEL 3. Tighten: • Rear wheel axle nut Tighten the self-locking nuts in stages and in a • Rear brake caliper bolts crisscross pattern. 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...
  • Page 190 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. Front speed sensor Refer to “FRONT WHEEL” on page 4-17. Brake hose holder Right side Front brake caliper Brake pad clip...
  • Page 191 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 3-17. 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 192 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. 4-33...

  • Page 193: Front Brake

    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. Front speed sensor Refer to “FRONT WHEEL” on page 4-17. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 194 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 kit Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For installation, reverse the removal proce- dure.
  • Page 195 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 196 FRONT BRAKE ECA1CW1401 EAS14B1004 REPLACING THE FRONT BRAKE PADS Replace the brake disc bolts with new • When replacing the brake pads, it is not nec- ones. essary to disconnect the brake hose or dis- assemble the brake caliper. • When installing the brake disc and front •...
  • Page 197 FRONT BRAKE 4. 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 new brake pads and a new brake Brake lining thickness...
  • Page 198 FRONT BRAKE 8. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-17. EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers.
  • Page 199 FRONT BRAKE EAS22390 • Whenever a brake caliper is disassem- CHECKING THE FRONT BRAKE CALIPERS bled, replace the brake caliper piston dust Recommended brake component replace- seals and brake caliper piston seals. ment schedule Recommended fluid Brake pads If necessary DOT 4 Piston dust seals and Every two years...
  • Page 200 FRONT BRAKE “a” touches the projection “b” on the brake caliper. 6. Check: • 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 201 FRONT BRAKE EAS22510 EAS22520 CHECKING THE FRONT BRAKE MASTER ASSEMBLING THE FRONT BRAKE MAS- CYLINDER TER CYLINDER 1. Check: EWA13520 WARNING • Brake master cylinder Damage/scratches/wear → Replace. • Before installation, all internal brake com- • Brake fluid delivery passages ponents should be cleaned and lubricated (brake master cylinder body) with clean or new brake fluid.
  • Page 202 FRONT BRAKE EWA13530 ECA13540 WARNING Proper brake hose routing is essential to Brake fluid may damage painted surfaces insure safe vehicle operation. Refer to and plastic parts. Therefore, always clean “CABLE ROUTING” on page 2-49. up any spilt brake fluid immediately. 4.
  • Page 203 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 kit Bleed screw Brake pad spring For installation, reverse the removal proce- dure.
  • Page 204 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 3-17. 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 205 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 Dust cover Circlip Hose joint O-ring Brake master cylinder body For installation, reverse the removal proce- dure.
  • Page 206 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. 4-47...
  • Page 207 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Brake pad kit 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 208: 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 4-36. •...
  • Page 209 REAR BRAKE 3. Measure: b. Loosen the bleed screw and push the • Brake pad wear limit “a” brake caliper pistons into the brake caliper Out of specification → Replace the brake with your finger. pads as a set. c. Tighten the bleed screw. Brake lining thickness...
  • Page 210 REAR BRAKE 7. Check: b. Blow compressed air into the brake hose • Brake pedal operation joint opening “b” to force out the piston from Soft or spongy feeling → Bleed the brake the brake caliper. system. EWA13550 WARNING Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 211 REAR BRAKE EAS22670 INSTALLING THE REAR BRAKE CALIPER 1. Install: • Brake caliper “1” (temporarily) • Washers • Brake hose “2” • Union bolt “3” Rear brake hose union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) EWA14B1005 EWA13530 WARNING WARNING Whenever a brake caliper is disassembled, Proper brake hose routing is essential to replace the brake caliper piston dust seal...
  • Page 212 REAR BRAKE 4. Fill: 7. Check: • Brake fluid reservoir • Brake pedal operation Soft or spongy feeling → Bleed the brake (with the specified amount of the recom- mended brake fluid) system. Refer to “BLEEDING THE HYDRAULIC Recommended fluid BRAKE SYSTEM”...
  • Page 213 REAR BRAKE 2. Check: EAS22740 INSTALLING THE REAR BRAKE MASTER • Brake fluid reservoir tank “1” CYLINDER Cracks/damage → Replace. 1. Install: • Brake fluid reservoir diaphragm “2” Cracks/damage → Replace. • Washers • Brake hoses • Brake fluid reservoir diaphragm holder “3” Cracks/damage →...
  • Page 214 REAR BRAKE 6. Adjust: Recommended fluid • Brake pedal position DOT 4 Refer to “ADJUSTING THE REAR DISC BRAKE” on page 3-16. EWA13090 WARNING Brake pedal position (from the • Use only the designated brake fluid. top of the brake pedal to the Other brake fluids may cause the rubber center of the bolt mount on the seals to deteriorate, causing leakage and...
  • Page 215 HANDLEBARS EAS22850 HANDLEBARS Removing the handlebars 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 cowling Refer to “GENERAL CHASSIS” on page 4-1. Front brake master cylinder Refer to “FRONT BRAKE”...
  • Page 216 HANDLEBARS Removing the handlebars Order Job/Parts to remove Q’ty Remarks Throttle grip Brake switch connector Disconnect. Right handlebar switch Handlebar pinch bolt Loosen. Handlebar bolt Loosen. Upper bracket pinch bolt Loosen. Steering stem nut Main switch coupler Disconnect. Immobilizer unit coupler Disconnect.
  • Page 217 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 218 HANDLEBARS 6. Install: • Left handlebar switch “1” • Align the projection “a” on the left handlebar switch with the hole “b” on the left handlebar. • There should be 2.0–2.5 mm (0.08–0.10 in) of clearance between left handlebar switch and clutch lever holder.
  • Page 219 HANDLEBARS 9. Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-34. Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 4-60...
  • Page 220 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 4-17. Front fender Upper bracket pinch bolt Loosen.
  • Page 221 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 222 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. 4-63...

