Yamaha SR400 2014 Service Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Motorcycle
  5. SR400 2014
  6. Service manual

Yamaha SR400 2014 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
2014
SERVICE MANUAL
SR400
SR400E
2RD-28197-E0

Advertisement

Table of Contents
loading

Related Manuals for Yamaha SR400 2014

Summary of Contents for Yamaha SR400 2014

  • Page 1 2014 SERVICE MANUAL SR400 SR400E 2RD-28197-E0...
  • Page 3 EAS20040 SR400 SR400E SERVICE MANUAL ©2013 by Yamaha Motor Co., Ltd. First edition, November 2013 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 5: How To Use This Manual

    EAS20091 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 6: Symbols

    Brake fluid Special tool Wheel bearing grease Tightening torque Lithium-soap-based grease Wear limit, clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data YAMAHA GREASE “F” Engine oil Apply locking agent (LOCTITE®). Silicone fluid Replace the part with a new one.

  • Page 7: Table Of Contents

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

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .....................1-1 VEHICLE IDENTIFICATION NUMBER ............1-1 MODEL LABEL...................1-1 FEATURES.......................1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 FUEL LINE CHART ..................1-4 IMPORTANT INFORMATION ................1-5 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-5 REPLACEMENT PARTS................1-5 GASKETS, OIL SEALS AND O-RINGS .............1-5 LOCK WASHERS/PLATES AND COTTER PINS ........1-5 BEARINGS AND OIL SEALS ..............1-5 CIRCLIPS ....................1-6 RUBBER PARTS..................1-6...

  • 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 frame under the rider seat. This information will be needed to order spare parts.

  • Page 11: Features

    FEATURES EAS20170 FEATURES EAS2RD1001 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 12: Fi System

    FEATURES EAS2RD1003 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 remain open.

  • Page 13: Fuel Line Chart

    FEATURES EAS2RD1002 FUEL LINE CHART 1. Fuel tank 2. Fuel cock 3. Fuel pump case 4. Fuel pump 5. Fuel injector 6. Pressure regulator A. Feeding side B. Return side...

  • Page 14: Important Information

    5. Keep all parts away from any source of fire. 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 15: Circlips

    IMPORTANT INFORMATION manufacturer marks or numbers are visible. low any items other than the specified one to When installing oil seals, lubricate the oil seal contact the parts. lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

  • Page 16: Basic Service Information

    BASIC SERVICE INFORMATION EAS30380 BASIC SERVICE INFORMATION EAS30390 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. 2. Install: • Quick fastener To install the quick fastener, insert the fastener into the part to be secured and tighten the screw “a”.
  • Page 17 BASIC SERVICE INFORMATION the battery, be sure to disconnect the nega- while only the negative battery lead is con- tive battery lead first, then the positive bat- nected, a spark could be generated, which is tery lead. If a tool or similar item contacts the extremely dangerous.
  • Page 18 BASIC SERVICE INFORMATION ECA16640 NOTICE When resetting the ECU by turning the main For waterproof couplers, never insert the switch to “OFF”, be sure to wait approximately tester probes directly into the coupler. When 5 seconds before turning the main switch back performing any checks using a waterproof to “ON”.
  • Page 19 BASIC SERVICE INFORMATION • Make sure all connections are tight. ECA16790 NOTICE When disconnecting a connector, do not pull the leads. Hold both sections of the connec- tor securely, and then disconnect the con- nector. 4. Check: • Continuity (with the pocket tester) Pocket tester 90890-03112 Analog pocket tester...
  • Page 20 BASIC SERVICE INFORMATION 5. Check: • Resistance Pocket tester 90890-03112 Analog pocket tester YU-03112-C The resistance values shown were obtained at the standard measuring temperature of 20 C (68 F). If the measuring temperature is not 20 C (68 F), the specified measuring conditions will be shown.
  • Page 21 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 inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor 5-17, 5-22 90890-01253 Ring nut wrench 4-46 90890-01268 Spanner wrench YU-01268 Crankshaft installer pot 5-54 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-54 90890-01275 Bolt YU-90060 Adapter (M12) 5-54 90890-01278 Adapter #3...
  • Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston pin puller set 5-24 90890-01304 Piston pin puller YU-01304 YU-01304 T-handle 4-39, 4-41 90890-01326 T-handle 3/8" drive 60 cm long YM-01326 Fork seal driver weight 4-41, 4-42 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø35) 4-41 90890-01369...
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 90890-03081 Engine compression tester YU-33223 Pocket tester 1-10, 1-11, 90890-03112 7-57, 7-58, Analog pocket tester 7-59, 7-63, YU-03112-C 7-64, 7-65, 7-66, 7-67, 7-68, 7-69, 7-70, 7-71, 7-72 Pressure gauge 6-12 90890-03153 Pressure gauge YU-03153...
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness S– pressure sensor 5S7 7-71 (3P) 90890-03211 Test harness S– pressure sensor 5S7 (3P) YU-03211 Test harness– lean angle sensor (3P) 7-67 90890-03213 Test harness– lean angle sensor (3P) YU-03213 Valve guide remover &...

  • Page 26: Special Tools

    Tool name/Tool No. Illustration pages Ignition checker 7-66 90890-06754 Oppama pet–4000 spark checker YM-34487 Digital tachometer 90890-06760 Digital tachometer YU-39951-B Vacuum/pressure pump gauge set 6-12 90890-06945 Pressure/vacuum tester YB-35956-B Yamaha bond No. 1215 5-11, 5-50 90890-85505 (Three bond No.1215®) 1-17...

  • Page 27: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS .................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-16 LUBRICATION POINTS AND LUBRICANT TYPES ........2-20 ENGINE....................2-20 CHASSIS....................2-21 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-23 ENGINE OIL LUBRICATION CHART ............2-23 LUBRICATION DIAGRAMS ..............2-25 CABLE ROUTING ..................2-33...

  • Page 28: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 2RD1 (EUR) 2RD4 (AUS) Dimensions Overall length 2085 mm (82.1 in) Overall width 750 mm (29.5 in) Overall height 1095 mm (43.1 in) Seat height 785 mm (30.9 in) Wheelbase 1410 mm (55.5 in) Ground clearance 130 mm (5.12 in) Minimum turning radius...

  • Page 29: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Air cooled 4-stroke, SOHC Displacement 399 cm Cylinder arrangement Single cylinder Bore  stroke 87.0  67.2 mm (3.43  2.65 in) Compression ratio 8.50 : 1 Standard compression pressure (at sea level) 1050 kPa/700 r/min (10.5 kgf/cm /700 r/min, 149.3 psi/700 r/min)
  • Page 30 ENGINE SPECIFICATIONS Camshaft Drive system Chain drive (right) Camshaft lobe dimensions Lobe height (Intake) 38.860–38.960 mm (1.5299–1.5339 in) Limit 38.850 mm (1.5295 in) Base circle diameter (Intake) 32.170–32.270 mm (1.2665–1.2705 in) Limit 32.160 mm (1.2661 in) Lobe height (Exhaust) 38.890–38.990 mm (1.5311–1.5350 in) Limit 38.880 mm (1.5307 in) Base circle diameter (Exhaust)
  • Page 31 ENGINE SPECIFICATIONS Limit 43.00 mm (1.69 in) Installed length (intake) 38.00 mm (1.50 in) Installed length (exhaust) 38.00 mm (1.50 in) Spring rate K1 (intake) 16.40 N/mm (1.67 kgf/mm, 93.64 lbf/in) Spring rate K2 (intake) 20.80 N/mm (2.12 kgf/mm, 118.77 lbf/in) Spring rate K1 (exhaust) 16.40 N/mm (1.67 kgf/mm, 93.64 lbf/in) Spring rate K2 (exhaust)
  • Page 32 ENGINE SPECIFICATIONS 2nd ring Ring type Taper End gap (installed) 0.30–0.50 mm (0.0118–0.0197 in) Limit 0.80 mm (0.0315 in) Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in) Limit 0.150 mm (0.0059 in) Oil ring End gap (installed) 0.20–0.90 mm (0.0079–0.0354 in) Crankshaft Crank assembly width 74.95–75.00 mm (2.951–2.953 in)
  • Page 33 ENGINE SPECIFICATIONS Fuel pump Pump type Electrical Fuel injector Model/quantity 4C8/1 Throttle body Type/quantity 34EHS/1 ID mark 2RD1 00 Throttle position sensor Resistance 1.75–3.25 k (L-B/L) Idling condition Engine idling speed 1200–1400 r/min 170.0–190.0 C (338.00–374.00 F) Plug seat temperature CO% (AI system ON) 3.00 % Intake vacuum...

  • Page 34: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Semi double cradle 27.70  Caster angle Trail 111 mm (4.4 in) Front wheel Wheel type Spoke wheel 18  1.85 Rim size Rim material Aluminum Wheel travel 150 mm (5.9 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit...
  • Page 35 CHASSIS SPECIFICATIONS Brake disc thickness limit 4.5 mm (0.18 in) Brake disc runout limit (as measured on 0.15 mm (0.0059 in) wheel) Brake pad lining thickness (inner) 6.2 mm (0.24 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (outer) 6.2 mm (0.24 in) Limit 0.8 mm (0.03 in)
  • Page 36 CHASSIS SPECIFICATIONS Spring preload adjusting positions Minimum Standard Maximum Swingarm Swingarm end free play limit (radial) 1.0 mm (0.04 in) Swingarm end free play limit (axial) 0.5 mm (0.02 in) Drive chain Type/manufacturer 428HVS/DAIDO Number of links Drive chain slack 30.0–40.0 mm (1.18–1.57 in) 15-link length limit 191.5 mm (7.54 in)

  • Page 37: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Digital 10.0 1300 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer TBDFL5/DENSO Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64  Primary coil resistance Secondary coil resistance 8.64–12.96 k...
  • Page 38 ELECTRICAL SPECIFICATIONS 12 V, 1.7 W  1 Engine trouble warning light Horn Horn type Plane Quantity Maximum amperage 3.0 A 1.19–1.25  Coil resistance Turn signal/hazard relay Relay type Full transistor Built-in, self-canceling device Turn signal blinking frequency 75–95 cycles/min Fuel sender unit 1350–1900 @25 C (1350–1900 @77 F) Sender unit resistance (thermistor)

