Yamaha Star XVS950A 2009 Service Manual
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Yamaha Star XVS950A 2009 Service Manual

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2009
SERVICE MANUAL
XVS950A(Y)
26P-28197-E0

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Summary of Contents for Yamaha Star XVS950A 2009

  • Page 1 2009 SERVICE MANUAL XVS950A(Y) 26P-28197-E0...
  • Page 2 EAS20040 XVS950A(Y) SERVICE MANUAL ©2008 by Yamaha Motor Co., Ltd. First edition, November 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3 EAS20071 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 4 EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine Gear oil mounted Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE 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 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ...............1-6 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-6 REPLACEMENT PARTS.................1-6 GASKETS, OIL SEALS AND O-RINGS..........1-6 LOCK WASHERS/PLATES AND COTTER PINS ........1-6 BEARINGS AND OIL SEALS ..............1-7 CIRCLIPS ....................1-7 CHECKING THE CONNECTIONS ...............1-8...

  • 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. This information will be needed to order spare parts.

  • Page 11: Features

    FEATURES EAS20170 FEATURES EAS5S71022 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 12: Fi System

    FEATURES EAS5S71020 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 392 kPa (3.92 kg/cm², 56.9 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus- ing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 13: Instrument Functions

    FEATURES EAS5S71021 Speedometer INSTRUMENT FUNCTIONS Multi-function meter unit EWA5S71001 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function meter unit. 1. Speedometer The speedometer shows the riding speed. When the key is turned to “ON”, the speedom- eter needle will sweep once across the speed range and then return to zero in order to test the electrical circuit.
  • Page 14 FEATURES Odometer, tripmeter, and fuel reserve trip- odometer/tripmeter/clock display will indicate a meter modes two-digit error code (e.g., 12, 13, 14). This model is also equipped with a self-diagno- sis device for the immobilizer system. If any of the immobilizer system circuits are defective, the immobilizer system indicator light will flash, and then the right display will indicate a two-digit error code.

  • Page 15: 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...

  • Page 16: Bearings And Oil Seals

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

  • Page 17: Checking The Connections

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

  • Page 18: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 19 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Extension 5-23 90890-04136 Extension 5-23 90890-04082 Oil filter wrench 3-25 90890-01426 YU-38411 Belt tension gauge 3-19 90890-03170 Rear drive belt tension gauge YM-03170 Steering nut wrench 3-21, 4-56 90890-01403 Exhaust flange nut wrench YU-A9472 Damper rod holder 4-49, 4-51...
  • Page 20 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rotor holding tool 5-14, 5-18, 5-19 90890-01235 Universal magneto & rotor holder YU-01235 Slide hammer bolt 5-15 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 5-15 90890-01084 YU-01083-3 YU-01083-3 Valve spring compressor 5-26, 5-31 90890-04019 YM-04019...
  • Page 21 Piston pin puller set 5-34 90890-01304 Piston pin puller YU-01304 YU-01304 Sheave holder 5-42, 5-43, 5- 90890-01701 49, 5-51 Primary clutch holder YS-01880-A Flywheel puller set 5-42 90890-01468 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-43, 5-64 90890-85505 (Three Bond No.1215®) 1-12...
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-49, 5-52 90890-04086 YM-91042 Pressure gauge 6-9, 6-11 90890-03153 YU-03153 Fuel pressure adapter 6-11 90890-03176 YM-03176 Digital circuit tester 5-58, 6-11 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Ignition checker 7-98 90890-06754 Opama pet-4000 spark checker...

  • Page 23: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-8 ELECTRICAL SPECIFICATIONS...............2-11 TIGHTENING TORQUES................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-14 ENGINE TIGHTENING TORQUES ............2-15 CHASSIS TIGHTENING TORQUES ............2-18 LUBRICATION POINTS AND LUBRICANT TYPES ........2-22 ENGINE ....................2-22 CHASSIS ....................2-23 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-25 ENGINE OIL LUBRICATION CHART ...........2-25 LUBRICATION DIAGRAMS ..............2-27 CABLE ROUTING ..................2-35...

  • Page 24: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model XVS950A 26P1 (Europe) XVS950AY 27B1, 27B2 (AUS) Dimensions Overall length 2435 mm (95.9 in) Overall width 1000 mm (39.4 in) Overall height 1080 mm (42.5 in) Seat height 675 mm (26.6 in) Wheelbase 1685 mm (66.3 in) Ground clearance 145 mm (5.71 in)

  • Page 25: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Air cooled 4-stroke, SOHC Displacement 942.0 cm Cylinder arrangement V-type 2-cylinder Bore × stroke 85.0 × 83.0 mm (3.35 × 3.27 in) Compression ratio 9.00 : 1 Standard compression pressure (at sea level) 1400 kPa/400 r/min (14.0 kgf/cm /400 r/min, 199.1 psi/400 r/min)
  • Page 26 ENGINE SPECIFICATIONS Cylinder head Volume 40.50–42.70 cm (2.47–2.61 cu.in) Warpage limit 0.05 mm (0.0020 in) Camshaft Drive system Chain drive (left and right) Camshaft journal diameter 20.959–20.980 mm (0.8252–0.8260 in) Camshaft lobe dimensions Intake A 42.470–42.570 mm (1.6720–1.6760 in) Limit 42.370 mm (1.6681 in) Intake B 37.041–37.141 mm (1.4583–1.4622 in)
  • Page 27 ENGINE SPECIFICATIONS Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.06 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.06 in) Valve margin thickness D (intake) 1.00 mm (0.0394 in) Valve margin thickness D (exhaust) 1.00 mm (0.0394 in) Valve stem diameter (intake) 5.975–5.990 mm (0.2352–0.2358 in)
  • Page 28 ENGINE SPECIFICATIONS Spring tilt (intake) 2.5°/1.9 mm (0.075 in) Spring tilt (exhaust) 2.5°/1.9 mm (0.075 in) Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Cylinder Bore 85.000–85.010 mm (3.3465–3.3468 in) Wear limit 85.100 mm (3.3504 in) Out of round limit 0.050 mm (0.0020 in) Piston Piston-to-cylinder clearance...
  • Page 29 ENGINE SPECIFICATIONS Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in) Limit 0.130 mm (0.0051 in) Oil ring Dimensions (B × T) 2.00 × 2.50 mm (0.08 × 0.10 in) End gap (installed) 0.20–0.70 mm (0.0079–0.0276 in) Connecting rod Oil clearance (using plastigauge®) 0.022–0.046 mm (0.0009–0.0018 in) Limit 0.09 mm (0.0035 in)
  • Page 30 ENGINE SPECIFICATIONS Transmission Transmission type Constant mesh 5-speed Primary reduction system Spur gear Primary reduction ratio 72/43 (1.674) Secondary reduction system Belt drive Secondary reduction ratio 70/30 (2.333) Operation Left foot operation Gear ratio 46/15 (3.067) 33/16 (2.063) 30/19 (1.579) 34/27 (1.259) 25/24 (1.042) Main axle runout limit...

  • Page 31: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle 32.10° Trail 145.0 mm (5.71 in) Front wheel Wheel type Cast wheel 18M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 135.0 mm (5.31 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 32 Spring stroke K1 0.0–135.0 mm (0.00–5.31 in) Inner tube outer diameter 41.0 mm (1.61 in) Optional spring available Recommended oil Yamaha fork oil 10WT Quantity 488.0 cm (16.50 US oz, 17.21 Imp oz) Level 107.0 mm (4.21 in) Rear suspension...
  • Page 33 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) 1.0 mm (0.04 in) Drive belt Model/manufacturer MD01/MITSUBOSHI Drive belt slack (on the sidestand) 3.0–5.0 mm (0.12–0.20 in) Drive belt slack (on a suitable stand) 3.0–5.0 mm (0.12–0.20 in)

  • Page 34: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system TCI (digital) Advancer type Throttle position sensor and electrical Ignition timing (B.T.D.C.) 5.0°/1000 r/min Engine control unit Model/manufacturer FUA0029/MITSUBISHI Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω...
  • Page 35 ELECTRICAL SPECIFICATIONS Indicator light Neutral indicator light Turn signal indicator light Oil level warning light High beam indicator light Fuel level warning light Engine trouble warning light Immobilizer indicator light Electric starting system System type Constant mesh Starter motor Power output 0.80 kW 0.0050–0.0150 Ω...
  • Page 36 ELECTRICAL SPECIFICATIONS Speed sensor Output voltage reading cycle 0.6 V to 4.8 V to 0.6 V to 4.8 V Fuses Main fuse 40.0 A Headlight fuse 20.0 A Signaling system fuse 10.0 A Ignition fuse 15.0 A Fuel injection system fuse 10.0 A Backup fuse 10.0 A...

  • Page 37: Tightening Torques

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

  • Page 38: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kgf, 11 ft·lbf) pipe) Oil check bolt 15 Nm (1.5 m·kgf, 11 ft·lbf) Cylinder head nut 65 Nm (6.5 m·kgf, 47 ft·lbf) See TIP Cylinder head bolt 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
  • Page 39 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Muffler and muffler bracket bolt 35 Nm (3.5 m·kgf, 25 ft·lbf) Rear exhaust pipe joint nut 15 Nm (1.5 m·kgf, 11 ft·lbf) Exhaust pipe bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Rear exhaust pipe joint cover bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Exhaust pipe stay and exhaust...
  • Page 40 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Speed sensor bracket bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Speed sensor lead bracket screw 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Cylinder head nut 1. Apply engine oil on the screw part of the bolt and both sides of the washer well. 2.

  • Page 41: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting nut (front upper 88 Nm (8.8 m·kgf, 64 ft·lbf) side) Engine mounting nut (front lower 88 Nm (8.8 m·kgf, 64 ft·lbf) side) Engine mounting nut (rear upper 88 Nm (8.8 m·kgf, 64 ft·lbf) side) Engine mounting nut (rear lower...
  • Page 42 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Seat lock bracket bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Seat bracket bolt 19 Nm (1.9 m·kgf, 13 ft·lbf) Passenger seat bracket bolt 16 Nm (1.6 m·kgf, 11 ft·lbf) Passenger seat guide bolt 16 Nm (1.6 m·kgf, 11 ft·lbf) Passenger seat bolt 16 Nm (1.6 m·kgf, 11 ft·lbf)
  • Page 43 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Headlight body screw 4 Nm (0.4 m·kgf, 2.9 ft·lbf) Headlight stay bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Front turn signal light nut 11 Nm (1.1 m·kgf, 8.0 ft·lbf) Air temperature sensor screw 4 Nm (0.4 m·kgf, 2.9 ft·lbf) Throttle cable locknut 4 Nm (0.4 m·kgf, 2.9 ft·lbf)
  • Page 44 TIGHTENING TORQUES Passenger seat bolt Tighten the left side first, then the right side. Front wheel axle pinch bolt Tighten the front wheel axle pinch bolts to specification twice. Tighten the inside and outside bolts alternately, starting with the inside bolt. Lower ring nut 1.

  • Page 45: Lubrication Points And Lubricant Types

    Clutch boss nut and washer Transmission gears (wheel and pinion) and collar Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal (lip) Yamaha bond Crankcase (mating surface) No.1215 (Three Bond No.1215®) Yamaha bond Crankshaft position sensor lead grommet No.1215 (Three Bond...

  • Page 46: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing race cover (lip) Lower bearing steering seal (lip) Front wheel oil seals (lip) Rear wheel oil seal (lip) Rear wheel drive hub (mating surface) Brake pedal shaft (pivoting point) Shift pedal (pivoting point) Sidestand (pivoting point) and metal-to-metal moving parts Throttle grip tube guide (inner surface) and throttle cables...
  • Page 47 LUBRICATION POINTS AND LUBRICANT TYPES 2-24...