  • Page 223: Front Fork

    FRONT FORK EAS14B1006 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Each front fork leg is equipped with a spring preload adjusting bolt, the right fork leg is equipped with a rebound damping force adjusting screen and left front fork is equipped with a compression damping force adjusting screw.
  • Page 224 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 225 FRONT FORK EAS23010 • When disassembling and assembling the CHECKING THE FRONT FORK LEGS front fork leg, do not allow any foreign The following procedure applies to both of the material to enter the front fork. front fork legs. 1. Check: •...
  • Page 226 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. 2. Lubricate: • Inner tube’s outer surface Recommended oil Suspension oil M1 or equiva- lent 3.
  • Page 227 FRONT FORK 8. Install: 10. Fully compress the front fork leg. • Dust seal “1” 11. Fill: (with the fork seal driver weight “2”) • Front fork leg (with the specified amount of the recom- Fork seal driver mended fork oil) 90890-01442 Adjustable fork seal driver (36–...
  • Page 228 FRONT FORK Be sure to bleed the front fork leg of any resid- Install the spring with the smaller diameter “a” ual air. facing up “A”. 14. Measure: • Front fork leg oil level “a” (from the top of the outer tube, with the outer tube fully compressed and without the fork spring) Out of specification →...
  • Page 229 FRONT FORK j. Remove the rod puller and rod puller o. Remove the rod holder and fork spring attachment. compressor. k. Install the nut “1” all the way onto the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ damper rod assembly. 16. Install: • Cap bolt (to the outer tube) •...
  • Page 230 FRONT FORK 5. Install: • Plastic band “1” Fasten the front brake hose to the right front fork leg with the plastic locking tie. 3. Tighten: • Cap bolt “1” Cap bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) • Handlebar bolt “2” 6.

  • Page 231: 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 speed sensor Refer to “FRONT WHEEL” on page 4-17. Front fork legs Refer to “FRONT FORK”...
  • Page 232 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 233 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 234 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 235: 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 236 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 237 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 238 REAR SHOCK ABSORBER ASSEMBLY Rear shock absorber assembly bracket and frame 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. Install: • Connecting arm When installing the connecting arm, lift up the swingarm.
  • Page 239 SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-25. Refer to “REAR SHOCK ABSORBER Rear shock absorber assembly ASSEMBLY” on page 4-76. Drive chain guard Rear fender Left footrest Drive chain guide Brake hose holder Pivot shaft nut/washer...
  • Page 240 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Oil seal Circlip Bearing Bearing For installation, reverse the removal proce- dure. 4-81...
  • Page 241 SWINGARM EAS23350 REMOVING THE SWINGARM Swingarm side play (at the end 1. Stand the vehicle on a level surface. of the swingarm) 1.0 mm (0.04 in) EWA13120 WARNING d. Check the swingarm vertical movement “B” Securely support the vehicle so that there by moving the swingarm up and down.
  • Page 242 SWINGARM 3. Wash: Damper rod holder (22 mm) • Pivot shaft 90890-01365 • Dust cover • Spacer • Washers • Bearings Recommended cleaning solvent Kerosene 4. Check: • Dust cover “1” • Spacer “2” • Collar “3” • Bearings “4” Damage/wear →...
  • Page 243 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 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Tighten the pivot shaft with the damper rod...
  • Page 244 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 3-21. Locknut Shift rod Shift arm Shift pedal Drive sprocket cover Drive sprocket nut Washer Drive chain guide (drive sprocket side)
  • Page 245 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 246 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 247 CHAIN DRIVE • While applying the rear brake, tighten the drive sprocket nut. • Stake the drive sprocket nut at cutouts, “a” in the drive axle. b. After riveting, make sure the diameter between the edges “b” of the connecting pin “2”...
  • Page 248 CHAIN DRIVE 4-89...
  • Page 249 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 ............5-16 CHECKING THE CAMSHAFTS ............5-17 CHECKING THE TIMING CHAIN AND SPROCKET......5-18 CHECKING THE TIMING CHAIN GUIDES ..........5-19 CHECKING THE TIMING CHAIN TENSIONER ........5-19 INSTALLING THE CAMSHAFTS ............5-19 CYLINDER HEAD..................5-24...
  • Page 250 OIL PUMP ....................5-50 REMOVING THE OIL PAN ..............5-53 CHECKING THE SPROCKET AND CHAIN .........5-53 CHECKING THE OIL PUMP ..............5-53 CHECKING THE RELIEF VALVE ............5-54 CHECKING THE OIL DELIVERY PIPES..........5-54 CHECKING THE OIL STRAINER............5-54 ASSEMBLING THE OIL PUMP ............5-55 INSTALLING THE OIL/WATER PUMP ASSEMBLY......5-55 INSTALLING THE OIL PAN ..............5-56 CLUTCH......................5-58 REMOVING THE CLUTCH..............5-62...
  • Page 251 TRANSMISSION..................5-91 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 252 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 253 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 254: 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 tail cover Refer to “GENERAL CHASSIS” on page 4-1. Side cowling Refer to “GENERAL CHASSIS”...
  • Page 255 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 256 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 257 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 258 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Rear 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 259 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 Holder 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 260 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Engine mount nut (rear lower side) 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 261: Pivot Shaft Wrench Adapter

    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 pipe when (temporary tighten) removing the engine and moving the engine by itself.
  • Page 262 ENGINE REMOVAL 8. Tighten: • Engine mounting bolt (front left side) “1” 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 lower side) 51 Nm (5.1 m·kgf, 37 ft·lbf)
  • Page 263 ENGINE REMOVAL Installed depth of gasket “c” 3.5 mm (0.14 in) 5-12...
  • Page 264 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 265 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Pickup coil cover 2 Refer to “PICKUP ROTOR” on page 5-42. Generator cover Refer to “GENERATOR” on page 5-36. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Exhaust camshaft cap Intake camshaft Exhaust camshaft Intake camshaft sprocket...
  • Page 266 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Crankshaft sprocket Collar Straight key For installation, reverse the removal proce- dure. 5-15...
  • Page 267 CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: • Pickup rotor cover 2 Refer to “PICKUP ROTOR” on page 5-42. 2. Align: • “K” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ECA14B1034 When turning the crankshaft with a tool, remove all the spark plugs.
  • Page 268 CAMSHAFTS Camshaft lobe dimension limit Intake A 37.350–37.450 mm (1.4705– 1.4744 in) Limit 37.250 mm (1.4665 in) Intake B 28.034–28.134 mm (1.1037– 1.1076 in) Limit 7. Remove: 27.934 mm (1.0998 in) • Dowel pins Exhaust A • Timing chain guide (intake side) 36.450–36.550 mm (1.4350–...
  • Page 269 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 270 CAMSHAFTS a. 1/4 tooth b. Correct 3. Hand press 1. Timing chain 4. Bearing 2. Camshaft sprocket or crankshaft sprocket b. Keep pressing the timing chain tensioner EAS23950 rod, mount clip “5” into groove “6”, and lock CHECKING THE TIMING CHAIN GUIDES the timing chain tensioner rod.
  • Page 271 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 272 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 273 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 274 CAMSHAFTS • Tighten the cylinder head cover bolts stages and in a crisscross pattern. Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 5-23...