  • Page 39: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20331 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 40: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tappet cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Exhaust tappet cover bolt (right 10 Nm (1.0 m·kgf, 7.2 ft·lbf) side of the vehicle) Cylinder head cover nut 38 Nm (3.8 m·kgf, 27 ft·lbf)
  • Page 41 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Timing chain tensioner cap 18 Nm (1.8 m·kgf, 13 ft·lbf) Rocker arm shaft lock washer 10 Nm (1.0 m·kgf, 7.2 ft·lbf) bolt Decomp cam bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Timing chain guide bolt (exhaust 8 Nm (0.8 m·kgf, 5.8 ft·lbf) side)
  • Page 42 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Muffler and frame bracket bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Frame muffler bracket nut 30 Nm (3.0 m·kgf, 22 ft·lbf) Muffler bracket and frame bolt 60 Nm (6.0 m·kgf, 43 ft·lbf) Air induction system pipe bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) (cylinder head side)

  • Page 43: Chassis Tightening Torques

    TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Throttle position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Intake air pressure sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) sensor 45 Nm (4.5 m·kgf, 33 ft·lbf) Intake air temperature sensor 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) screw Oil separator bolt...
  • Page 44 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil drain bolt (oil tank side) 16 Nm (1.6 m·kgf, 12 ft·lbf) Engine mount front bolt 35 Nm (3.5 m·kgf, 25 ft·lbf) Engine mounting nut (front side) 64 Nm (6.4 m·kgf, 46 ft·lbf) Engine mounting nut (front lower 60 Nm (6.0 m·kgf, 43 ft·lbf) side)
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Lower ring nut — See TIP. Steering stem nut 110 Nm (11 m·kgf, 80 ft·lbf) Rollover valve clamp bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Fuel cock screw 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Fuel tank bolt 16 Nm (1.6 m·kgf, 12 ft·lbf) Fuel sender screw...
  • Page 46 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Brake pedal adjusting bolt lock- 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Centerstand nut 32 Nm (3.2 m·kgf, 23 ft·lbf) Pivot shaft nut 104 Nm (10.4 m·kgf, 75 ft·lbf) Pivot shaft bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Sidestand bolt 40 Nm (4.0 m·kgf, 29 ft·lbf)

  • Page 47: 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 Bearings Cylinder head cover nut (M10) thread, bearing surface Cylinder head stud bolt Cylinder nut thread, bearing surface Cylinder stud bolt Crank pin outer circumference Connecting rod big end, thrust end surface Piston pin outer circumference...

  • Page 48: Chassis

    Transmission sliding portion, wheel gear and pinion gear inner surface, end surface Shift fork guide bar outer circumference, end surface Shift drum bearing Shift shaft bearing Yamaha bond No. Crankcase mating surfaces 1215 (Three bond No. 1215®) Yamaha bond No.
  • Page 49 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Speedometer gear O-ring and sliding part Rear brake camshaft mating surfaces, shaft Rear brake shoe plate pin pivot Rear wheel oil seal lip Rear wheel axle Rear wheel drive hub Brake caliper piston seal Master cylinder inside Brake caliper piston dust seal Caliper support bolt...

  • Page 50: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-23...
  • Page 51 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Rocker arm shaft 2. Crankshaft 3. Oil filter element 4. Check ball 5. Oil feed pump 6. Scavenging pump 7. Oil strainer 8. Drive axle 9. Main axle 10. Oil tank (frame) 2-24...

  • Page 52: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-25...
  • Page 53 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Engine oil level gauge 2. Breather hose 3. Oil tank 4. Union bolt 5. Oil delivery pipe clamp 6. Oil delivery pipe 7. Oil pipe 8. Oil hose 1 9. Oil drain bolt (oil tank side) 10.
  • Page 54 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 55 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil hose 2 2. Scavenging pump 3. Oil drain bolt (crankcase side) A. To oil tank 2-28...
  • Page 56 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Crankshaft 2. Oil filter element 3. Check ball 4. Oil feed pump 5. Oil strainer 6. Oil pipe 7. Oil delivery pipe 8. Rocker arm (exhaust side) 9. Camshaft 10. Rocker arm (intake side) A.
  • Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Clutch push lever shaft 2. Main axle 3. Oil pump 4. Drive axle A. To oil tank 2-32...

  • Page 60: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING Right side view 2-33...
  • Page 61 CABLE ROUTING 1. Rear brake light switch 2. Rear brake light switch lead 3. Throttle position sensor coupler 4. Fuel sender lead 5. Fuel tank 6. Oil hose 2 7. O sensor coupler 8. Right handlebar switch lead 9. Front brake light switch lead 10.
  • Page 62 CABLE ROUTING Left side front view 2-35...
  • Page 63 CABLE ROUTING 1. Speedometer cable 2. Clutch cable 3. Decompression cable 4. Left handlebar switch lead 5. Ignition coil 6. Wire harness 7. Spark plug lead 8. Throttle cable (decelerator) 9. Throttle cable (accelerator) 10. Engine temperature sensor 11. Fuel tank breather hose 12.
  • Page 64 CABLE ROUTING Left side rear view 2-37...
  • Page 65 CABLE ROUTING O. Fasten the breather hose and oil hose 2 with the 1. Breather hose clamp. 2. Oil hose 2 P. Fasten the sidestand switch lead with the frame 3. Intake air temperature sensor lead clamp. 4. Rear brake light switch coupler Q.
  • Page 66 CABLE ROUTING Upper front view 2-39...
  • Page 67 CABLE ROUTING 1. Clutch cable 2. Decompression cable 3. Brake hose 4. Throttle cable 5. Front brake light switch lead 6. Right handlebar switch lead 7. Left handlebar switch lead 8. Clutch switch lead 9. Handlebar A. Fasten the right handlebar switch lead and front brake light switch lead with the plastic locking tie.
  • Page 68 CABLE ROUTING Upper rear view 2-41...
  • Page 69 CABLE ROUTING 1. Rear brake light switch lead 2. Fuse box 3. Rear left turn signal light lead 4. Tail/brake light lead 5. Rear right turn signal light lead 6. Joint coupler 7. Battery lead 8. Hook-and-loop fastener 1 9. Hook-and-loop fastener 2 A.
  • Page 70 CABLE ROUTING Headlight 2-43...
  • Page 71 CABLE ROUTING 1. Meter lead 2. Clutch switch lead 3. Headlight coupler 4. Left handlebar switch lead 5. Front left turn signal light lead 6. Main switch lead 7. Auxiliary light lead 8. Front right turn signal light lead 9. Right handlebar switch lead 10.
  • Page 72 CABLE ROUTING Handle 2-45...
  • Page 73 CABLE ROUTING 1. Tachometer cable 2. Speedometer cable 3. Clutch cable 4. Decompression cable 5. Wire harness 6. Brake hose 7. Throttle cable A. Route the speedometer cable to the front of the lower bracket. B. Fasten the brake hose with the clamp. C.
  • Page 74 CABLE ROUTING Fuel tank breather hose 2-47...
  • Page 75 CABLE ROUTING 1. Fuel tank 2. Fuel hose (fuel tank–fuel pump case) 3. Fuel cock 4. Fuel sender 5. Fuel tank breather hose 2 6. Clamp 7. Rollover valve 8. Fuel tank breather hose 1 9. Tank stopper 10. Damper 11.
  • Page 76 CABLE ROUTING Fuel pump case 2-49...
  • Page 77 CABLE ROUTING 1. Fuel tank 2. Pump case breather hose (fuel pump case–fuel tank) 3. Fuel pump case 4. Fuel hose (fuel pump–fuel rail) 5. Fuel hose (fuel tank–fuel pump case) 6. Fuel cock 7. Fuel pump case box A. Insert the pump case breather hose (fuel pump case–fuel tank) to the base of the fuel tank pipe.
  • Page 78 CABLE ROUTING Throttle body (upper view) 2-51...
  • Page 79 CABLE ROUTING 1. Fuel pump case box 2. Breather hose 3. Pressure regulator 4. Fuel pipe 5. Fuel hose (pressure regulator–fuel pipe) 6. Fuel hose (fuel pipe–fuel tank) A. Avoid contact of the end of the breather hose with the damper. B.
  • Page 80 CABLE ROUTING Throttle body (side view) 2-53...
  • Page 81 CABLE ROUTING 1. Fuel tank 2. Fuel hose (pressure regulator–fuel tank) 3. Pressure regulator 4. Air filter case 5. Battery box 6. Oil separator 7. Air filter case drain hose 8. Oil hose 2 9. Breather hose 10. Clamp 11. Stator coil assembly lead 12.
  • Page 82 CABLE ROUTING Air induction system solenoid 2-55...
  • Page 83 CABLE ROUTING 1. Air cut-off valve 2. Air induction system hose (air filter case–air cut-off valve) 3. Air induction system hose (air cut-off valve–air induction system pipe) 4. Air induction system pipe A. Point the end of the clamp downward. B.
  • Page 84 CABLE ROUTING 2-57...

  • Page 85: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUG ..............3-5 ADJUSTING THE VALVE CLEARANCE ...........3-5 CHECKING THE ENGINE IDLING SPEED ..........3-7 CHECKING THE THROTTLE BODY JOINT..........3-7 ADJUSTING THE EXHAUST GAS VOLUME ..........3-7 CHECKING THE EXHAUST SYSTEM............3-8...
  • Page 86 ADJUSTING THE REAR BRAKE LIGHT SWITCH ........3-24 CHECKING AND LUBRICATING THE CABLES ........3-24 CHECKING THE THROTTLE GRIP............3-24 CHECKING AND CHARGING THE BATTERY........3-25 CHECKING THE FUSES .................3-25 REPLACING THE HEADLIGHT BULB.............3-25 ADJUSTING THE HEADLIGHT BEAM ............3-26...

  • Page 87: 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 88 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check operation, fluid level      ...
  • Page 89 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check operation and shock Shock absorber    ...

  • Page 90: Checking The Fuel Line

    PERIODIC MAINTENANCE EAS21030 CHECKING THE FUEL LINE The following procedure applies to all of the fuel, vacuum and breather hoses. 1. Remove: • Seat • Side cover (left) Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. 2.

  • Page 91: Checking The Spark Plug

    PERIODIC MAINTENANCE Refer to “GENERAL CHASSIS” on page 4-1. plug and gasket surface. 8. Connect: EAS20690 CHECKING THE SPARK PLUG • Spark plug cap 1. Remove: • Spark plug cap EAS20520 ADJUSTING THE VALVE CLEARANCE 2. Remove: The following procedure applies to all of the •...
  • Page 92 PERIODIC MAINTENANCE c. A position where the AC magneto “T” mark Direction “a” matches the crankcase alignment mark is the Valve clearance is increased. compression top dead center (TDC). Direction “b” d. Measure the valve clearance with a thickness Valve clearance is decreased. gauge “1”.