  • Page 48: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-25...
  • Page 49 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump assembly 3. Oil delivery pipe 2 4. Relief valve assembly 5. Drive axle 6. Oil filter cartridge 7. Main axle 8. Main gallery 9. Crankshaft 10.Clutch cover 11.Valve stem end (intake side) 12.Rear cylinder camshaft 13.Front cylinder camshaft 2-26...

  • Page 50: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27...
  • Page 51 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil delivery pipe 2 3. Relief valve assembly 2-28...
  • Page 52 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 53 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Crankshaft 2-30...
  • Page 54 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 55 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil drain bolt 2. Crankshaft 2-32...
  • Page 56 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Drive axle 2. Oil delivery pipe 1 3. Main axle 4. Oil delivery pipe 2 5. Oil pump assembly 6. Oil strainer 2-34...

  • Page 58: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-35...
  • Page 59 CABLE ROUTING 1. Clamp 2. Front brake master cylinder 3. Clutch cable guide 4. Clutch cable 5. Throttle cable (pull side) 6. Throttle cable (return side) 7. Rear brake light switch coupler 8. Starter motor lead 9. Rectifier/regulator lead 10.Rectifier/regulator 11.Corrugate tube 12.Rear brake light switch lead 13.Front brake hose...
  • Page 60 CABLE ROUTING 2-37...
  • Page 61 CABLE ROUTING 1. Main switch couplers 2. Left handlebar switch couplers 3. Intake air temperature sensor lead 4. Clamp 5. Right handlebar switch couplers 6. Front turn signal light coupler 7. Wire harness A. Route the main switch and left handlebar switch lead.
  • Page 62 CABLE ROUTING 2-39...
  • Page 63 CABLE ROUTING 1. Handlebar switch lead 2. Front brake hose 3. Throttle cable 4. TPS (throttle position sensor) lead 5. Plastic band 6. Wire harness 7. Clutch cable A. Route the handlebar switch lead outside of the throttle cable. B. To the throttle bodies C.
  • Page 64 CABLE ROUTING 2-41...
  • Page 65 CABLE ROUTING 1. Relay unit 2. Relay unit lead 3. Lean angle sensor lead 4. O sensor lead coupler 5. O sensor lead 6. Starter motor lead 7. Bracket 8. Taillight lead 9. Rear brake hose A. Route the seat lock cable under the joint coupler lead.
  • Page 66 CABLE ROUTING 2-43...
  • Page 67 CABLE ROUTING 1. Brake fluid reservoir 2. Clip 3. Brake fluid reservoir hose 4. Rear brake master cylinder 5. Rear brake hose 6. Clamp 7. Rear brake hose holder 8. Rear brake light switch 9. Rear brake light switch lead 10.Brake fluid reservoir cover A.
  • Page 68 CABLE ROUTING 2-45...
  • Page 69 CABLE ROUTING U. Press the brake hose against the stopper 1. Fuel delivery hose and tighten. 2. Sidestand switch lead V. Insert the front brake hose holder tab into 3. Clamp the stopper hole. 4. Front brake hose 5. Clutch cable 6.
  • Page 70 CABLE ROUTING 2-47...
  • Page 71 CABLE ROUTING Q. Clamp the wire harness. Face the end 1. Plastic band inside. 2. Clamp R. Clamp the starter motor lead and O sen- 3. Speed sensor lead bracket sor lead. Face the opening outside. 4. Neutral switch S. Clamp the starter motor lead. Face the 5.
  • Page 72 CABLE ROUTING 2-49...
  • Page 73 CABLE ROUTING 1. Intake air pressure sensor 2. Clamp 3. Crankcase breather hose 4. Clutch cable 5. Meter lead 6. Plastic band 7. Spark plug lead 8. Starter motor lead (black) 9. Battery lead (red) 10.Relay unit 11.Wire lead 12.Lean angle sensor 13.Lean angle sensor lead 14.Relay unit lead A.
  • Page 74 CABLE ROUTING 2-51...
  • Page 75 CABLE ROUTING 1. Meter lead 2. Clip 3. Fuel tank drain hose 4. Frame 5. Clamp 6. Fuel tank breather hose 7. Rollover valve 8. Wire harness 9. Crankcase breather hose 10.Fuel tank A. Face the fuel sender lead to the front. B.
  • Page 76 CABLE ROUTING 2-53...
  • Page 77 CABLE ROUTING 1. Tail/brake light wire harness 2. Tail/brake light wire harness (from taillight) 3. Tail/brake light assembly 4. Rear turn signal light lead 5. Rear turn signal light bracket cover 6. Grommet 7. License plate light coupler 8. Rear right turn signal light coupler 9.
  • Page 78 CABLE ROUTING 2-55...
  • Page 79 CABLE ROUTING 1. ISC (idle speed control) lead 2. Clamp 3. Engine temperature sensor lead 4. ISC (idle speed control) coupler 5. Fuel sender coupler (natural) 6. Fuel pump coupler (black) 7. Side cover (cylinder head) 8. Rear cylinder ignition coil 9.
  • Page 80 CABLE ROUTING 2-57...
  • Page 81 CABLE ROUTING 1. Clip 2. Throttle body 3. Intake air pressure sensor 4. Intake air pressure hose A. Face the knob to the right and install. B. Route the intake air pressure hose inside of the frame bracket. C. Face the white paint mark to the right and install.
  • Page 82 CABLE ROUTING 2-59...
  • Page 83 CABLE ROUTING 1. Crankcase breather hose 2. Clamp 3. Crankcase breather pipe 4. Right crankcase 5. Air filter case 6. Clip A. The opening can face either right or left. B. Install by aligning with the white paint. C. Adjust the knob diagonally to the back. D.
  • Page 84 CABLE ROUTING 2-61...

  • 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 .....3-2 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS............3-4 CHECKING THE IGNITION TIMING ............3-5 ADJUSTING THE VALVE CLEARANCE ..........3-5 CHECKING THE CRANKCASE BREATHER HOSE ......3-8 SYNCHRONIZING THE THROTTLE BODIES ........3-8 CHECKING THE EXHAUST SYSTEM ..........3-10...
  • Page 86 CHECKING THE THROTTLE CABLE OPERATION ......3-28 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-28 LUBRICATING THE THROTTLE GRIP HOUSING AND CABLE ..3-29 CHECKING AND CHARGING THE BATTERY........3-29 CHECKING THE FUSES..............3-29 CHECKING THE SWITCHES...............3-29 ADJUSTING THE HEADLIGHT BEAM ..........3-29 REPLACING THE HEADLIGHT BULB ..........3-29...

  • Page 88: Periodic Maintenance

    • Check for leakage. • Tighten if necessary. √ √ √ √ √ √ 6 * Exhaust system • Replace gasket(s) if neces- sary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

  • Page 89: General Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE EAS5S71019 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS 19000 km 25000 km 31000 km 13000 km 1000 km 7000 km (12000 (16000 (20000 (8000 mi) ITEM ROUTINE (600 mi) (4000 mi) 1 month 6 months months months months months 1 * Air filter element...
  • Page 90 • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. From 37000 km (24000 mi) or 36 months, repeat the maintenance intervals starting from 13000 km (8000 mi) or 12 months.

  • Page 91: Checking The Fuel Line

    PERIODIC MAINTENANCE EAS21030 ECA13320 CHECKING THE FUEL LINE The following procedure applies to all of the Before removing the spark plugs, blow fuel and breather hoses. away any dirt accumulated in the spark 1. Remove: plug wells with compressed air to prevent it •...

  • Page 92: Checking The Ignition Timing

    PERIODIC MAINTENANCE 10. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Rear cylinder right plastic cover a. Start the engine, warm it up for several Refer to “ENGINE REMOVAL” on page 5- minutes, and then let it run at the specified engine idling speed. Engine idling speed EAS20700 CHECKING THE IGNITION TIMING 950–1050 r/min...
  • Page 93 PERIODIC MAINTENANCE • Fuel tank Valve clearance (cold) Refer to “FUEL TANK” on page 6-1. Intake • Front cylinder upper plastic cover 0.08–0.12 mm (0.0032–0.0047 • Front cylinder lower plastic cover • Rear cylinder left plastic cover Exhaust • Rear cylinder right plastic cover 0.22–0.26 mm (0.0087–0.0102 •...
  • Page 94 PERIODIC MAINTENANCE Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Rear cylinder a. Turn the crankshaft counterclockwise from the front cylinder piston TDC by 300 b. Insert a thickness gauge “2” between the degrees. end of the adjusting screw “3” and the valve b.

  • Page 95: Checking The Crankcase Breather Hose

    PERIODIC MAINTENANCE 9. Install: • Rear cylinder tappet covers • Front cylinder tappet covers Rear cylinder tappet cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Front cylinder tappet cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 10. Install: • Crankshaft end accessing screw (along with the O-ring 3.
  • Page 96 PERIODIC MAINTENANCE 3. Remove: • Rider seat • Side cover (cylinder head) Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. 4. Disconnect: • Intake air pressure sensor hose “1” • Cap “2” 5.

  • Page 97: Checking The Exhaust System

    PERIODIC MAINTENANCE 9. Connect: • Intake air pressure sensor hose • Cap 10. Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-28. Throttle cable free play 4.0–6.0 mm (0.16–0.24 in) 11. Install: EAS26P1001 •...

  • Page 98: Replacing The Air Filter Element

    PERIODIC MAINTENANCE • To decrease the CO adjustment volume, press the “RESET” switch. • To increase the CO adjustment volume, press the “SELECT” switch. 8. Release the switch to execute the selec- tion. 9. Simultaneously press the “SELECT” and “RESET” switches to return to the cylinder selection (step 5).

  • Page 99: Checking The Clutch Operation

    PERIODIC MAINTENANCE ECA5S71009 Never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect throttle body synchronization, leading to poor engine performance and possible overheating.

  • Page 100: Checking The Brake Operation

    PERIODIC MAINTENANCE Direction “a” Clutch cable free play is increased. Direction “b” Clutch cable free play is decreased. d. Tighten the locknut. e. Slide the rubber covers to its original posi- tion. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS5S71033 CHECKING THE BRAKE OPERATION 1. Check: A.

  • Page 101: Adjusting The Front Brake Lever Free Play

    PERIODIC MAINTENANCE EAS21150 2. Check: ADJUSTING THE FRONT BRAKE LEVER • Front brake pad FREE PLAY Wear indicators “a” almost touch the 1. Check: brake disc → Replace the brake pads as • Front brake lever free play “a” a set. Out of specification →...

  • Page 102: Checking The Rear Brake Pads

    PERIODIC MAINTENANCE c. Tighten the locknut to specification. EAS21350 BLEEDING THE HYDRAULIC BRAKE SYS- Locknut EWA13100 18 Nm (1.8 m·kgf, 13 ft·lbf) WARNING EWA5S71006 Bleed the hydraulic brake system when- WARNING ever: A soft or spongy feeling in the brake pedal •...

  • Page 103: Checking The Front Brake Hose

    PERIODIC MAINTENANCE Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. h. Tighten the bleed screw and then release the brake lever or brake pedal. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.

  • Page 104: Checking The Rear Brake Hoses

    PERIODIC MAINTENANCE 3. Hold the vehicle upright and apply the 1. Check: brake several times. • Wheel Damage/out-of-round → Replace. 4. Check: • Brake hose EWA13260 Brake fluid leakage → Replace the brake WARNING hose. Never attempt to make any repairs to the Refer to “FRONT BRAKE”...
  • Page 105 No guarantee Rear concerning handling characteristics can be given if a tire combination other than one 250 kPa (2.50 kgf/cm , 36 psi) approved by Yamaha is used on this vehi- Loading condition cle. 90–210 kg (198–463 lb) Front Front tire 225 kPa (2.25 kgf/cm...