  • Page 275: 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 276 CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAM- SHAFTS” on page 5-16. 2. Remove: • Cylinder head nuts • Cylinder head bolts • Loosen the nuts in the proper sequence as ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 277 CYLINDER HEAD 5. Install: • Exhaust camshaft • Intake camshaft Refer to “INSTALLING THE CAM- SHAFTS” on page 5-19. 3. Install: • Cylinder head • Washers • Cylinder head nuts • Cylinder head bolts • Pass the timing chain through the timing chain cavity.

  • Page 278: Valves And Valve Springs

    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 5-24. Intake valve lifter Intake valve pad Intake valve cotter Intake valve spring retainer Intake valve spring Intake valve Intake valve stem seal...
  • Page 279 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 spring retainer Exhaust valve spring Exhaust valve Exhaust valve stem seal Exhaust valve spring seat Exhaust valve guide For installation, reverse the removal proce- dure.
  • Page 280 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 281 VALVES AND VALVE SPRINGS EAS24290 2. Replace: CHECKING THE VALVES AND VALVE • Valve guide GUIDES The following procedure applies to all of the To ease valve guide removal and installation, valves and valve guides. and to maintain the correct fit, heat the cylinder 1.
  • Page 282 VALVES AND VALVE SPRINGS After replacing the valve guide, reface the valve seat. 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) 6. Measure: YM-04097 • Valve stem runout Valve guide installer (ø4.5) Out of specification →...
  • Page 283 VALVES AND VALVE SPRINGS 4. Lap: Valve seat width • Valve face Valve seat width (intake) • Valve seat 0.90–1.10 mm (0.0354–0.0433 After replacing the cylinder head or replacing Limit the valves and valve guides, the valve seat and 1.60 mm (0.06 in) valve face should be lapped.
  • Page 284 VALVES AND VALVE SPRINGS EAS24310 CHECKING THE VALVE SPRINGS For the best lapping results, lightly tap the The following procedure applies to all of the valve seat while rotating the valve back and valve springs. forth between your hands. 1. Measure: •...
  • Page 285 VALVES AND VALVE SPRINGS EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • Valve stem end (with an oil stone) b. Installed length 3. Measure: • Valve spring tilt “a” Out of specification →...
  • Page 286 VALVES AND VALVE SPRINGS • When installing the valve stem seal to the valve guide, apply silicon fluid to the valve stem seal. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer.
  • Page 287 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 288 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 289 GENERATOR 4. Apply: • Sealant (onto the stator coil lead grommet “1”) Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 5-38...

  • Page 290: 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 5-58. Starter clutch gear Bearing Starter clutch assembly Starter idle gear For installation, reverse the removal proce- dure.
  • Page 291 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 292 STARTER CLUTCH • While holding the clutch housing assembly “1” with the sheave holder “2”, tighten the starter clutch holder bolt “3”. • Fix the flat surface of the clutch housing assembly with the sheave holder. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 5-41...
  • Page 293 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 5-36. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Pickup rotor cover 1 O-ring Crankshaft position sensor coupler...
  • Page 294 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 295 PICKUP ROTOR Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 5-44...

  • Page 296: 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 297 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. 5-46...
  • Page 298 ELECTRIC STARTER EAS24790 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ CHECKING THE STARTER MOTOR a. Measure the armature assembly resis- 1. Check: tances with the digital circuit tester. • Commutator Dirt → Clean with 600 grit sandpaper. Digital circuit tester 2. Measure: 90890-03174 • Commutator diameter “a” Model 88 Multimeter with Out of specification →...
  • Page 299 ELECTRIC STARTER 6. Measure: • Brush spring force Out of specification → Replace the brush holder. Brush spring force 5.28–7.92 (538–808 19.01–28.51 oz) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: • Rear cover “1” Align the tab “a” on the brush holder “2” with the tab “b”...
  • Page 300 ELECTRIC STARTER Align the match marks “a” on the starter motor yoke with the match marks “b” on the front and rear covers. 5-49...

  • Page 301: 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 302 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 303 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. 5-52...
  • Page 304 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 305 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 306 OIL PUMP EAS25010 ASSEMBLING THE OIL PUMP 1. Lubricate: • Inner rotor • Outer rotor • Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: 4. Check: • Pin “1” • Oil pump operation • Inner rotor “2” Refer to “CHECKING THE OIL PUMP”...
  • Page 307 OIL PUMP ECA14B1018 After installing the oil/water pump assem- bly drive chain and drive sprocket, make sure the oil/water pump turns smoothly. 5. Install: • Relief valve assembly “1” • O-ring Relief valve assembly bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 3.
  • Page 308 OIL PUMP Oil pan bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil level switch bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Engine oil drain bolt • Gasket 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.
  • Page 309 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. 5-58...
  • Page 310 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. 5-59...
  • Page 311 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 312 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. 5-61...
  • Page 313 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 314 CLUTCH 7. Remove: EAS25110 CHECKING THE CLUTCH PLATES • Clutch boss nut The following procedure applies to all of the • Springs clutch plates. • Clutch boss 1. Check: • Pressure plate 2 • Clutch plate • Conical spring washer Damage →...
  • Page 315 CLUTCH EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: • Clutch spring Damage → Replace the clutch springs as a set. 2. Measure: • Clutch spring free length “a” Out of specification → Replace the clutch springs as a set.
  • Page 316 CLUTCH EAS25160 CHECKING THE CLUTCH BOSS 1. Check: • Clutch boss splines Damage/pitting/wear → Replace the clutch boss. Pitting on the clutch boss splines will cause erratic clutch operation. EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: •...
  • Page 317 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 318 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 319 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 4-85. Clutch assembly Refer to “CLUTCH” on page 5-58. Circlip Washer Shift shaft Washer Circlip Washer Stopper lever...