  • Page 93: Checking The Engine Idling Speed

    PERIODIC MAINTENANCE • Crankcase cover (left) 3. Install: Refer to “GENERATOR” on page 5-46. • Throttle body • Fuel tank Refer to “THROTTLE BODY” on page 6-9. Refer to “FUEL TANK” on page 6-1. EAS20600 • Seat ADJUSTING THE EXHAUST GAS VOLUME Refer to “GENERAL CHASSIS”...

  • Page 94: Checking The Exhaust System

    PERIODIC MAINTENANCE Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. 2. Check: • Exhaust pipe “1” • Muffler “2” Cracks/damage  Replace. • Gasket “3” Exhaust gas leaks  Replace the gasket. d.

  • Page 95: Checking The Air Induction System

    PERIODIC MAINTENANCE Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: • Air filter case cover “1” 3. Check: • Air filter element “1” Dirt/damage  Replace. • Replace the air filter element every 20000 km (12500 mi) of operation. •...

  • Page 96: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE EAS20870 ADJUSTING THE CLUTCH LEVER FREE PLAY 1. Check: • Clutch lever free play “a” Out of specification  Adjust. Clutch lever free play 5.0–10.0 mm (0.20–0.39 in) 2. Check: • Rod “1” Check if the rod end “1” is flush with the ad- juster end “2”.

  • Page 97: Adjusting The Decompression Lever Free Play

    PERIODIC MAINTENANCE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Timing chain tensioner cap a. Loosen the locknut “1”. 18 Nm (1.8 m·kgf, 13 ft·lbf) b. Turn the adjusting nut “2” in direction “a” or “b” until decompression lever free play is ob- EAS2RD1007 tained. ADJUSTING THE DECOMPRESSION LEVER FREE PLAY Direction “a”...

  • Page 98: Adjusting The Front Disc Brake

    PERIODIC MAINTENANCE Below the minimum level mark “a”  Add the specified brake fluid to the proper level. Specified brake fluid DOT 4 2. Adjust: • Brake lever free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Turn the adjusting screw “2” in direction “a” or “b”...

  • Page 99: Adjusting The Rear Drum Brake

    PERIODIC MAINTENANCE 1. Operate the brake. Locknut 2. Check: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) • Front brake pad “1” Wear indicator grooves “2” almost disap- peared  Replace the brake pads as a set. Refer to “FRONT BRAKE” on page 4-17. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 100: Checking The Rear Brake Shoes

    PERIODIC MAINTENANCE 2. Check: ECA13520 NOTICE • Brake hose clamp After adjusting the brake pedal position and Loose  Tighten the clamp bolt. free play, make sure there is no brake drag. 3. Hold the vehicle upright and apply the front brake several times.

  • Page 101: Checking The Wheels

    PERIODIC MAINTENANCE with the specified brake fluid. EWA13260 WARNING b. Install the brake master cylinder reservoir di- Never attempt to make any repairs to the aphragm. wheel. c. Connect a clear plastic hose “1” tightly to the bleed screw “2”. After a tire or wheel has been changed or re- placed, always balance the wheel.

  • Page 102: Checking The Tires

    PERIODIC MAINTENANCE Tire air pressure (measured on cold tires) Loading condition 0–90 kg (0–198 lb) Front 175 kPa (1.75 kgf/cm , 25 psi) Rear 200 kPa (2.00 kgf/cm , 29 psi) Loading condition 90–150 kg (198–331 lb) Front 200 kPa (2.00 kgf/cm , 29 psi) EAS21650 CHECKING THE TIRES...

  • Page 103: Checking The Wheel Bearings

    • Swingarm operation en if a tire combination other than one Swingarm not working properly  Check the approved by Yamaha is used on this vehicle. swingarm. Refer to “REAR SHOCK ABSORBER AS- Front tire SEMBLY AND SWINGARM”...

  • Page 104: Adjusting The Drive Chain Slack

    PERIODIC MAINTENANCE 4. Adjust: • Drive chain slack ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen wheel axle nut “1”. b. Loosen the brake pedal free play adjusting nut and tension bar nut. c. Loosen both locknuts “2”. d. Turn the adjusting bolts “3” in direction “a” or “b”...

  • Page 105: Checking And Adjusting The Steering Head

    PERIODIC MAINTENANCE vehicle is used in dusty areas. b. Tighten the lower ring nut “4” to specification This vehicle has a drive chain with small rubber with a steering nut wrench “5”. O-rings between each side plate. Steam clean- ing, high-pressure washing, certain solvents, Set the torque wrench at a right angle to the and the use of a coarse brush can damage steering nut wrench.

  • Page 106: Lubricating The Steering Head

    PERIODIC MAINTENANCE EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. Recommended lubricant Lithium-soap-based grease EAS2RD1026 CHECKING THE SIDESTAND 1. Check: • Sidestand operation Check that the sidestand moves smoothly. Rough movement  Repair or replace. EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point, metal-to-metal mov-...

  • Page 107: Checking The Rear Shock Absorber Assembly

    PERIODIC MAINTENANCE 3. Hold the vehicle upright and apply the front Spring preload adjusting positions brake. Minimum 4. Check: • Front fork operation Standard Push down hard on the handlebar several times and check if the front fork rebounds Maximum smoothly.

  • Page 108: Changing The Engine Oil

    PERIODIC MAINTENANCE Recommended brand YAMALUBE Type SAE 10W-30, 10W-40, 10W-50, 15W-40, 20W-40 or 20W-50 Recommended engine oil grade API service SG type or higher, JASO standard MA 130 °F 10 30 50 70 90 110 4. Remove: SAE 10W-30 • Engine oil level gauge SAE 10W-40 •...
  • Page 109 PERIODIC MAINTENANCE Engine oil quantity Quantity (disassembled) 2.40 L (2.54 US qt, 2.11 Imp.qt) Without oil filter element replace- ment 2.00 L (2.11 US qt, 1.76 Imp.qt) With oil filter element replace- ment 2.10 L (2.22 US qt, 1.85 Imp.qt) 9.

  • Page 110: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE d. Start the engine after solving the problem(s) EAS21690 CHECKING AND LUBRICATING THE and make sure that oil seeps out. CABLES e. Tighten the oil check bolt to specification. The following procedure applies to all of the in- Oil check bolt ner and outer cables.

  • Page 111: Checking And Charging The Battery

    PERIODIC MAINTENANCE b. Turn the adjusting nut “2” in direction “a” or “b” Throttle grip free play until the specified throttle grip free play is ob- 3.0–5.0 mm (0.12–0.20 in) tained. Direction “a” Throttle grip free play is increased. Direction “b” Throttle grip free play is decreased.

  • Page 112: Adjusting The Headlight Beam

    PERIODIC MAINTENANCE affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 7. Hook: • Headlight bulb holder 8. Install: • Headlight bulb cover 9. Connect: • Headlight coupler 10.Install: 2. Disconnect: •...
  • Page 113 PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-27...
  • Page 114 PERIODIC MAINTENANCE 3-28...

  • Page 115: Chassis

    CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE SIDE COVERS ..............4-4 INSTALLING THE SIDE COVERS.............4-4 FRONT WHEEL....................4-5 REMOVING THE FRONT WHEEL.............4-7 CHECKING THE FRONT WHEEL .............4-7 CHECKING THE SPEEDOMETER GEAR UNIT ........4-8 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-8 INSTALLING THE FRONT WHEEL ............4-9 REAR WHEEL ....................4-11 REMOVING THE REAR WHEEL (DRUM)..........4-14 CHECKING THE REAR WHEEL DRIVE HUB .........4-14...
  • Page 116 ASSEMBLING THE FRONT FORK LEGS ..........4-40 INSTALLING THE FRONT FORK LEGS ..........4-42 STEERING HEAD...................4-44 REMOVING THE LOWER BRACKET............4-46 CHECKING THE STEERING HEAD ............4-46 INSTALLING THE STEERING HEAD ............4-47 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM .......4-48 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES ....4-49 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....4-49 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ....4-49 REMOVING THE SWINGARM..............4-49...

  • Page 117: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and side covers 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • • •...
  • Page 118 GENERAL CHASSIS Removing the battery and battery box 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Seat Battery band Clamp Remove the battery lead. Battery connector Battery Battery box...
  • Page 119 GENERAL CHASSIS Removing the electrical components 0.5 Nm ( 0.05 m kgf, 0.36 ft lbf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Seat...

  • Page 120: Removing The Side Covers

    GENERAL CHASSIS EAS2RD1010 EAS2RD1030 REMOVING THE SIDE COVERS INSTALLING THE SIDE COVERS 1. Remove: 1. Install: • Bolt “1” • Side cover (right) “1” • Side cover (right) “2” • Bolt “2” Side cover (right) bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 2.
  • Page 121 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake disc 104 Nm (10.4 m kgf, 75 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 23 Nm (2.3 m kgf,17 ft Ibf) • •...
  • Page 122 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Clutch retainer Meter clutch Oil seal Bearing Spacer Bearing Front wheel...

  • Page 123: Front Wheel

    FRONT WHEEL wheel runout. EAS21890 REMOVING THE FRONT WHEEL 4. Measure: 1. Stand the vehicle on a level surface. • Front wheel radial runout “a” EWA13120 • Front wheel lateral runout “b” WARNING Securely support the vehicle so that there is Over the specified limits ...

  • Page 124: Checking The Speedometer Gear Unit

    FRONT WHEEL ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Remove the oil seals “1” with a flathead EAS21940 screwdriver. CHECKING THE SPEEDOMETER GEAR UNIT To prevent damaging the wheel, place a rag “2” 1. Check: between the screwdriver and the wheel surface.

  • Page 125: Installing The Front Wheel

    FRONT WHEEL 4. Check: • Front wheel static balance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot.
  • Page 126 FRONT WHEEL 4. Tighten: • Wheel axle nut • Axle holder nut “1” ECA14140 NOTICE Before tightening the wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smooth- • Make sure that an arrow of the axle holder points toward the front “A”.

  • Page 127: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel and rear brake 16 Nm (1.6 m kgf, 12 ft Ibf) • • 129 Nm (12.9 m kgf, 93 ft Ibf) • • 19 Nm (1.9 m kgf, 14 ft Ibf) •...
  • Page 128 REAR WHEEL Removing the rear wheel sprocket 26 Nm (2.6 m kgf, 19 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Circlip Hub dust seal Hub stopper Rear wheel sprocket Drive hub Drive hub damper 4-12...
  • Page 129 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Bearing Spacer Flange spacer Oil seal Bearing Bearing 4-13...