  • Page 106: Checking The Wheel Bearings

    PERIODIC MAINTENANCE Place the vehicle on the sidestand or on a suit- able stand so that the rear wheel is elevated. 2. Check: • Drive belt slack “a” Out of specification → Adjust. Drive belt slack (on the side- stand) 3.0–5.0 mm (0.12–0.20 in) Drive belt slack (on a suitable EAS5S71024...

  • Page 107: Checking And Adjusting The Steering Head

    PERIODIC MAINTENANCE 3. Remove: e. Tighten the rear wheel axle nut to specifi- • Muffler cation. Refer to “ENGINE REMOVAL” on page 5- Rear wheel axle nut 150 Nm (15.0 m·kgf, 110 ft·lbf) 4. Adjust: • Drive belt slack ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 108: Lubricating The Steering Bearings

    PERIODIC MAINTENANCE d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to “STEERING HEAD” on page 4-54. e.

  • Page 109: Lubricating The Brake Lever

    PERIODIC MAINTENANCE EAS21700 LUBRICATING THE BRAKE LEVER Direction “a” Installed shift rod length is increased. Lubricate the pivoting point and metal-to-metal Direction “b” moving parts of the brake lever. Installed shift rod length is decreased. Recommended lubricant Silicone grease EAS21710 LUBRICATING THE BRAKE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the brake pedal.

  • Page 110: Lubricating The Sidestand

    PERIODIC MAINTENANCE Sidestand nut 64 Nm (6.4 m·kgf, 46 ft·lbf) b. Check the sidestand vertical movement “A” by moving the sidestand up and down. c. Check the sidestand axial movement “B” by moving the sidestand up and down. EAS5S71025 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1.

  • Page 111: Lubricating The Rear Suspension

    PERIODIC MAINTENANCE 2. Adjust: Recommended lubricant • Spring preload Lithium-soap-based grease ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Adjust the spring preload with the special EAS20750 wrench “1” and wrench handle “2” included CHECKING THE ENGINE OIL LEVEL in the owner’s tool kit. 1. Place the vehicle on a level surface and b.

  • Page 112: Changing The Engine Oil

    PERIODIC MAINTENANCE Before checking the engine oil level, wait a few minutes until the oil has settled. EAS20780 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt.
  • Page 113 PERIODIC MAINTENANCE Engine oil quantity Total amount 4.30 L (4.55 US qt, 3.78 Imp.qt) Without filter cartridge replacement 3.70 L (3.91 US qt, 3.26 Imp.qt) With oil filter cartridge replace- ment 4.00 L (4.23 US qt, 3.52 Imp.qt) 9. Start the engine, warm it up for several b.

  • Page 114: Checking The Front And Rear Brake Light Switch

    PERIODIC MAINTENANCE EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH The rear brake light switch is operated by movement of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.
  • Page 115 PERIODIC MAINTENANCE 2. Check: Throttle cable free play • Cable operation Rough movement → Lubricate or 4.0–6.0 mm (0.16–0.24 in) replace. 2. Remove: • Rider seat Recommended lubricant • Side cover (cylinder head) Engine oil or a suitable cable Refer to “GENERAL CHASSIS” on page lubricant 4-1.
  • Page 116 PERIODIC MAINTENANCE Direction “a” Direction “a” Throttle cable free play is increased. Headlight beam is raised. Direction “b” Direction “b” Throttle cable free play is decreased. Headlight beam is lowered. c. Tighten the locknut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: •...
  • Page 117 PERIODIC MAINTENANCE EWA13320 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 7. Install: • Headlight bulb Secure the new headlight bulb with the headlight bulb holder. ECA13690 2.
  • Page 118 PERIODIC MAINTENANCE 3-31...

  • Page 119: Chassis

    CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEEL ....................4-7 REMOVING THE FRONT WHEEL ............4-9 DISASSEMBLING THE FRONT WHEEL ..........4-9 CHECKING THE FRONT WHEEL............4-9 ASSEMBLING THE FRONT WHEEL ...........4-10 ADJUSTING THE FRONT WHEEL STATIC BALANCE .......4-10 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC) ....4-11 REAR WHEEL ....................4-13 REMOVING THE REAR WHEEL (DISC) ..........4-17 DISASSEMBLING THE REAR WHEEL ..........4-17...
  • Page 120 HANDLEBAR....................4-42 REMOVING THE HANDLEBAR ............4-43 CHECKING THE HANDLEBAR............4-43 INSTALLING THE HANDLEBAR ............4-43 FRONT FORK .....................4-46 REMOVING THE FRONT FORK LEGS ..........4-49 DISASSEMBLING THE FRONT FORK LEGS ........4-49 CHECKING THE FRONT FORK LEGS..........4-50 ASSEMBLING THE FRONT FORK LEGS ...........4-50 INSTALLING THE FRONT FORK LEGS ..........4-52 STEERING HEAD..................4-54 REMOVING THE LOWER BRACKET ..........4-56 CHECKING THE STEERING HEAD ............4-56...
  • Page 122 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the rider seat and side cover Order Job/Parts to remove Q’ty Remarks Rider seat Passenger seat Right side cover Left side cover Seat lock cable assembly Disconnect. Key cylinder (seat lock) Meter coupler Disconnect. Seat lock bracket Side cover (cylinder head) For installation, reverse the removal proce-...
  • Page 123 GENERAL CHASSIS Removing the headlight Order Job/Parts to remove Q’ty Remarks Turn signal light bracket cover Headlight lens unit Headlight coupler Disconnect. Turn signal light coupler Disconnect. Wire harness clamp Disconnect. Headlight body For installation, reverse the removal proce- dure.

  • Page 124: General Chassis

    GENERAL CHASSIS Removing the battery Order Job/Parts to remove Q’ty Remarks Rider seat/Side cover Refer to “GENERAL CHASSIS” on page 4-1. Battery band Tool kit Negative battery lead Disconnect. Positive battery lead (battery) Disconnect. Battery ECU coupler Disconnect. ECU (engine control unit) Starter relay coupler Disconnect.
  • Page 125 GENERAL CHASSIS Removing the battery Order Job/Parts to remove Q’ty Remarks Lean angle sensor coupler Disconnect. Lean angle sensor For installation, reverse the removal proce- dure.
  • Page 126 GENERAL CHASSIS Removing the air filter case Order Job/Parts to remove Q’ty Remarks Air filter case cover Air filter element Air filter case Crankcase breather hose Disconnect. For installation, reverse the removal proce- dure.
  • Page 127 GENERAL CHASSIS Removing the rear fender Order Job/Parts to remove Q’ty Remarks Rider seat/Passenger seat/Seat lock bracket Refer to “GENERAL CHASSIS” on page 4-1. Tail/brake light wire harness coupler Disconnect. Rear fender bracket Passenger seat bracket Passenger seat guide Rear fender Mudguard (front) Rear turn signal light bracket cover Rear turn signal light coupler...
  • Page 128 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake disc Order Job/Parts to remove Q’ty Remarks Place the vehicle on a suitable stand so that the front wheel is elevated. Front brake caliper Front wheel axle pinch bolt Loosen.
  • Page 129 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure.

  • Page 130: Front Wheel

    FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Front brake caliper ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Do not apply the brake lever when removing the brake caliper.

  • Page 131: Assembling The Front Wheel

    FRONT WHEEL 4. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Wheel bearings Front wheel turns roughly or is loose → EAS21970 ADJUSTING THE FRONT WHEEL STATIC Replace the wheel bearings. BALANCE • Oil seals Damage/wear → Replace. • After replacing the tire, wheel or both, the front wheel static balance should be adjusted.

  • Page 132: Installing The Front Wheel (Front Brake Disc)

    FRONT WHEEL ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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. g. The spot where all the marks come to rest b.
  • Page 133 FRONT WHEEL Install the tire and wheel with the marks “1” pointing in the direction of wheel rotation. 5. Tighten: • Front wheel axle • Front wheel axle pinch bolts Front wheel axle 59 Nm (5.9 m·kgf, 43 ft·lbf) Front wheel axle pinch bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) ECA3D81011 Before tightening the wheel axle, push...

  • Page 134: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Place the vehicle on a suitable stand so that the rear wheel is elevated. Muffler Refer to “ENGINE REMOVAL” on page 5-1. Rear brake caliper Rear brake pad Brake pad spring Drive belt upper guard...
  • Page 135 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Rear brake caliper bracket Collar (right) Black Collar (left) Silver Rear wheel For installation, reverse the removal proce- dure. 4-14...
  • Page 136 REAR WHEEL Removing the rear brake disc and rear wheel drive hub Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel pulley Oil seal Circlip Rear wheel drive hub Circlip Bearing Collar Bearing Rear wheel drive hub damper Rear wheel For installation, reverse the removal proce- dure.
  • Page 137 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Oil seal Circlip Bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-16...

  • Page 138: Removing The Rear Wheel (Disc)

    REAR WHEEL EAS28760 • Oil seals REMOVING THE REAR WHEEL (DISC) Refer to “CHECKING THE FRONT 1. Stand the vehicle on a level surface. WHEEL” on page 4-9. EWA13120 2. Check: WARNING • Tire Securely support the vehicle so that there •...

  • Page 139: Assembling The Rear Wheel

    REAR WHEEL Rear wheel pulley self-locking Rear brake disc bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) 95 Nm (9.5 m·kgf, 68 ft·lbf) LOCTITE® Tighten the self-locking nuts in stages and in a • Apply locking agent (LOCTITE®) to the crisscross pattern. threads of the brake disc bolts.

  • Page 140: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Front brake caliper retaining bolt Front brake caliper Front brake pad Front brake pad spring Front brake pad support For installation, reverse the removal proce- dure.
  • Page 141 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. Right rear view mirror Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Brake lever...
  • Page 142 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-21...
  • Page 143 FRONT BRAKE Removing the front brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. Front brake hose union bolt Washer Front brake hose Front brake caliper bracket bolt Front brake caliper For installation, reverse the removal proce- dure.
  • Page 144 FRONT BRAKE Disassembling the front brake caliper Order Job/Parts to remove Q’ty Remarks Front brake caliper retaining bolt Brake pad spring Brake pad Brake pad support Brake caliper bracket Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.

  • Page 145: Introduction

    FRONT BRAKE EAS22220 INTRODUCTION Brake disc deflection limit EWA14100 0.15 mm (0.0059 in) WARNING ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Disc brake components rarely require dis- a. Place the vehicle on a suitable stand so assembly. Therefore, always follow these that the front wheel is elevated. preventive measures: b.

  • Page 146: Replacing The Front Brake Pads

    FRONT BRAKE Always install new brake pads and a new brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. d.

  • Page 147: Removing The Front Brake Caliper

    FRONT BRAKE LOWER 6. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Brake lever operation a. Blow compressed air into the brake hose Soft or spongy feeling → Bleed the brake joint opening “a” to force out the piston from system. the brake caliper. Refer to “BLEEDING THE HYDRAULIC EWA3D81009 WARNING BRAKE SYSTEM”...

  • Page 148: Assembling The Front Brake Caliper

    FRONT BRAKE • Brake caliper cylinders “2” EAS22440 INSTALLING THE FRONT BRAKE CALIPER Scratches/wear → Replace the brake cal- 1. Install: iper assembly. • Front brake caliper “1” • Brake caliper body “3” (temporarily) Cracks/damage → Replace the brake • Washers caliper assembly.

  • Page 149: Removing The Front Brake Master Cylinder

    FRONT BRAKE EAS22490 REMOVING THE FRONT BRAKE MASTER Recommended fluid CYLINDER DOT 4 EWA3D81010 Before removing the front brake master cylin- WARNING der, drain the brake fluid from the entire brake • Use only the designated brake fluid. system. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and 1.

  • Page 150: Assembling The Front Brake Master Cylinder

    FRONT BRAKE EAS22520 EWA13530 ASSEMBLING THE FRONT BRAKE MAS- WARNING TER CYLINDER Proper brake hose routing is essential to EWA13520 insure safe vehicle operation. Refer to WARNING “CABLE ROUTING” on page 2-35. • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
  • Page 151 FRONT BRAKE ECA13540 Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. 5. Check: • Brake fluid level Below the minimum level mark “a”...