  • Page 320: 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 321 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 5-24. Refer to “ELECTRIC STARTER” on page 5- Starter motor Stator coil assembly Refer to “GENERATOR”...
  • Page 322 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. * Following the tightening order, loosen the bolt one by one and then retighten it to the specific torque.
  • Page 323 • 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 324 CRANKCASE *Following the tightening order, loosen the bolt one by one and then retighten it to the specific torque. EWA14B1030 WARNING If the crankcase bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Instead, replace the crankcase bolt with a new one and perform the procedure again.

  • Page 325: Connecting Rods And Pistons

    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 5-70. Connecting rod cap Big end lower bearing Big end upper bearing Connecting rod Piston pin clip Piston pin...
  • Page 326 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 327 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 328 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 329 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 330 CONNECTING RODS AND PISTONS • After installing the big end bearing, assemble the connecting rod and connecting rod cap • Do not move the connecting rod or crank- without installing them onto the crankshaft. shaft until the clearance measurement has been completed.
  • Page 331 CONNECTING RODS AND PISTONS 2. Select: • Big end bearings (P1–P4) • The numbers “A” stamped into the crank- shaft web and the numbers “1” on the con- necting rods are used to determine the replacement big end bearings sizes. •...
  • Page 332 CONNECTING RODS AND PISTONS EAS26190 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ INSTALLING THE CONNECTING ROD AND a. Replace the connecting rod bolts with new PISTON ones. The following procedure applies to all of the b. Clean the connecting rod bolts and lubri- connecting rods and pistons. cate the bolt threads and seats with molyb- 1.
  • Page 333 CONNECTING RODS AND PISTONS Recommended lubricant Engine oil 6. Offset: • Piston ring end gaps 4. Install: • Piston “1” (onto the respective connecting rod “2”) • Piston pin “3” • Piston pin clip “4” a. Top ring b. 2nd ring •...
  • Page 334 CONNECTING RODS AND PISTONS 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. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Tighten the connecting rod bolts using the fol- lowing procedure.
  • Page 335 CONNECTING RODS AND PISTONS EWA13400 WARNING If the connecting rod bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Instead, replace the connecting rod bolt with a new one and perform the procedure again. ECA13950 Do not use a torque wrench to tighten the connecting rod bolt to the specified angle.
  • Page 336 CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-70. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS” on page 5-75. Balancer shaft Balancer shaft journal lower bearing Balancer shaft journal upper bearing Crankshaft Crankshaft journal lower bearing...
  • Page 337 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 338 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 339 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 340 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 341 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 342 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 5-70. Drive axle assembly Shift drum retainer Spring Shift fork guide bar Shift fork-L Shift fork-R Shift drum assembly Shift fork-C...
  • Page 343 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks When installing 2nd pinion gear, install the 2nd pinion gear gear with groove “a” facing to the toothed lock washer. Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip...
  • Page 344 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip Bearing 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 5-93...
  • Page 345 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip 6th wheel gear Circlip Washer 2nd wheel gear Collar Collar Oil seal Circlip Bearing Drive axle For installation, reverse the removal proce- dure. 5-94...
  • Page 346 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 347 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 348 TRANSMISSION 4. Check: • Transmission gear engagement • With the toothed lock washer retainer “1” in (each pinion gear to its respective wheel the groove “a” in the axle, align the projection gear) “c” on the retainer with an axle spline “b”, and Incorrect →...
  • Page 349 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 350 TRANSMISSION 5-99...
  • Page 351 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 352 RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-32. 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 353 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 354 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 355 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 356: 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 3-32. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-29. Side cowling Refer to “GENERAL CHASSIS” on page 4-1. Lower cowling Refer to “GENERAL CHASSIS”...
  • Page 357 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 358 OIL COOLER EAS26420 3. Fill: CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage → Replace. Refer to “CHANGING THE COOLANT” 2. Check: on page 3-32. • Oil cooler inlet hose •...
  • Page 359 THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-32. 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 360 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 361 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 362 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 3-32. 2. Check: • Cooling system Leaks → Repair or replace any faulty part.

  • Page 363: 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 5-50. Oil pump rotor Refer to “OIL PUMP” on page 5-50. Water pump cover O-ring Impeller shaft (along with the impeller) Water pump seal Oil seal O-ring...
  • Page 364 WATER PUMP EAS26520 EAS26540 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Water pump seal “1” • Water pump housing cover “1” • Impeller shaft “2” Cracks/damage/wear → Replace. Remove the water pump seal from the inside •...
  • Page 365 WATER PUMP ECA14090 Mechanical seal installer 90890-04132 Make sure the rubber damper and rubber Water pump seal installer damper holder are flush with the impeller. YM-33221-A Middle driven shaft bearing Impeller shaft tilt limit driver 0.15 mm (0.006 in) 90890-04058 Bearing driver 40 mm YM-04058 1.
  • Page 366 WATER PUMP 6-15...
  • Page 367 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 (BEFORE...
  • Page 368 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 Bolt Bolt/collar/washer 2/2/2 Fuel tank breather hose Disconnect. Fuel tank overflow hose Disconnect.
  • Page 369 FUEL TANK Removing the fuel tank and fuel pump Order Job/Parts to remove Q’ty Remarks Fuel pump bracket Fuel pump Fuel pump gasket For installation, reverse the removal proce- dure.