  • Page 130: Removing The Rear Wheel (Drum)

    REAR WHEEL EAS22060 REMOVING THE REAR WHEEL (DRUM) 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 131: Checking And Replacing The Rear Wheel Sprocket

    REAR WHEEL Refer to “CHECKING THE FRONT WHEEL” on page 4-7. EAS22120 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: • Rear wheel sprocket More than 1/4 tooth “a” wear  Replace the drive sprocket, the rear wheel sprocket and the drive chain as a set.
  • Page 132 REAR WHEEL Recommended lubricant Lithium-soap-based grease 3. Install: • Rear wheel • Drive chain • Chain puller (left/right) • Toothed spacer • Wheel axle • Wheel axle nut 4. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...

  • Page 133: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake hose holder Caliper support bolt Caliper assembly Brake pad/shim Pad support...
  • Page 134 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 135 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Master cylinder kit 4-19...
  • Page 136 FRONT BRAKE Removing the front brake caliper 30 Nm (3.0 m kgf, 22 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) •...
  • Page 137 FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw Brake caliper cylinder 4-21...

  • Page 138: Introduction

    FRONT BRAKE EAS22221 INTRODUCTION EWA14101 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 139: Replacing The Front Brake Pads

    • Brake pad “1” b. Loosen the bleed screw and push the brake • Shim “2” caliper pistons into the brake caliper using a • Pad support “3” caliper piston presser “3” (recommended by • Pad spring YAMAHA). 4-23...

  • Page 140: Removing The Front Brake Caliper

    FRONT BRAKE 7. Check: c. Tighten the bleed screw. • Brake lever operation Bleed screw Soft or spongy feeling  Bleed the brake sys- 6 Nm (0.6 m·kgf, 4.3 ft·lbf) tem. Refer to “BLEEDING THE HYDRAULIC d. Install the shims “4” onto each brake pad “5”. BRAKE SYSTEM”...

  • Page 141: Checking The Front Brake Caliper

    FRONT BRAKE Rust/scratches/wear  Replace the brake caliper pistons. • Brake caliper cylinder “2” Scratches/wear  Replace the brake caliper assembly. • Brake caliper body “3” Cracks/damage  Replace the brake caliper assembly. • Brake fluid delivery passage (brake caliper body) Obstruction ...

  • Page 142: Installing The Front Brake Caliper

    FRONT BRAKE and brake caliper piston seals. • Brake pad • Pad spring • Pad support Specified brake fluid DOT 4 • Caliper support bolt • Brake caliper • Brake hose holder EAS22420 INSTALLING THE FRONT BRAKE CALIPER Refer to “REPLACING THE FRONT BRAKE 1.

  • Page 143: Removing The Front Brake Master Cylinder

    FRONT BRAKE 7. Check: EAS22500 CHECKING THE FRONT BRAKE MASTER • Brake lever operation CYLINDER Soft or spongy feeling  Bleed the brake sys- 1. Check: tem. • Brake master cylinder “1” Refer to “BLEEDING THE HYDRAULIC Damage/scratches/wear  Replace. BRAKE SYSTEM”...

  • Page 144: Assembling The Front Brake Master Cylinder

    FRONT BRAKE 4. Check: 2. Install: • Brake hose • Gasket Cracks/damage/wear  Replace. • Brake hose • Union bolt EAS22520 ASSEMBLING THE FRONT BRAKE MASTER Brake hose union bolt CYLINDER 30 Nm (3.0 m·kgf, 22 ft·lbf) EWA13520 WARNING EWA2RD1011 •...
  • Page 145 FRONT BRAKE is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. • When refilling, be careful that water does not enter the brake master cylinder reser- voir. Water will significantly lower the boil- ing point of the brake fluid and could cause vapor lock.

  • Page 146: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Disassembling the rear brake 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake shoe kit Brake camshaft lever Indicator plate Oil seal Brake camshaft Camshaft shim 4-30...

  • Page 147: Disassembling The Rear Brake Shoe Plate

    REAR BRAKE EAS2RD1031 DISASSEMBLING THE REAR BRAKE SHOE Lining thickness 4.0 mm (0.16 in) PLATE Limit 1. Remove: 2.0 mm (0.08 in) • Brake shoe kit “1” 2. Remove: 3. Measure: • Brake camshaft lever “1” • Brake drum inside diameter “b” •...
  • Page 148 REAR BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the brake camshaft so its punch mark is positioned as shown. b. Align the projection “a” on the indicator plate with the notch “b” in the brake camshaft. c. Check that the brake shoes are properly po- sitioned.

  • Page 149: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kgf, 5.1 ft Ibf) 23 Nm (2.3 m kgf, 17 ft Ibf) • • • • 2.3 Nm (0.23 m kgf, 1.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 150 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kgf, 5.1 ft Ibf) 23 Nm (2.3 m kgf, 17 ft Ibf) • • • • 2.3 Nm (0.23 m kgf, 1.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 151: Removing The Handlebar

    HANDLEBAR EAS22860 REMOVING THE HANDLEBAR Upper handlebar holder bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) 1. Stand the vehicle on a level surface. EWA13120 WARNING ECA14250 NOTICE Securely support the vehicle so that there is • First, tighten the bolts on the front side of no danger of it falling over.
  • Page 152 HANDLEBAR MASTER CYLINDER” on page 4-28. EWA13700 WARNING EWA13720 Do not touch the handlebar grip until the rub- WARNING Make sure the throttle grip operates smooth- ber adhesive has fully dried. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 8. Install: The mating surfaces of the right handlebar •...

  • Page 153: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 16 Nm (1.6 m kgf, 12 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf)
  • Page 154 FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kgf, 17 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Dust boot...

  • Page 155: Removing The Front Fork Legs

    FRONT FORK • Dust boot EAS22970 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the EAS22980 DISASSEMBLING THE FRONT FORK LEGS front fork legs. The following procedure applies to both of the 1. Stand the vehicle on a level surface. front fork legs.

  • Page 156: Checking The Front Fork Legs

    FRONT FORK 4. Remove: 2. Measure: • Inner tube • Spring free length “a” Out of specification  Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally. Fork spring free length b. Securely clamp the brake caliper bracket in a 492.9 mm (19.41 in) vise with soft jaws.
  • Page 157 FRONT FORK –Piston metal –Oil seal –Dust seal • Before assembling the front fork leg, make sure all of the components are clean. 1. Install: • Slide metal “1” • Piston metal “2” • Damper rod assembly “3” • Oil lock piece “4” 4.

  • Page 158: Installing The Front Fork Legs

    FRONT FORK Quantity 204.0 cm (6.90 US oz, 7.20 Imp.oz) Recommended oil Fork oil 10W or equivalent Level 182.0 mm (7.17 in) *At position “a” from the inner 342-034 tube top end when the inner tube is fully compressed in the outer 5.
  • Page 159 FRONT FORK front fork legs. 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. Make sure the inner tube is flush with the top of the upper bracket. 2. Tighten: • Lower bracket pinch bolt “1” Lower bracket pinch bolt 17 Nm (1.7 m·kgf, 12 ft·lbf) •...

  • Page 160: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the headlight unit, meter assembly, and turn signal lights 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) •...
  • Page 161 STEERING HEAD Removing the lower bracket 110 Nm (11 m kgf, 80 ft Ibf) • • 38 Nm (3.8 m kgf, 27 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Front fork leg...

  • Page 162: Removing The Lower Bracket

    STEERING HEAD EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Upper ring nut • Lower ring nut 3.

  • Page 163: Installing The Steering Head

    STEERING HEAD • Lower bracket (along with the steering stem) Bends/cracks/damage  Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing • Bearing race Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” •...

  • Page 164: Rear Shock Absorber Assembly And Swingarm

    REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM EAS2RD1027 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM Removing the rear shock absorber assembly and swingarm 104 Nm (10.4 m kgf, 75 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • • •...

  • Page 165: Removing The Rear Shock Absorber Assemblies

    REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM • Washer EAS23220 REMOVING THE REAR SHOCK ABSORBER • Rear shock absorber assembly lower nut ASSEMBLIES 2. Install: 1. Stand the vehicle on a level surface. • Washer EWA13120 • Grab bar WARNING • Washer Securely support the vehicle so that there is •...

  • Page 166: Checking The Swingarm

    REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM ing the swingarm from side to side. c. If the swingarm side play is out of specifica- tion, check the spacers and bearings. Swingarm end free play limit (ra- dial) 1.0 mm (0.04 in) d.

  • Page 167: Installing The Swingarm

    REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM • Collar Size “b” (swingarm pivot shaft • Dust cover length + thickness of both bear- • Oil seal ings “1” + thickness of cover “2”) • Pivot shaft 196.7–196.9 mm (7.74–7.75 in) Recommended lubricant Lithium-soap-based grease 2.
  • Page 168 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 4. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-18 Drive chain slack 30.0–40.0 mm (1.18–1.57 in) 4-52...

  • Page 169: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE EAS23420 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 170: Checking The Drive Sprocket

    CHAIN DRIVE ECA2RD1006 EAS23460 CHECKING THE DRIVE SPROCKET NOTICE 1. Check: This vehicle has a drive chain with small rub- • Drive sprocket ber O-rings “1” between the drive chain side More than 1/4 tooth “a” wear  Replace the plates.
  • Page 171 CHAIN DRIVE 4. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-18. Drive chain slack 30.0–40.0 mm (1.18–1.57 in) ECA13550 NOTICE A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident.
  • Page 172 CHAIN DRIVE 4-56...

  • Page 173: Engine

    ENGINE ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-2 INSTALLING THE ENGINE................5-5 CYLINDER HEAD.....................5-6 REMOVING THE CYLINDER HEAD............5-7 CHECKING THE CYLINDER HEAD ............5-8 CHECKING THE CAMSHAFT..............5-8 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ....5-9 CHECKING THE TIMING CHAIN TENSIONER.........5-9 INSTALLING THE CYLINDER HEAD ............5-9 ROCKER ARMS .....................5-13 REMOVING THE ROCKER ARMS AND ROCKER ARM SHAFTS..5-14...
  • Page 174 INSTALLING THE CLUTCH..............5-33 KICKSTARTER ....................5-36 CHECKING THE KICKSTARTER ............5-38 INSTALLING THE KICKSTARTER ............5-38 OIL PUMP.......................5-39 REMOVING THE OIL PUMP..............5-41 CHECKING THE OIL PUMP ..............5-41 ASSEMBLING THE OIL PUMP..............5-41 INSTALLING THE OIL PUMP ..............5-42 SHIFT SHAFT....................5-43 REMOVING THE SHIFT SHAFT..............5-44 CHECKING THE SHIFT SHAFT ..............5-44 CHECKING THE STOPPER LEVER ............5-44 INSTALLING THE SHIFT SHAFT ............5-44 GENERATOR ....................5-46...