  • Page 152: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt Rear brake caliper Rear brake pad Brake pad spring For installation, reverse the removal proce- dure. 4-31...
  • Page 153 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. Brake fluid reservoir cap cover Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose...
  • Page 154 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake hose joint Bush Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-33...
  • Page 155 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. Rear brake hose union bolt Copper washer Rear brake hose Rear brake caliper retaining bolt Rear brake caliper For installation, reverse the removal proce- dure.
  • Page 156 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure. 4-35...

  • Page 157: Introduction

    REAR BRAKE EAS22560 4. Measure: INTRODUCTION • Brake disc thickness EWA14100 Measure the brake disc thickness at a WARNING few different locations. Disc brake components rarely require dis- Out of specification → Replace. assembly. Therefore, always follow these Refer to “CHECKING THE FRONT preventive measures: BRAKE DISC”...

  • Page 158: Removing The Rear Brake Caliper

    REAR BRAKE 2. Install: 5. Check: • Brake pads • Brake pedal operation • Brake pad springs Soft or spongy feeling → Bleed the brake system. Always install new brake pads and brake pad Refer to “BLEEDING THE HYDRAULIC springs as a set. BRAKE SYSTEM”...

  • Page 159: Checking The Rear Brake Caliper

    REAR BRAKE EWA13550 WARNING • Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper. • Never try to pry out the brake caliper pis- ton. EAS22650 ASSEMBLING THE REAR BRAKE CALIPER EWA3D84004...

  • Page 160: Removing The Rear Brake Master Cylinder

    REAR BRAKE 5. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. 6. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE 2.

  • Page 161: Checking The Rear Brake Master Cylinder

    REAR BRAKE Rear brake hose union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) EWA13530 WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” on page 2-35. ECA3D81005 When installing the brake hose onto the EAS22720 CHECKING THE REAR BRAKE MASTER brake master cylinder, make sure the brake...
  • Page 162 REAR BRAKE ECA13540 Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 3. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. 4. Check: • Brake fluid level Below the minimum level mark “a”...
  • Page 163 HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Rear view mirror (right)/Front brake master cylin- Refer to “FRONT BRAKE” on page 4-19. Rear view mirror (left) Plastic clamp Right handlebar switch Throttle cable Disconnect. Grip end Throttle grip Clutch switch coupler Disconnect.

  • Page 164: Handlebar

    HANDLEBAR EAS22860 • Turn the handlebar all the way to the left REMOVING THE HANDLEBAR and right. If there is any contact with the 1. Stand the vehicle on a level surface. fuel tank, adjust the handlebar position. EWA13120 WARNING Align the end of the upper handlebar holder Securely support the vehicle so that there is no danger of it falling over.
  • Page 165 HANDLEBAR 7. Install: 5. Install: • Right handlebar switch “1” • Handlebar grip “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Align the projection “a” on the right handlebar a. Apply a thin coat of rubber adhesive onto switch with the hole “b” in the handlebar. the left end of the handlebar.
  • Page 166 HANDLEBAR 10. Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-28. Throttle cable free play 4.0–6.0 mm (0.16–0.24 in) 4-45...

  • Page 167: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Headlight body Refer to “GENERAL CHASSIS” on page 4-1. Front wheel Refer to “FRONT WHEEL” on page 4-7. Rear handlebar holder Refer to “HANDLEBAR”...
  • Page 168 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks Lower bracket pinch bolt Loosen. Lower front fork cover Front fork leg For installation, reverse the removal proce- dure. 4-47...
  • Page 169 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Spring seat Fork spring Dust seal Oil seal clip Damper rod bolt Copper washer Damper rod Inner tube...

  • Page 170: Removing The Front Fork Legs

    FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 3.

  • Page 171: Checking The Front Fork Legs

    • Oil flow stopper Damage → Replace. 2. Lubricate: • Inner tube’s outer surface ECA14200 Recommended oil • The front fork leg has a built-in damper Yamaha fork oil 10WT adjusting rod and a very sophisticated 4-50...
  • Page 172 FRONT FORK 3. Install: • Inner tube (in the outer tube) 4. Install: • Copper washer • Damper rod bolt 5. Tighten: • Damper rod bolt “1” Damper rod bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) 7. Install: LOCTITE® • Oil seal “1” (with the fork seal driver “2”) ECA14220 While holding the damper rod assembly with...

  • Page 173: Installing The Front Fork Legs

    Make sure the inner tube end is flush with the Imp oz) top of the upper bracket. Recommended oil Yamaha fork oil 10WT 11. Measure: • Front fork leg oil level “a” (from the top of the inner tube, with the...
  • Page 174 FRONT FORK 2. Tighten: • Lower bracket pinch bolts Lower bracket pinch bolt 45 Nm (4.5 m·kgf, 32 ft·lbf) 3. Remove: • Upper bracket 4. Tighten: • Lower front fork cover bolts Lower front fork cover bolt 18 Nm (1.8 m·kgf, 13 ft·lbf) 5.

  • Page 175: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Upper bracket/Front fork legs Refer to “FRONT FORK” on page 4-46. Front turn signal light Air temperature sensor coupler Disconnect. Front turn signal light bracket Air temperature sensor Front brake hose holder Front brake hose joint...
  • Page 176 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Bearing outer race For installation, reverse the removal proce- dure. 4-55...

  • Page 177: Removing The Lower Bracket

    STEERING HEAD EAS23110 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ REMOVING THE LOWER BRACKET a. Remove the bearing races from the steer- 1. Stand the vehicle on a level surface. ing head pipe with a long rod “1” and ham- EWA13120 mer. WARNING b. Remove the bearing race from the lower Securely support the vehicle so that there bracket with a floor chisel “2”...
  • Page 178 STEERING HEAD Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-20. 3. Install: • Front brake hose joint “1” •...

  • Page 179: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Battery box Refer to “GENERAL CHASSIS” on page 4-1. Muffler Refer to “ENGINE REMOVAL” on page 5-1. Rear wheel Refer to “REAR WHEEL”...

  • Page 180: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 EWA13120 HANDLING THE REAR SHOCK ABSORBER WARNING EWA13740 Securely support the vehicle so that there WARNING is no danger of it falling over. This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make Place the vehicle on a suitable stand so that sure you understand the following informa- the rear wheel is elevated.

  • Page 181: Checking The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23240 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • Rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • Rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. •...
  • Page 182 REAR SHOCK ABSORBER ASSEMBLY 4. Tighten: • Rear shock absorber assembly upper nut Rear shock absorber assembly upper nut 48 Nm (4.8 m·kgf, 35 ft·lbf) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 48 Nm (4.8 m·kgf, 35 ft·lbf) 5.

  • Page 183: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Drive belt puller/Drive belt upper guard Refer to “REAR WHEEL” on page 4-13. Refer to “REAR SHOCK ABSORBER Connecting arms ASSEMBLY” on page 4-58. Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1. Drive belt lower guard Right side cover (lower) Pivot shaft nut cover...

  • Page 184: Removing The Swingarm

    SWINGARM EAS23350 REMOVING THE SWINGARM 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 185: Installing The Swingarm

    SWINGARM 6. Check: • Spacer Damage/scratches → Replace. EAS28780 INSTALLING THE SWINGARM 1. Lubricate: • Bearings • Spacers • Dust covers • Pivot shaft Recommended lubricant Lithium-soap-based grease 2. Install: • Bearings “1” 2. Swingarm A. Left side B. Right side Installed depth “a”...

  • Page 186: Belt Drive

    BELT DRIVE EAS23510 BELT DRIVE Removing the drive belt Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-13. Swingarm Refer to “SWINGARM” on page 4-62. Refer to “REAR SHOCK ABSORBER Rear shock absorber ASSEMBLY” on page 4-58. Air duct Drive pulley cover Drive belt...

  • Page 187: Removing The Drive Belt And Drive Pulley

    BELT DRIVE EAS23520 REMOVING THE DRIVE BELT AND DRIVE PULLEY Loosen the drive pulley nut before removing the rear wheel. 1. Loosen: • Drive pulley nut When loosening the drive pulley nut, press 3. Check: down on the brake pedal so the drive pulley •...
  • Page 188 BELT DRIVE • When tightening the drive pulley nut, press down on the brake pedal so the drive pulley does not move. 5. Adjust: • Drive belt slack Refer to “ADJUSTING THE DRIVE BELT SLACK” on page 3-19. 4-67...

  • Page 189: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE EXHAUST PIPE AND MUFFLER......5-3 INSTALLING THE CYLINDER COVERS ..........5-6 INSTALLING THE SHIFT ARM...............5-6 INSTALLING THE ENGINE ..............5-10 CAMSHAFTS....................5-12 REMOVING THE CAMSHAFTS AND ROCKER ARMS.......5-14 CHECKING THE CAMSHAFTS ............5-15 CHECKING THE CAMSHAFT SPROCKETS........5-16 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ..5-16 CHECKING THE TIMING CHAIN TENSIONERS.........5-17 INSTALLING THE ROCKER ARMS AND CAMSHAFTS......5-17 INSTALLING THE CYLINDER HEAD COVERS ........5-20...
  • Page 190 CHECKING THE CLUTCH PLATES.............5-50 CHECKING THE CLUTCH SPRING PLATE ........5-50 CHECKING THE CLUTCH HOUSING ..........5-50 CHECKING THE CLUTCH BOSS ............5-50 CHECKING THE PRESSURE PLATE ..........5-51 CHECKING THE PRIMARY DRIVE GEAR ..........5-51 CHECKING THE PRIMARY DRIVEN GEAR........5-51 CHECKING THE PULL LEVER SHAFT AND PULL ROD....5-51 CHECKING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVE CHAIN ..............5-51 INSTALLING THE PRIMARY DRIVE GEAR.........5-51...
  • Page 191 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY..5-78...

  • Page 192: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the muffler and exhaust pipe Order Job/Parts to remove Q’ty Remarks Right footrest Refer to “REAR BRAKE” on page 4-31. sensor coupler Disconnect. Muffler Clamp Gasket Exhaust pipe stay Exhaust pipe Silencer plate Gasket Clamp Exhaust pipe protector 1 Exhaust pipe protector 3...
  • Page 193 ENGINE REMOVAL Removing the muffler and exhaust pipe Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure.

  • Page 194: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL EAS5S71005 INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • Exhaust pipe cover clamp screws Exhaust pipe cover clamp screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Do not retighten the exhaust pipe cover clamp screws; always replace them with new ones if they are loosened.
  • Page 195 ENGINE REMOVAL Removing the sidestand and drive pulley housing Order Job/Parts to remove Q’ty Remarks Drive belt Refer to “BELT DRIVE” on page 4-65. Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 6-1. Sidestand switch coupler Disconnect.
  • Page 196 ENGINE REMOVAL Removing the sidestand and drive pulley housing Order Job/Parts to remove Q’ty Remarks Dowel pin For installation, reverse the removal proce- dure.

  • Page 197: Installing The Cylinder Covers

    ENGINE REMOVAL EAS5S71006 INSTALLING THE CYLINDER COVERS 1. Install: • Front cylinder lower plastic cover “1” • Front cylinder upper plastic cover “2” • Rear cylinder left plastic cover bracket “3” • Rear cylinder right plastic cover bracket “4” • Rear cylinder left plastic cover “5” •...
  • Page 198 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (cylinder head) Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 6-1. Intake manifold assembly Refer to “THROTTLE BODIES”...
  • Page 199 ENGINE REMOVAL Removing the down tube and engine Order Job/Parts to remove Q’ty Remarks Rear brake hose bracket Refer to “REAR BRAKE” on page 4-31. Engine oil Drain. Rectifier/regulator bracket Engine mounting nut (front lower side) Engine mounting bolt (front lower side) Down tube bolt (front side) Down tube bolt (rear side) Down tube...
  • Page 200 ENGINE REMOVAL Removing the down tube and engine Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure.