  • Page 370: Fuel Tank

    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 371 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 372: 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 373 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 374 AIR FILTER CASE EAS14B1105 EAS14B1106 CHECKING THE SECONDARY INJECTORS REMOVING THE SECONDARY INJECTORS (BEFORE REMOVING) EWA14B1027 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 375 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 376 AIR FILTER CASE 2. Check: EAS14B1067 INSTALLING THE INTAKE FUNNEL AND • Injector resistance LOWER AIR FILTER CASE Refer to “CHECKING THE FUEL INJEC- 1. Install: TORS” on page 8-148. • Intake funnel servo motor • Intake funnel servo motor rod assembly EAS14B1113 CHECKING THE AIR FILTER CASE SEAL •...
  • Page 377 AIR FILTER CASE EAS14B1107 5. Install: INSTALLING THE SECONDARY INJEC- • Upper air filter case seal “1” TORS • Secondary injector assembly seal “2” ECA14B1046 • Always use new O-rings. • When checking the injectors, do not allow The matching adhesion portion of the seal any foreign material to enter or adhere to should be positioned within a range of “a”.
  • Page 378 AIR FILTER CASE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS14B1069 INSTALLING THE FUEL HOSE (PRIMARY INJECTOR JOINT SIDE AND SECONDARY INJECTOR JOINT SIDE) 1. Connect: • Fuel hose (primary injector joint side and secondary injector joint side) ECA14B1033 When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position, otherwise the fuel...

  • Page 379: Throttle Bodies

    THROTTLE BODIES EAS26970 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.
  • Page 380 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 381 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 382 THROTTLE BODIES EAS14B1108 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. EAS14B1109 REMOVING THE PRIMARY INJECTORS EAS14B1110 EWA14B1028 CHECKING THE PRIMARY INJECTORS WARNING 1. Check: •...
  • Page 383 THROTTLE BODIES If the protector “a” is scratched or damaged, replace the throttle bodies as a set. c. Push the lever in the direction shown in the illustration to hold the throttle valves in the open position. EWA14B1022 WARNING When cleaning the throttle bodies, be care- 2.
  • Page 384 THROTTLE BODIES ECA14B1029 • If an injector is subject to strong shocks or excessive force, replace it. • If installing the original fuel rails and • Do not use a tool, such as a wire brush, to remove the carbon deposits; otherwise, bolts, remove the white paint marks using a cleaning solvent.

  • Page 385: Fuel Pressure Adapter

    THROTTLE BODIES EWA14B1001 Pressure gauge WARNING 90890-03153 Cover fuel hose connections with a cloth YU-03153 when disconnecting them. Residual pres- Fuel injector pressure adapter sure in the fuel lines could cause fuel to 90890-03210 spurt out when removing the hoses. YU-03210 ECA14B1003 Be sure to disconnect the fuel hose by...
  • Page 386 THROTTLE BODIES EAS14B1073 ADJUSTING THE THROTTLE POSITION SENSOR EWA14B1023 WARNING • Handle the throttle position sensor with special care. • Never subject the throttle position sensor to strong shocks. If the throttle position sensor is dropped, replace it. 1. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 387 THROTTLE BODIES “dIAG” appears on the odometer LCD. f. Diagnostic code number “D:14” is selected. g. Adjust the position of the accelerator posi- tion sensor angle so that 12–22 can appear in the meter. h. After adjusting the accelerator position sen- sor angle, tighten the accelerator position sensor screws “1”.

  • Page 388: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-21...
  • Page 389 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 390 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 391 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 392 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 393 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 (air induc- Refer to “CHECKING THE AIR INDUC- tion system) TION SYSTEM SOLENOID”...
  • Page 394 AIR INDUCTION SYSTEM 7-27...

  • Page 395: General Information

    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 396 ELECTRICAL COMPONENTS..............8-121 CHECKING THE SWITCHES.............8-125 CHECKING THE BULBS AND BULB SOCKETS.......8-128 CHECKING THE FUSES..............8-129 CHECKING AND CHARGING THE BATTERY........8-129 CHECKING THE RELAYS..............8-133 CHECKING THE TURN SIGNAL/HAZARD RELAY ......8-134 CHECKING THE RELAY UNIT (DIODE) ..........8-135 CHECKING THE IGNITION COILS ............8-136 CHECKING THE CRANKSHAFT POSITION SENSOR .....8-137 CHECKING THE LEAN ANGLE SENSOR .........8-138 CHECKING THE STARTER MOTOR OPERATION......8-138 CHECKING THE STATOR COIL............8-139...

  • Page 398: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 399 IGNITION SYSTEM 1. Main switch 4. Joint 5. Main fuse 9. Battery 10.Engine ground 14.Relay unit 17.Gear position sensor 18.Sidestand switch 21.Joint coupler 22.ECU (engine control unit) 23.Ignition coil #1 24.Ignition coil #2 25.Ignition coil #3 26.Ignition coil #4 27.Spark plug 44.Crankshaft position sensor 50.Lean angle sensor 51.Cylinder identification sensor...
  • Page 400 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 401 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 402 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 403 IGNITION SYSTEM 8. Check the main switch. NG→ Replace the main switch/immobilizer Refer to “CHECKING THE unit assembly. SWITCHES” on page 8-125. OK↓ 9. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-125. OK↓...

  • Page 404: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 405 ELECTRIC STARTING SYSTEM 1. Main switch 4. Joint 5. Main fuse 9. Battery 10.Engine ground 12.Starter relay 13.Starter motor 14.Relay unit 15.Starting circuit cut-off relay 17.Gear position sensor 18.Sidestand switch 21.Joint coupler 69.Right handlebar switch 71.Engine stop switch 73.Start switch 74.Engine ground 77.Left handlebar switch 82.Clutch switch...
  • Page 406 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 407 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 408 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 409 ELECTRIC STARTING SYSTEM 8. Check the main switch. NG→ Replace the main switch/immobilizer Refer to “CHECKING THE unit. SWITCHES” on page 8-125. OK↓ 9. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-125. OK↓...

  • Page 410: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-13...
  • Page 411 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Joint 5. Main fuse 9. Battery 10.Engine ground 74.Engine ground 8-14...
  • Page 412 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 8-129. OK↓...
  • Page 413 CHARGING SYSTEM 8-16...