  • Page 175: Engine Inspection

    ENGINE INSPECTION EAS2RD1039 ENGINE INSPECTION Standard compression pressure (at sea level) 1050 kPa/700 r/min (10.5 EAS20720 MEASURING THE COMPRESSION kgf/cm /700 r/min, 149.3 psi/700 PRESSURE r/min) The following procedure applies to checking and Minimum–maximum 910–1180 kPa/700 r/min adjusting the compression pressure. (9.1–11.8 kgf/cm /700 r/min, 129.4–167.8 psi/700 r/min)

  • Page 176: Engine Removal

    ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the exhaust pipe and muffler 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
  • Page 177 ENGINE REMOVAL Disconnecting the cables, leads, and hoses 32 Nm (3.2 m kgf, 23 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 90 Nm (9.0 m kgf, 65 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 178: Removing The Engine

    ENGINE REMOVAL Removing the engine 35 Nm (3.5 m kgf, 25 ft Ibf) 35 Nm (3.5 m kgf, 25 ft Ibf) • • • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 35 Nm (3.5 m 42 Nm (4.2 m kgf, 25 ft kgf, 30 ft Ibf)

  • Page 179: Installing The Engine

    ENGINE REMOVAL • Engine mount rear bolt EAS23720 INSTALLING THE ENGINE • Engine mounting nut (rear side) 1. Install: • Engine mount front “1” Engine mount rear bolt 42 Nm (4.2 m·kgf, 30 ft·lbf) • Engine mounting bolt/nut (front side) “2” Engine mounting nut (rear side) •...

  • Page 180: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head and camshaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) 18 Nm (1.8 m kgf, 13 ft Ibf) • • • • 25 Nm (2.5 m kgf, 18 ft Ibf) • •...

  • Page 181: Removing The Cylinder Head

    CYLINDER HEAD EAS24130 REMOVING THE CYLINDER HEAD 1. Remove: • Crankcase cover (left) Refer to “GENERATOR” on page 5-46. 2. Align: • “T” mark “a” on the AC magneto (with the match mark “b” on the crankcase) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the AC magneto counterclockwise. b.

  • Page 182: Checking The Cylinder Head

    CYLINDER HEAD 3. Measure: • Cylinder head warpage Out of specification  Resurface the cylinder head. Warpage limit 0.03 mm (0.0012 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place a straightedge “1” and a thickness gauge “2” across the mating surface of the cylinder head. 7.

  • Page 183: Checking The Timing Chain And Camshaft Sprocket

    CYLINDER HEAD 2. Check: Camshaft lobe dimensions • Camshaft sprocket Lobe height (Intake) • Crankshaft sprocket 38.860–38.960 mm More than 1/4 tooth wear “a”  Replace the (1.5299–1.5339 in) camshaft sprocket, crankshaft sprocket, and Limit timing chain as a set. 38.850 mm (1.5295 in) Base circle diameter (Intake) 32.170–32.270 mm...
  • Page 184 CYLINDER HEAD 3. Tighten: • Cylinder head nut ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: Cylinder head nut • Timing chain “1” 38 Nm (3.8 m·kgf, 27 ft·lbf) • Camshaft sprocket “2” • Cylinder head bolt • Align the camshaft with the dowel pin hole “a” Cylinder head bolt on the camshaft sprocket.
  • Page 185 (mating surfaces between the cylinder head cover assembly and the cylinder head) While holding the AC magneto “1” with the rotor Yamaha bond No. 1215 holding tool “2”, tighten the camshaft sprocket 90890-85505 bolt. (Three bond No.1215®)
  • Page 186 CYLINDER HEAD Do not allow any sealant to come into contact with the oil gallery. 20.Install: • Timing chain tensioner cap Timing chain tensioner cap 17.Install: 18 Nm (1.8 m·kgf, 13 ft·lbf) • Cylinder head cover assembly Cylinder head cover nut (10 mm: “1”–“4”) 38 Nm (3.8 m·kgf, 27 ft·lbf) Cylinder head cover nut (8 mm:...

  • Page 187: Rocker Arms

    ROCKER ARMS EAS2RD1012 ROCKER ARMS Removing the rocker arms and rocker arm shaft 27 Nm (2.7 m kgf, 20 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) •...

  • Page 188: Removing The Rocker Arms And Rocker Arm Shafts

    ROCKER ARMS Damage/wear  Replace. EAS2RD1040 REMOVING THE ROCKER ARMS AND ROCKER ARM SHAFTS 1. Remove: • Lock washer “1” Straighten the lock washer tab and remove the bolt “2”. 2. Check: • Rocker arm shaft Blue discoloration/excessive wear/pit- ting/scratches  Replace or check the lubri- cation system.

  • Page 189: Checking The Cylinder Head Cover, Tappet Cover, And Viewer Plug

    ROCKER ARMS Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm YU-01083-1 5. Calculate: • Rocker-arm-to-rocker-arm-shaft clearance Calculate the clearance by subtracting the rock- er arm shaft outside diameter from the rocker arm inside diameter. Out of specification  Replace. Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.033 mm (0.0004–0.0013...
  • Page 190 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-2. Cylinder head, camshaft Refer to “CYLINDER HEAD” on page 5-6. Valve cotter Valve spring retainer Valve spring (outer) Valve spring (inner)

  • Page 191: Valves And Valve Springs

    VALVES AND VALVE SPRINGS 3. Remove: EAS24280 REMOVING THE VALVES • Valve spring retainer “1” The following procedure applies to all of the • Outer valve spring “2” valves and related components. • Inner valve spring “3” • Valve “4” Before removing the internal parts of the cylinder •...
  • Page 192 VALVES AND VALVE SPRINGS c. After installing the valve guide, bore the valve guide with the valve guide reamer “3” to ob- tain the proper valve-stem-to-valve-guide clearance. After replacing the valve guide, reface the valve seat. Valve guide remover & installer set (ø8.0) 90890-04014 2.

  • Page 193: Checking The Valve Seats

    VALVES AND VALVE SPRINGS b. Install the valve into the cylinder head. EAS24300 CHECKING THE VALVE SEATS c. Press the valve through the valve guide and The following procedure applies to all of the onto the valve seat to make a clear impres- valves and valve seats.

  • Page 194: Checking The Valve Springs

    VALVES AND VALVE SPRINGS valve springs. 1. Measure: For the best lapping results, lightly tap the valve • Valve spring free length “a” seat while rotating the valve back and forth be- Out of specification  Replace the valve tween your hands. spring.

  • Page 195: Installing The Valves

    VALVES AND VALVE SPRINGS Inner spring Installed compression spring force (intake) 119.64 N (12.20 kgf, 26.90 lbf) Installed compression spring force (exhaust) 119.64 N (12.20 kgf, 26.90 lbf) Installed length (intake) 38.00 mm (1.50 in) Installed length (exhaust) 38.00 mm (1.50 in) 2.
  • Page 196 VALVES AND VALVE SPRINGS a. Larger pitch b. Smaller pitch 4. Install: • Valve cotter “1” Install the valve cotters by compressing the valve spring with the valve spring compressor “2”. Valve spring compressor 90890-01253 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.

  • Page 197: Cylinder And Piston

    CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston 38 Nm (3.8 m kgf, 27 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 198: Removing The Piston

    CYLINDER AND PISTON over the piston crown. EAS24380 REMOVING THE PISTON 1. Remove: • Piston pin clip “1” • Piston pin “2” • Piston “3” ECA13810 NOTICE Do not use a hammer to drive the piston pin out. • Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent EAS24390 CHECKING THE CYLINDER AND PISTON...

  • Page 199: Checking The Piston Rings

    CYLINDER AND PISTON EAS24430 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification  Replace the piston and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 200: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: Piston pin bore inside diameter • Piston ring end gap 20.004–20.015 mm Out of specification  Replace the piston (0.7876–0.7880 in) ring. Limit 20.045 mm (0.7892 in) The oil ring expander spacer’s end gap cannot be measured.
  • Page 201 CYLINDER AND PISTON • 2nd ring “4” • Top ring “5” 120˚ Be sure to install the 2nd ring so that the manu- facturer’s mark “N” faces up. 120˚ 120˚ a. Top ring b. Upper oil ring rail c. Oil ring expander d.

  • Page 202: Clutch

    CLUTCH EAS25061 CLUTCH Removing the kick crank and right crankcase cover 20 Nm (2.0 m kgf, 14 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
  • Page 203 CLUTCH Removing the clutch assembly 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Crankcase cover (right) Conical washer...
  • Page 204 CLUTCH Removing the push lever shaft 18 Nm (1.8 m kgf, 13 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drive sprocket cover Clutch cable Clutch assembly Locknut/gasket Adjuster Push lever shaft Torsion spring Washer Oil seal 5-30...

  • Page 205: Removing The Clutch

    CLUTCH EAS25070 REMOVING THE CLUTCH 1. Loosen: • Primary drive gear nut “1” Insert aluminum plate “a” between the primary drive gear “2” and clutch housing “3”, and loosen the primary drive gear nut. EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates.

  • Page 206: Checking The Clutch Springs

    CLUTCH Warpage limit 0.05 mm (0.002 in) EAS25160 CHECKING THE CLUTCH BOSS 1. Check: • Clutch boss spline EAS25140 CHECKING THE CLUTCH SPRINGS Damage/pitting/wear  Replace the clutch The following procedure applies to all of the boss. clutch springs. 1. Check: Pitting on the clutch boss splines will cause er- •...

  • Page 207: Checking The Primary Drive Gear

    CLUTCH 2. Check: • Primary-drive-gear-to-primary-driven-gear free play Free play exists  Replace the primary drive gear and primary driven gear (clutch housing) as a set. EAS25260 INSTALLING THE CLUTCH 1. Install: • Clutch housing “1” 2. Measure: Align the recess “a” in the clutch housing with the •...
  • Page 208 CLUTCH 4. Lubricate: • Friction plate • Clutch plate (with the recommended lubricant) Recommended lubricant Engine oil 5. Install: • Friction plate • Clutch plate 8. Check: First, install a friction plate and then alternate be- • Push lever position tween a clutch plate and a friction plate.
  • Page 209 CLUTCH ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 10.Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-10. 11.Install: • Drive sprocket cover Drive sprocket cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 12.Install: • Dowel pin • Crankcase cover gasket •...

  • Page 210: Kickstarter

    KICKSTARTER EAS24820 KICKSTARTER Removing the kickstarter 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Crankcase cover (right) Refer to “CLUTCH” on page 5-28. Clutch Refer to “CLUTCH” on page 5-28. Kick pinion gear Circlip/washer Kick idle gear Kickstarter assembly...
  • Page 211 KICKSTARTER Disassembling the kickstarter Order Job/Parts to remove Q’ty Remarks Circlip/spring cover Compression spring Ratchet wheel Circlip/spacer Torsion spring Spring cover Circlip/washer Kick gear Washer Circlip Kick axle assembly 5-37...