  • Page 201: Installing The Engine

    ENGINE REMOVAL EAS23720 2. Tighten: INSTALLING THE ENGINE • Engine bracket bolts (front upper side) “3” 1. Install: • Engine bracket bolts (rear lower side) “7” • Engine “1” • Engine bracket bolts (rear upper side) “9” • Engine bracket (front upper side) “2” •...
  • Page 202 ENGINE REMOVAL Engine mounting nut (front upper side) 88 Nm (8.8 m·kgf, 64 ft·lbf) Engine mounting nut (rear lower side) 88 Nm (8.8 m·kgf, 64 ft·lbf) Engine mounting nut (rear upper side) 88 Nm (8.8 m·kgf, 64 ft·lbf) Engine mounting nut (front lower side) 88 Nm (8.8 m·kgf, 64 ft·lbf) 5-11...

  • Page 203: Camshafts

    CAMSHAFTS EAS23740 CAMSHAFTS Removing the cylinder head covers Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Tappet cover O-ring Front cylinder side cover Front cylinder side cover gasket Rear cylinder side cover Rear cylinder side cover gasket For installation, reverse the removal proce- dure.
  • Page 204 CAMSHAFTS Removing the camshafts and rocker arms Order Job/Parts to remove Q’ty Remarks Spark plug Locknut Valve clearance adjusting screw Timing chain tensioner Timing chain tensioner gasket Camshaft bolt Camshaft sprocket Camshaft retainer Front cylinder camshaft Rear cylinder camshaft Intake rocker arm shaft Intake rocker arm Exhaust rocker arm shaft Exhaust rocker arm...

  • Page 205: Removing The Camshafts And Rocker Arms

    CAMSHAFTS EAS5S71008 REMOVING THE CAMSHAFTS AND ROCKER ARMS 1. Align: • “I” mark on the front cylinder camshaft sprocket (with the arrow mark on the front cylinder head) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Front cylinder a. Turn the crankshaft counterclockwise. 3. Remove: b. When the front cylinder piston is at TDC on •...

  • Page 206: Checking The Camshafts

    CAMSHAFTS Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 90890-01084 YU-01083-3 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Remove: • Rear cylinder timing chain tensioner • Rear cylinder camshaft sprocket • Camshaft retainer • Rear cylinder camshaft • Intake rocker arm shaft •...

  • Page 207: Checking The Camshaft Sprockets

    CAMSHAFTS Camshaft lobe dimensions Intake A 42.470–42.570 mm (1.6720– 1.6760 in) Limit 42.370 mm (1.6681 in) Intake B 37.041–37.141 mm (1.4583– 1.4622 in) Limit a. 1/4 tooth 36.941 mm (1.4544 in) b. Correct Exhaust A 42.138–42.238 mm (1.6590– 1. Timing chain roller 1.6629 in) 2.

  • Page 208: Checking The Timing Chain Tensioners

    CAMSHAFTS Rocker arm shaft outside diam- eter 11.981–11.991 mm (0.4717– 0.4721 in) EAS24040 INSTALLING THE ROCKER ARMS AND CAMSHAFTS The following procedure applies to all of the rocker arms and camshafts. 5. Calculate: 1. Lubricate: • Rocker-arm-to-rocker-arm-shaft clear- • Rocker arm shafts ance Recommended lubricant Engine oil...
  • Page 209 CAMSHAFTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ While holding the camshaft sprocket with the Front cylinder rotor holding tool “2”, tighten the camshaft a. Turn the crankshaft counterclockwise. sprocket bolt. b. When the front cylinder piston is at TDC on the compression stroke, align the TDC Rotor holding tool mark “a”...
  • Page 210 CAMSHAFTS ECA13740 Do not turn the crankshaft when installing the camshaft(s) to avoid damage or improper valve timing. • To position the rear cylinder piston at TDC on the compression stroke, align the “I” mark “c” on the camshaft sprocket with the arrow mark “d”...

  • Page 211: Installing The Cylinder Head Covers

    CAMSHAFTS 13. Measure: • Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE” on page 3-5. EAS5S71009 INSTALLING THE CYLINDER HEAD COV- 1. Install: • Rear cylinder side cover • Tappet covers 11. Install: • Rear cylinder timing chain tensioner gas- Rear cylinder side cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ket “1”...

  • Page 212: Cylinder Heads

    CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads Order Job/Parts to remove Q’ty Remarks Oil check bolt Engine temperature sensor Cylinder head nut Cylinder head bolt Front cylinder head Rear cylinder head Dowel pin Cylinder head gasket Timing chain guide (exhaust side) Timing chain guide (intake side) Rear exhaust pipe joint cover Rear exhaust pipe joint...

  • Page 213: Removing The Cylinder Heads

    CYLINDER HEADS EAS24150 REMOVING THE CYLINDER HEADS 1. Remove: • Cylinder head bolts • Cylinder head nuts • Loosen the cylinder head nuts in the proper sequence as shown. • Loosen each cylinder head nut 1/2 of a turn at a time. After all of the cylinder head nut 2.

  • Page 214: Measuring The Compression Pressure

    CYLINDER HEADS Cylinder head nut Tighten the rear exhaust pipe joint nuts, and 1st: 15 Nm (1.5 m·kgf, 11 ft·lbf) then install the rear exhaust pipe joint cover 2nd: 25 Nm (2.5 m·kgf, 18 and bolts. ft·lbf) Final: 65 Nm (6.5 m·kgf, 47 ft·lbf) EAS20710 MEASURING THE COMPRESSION PRES-...
  • Page 215 CYLINDER HEADS Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage → Replace. Piston, valves or cyl- inder head gasket Same as without oil possibly defective → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Measure: 8.
  • Page 216 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both cyl- inders. Cylinder heads Refer to “CYLINDER HEADS” on page 5-21. Valve cotter Upper spring seat Valve spring Intake valve...

  • Page 217: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, and valve seats), make sure the valves properly seal. 1.
  • Page 218 VALVES AND VALVE SPRINGS Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 (0.0004– 0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 (0.0010– 0.0020 in) Limit b. Install the new valve guide with the valve 0.100 mm (0.0039 in) guide installer “2” and valve guide remover “1”.

  • Page 219: Checking The Valve Seats

    VALVES AND VALVE SPRINGS • If the valve is removed or replaced, always Valve guide remover (ø6) replace the valve stem seal. 90890-04064 Valve guide remover (6.0 mm) Valve stem runout YM-04064-A 0.010 mm (0.0004 in) Valve guide installer (ø6) 90890-04065 Valve guide installer (6.0 mm) YM-04065-A...
  • Page 220 VALVES AND VALVE SPRINGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face. c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound.

  • Page 221: Checking The Valve Springs

    VALVES AND VALVE SPRINGS Measure the valve seat width “c” again. If Installed compression spring the valve seat width is out of specification, force (intake) reface and lap the valve seat. 171–197 N (17.44–20.09 kgf, 38.45–44.30 lbf) Installed compression spring force (exhaust) 171–197 N (17.44–20.09 kgf, 38.45–44.30 lbf)
  • Page 222 VALVES AND VALVE SPRINGS 2. Lubricate: • Valve stem “1” • Valve stem seal “2” (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Lubricate: • Valve stem end (with the recommended lubricant) a. Larger pitch b. Smaller pitch Recommended lubricant Engine oil 5.
  • Page 223 VALVES AND VALVE SPRINGS 6. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. ECA13800 Hitting the valve tip with excessive force could damage the valve. 5-32...
  • Page 224 CYLINDERS AND PISTONS EAS24360 CYLINDERS AND PISTONS Removing the cylinders and pistons Order Job/Parts to remove Q’ty Remarks Cylinder heads Refer to “CYLINDER HEADS” on page 5-21. Front cylinder Rear cylinder Front cylinder gasket Rear cylinder gasket Dowel pin Circlip Piston pin Piston Top ring...

  • Page 225: Cylinders And Pistons

    CYLINDERS AND PISTONS EAS24380 REMOVING THE PISTONS When removing a piston ring, open the end The following procedure applies to all of the gap with your fingers and lift the other side of pistons. the ring over the piston crown. 1.

  • Page 226: Checking The Piston Rings

    CYLINDERS AND PISTONS Piston-to-cylinder clearance 0.030–0.055 (0.0012– 0.0022 in) Limit 0.15 mm (0.0059 in) f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. 10.0 mm (0.39 in) EAS24430 CHECKING THE PISTON RINGS b.

  • Page 227: Checking The Piston Pins

    CYLINDERS AND PISTONS 2. Measure: • Piston pin outside diameter “a” Level the piston ring in the cylinder with the Out of specification → Replace the piston piston crown. pin. Piston pin outside diameter 20.991–21.000 mm (0.8264– 0.8268 in) Limit 20.971 mm (0.8256 in) a.

  • Page 228: Installing The Pistons And Cylinders

    CYLINDERS AND PISTONS EAS24460 INSTALLING THE PISTONS AND CYLIN- DERS The following procedure applies to all of the pistons and cylinders. 1. Install: • Top ring “1” • 2nd ring “2” • Oil ring expander “3” • Lower oil ring rail “4” 3.
  • Page 229 CYLINDERS AND PISTONS 6. Install: • Cylinder “1” • While compressing the piston rings with one hand, install the cylinder with the other hand. • Pass the timing chain and timing chain guide through the timing chain cavity. 5-38...

  • Page 230: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil Order Job/Parts to remove Q’ty Remarks Side cover (cylinder head) Refer to “GENERAL CHASSIS” on page 4-1. Side stand Refer to “ENGINE REMOVAL” on page 5-1. Left footrest assembly Refer to “ENGINE REMOVAL”...
  • Page 231 GENERATOR AND STARTER CLUTCH Removing the stator coil Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-40...
  • Page 232 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Generator rotor Starter clutch Woodruff key Starter clutch gear Starter clutch idle gear 2 shaft Starter clutch idle gear 2 Starter clutch idle gear 1 shaft Starter clutch idle gear 1 For installation, reverse the removal proce- dure.

  • Page 233: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer • Starter clutch bolts “2” • While holding the generator rotor “3” with the sheave holder “4”, loosen the generator rotor bolt. • Do not allow the sheave holder to touch the EAS24560 projection on the generator rotor.

  • Page 234: Installing The Starter Clutch

    While holding the generator rotor “1” with the sheave holder “2”, tighten the starter clutch bolts. Sheave holder 90890-01701 3. Apply: Primary clutch holder • Sealant YS-01880-A (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 5-43...

  • Page 235: Installing The Generator Cover

    GENERATOR AND STARTER CLUTCH EAS5S71011 INSTALLING THE GENERATOR COVER 1. Install: Generator cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Temporally tighten “a” and “b” and then tighten the generator cover bolts in the order shown in the illustration. 5-44...

  • Page 236: Clutch

    CLUTCH EAS25060 CLUTCH Removing the primary drive gear Order Job/Parts to remove Q’ty Remarks Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Rear brake master cylinder Refer to “REAR BRAKE” on page 4-31. Rear brake light switch Refer to “REAR BRAKE” on page 4-31. Right footrest assembly Refer to “REAR BRAKE”...
  • Page 237 CLUTCH Removing the primary drive gear Order Job/Parts to remove Q’ty Remarks Primary drive gear nut Lock washer Spacer Primary drive gear Woodruff key For installation, reverse the removal proce- dure. 5-46...
  • Page 238 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever shaft Oil seal Bearing Bearing Oil seal retainer Oil seal For installation, reverse the removal proce- dure. 5-47...
  • Page 239 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Bearing Friction plate 1 Inside diameter: 124 mm (4.88 in) Clutch plate Friction plate 2 Inside diameter: 124 mm (4.88 in) Clutch boss nut Conical spring washer...