  • Page 414: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-17...
  • Page 415 LIGHTING SYSTEM 1. Main switch 4. Joint 5. Main fuse 9. Battery 10.Engine ground 21.Joint coupler 22.ECU (engine control unit) 52.Meter assembly 64.High beam indicator light 67.Meter light 74.Engine ground 77.Left handlebar switch 79.Pass switch 80.Dimmer switch 89.Headlight 90.Auxiliary light 91.License plate light 93.Tail/brake light 94.Headlight relay...
  • Page 416 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 417 LIGHTING SYSTEM 8. 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 418: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21...
  • Page 419 SIGNALING SYSTEM 1. Main switch 4. Joint 5. Main fuse 9. Battery 10.Engine ground 14.Relay unit 17.Gear position sensor 19.Fuel sender 21.Joint coupler 22.ECU (engine control unit) 43.Coolant temperature sensor 47.Rear speed sensor 52.Meter assembly 54.Fuel level warning light 55.Oil level warning light 56.Neutral indicator light 57.Tachometer 58.Shift timing indicator light...
  • Page 420 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 421 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 422 SIGNALING SYSTEM 4. Check the turn signal/hazard relay. NG→ Refer to “CHECKING THE TURN Replace the turn signal/hazard relay. SIGNAL/HAZARD RELAY” on page 8-134. OK↓ 5. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring.
  • Page 423 SIGNALING SYSTEM The fuel level warning light fails to come on. 1. Check the fuel sender. NG→ Refer to “CHECKING THE FUEL Replace the fuel pump assembly. SENDER” on page 8-141. OK↓ 2. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM”...
  • Page 424 SIGNALING SYSTEM The shift timing indicator light fails to come on. 1. Check that the shift timing indicator NG→ light is set to come on and that the brightness level of the light is Replace the meter assembly. adjusted properly. Refer to “FEATURES”...
  • Page 425 SIGNALING SYSTEM 8-28...

  • Page 426: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-29...
  • Page 427 COOLING SYSTEM 1. Main switch 4. Joint 5. Main fuse 9. Battery 10.Engine ground 22.ECU (engine control unit) 43.Coolant temperature sensor 74.Engine ground 95.Left radiator fan motor 96.Right radiator fan motor 97.Left radiator fan motor fuse 98.Right radiator fan motor fuse 99.Radiator fan motor relay 101.Ignition fuse 8-30...
  • Page 428 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 and radiator fan motor) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-129. OK↓...
  • Page 429 COOLING SYSTEM 8-32...

  • Page 430: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-33...
  • Page 431 FUEL INJECTION SYSTEM 101.Ignition fuse 1. Main switch 103.Headlight fuse 4. Joint 104.Steering damper fuse 5. Main fuse 6. ETV (Electronic Throttle Valve) fuse 9. Battery 10.Engine ground 11.Fuel injection system fuse 14.Relay unit 15.Starting circuit cut-off relay 16.Fuel pump relay 17.Gear position sensor 18.Sidestand switch 20.Fuel pump...
  • Page 432 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 433 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 434 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 435 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 436 FUEL INJECTION SYSTEM If the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ ” again. 9. Turn the main switch to “OFF” to cancel the diagnostic mode. 8-39...
  • Page 437 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 97–106 Check with throttle valves 85–94 for FRA/BEL (1KB9/ fully open.
  • Page 438 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:13 Throttle position sensor sig- nal 2 • Fully closed position 9–23 Check with throttle valves fully closed. • Fully opened position 94–108 Check with throttle valves 82–96 for FRA/BEL (1KB9/ fully open.
  • Page 439 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:60 EEPROM fault code display — • No history • No malfunctions detected (If the self-diagnosis fault code 44 is indicated, the ECU is defective.) • History exists 01–04 (Cylinder fault code) •...
  • Page 440 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:63 Malfunction code reinstate- ment (for fault code No. 24, 40 only) • No malfunction code — • Malfunction code exists Fault code 24, 40 To reinstate, set the engine •...
  • Page 441 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code D:36 Primary injector #1 Actuates the primary injector Check the operating sound #1 five times at one-second of the injector #1 five times. intervals. ECA1KB8801 Illuminates the engine trou- ble warning light. Disconnect the fuel pump coupler.
  • Page 442 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code D:43 Secondary injector #4 Actuates the secondary injec- Check the operating sound tor #4 five times at one-sec- of the secondary injector #4 ond intervals. five times. Illuminates the engine trou- ECA1KB8801 ble warning light.
  • Page 443 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 444 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 445 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 446 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 447 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 448 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 449 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 •...
  • Page 450 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 •...
  • Page 451 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 •...
  • Page 452 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 453 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 454 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 455 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 456 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. When engine is cold: Displays temperature closer to air temperature Meter display When engine is hot: Displays current coolant temperature Compare the actually measured coolant temperature with the meter Checking method...
  • Page 457 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. When engine is cold: Displays temperature closer to air temperature Meter display When engine is hot: Displays current coolant temperature Compare the actually measured coolant temperature with the meter Checking method...
  • Page 458 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. When engine is cold: Displays temperature closer to air temperature Meter display When engine is hot: Air temperature + approx.
  • Page 459 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 460 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 461 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 462 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 463 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 464 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 465 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 466 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 467 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 468 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 469 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 470 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 471 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 472 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 473 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 474 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 475 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 476 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 477 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 478 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 479 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 480 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 481 FUEL INJECTION SYSTEM Fault code No. A. Normal signals are not received from the rear speed sen- sor. Symptom B. Open or short circuit of gear position sensor lead C. Normal signals are not received from the clutch switch. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitoring...
  • Page 482 FUEL INJECTION SYSTEM A. Rear speed sensor system malfunction Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection → Connect Connection of rear speed Start the engine, and check sensor (meter) coupler it securely, or repair/replace the connection of the coupler Check the connection of the the wire harness.
  • Page 483 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 484 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 485 FUEL INJECTION SYSTEM Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Open short circuit → Replace Continuity of wire harness Start the engine, and check the wire harness. the secure connection of the Black/Yellow–Black/Yellow coupler. Blue/Yellow–Blue/Yellow Ride the vehicle at a low speed (approx.
  • Page 486 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 487 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 488 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 489 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 490 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 491 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 492 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 493 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 494 FUEL INJECTION SYSTEM Fault code No. Symptom Defect Found in YCC-T Drive 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 dure...
  • Page 495 FUEL INJECTION SYSTEM Fault code No. Symptom Defect Found in YCC-T Drive 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 dure...
  • Page 496 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 497 FUEL INJECTION SYSTEM Fault code No. Item Normal signals are not received from the front speed sensor. Engine startup: Possible Fail-safe system Riding: Possible Diagnostic code No. D:16 Meter display Vehicle speed pulses: 0–999 Make sure that the indication value increases when the rotation Checking method speed of the front wheel increases.
  • Page 498 FUEL INJECTION SYSTEM Fault code No. Item Normal signals are not received from the front speed sensor. Engine startup: Possible Fail-safe system Riding: Possible Diagnostic code No. D:16 Meter display Vehicle speed pulses: 0–999 Make sure that the indication value increases when the rotation Checking method speed of the front wheel increases.
  • Page 499 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signal is received from the ECU. Engine startup: Possible, Impossible if ECU Failure Fail-safe action Riding: Possible, Impossible if ECU Failure Diagnostic monitor- — ing code No. Meter display — Checking method —...
  • Page 500 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 501 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 502 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 503 FUEL INJECTION SYSTEM 8-106...