  • Page 212: Checking The Kickstarter

    KICKSTARTER EAS24850 CHECKING THE KICKSTARTER Align the ratchet wheel “2” with the stopper “3” 1. Check: and put the torsion spring “4” on the kick spring • Kick pinion gear “1” stopper “5”. • Kick idle gear “2” Damage/wear  Replace. 2.

  • Page 213: Oil Pump

    OIL PUMP EAS24911 OIL PUMP Removing the oil pump 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Crankcase cover (right) Refer to “CLUTCH” on page 5-28. Clutch Refer to “CLUTCH” on page 5-28. Oil pump drive gear Circlip Plate washer...
  • Page 214 OIL PUMP Disassembling the oil pump 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump cover Feed side outer rotor Feed side inner rotor Dowel pin Scavenger side outer rotor Pump shaft Dowel pin Scavenger side inner rotor Dowel pin...

  • Page 215: Removing The Oil Pump

    OIL PUMP EAS24940 REMOVING THE OIL PUMP Inner-rotor-to-outer-rotor-tip clearance 1. Drain: 0.070–0.120 mm (0.0028–0.0047 • Engine oil (completely from the crankcase and oil tank) Limit Refer to “CHANGING THE ENGINE OIL” on 0.20 mm (0.0079 in) page 3-22. Outer-rotor-to-oil-pump-housing 2. Remove: clearance •...

  • Page 216: Installing The Oil Pump

    OIL PUMP EAS25020 Recommended lubricant INSTALLING THE OIL PUMP Lithium-soap-based grease 1. Install: • Gasket • Oil pump shaft • Oil pump “1” (with the recommended lubricant) Oil pump bolt Recommended lubricant 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Engine oil ECA13890 2.

  • Page 217: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch Refer to “CLUTCH” on page 5-28. Circlip Stopper lever assembly Circlip Washer Shift shaft assembly Torsion spring...

  • Page 218: Removing The Shift Shaft

    SHIFT SHAFT EAS2RD1014 EAS25451 REMOVING THE SHIFT SHAFT INSTALLING THE SHIFT SHAFT 1. Remove: 1. Install: • Circlip “1” • Oil seal (left side of the crankcase) “1” • Stopper lever assembly “2” (to the crankcase) • Circlip (left side of the crankcase) Installed depth “a”...
  • Page 219 SHIFT SHAFT 4. Check: • Shift lever 3 match mark “a” Shift the gear into 2nd and check for align- ment with the match mark “b” in the shift drum. Not aligned  Adjust. Loosen the locknut “1” and adjust with the ad- juster “2”.

  • Page 220: Generator

    GENERATOR EAS24480 GENERATOR Removing the stator coil assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 221: Removing The Generator

    GENERATOR EAS24490 REMOVING THE GENERATOR Stator coil assembly bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 1. Remove: • AC magneto nut “1” 2. Install: • Washer • Woodruff key • AC magneto While holding the AC magneto with the rotor •...

  • Page 222: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 223 CRANKCASE Disassembling the crankcase 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 224: Disassembling The Crankcase

    1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) EAS25580 CHECKING THE CRANKCASE Do not allow any sealant to come into contact 1.
  • Page 225 CRANKCASE 3. Install: • Dowel pin 4. Install: • Crankcase bolt • Stay “1” Crankcase bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Tighten the bolts in stages and in a crisscross pattern. 5. Install: • Oil strainer • Oil strainer cover •...

  • Page 226: Crankshaft Assembly

    CRANKSHAFT ASSEMBLY EAS25970 CRANKSHAFT ASSEMBLY Removing the crankshaft assembly Order Job/Parts to remove Q’ty Remarks Separate the crankcase. Refer to “CRANKCASE” on page 5-48. Crankshaft assembly Oil seal Bearing 5-52...

  • Page 227: Removing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY 2. Measure: EAS26000 REMOVING THE CRANKSHAFT ASSEMBLY • Big end side clearance 1. Remove: Out of specification  Replace the crank- • Crankshaft assembly “1” shaft assembly. Big end side clearance 0.350–0.650 mm (0.0138–0.0256 ECA2RD1005 NOTICE Do not tap the crankshaft directly with a hammer, etc.

  • Page 228: Installing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY Hold the connecting rod at top dead center (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other. Turn the crankshaft installer nut until the crankshaft as- sembly bottoms against the bearing in the crank- case.

  • Page 229: Transmission

    TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) •...
  • Page 230 TRANSMISSION Disassembling the transmission Order Job/Parts to remove Q’ty Remarks Circlip/washer 1st wheel gear 4th wheel gear Circlip/washer 3rd wheel gear Circlip/washer 5th wheel gear Circlip/washer 2nd wheel gear Drive axle Circlip/washer 2nd pinion gear 5th pinion gear Circlip/washer 3rd pinion gear Circlip/washer 4th pinion gear Main axle...

  • Page 231: Removing The Transmission

    TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Stopper cam assembly 2. Remove: • Drive axle assembly “1” • Main axle assembly “2” Remove the drive axle assembly and the main axle assembly simultaneously. 3. Check: • Shift fork movement (along the shift fork guide bar) Rough movement ...

  • Page 232: Checking The Transmission

    TRANSMISSION 4. Check: EAS26300 CHECKING THE TRANSMISSION • Transmission gear engagement 1. Measure: (each pinion gear to its respective wheel • Main axle runout gear) (with a centering device and dial gauge “1”) Incorrect  Reassemble the transmission Out of specification  Replace the main axle. axle assemblies.

  • Page 233: Installing The Shift Forks And Shift Drum Assembly

    TRANSMISSION 3. Check: d. Chamfer side • Shift cam operation EAS26320 Rough movement  Reassemble the trans- INSTALLING THE SHIFT FORKS AND SHIFT mission. DRUM ASSEMBLY 1. Install: By turning the shift cam, make sure that the shift • Shift drum “1” fork, main axle, and drive axle move smoothly.
  • Page 234 TRANSMISSION 5-60...

  • Page 235: Fuel System

    FUEL SYSTEM FUEL TANK......................6-1 REMOVING THE FUEL TANK ..............6-4 REMOVING THE FUEL PUMP CASE ............6-5 REMOVING THE FUEL PUMP ..............6-6 CHECKING THE FUEL COCK..............6-6 CHECKING THE ROLLOVER VALVE ............6-7 CHECKING THE FUEL PUMP BODY............6-7 CHECKING THE FUEL PUMP OPERATION..........6-7 INSTALLING THE FUEL PUMP..............6-7 INSTALLING THE FUEL TANK..............6-7 INSTALLING THE FUEL PUMP CASE ............6-8 THROTTLE BODY....................6-9...
  • Page 236 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank breather hose and rollover valve 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Engine protector Refer to “ENGINE REMOVAL” on page 5-2. Clamp 1 Rollover valve clamp Clamp 2 Plastic locking tie...

  • Page 237: Fuel Tank

    FUEL TANK Removing the fuel tank 16 Nm (1.6 m kgf, 12 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 238 FUEL TANK Removing the fuel pump case 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...

  • Page 239: Removing The Fuel Tank

    FUEL TANK EAS26630 REMOVING THE FUEL TANK • Repeating main switch turning “ON” and turn- EWA2RD1010 ing “OFF” allows the fuel in the fuel pump case WARNING to be sent to the fuel tank. Gasoline is very flammable and dangerous. •...

  • Page 240: Removing The Fuel Pump Case

    FUEL TANK ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS2RD1034 REMOVING THE FUEL PUMP CASE EWA2RD1010 WARNING Gasoline is very flammable and dangerous. While handling gasoline, keep it away from an open flame as well as a spark or any other source of high heat. i. Remove the clamp “1” and disconnect the fuel sender coupler “2”.

  • Page 241: Removing The Fuel Pump

    FUEL TANK • Repeating main switch turning “ON” and turn- To remove the fuel hose from the fuel pump, ing “OFF” allows the fuel in the fuel pump case slide the fuel hose connector cover “1” on the to be sent to the fuel tank. end of the hose in the direction of the arrow •...

  • Page 242: Checking The Rollover Valve

    FUEL TANK stages in order shown in the illustration. EAS2RD1018 CHECKING THE ROLLOVER VALVE 1. Check: • Rollover valve Cracks/damage  Replace. • Check that air flows smoothly only in the direc- tion of the arrow shown in the illustration. •...

  • Page 243: Installing The Fuel Pump Case

    FUEL TANK end of the hose in the direction of the arrow shown. 3. Install: • Side cover (left) • Seat Refer to “GENERAL CHASSIS” on page 4-1. 2. Install: • Side cover (left) EAS2RD1035 Refer to “GENERAL CHASSIS” on page 4-1. INSTALLING THE FUEL PUMP CASE 1.

  • Page 244: Throttle Body

    THROTTLE BODY EAS26970 THROTTLE BODY Removing the throttle body 2.0 Nm (0.20 m kgf, 1.5 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
  • Page 245 THROTTLE BODY Removing the throttle body 2.0 Nm (0.20 m kgf, 1.5 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Cover...
  • Page 246 THROTTLE BODY Disassembling the throttle body 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel rail/pressure regulator assembly Fuel injector Intake air pressure sensor Hose Throttle position sensor 6-11...

  • Page 247: Checking The Injector

    THROTTLE BODY EAS26980 CHECKING THE INJECTOR 1. Check: • Injector Damage  Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TOR” on page 7-72. EAS27000 CHECKING THE PRESSURE REGULATOR 1. Check: • Pressure regulator Damage  Replace. EAS27010 CHECKING THE PRESSURE REGULATOR OPERATION...
  • Page 248 THROTTLE BODY special care. • Never subject the throttle position sensor to strong shocks. If the throttle position sensor is dropped, replace it. 1. Check: • Throttle position sensor Refer to “CHECKING THE THROTTLE PO- SITION SENSOR” on page 7-70. 2.
  • Page 249 THROTTLE BODY 6-14...

  • Page 250: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 6-15...
  • Page 251 AIR INDUCTION SYSTEM 1. Air filter case 2. Air induction system hose (air filter case–air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve–air induction system pipe) 5. Air induction system pipe 6-16...
  • Page 252 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Air induction system solenoid coupler Disconnect. Air induction system hose (air filter case–air Remove from the air filter case side cut-off valve) Air cut-off valve Air induction system hose (air cut-off valve–air...