  • Page 240: Removing The Clutch

    CLUTCH EAS25080 REMOVING THE CLUTCH 1. Loosen: • Clutch boss nut “1” While holding the clutch boss “2” with the uni- versal clutch holder “3”, loosen the clutch boss nut. Universal clutch holder 90890-04086 YM-91042 EAS25100 CHECKING THE FRICTION PLATES 2.

  • Page 241: Checking The Clutch Plates

    CLUTCH EAS25130 CHECKING THE CLUTCH SPRING PLATE 1. Check: • Clutch spring plate Damage → Replace. 2. Check: • Clutch spring plate seat Damage → Replace. EAS25150 CHECKING THE CLUTCH HOUSING 1. Check: • Clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch hous- ing.

  • Page 242: Checking The Pressure Plate

    CLUTCH EAS25170 EAS5S71001 CHECKING THE PRESSURE PLATE CHECKING THE OIL PUMP DRIVE 1. Check: SPROCKET AND OIL PUMP DRIVE CHAIN • Pressure plate 1. Check: Cracks/damage → Replace. • Oil pump drive sprocket Cracks/damage/wear → Replace the oil • Bearing Damage/wear →...

  • Page 243: Installing The Clutch

    CLUTCH 2. Bend lock washer tab along a flat side of the nut. EAS25240 INSTALLING THE CLUTCH 1. Install: • Oil pump drive sprocket “1” • Oil pump drive chain “2” Install the oil pump drive sprocket with its pro- 3.
  • Page 244 CLUTCH 7. Install: • Primary drive gear cover Primary drive gear cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Temporally tighten “a” and “b” and then tighten the primary drive gear cover bolts in the order shown in the illustration. 4.

  • Page 245: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Drive pulley cover Refer to “BELT DRIVE” on page 4-65. Shift arm Refer to “ENGINE REMOVAL” on page 5-1. Primary drive gear cover Refer to “CLUTCH”...

  • Page 246: Checking The Shift Shaft

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

  • Page 247: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor lead Disconnect. Starter motor For installation, reverse the removal proce- dure. 5-56...
  • Page 248 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Armature assembly Starter motor yoke Gasket Starter motor rear cover Brush set assembly O-ring For assembly, reverse the disassembly pro- cedure. 5-57...

  • Page 249: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.

  • Page 250: Assembling The Starter Motor

    ELECTRIC STARTER 6. Check: • Gear teeth Damage/wear → Replace the starter motor. 7. Check: • Bearing Damage/wear → Replace the starter motor. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush set assembly 2. Install: • Starter motor yoke “1” •...

  • Page 251: Crankcase

    CRANKCASE EAS25540 CRANKCASE Removing the oil delivery pipes and timing chains Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Refer to “CYLINDERS AND PISTONS” on Piston page 5-33. Clutch Refer to “CLUTCH” on page 5-45. Primary drive gear Refer to “CLUTCH”...
  • Page 252 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Oil baffle plate 1 Left crankcase Dowel pin Joint pipe O-ring Oil baffle plate 2 Gasket Right crankcase Stud bolt l = 239 mm (9.41 in) Stud bolt l = 210 mm (8.27 in) For installation, reverse the removal proce- dure.
  • Page 253 CRANKCASE Removing the oil seal and bearings Order Job/Parts to remove Q’ty Remarks Oil pump assembly Refer to “OIL PUMP” on page 5-66. Crankshaft Refer to “CRANKSHAFT” on page 5-69. Transmission Refer to “TRANSMISSION” on page 5-74. Bearing retainer Oil seal Bearing For installation, reverse the removal proce- dure.

  • Page 254: Disassembling The Crankcase

    CRANKCASE EAS25560 3. Check: DISASSEMBLING THE CRANKCASE • Crankcase 1. Remove: Cracks/damage → Replace. • Crankcase bolts • Oil delivery passages Obstruction → Blow out with compressed Loosen each bolt 1/4 of a turn at a time, in air. stages and in a crisscross pattern. After all of EAS3D81029 the bolts are fully loosened, remove them.

  • Page 255: Assembling 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®) Do not allow any sealant to come into contact • M6 × 120 mm bolts: “a”...
  • Page 256 CRANKCASE 5. Apply: • Engine oil (onto the crankshaft pin bearings and oil delivery holes) 6. Check: • Crankshaft and transmission operation Rough movement → Repair. 5-65...

  • Page 257: Oil Pump

    OIL PUMP EAS24910 OIL PUMP Removing the oil pump assembly Order Job/Parts to remove Q’ty Remarks Crankcase Refer to “CRANKCASE” on page 5-60. Relief valve assembly Oil pump assembly Dowel pin Oil pump housing Dowel pin Impeller shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing cover Bearing...

  • Page 258: Checking The Oil Pump

    OIL PUMP EAS24960 CHECKING THE OIL PUMP 1. Check: • Oil pump housing Cracks/damage/wear → Replace the oil pump assembly. 2. Measure: • Inner-rotor-to-outer-rotor-tip clearance “a” • Outer-rotor-to-oil-pump-housing clear- ance “b” • Oil-pump-housing-to-inner-rotor-and- outer-rotor clearance “c” Out of specification → Replace the oil pump assembly.

  • Page 259: Checking The Oil Strainer

    OIL PUMP 3. Check: EAS24990 CHECKING THE OIL STRAINER • Oil pump operation 1. Check: Refer to “CHECKING THE OIL PUMP” on • Oil strainer “1” page 5-67. Damage → Replace. Contaminants → Clean with solvent. EAS5S71004 INSTALLING THE OIL PUMP ASSEMBLY 1.

  • Page 260: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-60. Crankshaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal proce- dure.

  • Page 261: Removing The Connecting Rods

    CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS clearance (using plasti- 1. Remove: gauge®) • Connecting rod caps “1” 0.022–0.046 (0.0009– • Connecting rods 0.0018 in) • Big end bearings The following procedure applies to all of the connecting rods. Identify the position of each big end bearing so ECA13930 that it can be reinstalled in its original place.
  • Page 262 CRANKSHAFT • Do not move the connecting rod or crank- • The numbers “a” on the connecting rods are shaft until the clearance measurement has used to determine the replacement big end been completed. bearing sizes. • Lubricate the bolts threads and nut seats •...

  • Page 263: Installing The Connecting Rods

    CRANKSHAFT EAS26150 INSTALLING THE CONNECTING RODS 1. Lubricate: • Bolt threads (with the recommended lubricant) Recommended lubricant Molybdenum disulfide grease 2. Lubricate: • Crankshaft pin 6. Measure: • Big end bearings • Crankshaft journal bearing inside diame- • Connecting rod inner surface ter “a”...

  • Page 264: Installing The Crankshaft Assembly

    CRANKSHAFT EWA5S71003 4. Tighten: WARNING • Connecting rod bolts When a bolt is tightened more than the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ specified angle, do not loosen and then EWA5S71002 retighten it. WARNING Replace the bolt with a new one and per- • Replace the connecting rod bolts with form the procedure again.

  • Page 265: Transmission

    TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-60. Long shift fork guide bar Short shift fork guide bar Shift drum assembly Shift fork 1 Shift fork 2 Main axle assembly Drive axle assembly...
  • Page 266 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Circlip 2nd pinion gear Toothed lock washer Toothed lock washer retainer 4th pinion gear Collar Toothed washer Circlip 3rd pinion gear Circlip Toothed washer 5th pinion gear Collar Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure.
  • Page 267 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Toothed washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Circlip Toothed washer 2nd wheel gear Collar Drive axle...

  • Page 268: Checking The Shift Forks

    TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the 1. Check: shift forks and shift fork guide bars. • Shift drum grooves Damage/scratches/wear → Replace the 1. Check: • Shift fork cam follower “1” shift drum assembly.

  • Page 269: Assembling The Main Axle And Drive Axle

    TRANSMISSION 3. Check: 2. Install: • Transmission gears • Toothed lock washer retainer “1” Blue discoloration/pitting/wear → • Toothed lock washer “2” Replace the defective gear(s). • Transmission gear dogs • With the toothed lock washer retainer in the Cracks/damage/rounded edges → groove “a”...
  • Page 270 TRANSMISSION 2. Check: • Transmission Rough movement → Repair. • Apply molybdenum disulfide grease to each gear and bearing thoroughly. • Before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely. 5-79...

  • Page 271: Fuel System

    FUEL SYSTEM FUEL TANK ....................6-1 REMOVING THE FUEL TANK ..............6-4 REMOVING THE FUEL PUMP...............6-4 CHECKING THE FUEL PUMP BODY ............6-4 CHECKING THE ROLLOVER VALVE ............6-4 INSTALLING THE FUEL PUMP..............6-4 THROTTLE BODIES..................6-6 CHECKING THE INJECTORS ...............6-9 INSTALLING THE INJECTORS ..............6-9 CHECKING THE INJECTOR PRESSURE ..........6-9 CHECKING THE THROTTLE BODIES ..........6-10 CHECKING AND CLEANING THE THROTTLE BODIES ....6-10 CHECKING THE INTAKE MANIFOLD JOINTS........6-11...

  • Page 272: Fuel Tank

    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (cylinder head) Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank bracket bolt Meter coupler 1 Disconnect.
  • Page 273 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Fuel sender gasket For installation, reverse the removal proce- dure.
  • Page 274 FUEL TANK Removing the rollover valve Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 6-1. Fuel tank drain hose Refer to “FUEL TANK” on page 6-1. Fuel tank breather hose Rollover valve For installation, reverse the removal proce-...

  • Page 275: Removing The Fuel Tank

    FUEL TANK EAS5S71013 EAS5S71041 REMOVING THE FUEL TANK CHECKING THE ROLLOVER VALVE 1. Extract the fuel in the fuel tank through the 1. Check: fuel tank cap with a pump. • Rollover valve “1” Damage/faulty → Replace. EAS5S71014 REMOVING THE FUEL PUMP •...
  • Page 276 FUEL TANK 2. Install: • Fuel hose ECA5S71006 When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position, otherwise the fuel hose will not be properly installed. •...
  • Page 277 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle body Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 6-1. Throttle position sensor coupler Disconnect.
  • Page 278 THROTTLE BODIES Removing the intake manifold assembly Order Job/Parts to remove Q’ty Remarks Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 6-1. Throttle body Refer to “THROTTLE BODIES” on page 6-6. Fuel hose Clutch cable holder 2 Fuel injector coupler...
  • Page 279 THROTTLE BODIES Disassembling the intake manifold Order Job/Parts to remove Q’ty Remarks Fuel return hose Pressure regulator O-ring Fuel delivery pipe 2 Fuel delivery hose Fuel delivery pipe 1 Injector O-ring Gasket Intake manifold For assembly, reverse the disassembly pro- cedure.

  • Page 280: Throttle Bodies

    THROTTLE BODIES EAS26980 4. Check the injector pressure after the injec- CHECKING THE INJECTORS tors are installed to the throttle bodies. EWA5S71011 Refer to “CHECKING THE INJECTOR WARNING PRESSURE” on page 6-9. • Check the injectors in a well-ventilated area free of combustible materials. Make EAS5S71043 CHECKING THE INJECTOR PRESSURE sure that there is no smoking or use of...

  • Page 281: Checking The Throttle Bodies

    THROTTLE BODIES f. Close the valve on the injector pressure • To clean the throttle body, remove the adapter. throttle body from the vehicle. g. Check that the specified air pressure is • While cleaning, avoid injuring your fin- held for about one seconds. gers working around the throttle valve.

  • Page 282: Checking The Intake Manifold Joints

    THROTTLE BODIES EAS5S71038 CHECKING THE INTAKE MANIFOLD JOINTS 1. Check: • Intake manifold joints Cracks/damage → Replace. EAS5S71016 CHECKING THE FUEL PRESSURE 1. Check: • Fuel pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the fuel tank bolt and holdup the e. Start the engine. fuel tank.