  • Page 504: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-107...
  • Page 505 FUEL PUMP SYSTEM 1. Main switch 4. Joint 5. Main fuse 9. Battery 10.Engine ground 11.Fuel injection system fuse 14.Relay unit 16.Fuel pump relay 20.Fuel pump 22.ECU (engine control unit) 69.Right handlebar switch 71.Engine stop switch 74.Engine ground 101.Ignition fuse 8-108...
  • Page 506 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 507 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 8-107. OK↓ Replace the ECU. 8-110...

  • Page 508: Immobilizer System

    IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-111...
  • Page 509 IMMOBILIZER SYSTEM 1. Main switch 4. Joint 5. Main fuse 7. Backup fuse 8. Immobilizer unit 9. Battery 10.Engine ground 21.Joint coupler 22.ECU (engine control unit) 52.Meter assembly 53.Immobilizer system indicator light 59.Multi-function meter 74.Engine ground 101.Ignition fuse 8-112...
  • Page 510 IMMOBILIZER SYSTEM EAS27671 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • A code re-registering key (with a red bow) • Two standard keys (with a black bow) that can be re-registered with new codes •...
  • Page 511 IMMOBILIZER SYSTEM EAS27691 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS In the course of use, you may encounter the following cases where replacement of parts and regis- tration of code re-registering/standard keys are required. Each standard key is registered during production, therefore re-registering at purchase is not neces- sary.
  • Page 512 IMMOBILIZER SYSTEM Standby mode d. LED off a. Main switch “ON” e. Standby mode on b. Main switch “OFF” f. Standby mode off c. LED on Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
  • Page 513 IMMOBILIZER SYSTEM Standard key registration i. Registration mode a. Main switch “ON” b. Main switch “OFF” A. Registration of the second standard key is c. LED on complete. d. LED off B. Immobilizer system indicator light stops e. Less than 5.0 s flashing when the registration of the second f.
  • Page 514 IMMOBILIZER SYSTEM EAS27701 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. 1. Check the fuses. NG→ (Main, ignition and backup) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-129.
  • Page 515 IMMOBILIZER SYSTEM EAS27721 SELF-DIAGNOSIS FAULT CODE INDICATION When a system failure occurs, the error code number is indicated in the LCD display of meter and the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code.
  • Page 516 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Key code registra- Same standard key was Register another UNIT tion malfunction. attempted to be regis- standard key. tered two consecutive times. Undefinition code is Noise interference or dis- 1. Check the wire received.
  • Page 517 IMMOBILIZER SYSTEM 8-120...

  • Page 518: Electrical Components

    ELECTRICAL COMPONENTS EAS27972 ELECTRICAL COMPONENTS 8-121...
  • Page 519 ELECTRICAL COMPONENTS 1. Main switch 2. Immobilizer unit 3. Front brake light switch 4. Clutch switch 5. Ignition coil 6. Battery 7. Fuse box 8. Main fuse 9. Fuel injection system fuse 10.Starter relay 11.Rear brake light switch 12.Gear position sensor 13.Sidestand switch 14.O sensor...
  • Page 520 ELECTRICAL COMPONENTS 8-123...
  • Page 521 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Headlight relay 3. Turn signal/hazard 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 522 ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-125...
  • Page 523 ELECTRICAL COMPONENTS 1. Horn switch 2. Clutch switch 3. Main switch 4. Dimmer switch 5. Pass switch 6. Turn signal switch 7. Traction control system switch 8. Sidestand switch 9. Gear position sensor 10.Oil level switch 11.Hazard switch 12.Front brake light switch 13.Engine stop switch 14.Start switch 15.Rear brake light switch...
  • Page 524 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 525 ELECTRICAL COMPONENTS EAS27990 otherwise it may be pulled out of the ter- CHECKING THE BULBS AND BULB SOCK- minal in the coupler. • Avoid touching the glass part of the head- light bulb to keep it free from oil, other- Do not check any of the lights that use LEDs.
  • Page 526 ELECTRICAL COMPONENTS d. If the fuse immediately blows again, check the electrical circuit. Check each bulb socket for continuity in the same manner as described in the bulb section; Amperage Fuses Q’ty however, note the following. rating Main 50 A ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 527 ELECTRICAL COMPONENTS • Keep batteries away from fire, sparks or EWA1KB8801 WARNING open flames (e.g., welding equipment, lighted cigarettes). The battery cover material can conduct • DO NOT SMOKE when charging or han- electricity. If the battery cover has not been dling batteries.
  • Page 528 ELECTRICAL COMPONENTS b. Check the charge of the battery, as shown ECA13670 in the charts and the following example. • Never remove the VRLA (Valve Regulated Example Lead Acid) battery sealing caps. Open-circuit voltage = 12.0 V • Do not use a high-rate battery charger Charging time = 6.5 hours since it forces a high-amperage current Charge of the battery = 20–30%...
  • Page 529 ELECTRICAL COMPONENTS d. Adjust the voltage so that the current is at the standard charging level. e. Set the time according to the charging time suitable for the open-circuit voltage. f. If charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours.