  • Page 253: Checking The Air Induction System

    AIR INDUCTION SYSTEM 2. Check: EAS27060 CHECKING THE AIR INDUCTION SYSTEM • Air cut-off valve Air injection Cracks/damage  Replace. The air induction system burns unburned ex- 3. Check: haust gases by injecting fresh air (secondary air) • Air induction system solenoid into the exhaust port, reducing the emission of Refer to “CHECKING THE AIR INDUCTION hydrocarbons.
  • Page 254 AIR INDUCTION SYSTEM 6-19...

  • Page 255: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................7-1 CIRCUIT DIAGRAM ...................7-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION......7-3 TROUBLESHOOTING ................7-5 CHARGING SYSTEM..................7-7 CIRCUIT DIAGRAM ...................7-7 TROUBLESHOOTING ................7-9 LIGHTING SYSTEM ..................7-11 CIRCUIT DIAGRAM .................7-11 TROUBLESHOOTING ................7-13 SIGNALING SYSTEM ..................7-15 CIRCUIT DIAGRAM .................7-15 TROUBLESHOOTING ................7-17 FUEL INJECTION SYSTEM................7-21 CIRCUIT DIAGRAM .................7-21 ECU SELF-DIAGNOSTIC FUNCTION.............7-23 TROUBLESHOOTING METHOD.............7-25...
  • Page 256 CHECKING THE SPEED SENSOR ............7-70 CHECKING THE THROTTLE POSITION SENSOR ........7-70 CHECKING THE AIR INDUCTION SYSTEM SOLENOID .......7-71 CHECKING THE INTAKE AIR PRESSURE SENSOR ......7-71 CHECKING THE INTAKE AIR TEMPERATURE SENSOR .....7-72 CHECKING THE FUEL INJECTOR ............7-72...

  • Page 258: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM...
  • Page 259 IGNITION SYSTEM 1. Crankshaft position sensor 2. Neutral switch 5. Battery 6. Main fuse 7. Main switch 10.Ignition fuse 14.Right handlebar switch 16.Engine stop switch 19.Sidestand switch 20.Clutch switch 21.Diode 1 24.ECU (engine control unit) 25.Ignition coil 26.Spark plug 30.Lean angle sensor 35.Joint coupler 36.Frame ground...

  • Page 260: Engine Stopping Due To Sidestand Operation

    IGNITION SYSTEM EAS32020 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 ECU does not flow to the ignition coil or in- jector when the neutral switch circuit or sidestand switch circuit is open.
  • Page 261 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.Diode 1 11.Neutral switch 12.Negative battery lead 13.Frame ground...

  • Page 262: Troubleshooting

    IGNITION SYSTEM EAS27131 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Fuel tank 4. Crankcase cover (left) 5. Drive sprocket cover 1. Check the fuses. (Main and ignition) Replace the fuse(s).
  • Page 263 IGNITION SYSTEM 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. NG SWITCHES” on page 7-55. OK 10.Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. NG SWITCHES” on page 7-55. OK...

  • Page 264: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM...
  • Page 265 CHARGING SYSTEM 3. AC magneto 4. Rectifier/regulator 5. Battery 6. Main fuse 36.Frame ground...

  • Page 266: Troubleshooting

    CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Fuel tank 4. Crankcase cover (left) 1. Check the fuse. (Main) Replace the fuse(s). Refer to “CHECKING THE FUSES” NG...
  • Page 267 CHARGING SYSTEM 7-10...

  • Page 268: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-11...
  • Page 269 LIGHTING SYSTEM 5. Battery 6. Main fuse 7. Main switch 11.Signaling system fuse 12.Headlight fuse 24.ECU (engine control unit) 35.Joint coupler 36.Frame ground 39.Speedometer 42.Meter light 44.Tachometer 47.High beam indicator light 52.Headlight relay (on/off) 53.Left handlebar switch 54.Pass switch 55.Dimmer switch 58.Tail/brake light 63.Headlight 64.Auxiliary light...

  • Page 270: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, tail light, auxiliary light or meter light • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel side cover (left) 3. Fuel tank 4.
  • Page 271 LIGHTING SYSTEM 8. Check the entire lighting system wir- ing. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. NG page 7-11. OK Replace the ECU (engine control unit) or meter assembly. 7-14...

  • Page 272: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-15...
  • Page 273 SIGNALING SYSTEM 2. Neutral switch 5. Battery 6. Main fuse 7. Main switch 11.Signaling system fuse 13.Parking lighting fuse 14.Right handlebar switch 15.Hazard switch 24.ECU (engine control unit) 35.Joint coupler 36.Frame ground 37.Fuel sender 39.Speedometer 41.Speed sensor 43.Fuel level warning light 44.Tachometer 45.Neutral indicator light 46.Turn signal indicator light...

  • Page 274: Troubleshooting

    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. Seat 2. Side cover (left) 3.
  • Page 275 SIGNALING SYSTEM 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. NG page 7-15. OK This circuit is OK. The tail/brake light fails to come on. 1. Check the tail/brake light bulb and socket.
  • Page 276 SIGNALING SYSTEM 4. Check the turn signal/hazard relay. Refer to “CHECKING THE TURN Replace the turn signal/hazard relay. SIGNAL/HAZARD RELAY” on page NG 7-63. OK 5. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring.
  • Page 277 SIGNALING SYSTEM 7-20...

  • Page 278: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 7-21...
  • Page 279 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 2. Neutral switch 5. Battery 6. Main fuse 7. Main switch 8. Backup fuse 9. Fuel injection system fuse 10.Ignition fuse 12.Headlight fuse 14.Right handlebar switch 16.Engine stop switch 17.Fuel pump relay 18.Diode 2 19.Sidestand switch 21.Diode 1 23.O...

  • Page 280: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS30570 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 en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 281 FUEL INJECTION SYSTEM Engine trouble warning light indication and fuel injection system operation Warning light Fuel injection ECU operation Vehicle operation indication operation Warning provided Flashing* when unable to start Operation stopped Cannot be operated engine Operated with substi- tute characteristics in Can or cannot be oper- Remains on Malfunction detected...

  • Page 282: Troubleshooting Method

    FUEL INJECTION SYSTEM The engine operation is not normal, but the EAS30600 TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the engine trouble warning light comes on. 1. Check the operation of the following sensors 1.
  • Page 283 FUEL INJECTION SYSTEM 5. Turn the main switch to “OFF” to cancel the normal mode. 6. Disconnect the FI diagnostic tool and install the self-diagnosis signal coupler cap. Setting the diagnostic mode 1. Turn the main switch to “OFF” and engine stop switch to “...
  • Page 284 FUEL INJECTION SYSTEM 5. Press the “MODE” button. corresponding fault code number, the informa- tion is shown in “DIAGNOSTIC CODE TA- The diagnostic code number “D01” appears on BLE”. (Refer to “DIAGNOSTIC CODE TABLE” on page 7-42.) the LCD of the FI diagnostic tool. 6.

  • Page 285: Troubleshooting Details

    FUEL INJECTION SYSTEM EAS30651 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the FI diagnostic tool. Check and service 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 have been completed, reset the FI diagnostic tool display according to the reinstatement method.
  • Page 286 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. FI diagnostic tool display Displays the intake air pressure. Set the engine stop switch to “ ”, and then operate the throttle Procedure while cranking the engine. (If the display values change, the per- formance is OK.) Probable cause of malfunction Check or maintenance job...
  • Page 287 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction Item (clogged or detached hose). Reinstatement method Start the engine and let it run at idle. Fault code No. Item Throttle position sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle...
  • Page 288 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: stuck throttle position sensor Item detected. Throttle angle • 14–20 (fully closed position) FI diagnostic tool display • 79–85 (fully open position) • Check with throttle fully closed. Procedure • Check with throttle fully open. Probable cause of malfunction Check or maintenance job Installed condition of throttle position...
  • Page 289 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. FI diagnostic tool display Displays the intake air temperature. Compare the actually measured intake air temperature with the FI Procedure diagnostic tool display value.
  • Page 290 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sen- Item sor. • Check the coupler for any pins that may be Connections • O sensor coupler pulled out. • Check the locking condition of the coupler. •...
  • Page 291 FUEL INJECTION SYSTEM Fault code No. Item Engine temperature sensor: open or short circuit detected. Open or short circuit in wire harness • Repair or replace if there is an open or short and/or sub-wire harness. circuit. • Between engine temperature sensor coupler and ECU coupler.
  • Page 292 FUEL INJECTION SYSTEM Fault code No. Ignition coil: open or short circuit detected in the primary Item lead of the ignition coil. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. The ignition coil is actuated five times at one-second intervals, and Actuation the “WARNING”...
  • Page 293 FUEL INJECTION SYSTEM Fault code No. Item ISC valve: engine speed is high when the engine is idling. Throttle valve does not fully close. • Check the throttle body. Refer to “THROTTLE BODY” on page 6-9. • Check the throttle cables. Refer to “CHECKING THE THROTTLE GRIP”...
  • Page 294 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Open or short circuit in wire harness. • Repair or replace if there is an open or short circuit. • Between lean angle sensor coupler and ECU coupler.
  • Page 295 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: the ECU is unable to monitor the battery Item voltage (an open or short circuit in the wire harness to the ECU). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 296 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while read- Item ing or writing on EEPROM (CO adjustment value). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. EEPROM fault code display •...
  • Page 297 FUEL INJECTION SYSTEM Fault code No. Item Power supply to the fuel injection system is not normal. Open or short circuit in wire harness. • Repair or replace if there is an open or short circuit. • Between battery and main fuse terminal. R–R (red–red) •...
  • Page 298 FUEL INJECTION SYSTEM Fault code No. Engine idling stop: engine has been left idling. (The ECU Item automatically stops the engine after 20 minutes if it is left idling.) — — Reinstatement method — 7-41...

  • Page 299: Diagnostic Code Table

    FUEL INJECTION SYSTEM EAS30700 DIAGNOSTIC CODE TABLE Diag- nostic FI diagnostic tool dis- Item Procedure code play/Actuation Throttle angle • Fully closed position 14–20 Check with throttle fully closed. • Fully open position 79–85 Check with throttle fully open. Intake air pressure Displays the intake air pres- Set the engine stop switch sure.
  • Page 300 FUEL INJECTION SYSTEM Diag- nostic FI diagnostic tool dis- Item Procedure code play/Actuation Ignition coil When the engine stop switch Check that a spark is gen- is set from “ ” to “ ”, the erated five times. ignition coil is actuated five •...
  • Page 301 FUEL INJECTION SYSTEM Diag- nostic FI diagnostic tool dis- Item Procedure code play/Actuation ISC valve When the engine stop switch Check that the ISC unit is set from “ ” to “ ”, the vibrates when the ISC ISC valve is fully closed and valve operates.
  • Page 302 FUEL INJECTION SYSTEM Diag- nostic FI diagnostic tool dis- Item Procedure code play/Actuation Malfunction code reinstate- ment (for fault code No. 24 only) • No malfunction code — • Malfunction code exists 24: Fault code number To reinstate, set the engine stop switch to “...
  • Page 303 FUEL INJECTION SYSTEM 7-46...