  • Page 283: Installing The Intake Manifold Assembly

    THROTTLE BODIES d. Measure the throttle position sensor output b. Install the rear cylinder intake manifold joint voltage. “2” to the intake manifold assembly. e. Adjust the throttle position sensor angle so that the output voltage is within the speci- Make sure that the projection “b”...
  • Page 284 THROTTLE BODIES 6-13...

  • Page 285: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM..................7-1 CIRCUIT DIAGRAM................7-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION .....7-3 TROUBLESHOOTING ................7-5 ELECTRIC STARTING SYSTEM..............7-7 CIRCUIT DIAGRAM................7-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......7-9 TROUBLESHOOTING ................7-11 CHARGING SYSTEM .................7-13 CIRCUIT DIAGRAM................7-13 TROUBLESHOOTING ................7-15 LIGHTING SYSTEM ...................7-17 CIRCUIT DIAGRAM................7-17 TROUBLESHOOTING ................7-19 SIGNALING SYSTEM.................7-21 CIRCUIT DIAGRAM................7-21 TROUBLESHOOTING ................7-23...
  • Page 286 CHECKING THE FUSES..............7-91 CHECKING AND CHARGING THE BATTERY........7-92 CHECKING THE RELAYS..............7-95 CHECKING THE TURN SIGNAL/HAZARD RELAY ......7-96 CHECKING THE DIODES ..............7-97 CHECKING THE IGNITION SPARK GAP ..........7-98 CHECKING THE SPARK PLUG CAPS ..........7-98 CHECKING THE IGNITION COILS ............7-98 CHECKING THE CRANKSHAFT POSITION SENSOR .......7-99 CHECKING THE LEAN ANGLE SENSOR ...........7-99 CHECKING THE STARTER MOTOR OPERATION......7-100 CHECKING THE STATOR COIL............7-100...

  • Page 288: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 289 IGNITION SYSTEM 1. Main switch 4. Main fuse 5. Battery 10.Relay unit 13.Neutral switch 14.Sidestand switch 16.ECU (engine control unit) 17.Rear cylinder ignition coil 18.Spark plug 19.Front cylinder ignition coil 24.Crankshaft position sensor 29.Lean angle sensor 57.Right handlebar switch 59.Engine stop switch 69.Ignition fuse...

  • Page 290: Engine Stopping Due To Sidestand Operation

    IGNITION SYSTEM EAS3D81009 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
  • Page 291 IGNITION SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. ECU (engine control unit) 9. Sidestand switch 10.Relay unit (diode) 11.Neutral switch...

  • Page 292: Troubleshooting

    IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Seat lock bracket 3. Battery 4. Battery box 5. Fuel tank 6. Side cover (cylinder head) 1.
  • Page 293 IGNITION SYSTEM 8. Check the main switch. NG→ Replace the main switch/immobilizer Refer to “CHECKING THE unit. SWITCHES” on page 7-87. OK↓ 9. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 7-87. OK↓...

  • Page 294: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 295 ELECTRIC STARTING SYSTEM 1. Main switch 4. Main fuse 5. Battery 6. Starter motor 7. Starter relay 10.Relay unit 11.Starting circuit cut-off relay 13.Neutral switch 14.Sidestand switch 49.Left handlebar switch 50.Clutch switch 57.Right handlebar switch 59.Engine stop switch 60.Start switch 69.Ignition fuse...

  • Page 296: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 297 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.

  • Page 298: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Seat lock bracket 1. Check the fuses. NG→ (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 7-91.
  • Page 299 ELECTRIC STARTING SYSTEM 8. Check the main switch. NG→ Replace the main switch/immobilizer Refer to “CHECKING THE unit. SWITCHES” on page 7-87. OK↓ 9. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 7-87. OK↓...

  • Page 300: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-13...
  • Page 301 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Main fuse 5. Battery 7-14...

  • Page 302: Troubleshooting

    CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Seat lock bracket 1. Check the fuse. NG→ (Main) Replace the fuse. Refer to “CHECKING THE FUSES” on page 7-91. OK↓...
  • Page 303 CHARGING SYSTEM 7-16...

  • Page 304: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-17...
  • Page 305 LIGHTING SYSTEM 1. Main switch 4. Main fuse 5. Battery 16.ECU (engine control unit) 32.Meter assembly 34.Multi-function meter 38.Meter light 39.High beam indicator light 43.Accessory light (OPTION) 44.Headlight relay 45.Auxiliary light 46.Headlight 49.Left handlebar switch 53.Pass switch 54.Dimmer switch 66.License plate light 67.Tail/brake light 69.Ignition fuse 70.Parking lighting fuse...

  • Page 306: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, posi- tion light, meter light and accessory light (OPTION). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Seat lock bracket 3.
  • Page 307 LIGHTING SYSTEM 7. Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 7-17. OK↓ Replace the ECU or meter assembly. 7-20...

  • Page 308: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-21...
  • Page 309 SIGNALING SYSTEM 1. Main switch 4. Main fuse 5. Battery 10.Relay unit 13.Neutral switch 16.ECU (engine control unit) 28.Speed sensor 31.Oil level switch 32.Meter assembly 33.Neutral indicator light 34.Multi-function meter 35.Oil level warning light 37.Fuel level warning light 40.Turn signal indicator light 42.Fuel sender 47.Horn 48.Turn signal relay...

  • Page 310: 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. • The speedometer fails to operate. • Before troubleshooting, remove the following part(s): 1.
  • Page 311 SIGNALING SYSTEM 3. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 7-21. OK↓ This circuit is OK. The brake light fails to come on. 1. Check the brake light bulb and NG→...
  • Page 312 SIGNALING SYSTEM 3. Check the turn signal relay. NG→ Refer to “CHECKING THE Replace the turn signal relay. RELAYS” on page 7-95. OK↓ 4. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring.
  • Page 313 SIGNALING SYSTEM 2. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 7-21. OK↓ Replace the meter assembly. The fuel level warning light fails to come on. 1.

  • Page 314: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 7-27...
  • Page 315 FUEL INJECTION SYSTEM 1. Main switch 4. Main fuse 5. Battery 8. Fuel injection system fuse 10.Relay unit 12.Fuel pump relay 13.Neutral switch 14.Sidestand switch 15.Fuel pump 16.ECU (engine control unit) 17.Rear cylinder ignition coil 18.Spark plug 19.Front cylinder ignition coil 20.Rear cylinder injector 21.Front cylinder injector 22.O...

  • Page 316: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 317: Fail-Safe Actions

    FUEL INJECTION SYSTEM EAS27363 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.

  • Page 318: Trouble Shooting Chart

    FUEL INJECTION SYSTEM EAS5S71040 TROUBLE SHOOTING CHART 7-31...

  • Page 319: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS27420 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.