  • Page 530: Specifications

    ELECTRICAL COMPONENTS 2. Connect the pocket tester (Ω × 1) and bat- 6. Install: • Battery seat tery (12 V) to the relay terminal as shown. • Battery Check the relay operation. Out of specification → Replace. 7. Connect: • Battery leads Starter relay (to the battery terminals) ECA13630...
  • Page 531 ELECTRICAL COMPONENTS Relay unit (fuel pump relay) Radiator fan motor relay 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe Result Result Continuity...
  • Page 532 ELECTRICAL COMPONENTS EAS28050 CHECKING THE RELAY UNIT (DIODE) 1. Check: • Relay unit (diode) Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Turn the main switch to “ON”. The pocket tester or the analog pocket tester c.
  • Page 533 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Continuity a. Disconnect the relay unit coupler from the Positive tester probe wire harness. Sky blue “1” b. Connect the pocket tester (Ω × 1) to the Negative tester probe relay unit terminal as shown. Black/Yellow “2” c.

  • Page 534: Engine

    ELECTRICAL COMPONENTS 2. Check: • Secondary coil resistance Out of specification → Replace. Secondary coil resistance 8.50–11.50 kΩ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1 k) to the ignition coil as shown. Pocket tester 90890-03112 2. Ignition coil Analog pocket tester b.
  • Page 535 ELECTRICAL COMPONENTS c. Set the main switch to “ON”. b. Measure the crankshaft position sensor d. Turn the lean angle sensor to 45°. resistance. e. Measure the lean angle sensor output volt- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ age. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28130 CHECKING THE LEAN ANGLE SENSOR 1.
  • Page 536 ELECTRICAL COMPONENTS EAS28150 EAS28170 CHECKING THE STATOR COIL CHECKING THE RECTIFIER/REGULATOR 1. Disconnect: 1. Check: • Stator coil coupler • Rectifier/regulator input voltage Out of specification → Correct the stator (from the wire harness) 2. Check: coil condition. • Stator coil resistance Refer to “CHECKING THE STATOR Out of specification →...
  • Page 537 ELECTRICAL COMPONENTS b. Connect the pocket tester (Ω × 1) to the 2. Check: • Rectifier/regulator output voltage horn terminals. Out of specification → Replace the recti- Pocket tester fier/regulator. 90890-03112 Rectifier/regulator output volt- Analog pocket tester YU-03112-C 14.2–14.8 V •...
  • Page 538 ELECTRICAL COMPONENTS Fuel pump is atmosphere “A” Pocket tester → Fuel level warning light is come on 90890-03112 Fuel pump is soaked in fuel “B” Analog pocket tester → Fuel level warning light is goes off YU-03112-C Minimum level position “A” •...
  • Page 539 ELECTRICAL COMPONENTS 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 540 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Throttle position sensor resis- a. Connect the pocket tester (Ω × 100) to the tance coolant temperature sensor as shown. 1.2–2.8 kΩ Pocket tester ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 90890-03112 a. Connect the pocket tester (Ω × 1 k) to the Analog pocket tester throttle position sensor terminal as shown.
  • Page 541 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b. Connect the digital circuit tester to the a. Connect the pocket tester (Ω × 1 k) to the throttle servo motor coupler. accelerator position sensor terminal as Digital circuit tester shown. 90890-03174 Pocket tester Model 88 Multimeter with 90890-03112 tachometer Analog pocket tester...
  • Page 542 ELECTRICAL COMPONENTS • Positive tester probe • Positive tester probe Orange “1” Pink (wire harness color) • Negative tester probe • Negative tester probe Green “2” Black/blue (wire harness color) c. Measure the air induction system solenoid resistance. c. Turn the main switch to “ON”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 543 ELECTRICAL COMPONENTS b. Connect the digital circuit tester (DCV) to Pocket tester the test harness S-pressure sensor (3P). 90890-03112 Analog pocket tester Digital circuit tester YU-03112-C 90890-03174 Test harness-speed sensor (3P) Model 88 Multimeter with 90890-03208 tachometer YU-03208 YU-A1927 Test harness S-pressure sensor •...
  • Page 544 ELECTRICAL COMPONENTS 2. Check: Intake air temperature sensor • Steering damper solenoid resistance resistance Out of specification → Replace the steer- 5.4–6.6 kΩ at 0 °C (32 °F) ing damper assembly. 290–390 Ω at 80 °C (176 °F) Steering damper solenoid resis- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 545 ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C Result Neutral position Continuity Positive tester probe EAS14B1101 Sky blue “1” CHECKING THE FUEL INJECTORS Negative tester probe 1. Remove: Sensor terminal “a” • Fuel tank 1st position Refer to “FUEL TANK” on page 7-1. Continuity •...
  • Page 546 ELECTRICAL COMPONENTS 8-149...
  • Page 547 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 ..................9-2 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 548: Troubleshooting

    TROUBLESHOOTING EAS28451 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does • Improperly installed fuse not cover all the possible causes of trouble. It 3.
  • Page 549 TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •...

  • Page 550: Cooling System

    TROUBLESHOOTING 2. Engine oil • Faulty brake caliper kit • Incorrect oil level • Faulty brake caliper seal • Incorrect oil viscosity • Loose union bolt • Inferior oil quality • Damaged brake hose • Oil or grease on the brake disc Cooling system •...
  • Page 551 TROUBLESHOOTING 6. Tire(s) Turn signal blinks quickly • Uneven tire pressures (front and rear) • Incorrect turn signal bulb • Incorrect tire pressure • Faulty turn signal/hazard relay • Uneven tire wear • Burnt-out turn signal bulb 7. Wheel(s) Horn does not sound •...
  • Page 552 EAS28740 55. Oil level warning light Gray WIRING DIAGRAM 56. Neutral indicator light Blue 57. Tachometer YZF-R1(B) Light green 58. Shift timing indicator light Orange 1. Main switch 59. Multi-function meter Pink 2. AC magneto 60. Transmission gear display 3. Rectifier/regulator 61.
  • Page 555 WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES YZF-R1(B) YZF-R1(B) YZF-R1(B) YZF-R1(B) DE YZF-R1(B)
  • Page 556 WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES YZF-R1(B) YZF-R1(B) YZF-R1(B) YZF-R1(B) DE YZF-R1(B)

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