  • Page 304: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 7-47...
  • Page 305 FUEL PUMP SYSTEM 5. Battery 6. Main fuse 7. Main switch 9. Fuel injection system fuse 10.Ignition fuse 14.Right handlebar switch 16.Engine stop switch 17.Fuel pump relay 22.Fuel pump 24.ECU (engine control unit) 35.Joint coupler 36.Frame ground 7-48...

  • Page 306: Troubleshooting

    FUEL PUMP SYSTEM EAS27600 TROUBLESHOOTING When the engine speed changes, the EXUP servo motor does not operate. • Before troubleshooting, remove the following part(s): 1. Seat 2. Side cover (left) 3. Fuel tank 4. Fuel pump case 1. Check the fuses. (Main, ignition, fuel injection sys- tem) Replace the fuse(s).
  • Page 307 FUEL PUMP SYSTEM 7-50...

  • Page 308: Electrical Components

    ELECTRICAL COMPONENTS EAS27973 ELECTRICAL COMPONENTS 7-51...
  • Page 309 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Ignition coil 5. Fuel sender 6. Battery 7. Main fuse 8. Fuse box 9. Diode 1 10.Diode 2 11.Neutral switch 12.Rectifier/regulator 13.Sidestand switch 14.Rear brake light switch 15.Horn 7-52...
  • Page 310 ELECTRICAL COMPONENTS 7-53...
  • Page 311 ELECTRICAL COMPONENTS 1. Engine temperature sensor 2. Intake air pressure sensor 3. ISC (idle speed control) valve 4. Fuel injector 5. Throttle position sensor 6. ECU (engine control unit) 7. Headlight relay (on/off) 8. Fuel pump relay 9. Turn signal/hazard relay 10.Lean angle sensor 11.Fuel pump 12.Intake air temperature sensor...

  • Page 312: Checking The Switches

    ELECTRICAL COMPONENTS EAS27981 CHECKING THE SWITCHES Br/R Br/L R/Y Y Ch Br/W Dg Ch Br/W Dg R/B R/W 7-55...
  • Page 313 ELECTRICAL COMPONENTS 1. Clutch switch 2. Horn switch 3. Pass switch 4. Dimmer switch 5. Turn signal switch 6. Sidestand switch 7. Neutral switch 8. Main switch 9. Front brake light switch 10.Hazard switch 11.Engine stop switch 12.Rear brake light switch 7-56...
  • Page 314 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 NOTICE 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 315: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS keep flammable products and your hands EAS27990 CHECKING THE BULBS AND BULB away from the bulb until it has cooled down. SOCKETS ECA14380 Check each bulb and bulb socket for damage or NOTICE wear, proper connections, and also for continuity •...

  • Page 316: Checking The Fuses

    ELECTRICAL COMPONENTS 1. Check: 3. Replace: • Bulb socket (for continuity) • Blown fuse (with the pocket tester) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ No continuity  Replace. a. Turn the main switch to “OFF”. b. Install a new fuse of the correct amperage Pocket tester rating.

  • Page 317: Checking And Charging The Battery

    ELECTRICAL COMPONENTS maintained and battery performance will deteriorate. • Charging time, charging amperage and charging voltage for a VRLA (Valve Regu- lated Lead Acid) battery are different from those of conventional batteries. The VRLA (Valve Regulated Lead Acid) battery should be charged according to the appropriate charging method.
  • Page 318 ELECTRICAL COMPONENTS 4. Check: • Battery charge ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a pocket tester to the battery termi- nals. • Positive tester probe  Positive battery terminal • Negative tester probe  Negative battery terminal A. Open-circuit voltage (V) • The charge state of a VRLA (Valve Regulated B.
  • Page 319 ELECTRICAL COMPONENTS batteries can explode! standard charging level. • As shown in the following illustration, the e. Set the time according to the charging time open-circuit voltage of a VRLA (Valve Reg- suitable for the open-circuit voltage. ulated Lead Acid) battery stabilizes about f.

  • Page 320: Checking The Relays

    ELECTRICAL COMPONENTS Fuel pump relay 7. Connect: • Battery connector “1” (to the battery terminal) • Clamp “2” • Battery band “3” ECA2RD1020 NOTICE Fasten the battery lead with the clamp. 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4.

  • Page 321: Checking The Diode

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the turn signal/hazard relay coupler as shown. Pocket tester 90890-03112 Br/W Analog pocket tester YU-03112-C Br/R • Positive tester probe brown/red “1” b. Turn the main switch to “ON”. •...

  • Page 322: Checking The Spark Plug Cap

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Continuity a. Disconnect the diode from the wire harness. Positive tester probe  sky blue b. Connect the pocket tester (  1) to the diode “1” terminals as shown. Negative tester probe  c. Check the diode for continuity. black/red “2”...

  • Page 323: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS b. Connect the pocket tester (  1) to the igni- tion coil as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe orange “1” • Negative tester probe red/white “2” c. Measure the secondary coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 324: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS Lean angle sensor output voltage ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Less than 45° 3.6–4.5 V EAS28120 CHECKING THE CRANKSHAFT POSITION More than 45° SENSOR 0.7–1.4 V 1. Disconnect: • Crankshaft position sensor coupler ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ (from the wire harness) a. Connect the test harness “1” to the lean angle sensor “2”...

  • Page 325: Checking The Stator Coil

    ELECTRICAL COMPONENTS EAS28170 CHECKING THE RECTIFIER/REGULATOR ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Before checking the rectifier/regulator, check the EAS28150 CHECKING THE STATOR COIL stator coil. 1. Remove: 1. Check: • Stator coil coupler • Rectifier/regulator output voltage (from the wire harness) Out of specification  Replace the rectifi- 2.

  • Page 326: Checking The Engine Temperature Sensor

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  100) to the en- a. Disconnect the horn leads from the horn ter- minals. gine temperature sensor terminal as shown. b. Connect the pocket tester (  1) to the horn Pocket tester terminals.

  • Page 327: Checking The Speed Sensor

    ELECTRICAL COMPONENTS 2. Remove: harness. • Fuel sender coupler b. Connect the pocket tester (DC 20 V) to the (from the wire harness) speed sensor coupler as shown. 3. Check: Pocket tester • Fuel sender resistance 90890-03112 Analog pocket tester Sender unit resistance (thermis- YU-03112-C tor)

  • Page 328: Checking The Air Induction System Solenoid

    ELECTRICAL COMPONENTS Pocket tester Pocket tester 90890-03112 90890-03112 Analog pocket tester Analog pocket tester YU-03112-C YU-03112-C • Positive tester probe  • Positive tester probe  blue “1” red/white “1” • Negative tester probe  • Negative tester probe  black/blue “2”...

  • Page 329: Checking The Intake Air Temperature Sensor

    ELECTRICAL COMPONENTS “1” in a container filled with water “2”. • Positive tester probe pink/white (wire harness color) Make sure that the intake air temperature sensor • Negative tester probe terminals do not get wet. black/blue (wire harness color) c. Place a thermometer “3” in the water. c.
  • Page 330 ELECTRICAL COMPONENTS • Positive tester probe  Injector terminal “1” • Negative tester probe  Injector terminal “2” c. Measure the fuel injector resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7-73...

  • Page 331: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................8-1 GENERAL INFORMATION ................8-1 STARTING FAILURES................8-1 INCORRECT ENGINE IDLING SPEED .............8-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......8-2 FAULTY GEAR SHIFTING.................8-2 SHIFT PEDAL DOES NOT MOVE .............8-2 JUMPS OUT OF GEAR................8-2 FAULTY CLUTCH ..................8-2 OVERHEATING ..................8-2 POOR BRAKING PERFORMANCE............8-3 FAULTY FRONT FORK LEGS..............8-3 UNSTABLE HANDLING ................8-3 FAULTY LIGHTING OR SIGNALING SYSTEM .........8-3...

  • Page 332: Troubleshooting

    TROUBLESHOOTING Electrical system EAS28451 TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.

  • Page 333: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING • Worn or damaged electrode Transmission • Worn or damaged insulator • Worn gear dog • Faulty spark plug cap EAS28560 3. Ignition coil(s) FAULTY CLUTCH • Broken or shorted primary or secondary coils Clutch slips • Faulty spark plug lead 1.

  • Page 334: Poor Braking Performance

    TROUBLESHOOTING (improperly tightened ring nut) EAS28640 POOR BRAKING PERFORMANCE • Bent steering stem 1. Disc brake • Damaged ball bearing or bearing race • Worn brake pad 3. Front fork leg(s) • Worn brake disc • Uneven oil levels (both front fork legs) •...
  • Page 335 TROUBLESHOOTING • Poor contacts (main or rear brake light switch) • Burnt-out tail/brake light bulb Burnt-out tail/brake light bulb • Wrong tail/brake light bulb • Faulty battery • Faulty rectifier/regulator • Improperly grounded circuit • Faulty main switch • Incorrectly adjusted rear brake light switch •...
  • Page 336 TROUBLESHOOTING...
  • Page 337 58 Tail/brake light EAS28740 EAS28750 WIRING DIAGRAM COLOR CODE 59 Rear right turn signal light 60 Rear left turn signal light Black SR400/SR400E 2014 61 Front right turn signal light Brown 1 Crankshaft position sensor 62 Front left turn signal light Chocolate 2 Neutral switch 63 Headlight...
  • Page 341 SR400/SR400E 2014 SR400/SR400E 2014 SR400/SR400E 2014 SR400/SR400E 2014 SR400/SR400E 2014 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO Gy/G Br/R Br/L Br/W B/L Gy Gy/G Br/W Br/W Br/R LOCK Br/L L/B O/B R/L (Gy) L/B Br/L B B/R Br/Y Br/Y R/L B...
  • Page 342 SR400/SR400E 2014 SR400/SR400E 2014 SR400/SR400E 2014 SR400/SR400E 2014 SR400/SR400E 2014 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO LOCK (Gy) 7.5A 7.5A (Gy) 1.7W 7.5A (Br) 1.7W (Br) 1.7W 1.7W 1.7W 1.7W 1.7W...

This manual is also suitable for:

Sr400e 2014

Table of Contents