  • Page 320: Troubleshooting Details

    FUEL INJECTION SYSTEM EAS27460 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the meter display according to the reinstatement method.
  • Page 321 FUEL INJECTION SYSTEM Fault code No. Normal signals are not received from the crankshaft position sen- Symptom sor. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause...
  • Page 322 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. When engine is stopped: Make sure that the atmospheric pressure Meter display is indicated.
  • Page 323 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. When engine is stopped: Make sure that the atmospheric pressure Meter display is indicated.
  • Page 324 FUEL INJECTION SYSTEM Fault code No. The intake air pressure sensor has failed (due to clogging of hose or Symptom sensor disconnection). Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. When engine is stopped: Make sure that the atmospheric pressure Meter display is indicated.
  • Page 325 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- ing code No. Display the throttle opening (between 0 and 125 degrees) Meter display When throttle is fully closed: 15 to 18 degrees When throttle is fully opened: 97 to 102 degrees...
  • Page 326 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- ing code No. Display the throttle opening (between 0 and 125 degrees) Meter display When throttle is fully closed: 15 to 18 degrees When throttle is fully opened: 97 to 102 degrees...
  • Page 327 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of ECU input line (Blue/Yellow lead) Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- ing code No. Sidestand retracted: ON indication Meter display Sidestand extended: OFF indication Make sure that the ON and OFF indication is switched when the sid- Checking method estand is retracted and extended.
  • Page 328 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of ECU input line (Blue/Yellow lead) Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- ing code No. Sidestand retracted: ON indication Meter display Sidestand extended: OFF indication Make sure that the ON and OFF indication is switched when the sid- Checking method estand is retracted and extended.
  • Page 329 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. -30 to 120 °C During cold starting: A temperature close to the ambient tempera- Meter display ture is indicated.
  • Page 330 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. -30 to 120 °C During cold starting: A temperature close to the ambient tempera- Meter display ture is indicated.
  • Page 331 FUEL INJECTION SYSTEM Fault code No. The O sensor does not operate. Symptom Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause nance job procedure...
  • Page 332 FUEL INJECTION SYSTEM Fault code No. The O sensor does not operate. Symptom Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause nance job procedure...
  • Page 333 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of engine temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. -30 to 120 °C During cold starting: A temperature close to the ambient tempera- Meter display ture is indicated.
  • Page 334 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of engine temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. -30 to 120 °C During cold starting: A temperature close to the ambient tempera- Meter display ture is indicated.
  • Page 335 FUEL INJECTION SYSTEM Fault code No. Symptom Turnover of vehicle Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- ing code No. The lean angle sensor value is indicated. 0 to 0.5 V Meter display The vehicle is in a vertical position: 0.4–1.4 V The vehicle is turned over: 3.7–4.4 V Remove the lean angle sensor, tilt the vehicle more than 65 degrees, Checking method...
  • Page 336 FUEL INJECTION SYSTEM Fault code No. Symptom Front cylinder ignition coil primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- ing code No. Each ignition coil turns On or Off 5 times per second.
  • Page 337 FUEL INJECTION SYSTEM Fault code No. Symptom Front cylinder ignition coil primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- ing code No. Each ignition coil turns On or Off 5 times per second.
  • Page 338 FUEL INJECTION SYSTEM Fault code No. Symptom Rear cylinder ignition coil primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- ing code No. Each ignition coil turns On or Off 5 times per second.
  • Page 339 FUEL INJECTION SYSTEM Fault code No. Symptom Rear cylinder ignition coil primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- ing code No. Each ignition coil turns On or Off 5 times per second.
  • Page 340 FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling Engine startup: Possible (stuck fully closed unable) Fail-safe action Riding: Possible Diagnostic monitor- ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order...
  • Page 341 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of injector lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. When engine is stopped: Make sure that the atmospheric pressure Meter display is indicated. When engine is cranking: The indication value changes because the Checking method injector changes.
  • Page 342 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of lean angle sensor lead Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- ing code No. The lean angle sensor value is indicated. 0 to 5.0 V Meter display The vehicle is in a vertical position: 0.4–1.4 V The vehicle is turned over: 3.7–4.4 V Remove the lean angle sensor, tilt the vehicle more than 65 degrees,...
  • Page 343 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of lean angle sensor lead Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- ing code No. The lean angle sensor value is indicated. 0 to 5.0 V Meter display The vehicle is in a vertical position: 0.4–1.4 V The vehicle is turned over: 3.7–4.4 V Remove the lean angle sensor, tilt the vehicle more than 65 degrees,...
  • Page 344 FUEL INJECTION SYSTEM Fault code No. Symptom A. Normal signals are not received from the speed sensor. B. Open or short circuit of neutral switch lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- 07 (Speed sensor) ing code No. Meter display Vehicle speed pulses: 0–999 Make sure that the indication value increases when the rotation...
  • Page 345 FUEL INJECTION SYSTEM A. Speed sensor system malfunction Item/components and Check or mainte- Sensor inspection Order probable cause nance job procedure Poor connection → Connection of speed Start the engine, and sensor (meter) coupler Connect it securely, or check the connection of Check the connection repair/replace the wire the coupler is secure.
  • Page 346 FUEL INJECTION SYSTEM B. Neutral switch system malfunction Item/components and Check or mainte- Sensor inspection Order probable cause nance job procedure Poor connection → Connection of neutral Start the engine, and switch coupler Reconnect or repair the check the secure con- Check the connection coupler.
  • Page 347 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage supplied to the fuel injector and fuel pump Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. The relay turns On or Off 5 times per second. Meter display The engine warning light flashes according to the On/Off switching.
  • Page 348 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage supplied to the fuel injector and fuel pump Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. The relay turns On or Off 5 times per second. Meter display The engine warning light flashes according to the On/Off switching.
  • Page 349 FUEL INJECTION SYSTEM Fault code No. Symptom An error is detected while reading or writing on EEP-ROM Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. The in self diagnostic code 44 detected EEP-ROM errors are indi- cated.
  • Page 350 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage is supplied to the ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause nance job...
  • Page 351 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage is supplied to the ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause nance job...
  • Page 352 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signal is received from the ECU. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause nance job...
  • Page 353 FUEL INJECTION SYSTEM Fault code No. Er-2 Symptom No signal is sent from ECU. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause nance job...
  • Page 354 FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Correct data cannot be received from the ECU. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause...
  • Page 355 FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom No registration data can be received from the meter unit. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause...
  • Page 356 FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 7-69...
  • Page 357 FUEL PUMP SYSTEM 1. Main switch 4. Main fuse 5. Battery 8. Fuel injection system fuse 10.Relay unit 12.Fuel pump relay 15.Fuel pump 16.ECU (engine control unit) 57.Right handlebar switch 59.Engine stop switch 69.Ignition fuse 7-70...
  • Page 358 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING The fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Seat lock bracket 3. Fuel tank 1. Check the fuses. NG→ (Main, ignition and fuel injection system) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
  • Page 359 FUEL PUMP SYSTEM 7-72...
  • Page 360 IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 7-73...
  • Page 361 IMMOBILIZER SYSTEM 1. Main switch 4. Main fuse 5. Battery 9. Immobilizer unit 16.ECU (engine control unit) 32.Meter assembly 34.Multi-function meter 41.Immobilizer indicator light 69.Ignition fuse 73.Backup fuse 7-74...
  • Page 362 IMMOBILIZER SYSTEM EAS27671 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • A code re-registering key (with a red bow) • Two standard keys (with a black bow) that can be re-registered with new codes •...
  • Page 363 IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration Acces- bilizer unit Standard requirement sory lock* Main Immobi- and key switch lizer unit √ Standard key is lost New standard key All keys have been Code re-registering √ √ √...
  • Page 364 IMMOBILIZER SYSTEM Standby mode: To enable the immobilizer system, turn the ignition key to "OFF". 30 seconds later, the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours. After that time, the indicator light will stop flashing, but the immobilizer system is still enabled. Standby mode d.
  • Page 365 IMMOBILIZER SYSTEM Standard key registration i. Registration mode a. Main switch "ON" b. Main switch "OFF" A. Registration of the second standard key is c. LED on complete. d. LED off B. Immobilizer system indicator light stops e. Less than 5.0 s flashing when the registration of the sec- f.
  • Page 366 IMMOBILIZER SYSTEM EAS27701 TROUBLESHOOTING When the main switch is turned to "ON", the immobilizer system indicator light does not come on nor flashes. 1. Check the fuses. NG→ (Main, ignition and backup) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 7-91.
  • Page 367 IMMOBILIZER SYSTEM EAS27721 SELF-DIAGNOSIS FAULT CODE INDICATION When a system failure occurs, the error code number is indicated in the LCD display of meter and the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code.
  • Page 368 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Key code registration Same standard key was Register another UNIT malfunction. attempted to be regis- standard key. tered two consecutive times. Undefinition code is Noise interference or 1. Check the wire received.
  • Page 369 IMMOBILIZER SYSTEM 7-82...
  • Page 370 ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 7-83...
  • Page 371 ELECTRICAL COMPONENTS 1. Engine temperature sensor 2. Intake air pressure sensor 3. Rear cylinder ignition coil 4. Front cylinder ignition coil 5. Sub-wire harness 6. ECU (engine control unit) 7. Turn signal relay 8. Speed sensor 9. Neutral switch 10.Oil level switch 11.Horn 12.Air temperature sensor 7-84...
  • Page 372 ELECTRICAL COMPONENTS 7-85...
  • Page 373 ELECTRICAL COMPONENTS 1. Main switch/immobilizer unit 2. Rectifier/regulator 3. Fuse box 4. Headlight fuse 5. Backup fuse 6. Taillight fuse 7. Ignition fuse 8. Signaling system fuse 9. Main fuse 10.Battery 11.Lean angle sensor 12.Starter relay 13.Fuel injection system fuse 14.Relay unit 15.Headlight relay 16.Sidestand switch...
  • Page 374 ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 7-87...
  • Page 375 ELECTRICAL COMPONENTS 1. Main switch 2. Rear brake light switch 3. Front brake light switch 4. Reset switch 5. Select switch 6. Engine stop switch 7. Start switch 8. Hazard switch 9. Neutral switch 10.Sidestand switch 11.Pass switch 12.Dimmer switch 13.Turn signal switch 14.Horn switch 15.Clutch switch...
  • Page 376 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
  • Page 377 ELECTRICAL COMPONENTS EAS27990 EWA13320 CHECKING THE BULBS AND BULB SOCK- WARNING Since the headlight bulb gets extremely Check each bulb and bulb socket for damage hot, keep flammable products and your or wear, proper connections, and also for conti- hands away from the bulb until it has nuity between the terminals.
  • Page 378 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Checking the condition of the bulb sockets b. If the pocket tester indicates “∞”, replace The following procedure applies to all of the the fuse.
  • Page 379 ELECTRICAL COMPONENTS 4. Install: • Rider seat Since MF batteries are sealed, it is not possi- Refer to “GENERAL CHASSIS” on page ble to check the charge state of the battery by 4-1. measuring the specific gravity of the electro- lyte.
  • Page 380 ELECTRICAL COMPONENTS • If it is impossible to regulate the charging Example current on the battery charger, be careful Open-circuit voltage = 12.0 V not to overcharge the battery. Charging time = 6.5 hours • When charging a battery, be sure to Charge of the battery = 20–30% remove it from the vehicle.
  • Page 381 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Charging method using a variable-current Charging method using a constant voltage (voltage) charger charger a. Measure the open-circuit voltage prior to a. Measure the open-circuit voltage prior to charging. charging. Voltage should be measured 30 minutes after Voltage should be measured 30 minutes after the engine is stopped.
  • Page 382 ELECTRICAL COMPONENTS Starter relay 1. Positive battery terminal 8. Check: 2. Negative battery terminal • Battery terminals 3. Positive tester probe Dirt → Clean with a wire brush. 4. Negative tester probe Loose connection → Connect properly. 9. Lubricate: Result •...
  • Page 383 ELECTRICAL COMPONENTS Result Continuity (between “3” and “4”) Headlight relay b. Turn the main switch to “ON”. c. Measure the turn signal relay input voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • Turn signal relay output voltage 1. Positive battery terminal Out of specification → Replace. 2.
  • Page 384 ELECTRICAL COMPONENTS EAS28050 CHECKING THE DIODES Continuity Positive tester probe → sky Relay unit (diode) blue “1” Negative tester probe → black/ 1. Check: • Relay unit (diode) yellow “2” Out of specification → Replace. No continuity Positive tester probe → black/ Pocket tester yellow “2”...
  • Page 385 ELECTRICAL COMPONENTS b. Connect the pocket tester (Ω × 1) to the EAS28070 CHECKING THE SPARK PLUG CAPS relay unit terminals as shown. The following procedure applies to all of the c. Check the relay unit (diode) for continuity. spark plug caps. d.
  • Page 386 ELECTRICAL COMPONENTS EAS28120 • Positive tester probe → CHECKING THE CRANKSHAFT POSITION black/red “1” SENSOR • Negative tester probe → 1. Disconnect: orange or gray/red “2” • Crankshaft position sensor coupler (from the wire harness) 2. Check: • Crankshaft position sensor resistance Out of specification →...
  • Page 387 ELECTRICAL COMPONENTS EWA13810 Lean angle sensor output voltage WARNING Less than 45° • A wire that is used as a jumper lead must 0.4–1.4 V have at least the same capacity of the bat- More than 45° tery lead, otherwise the jumper lead may 3.7–4.4 V burn.
  • Page 388 ELECTRICAL COMPONENTS c. Start the engine and operate it run at • Positive tester probe → approximately 5000 r/min. white “2” d. Measure the charging voltage. • Negative tester probe → white “3” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28180 CHECKING THE HORN 1. Check: •...
  • Page 389 ELECTRICAL COMPONENTS 3. Check: 2. Remove: • Oil level switch resistance • Fuel sender Out of specification → Replace the oil (from the fuel tank) level switch. 3. Check: • Fuel sender resistance Oil level switch Out of specification → Replace the fuel Minimum level position resis- sender.
  • Page 390 ELECTRICAL COMPONENTS • Positive tester probe → white/yellow “1” • Negative tester probe → black/blue “2” EAS3D81015 CHECKING THE OIL LEVEL WARNING LIGHT This model is equipped with a self-diagnosis device for the oil level detection circuit. 1. Check: b. Set the main switch to “ON”. •...
  • Page 391 ELECTRICAL COMPONENTS • Tester positive probe → black/blue “1” • Negative tester probe → brown “2” b. Measure the throttle position sensor maxi- mum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Measure the engine temperature sensor 3. Install: resistance. • Throttle position sensor ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3.
  • Page 392 ELECTRICAL COMPONENTS d. Slowly heat the water, and then let it cool b. Set the main switch to “ON”. down to the specified temperature. c. Measure the intake air pressure sensor e. Measure the air temperature sensor resis- output voltage. tance.

  • Page 393: 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 ..................8-3 POOR BRAKING PERFORMANCE ............8-3 FAULTY FRONT FORK LEGS ..............8-3 UNSTABLE HANDLING................8-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........8-3...

  • Page 394: Troubleshooting

    TROUBLESHOOTING EAS28450 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does • Improperly installed fuse not cover all the possible causes of trouble. It 3.

  • Page 395: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING • Improper throttle cable free play Transmission • Flooded throttle body • Seized transmission gear • Foreign object between transmission gears Electrical system • Improperly assembled transmission 1. Battery • Discharged battery EAS28550 JUMPS OUT OF GEAR • Faulty battery 2.

  • Page 396: Overheating

    TROUBLESHOOTING EAS28600 Malfunction OVERHEATING • Bent or damaged inner tube • Bent or damaged outer tube Engine • Damaged fork spring 1. Cylinder head(s) and piston(s) • Worn or damaged outer tube bushing • Heavy carbon buildup • Bent or damaged damper rod 2.
  • Page 397 TROUBLESHOOTING • Incorrect connection • Faulty battery • Improperly grounded circuit • Blown, damaged or incorrect fuse • Poor contacts (main switch) • Faulty wire harness • Burnt-out headlight bulb Headlight bulb burnt out • Wrong headlight bulb • Faulty battery •...
  • Page 398 EAS28740 58. Front brake light switch Sb/W Sky blue/White WIRING DIAGRAM 59. Engine stop switch White/Green 60. Start switch XVS950A(Y) White/Yellow 61. Select switch 1. Main switch Yellow/Black 62. Reset switch 2. AC magneto Yellow/Green 63. Hazard switch 3. Rectifier/regulator Yellow/Blue 64.
  • Page 400 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 401 WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES XVS950A(Y) XVS950A(Y) XVS950A(Y) XVS950A(Y) DE XVS950A(Y)
  • Page 402 WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES XVS950A(Y) XVS950A(Y) XVS950A(Y) XVS950A(Y) DE XVS950A(Y)

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