Yamaha VMAX 2009 Service Manual

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2009

SERVICE MANUAL

VMX17(Y)

2S3-28197-E0

Table of Contents

Troubleshooting

Summary of Contents for Yamaha VMAX 2009

Page 1 2009 SERVICE MANUAL VMX17(Y) 2S3-28197-E0...
Page 2 EAS20040 VMX17(Y) 2009 SERVICE MANUAL ©2008 by Yamaha Motor Co., Ltd. First edition, October 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 3 EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Page 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 mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
Page 7: Table Of Contents
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
ABS OPERATION ................... 1-14 ABS SELF-DIAGNOSIS FUNCTION............1-17 ABS WARNING LIGHT AND OPERATION..........1-20 YCC-T (YAMAHA CHIP CONTROLLED THROTTLE)/YCC-I (YAMAHA CHIP CONTROLLED INTAKE) ..........1-22 INSTRUMENT FUNCTIONS ..............1-26 IMPORTANT INFORMATION ............... 1-34 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-34 REPLACEMENT PARTS................. 1-34 GASKETS, OIL SEALS AND O-RINGS ..........
Page 10: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame under the rider seat. This information will be needed to order spare parts.
Page 11: Features
FEATURES EAS20170 FEATURES EAS30340 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Page 12: Fi System
FEATURES EAS2S31083 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm², 47.0 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 13: Outline Of The Abs
13. Rear wheel sensor rotor 7. Front wheel sensor The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake.
Page 14 FEATURES Useful terms • Wheel speed: The rotation speed of the front and rear wheels. • Chassis speed: The speed of the chassis. When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced. •...
Page 15 FEATURES a. Friction force between the tire and road e. Less slippery road surface surface f. Controlling zone b. Brake force g. Slippery road surface c. Side force d. Slip ratio (%) Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors.
Page 16 FEATURES a. Chassis speed d. Depressurizing phase b. Wheel speed e. Pressurizing phase c. Brake force ABS operation and vehicle control If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the limit of control.
Page 17 Slip ratio (%) b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con- dition and allows normal braking even if the ABS is not operating properly.
Page 18: Abs Component Functions
FEATURES ABS block diagram 1. Rear brake master cylinder 9. Buffer chamber 2. Hydraulic unit assembly 10. Rear brake caliper 3. Front brake master cylinder 11. Rear wheel sensor 4. Inlet solenoid valve 12. ABS warning light 5. ABS motor 13.
Page 19 FEATURES The front and rear sensor rotors each have 92 magnetic poles (46 pairs) and are installed close to the wheel sensors. As the sensor rotor rotates, the Hall element in the Hall IC installed in the wheel sensor generates pulses. The pulse frequency, which is proportional to the magnetic flux density, is converted into a wave in the Hall IC so that it can be output.
Page 20 FEATURES Hydraulic unit assembly The hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an ABS motor, and ABS ECU. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according to signals transmitted from the ABS ECU.
Page 21 FEATURES • Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating. 1. Buffer chamber (pressurizing phase) 2. Buffer chamber (depressurizing phase) 3. Raised piston 1-12...
Page 22 FEATURES • ABS ECU The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design. As shown in the block following diagram, the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. 4 5 6 18 19 1.
Page 23: Abs Operation
FEATURES • Some types of malfunctions are not recorded in the memory of the ABS ECU (e.g., a blown ABS ECU fuse). • The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on.
Page 24 FEATURES Normal braking (ABS not activated) When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU. Therefore, when the brake lever is squeezed, the hydraulic pressure in the brake master cylinder increases and the brake fluid is sent to the brake caliper.
Page 25 FEATURES Emergency braking (ABS activated) 1. Depressurizing phase When the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” signal transmitted from the ABS ECU. When this occurs, the inlet solenoid valve compresses the spring and closes the brake line from the brake master cylinder.
Page 26: Abs Self-Diagnosis Function
FEATURES 2. Pressurizing phase The outlet solenoid valve is closed by the “pressurization” signal transmitted from the ABS ECU. At this time, the ABS ECU controls the opening of the inlet solenoid valve. As the inlet solenoid valve opens, the brake line from the brake master cylinder opens, allowing the brake fluid to be sent to the brake caliper.
Page 27 FEATURES Instances when the ABS warning light comes on 1. The ABS warning light comes on when the main switch is turned to “ON”. The ABS warning light comes on for 2 seconds while the ABS is performing a self-diagnosis, then goes off if there are no problems.
Page 28 FEATURES a. ABS warning light b. Comes on 4. The ABS warning light flashes while riding. If the ABS warning light flashes while riding, there is no problem with the function of the ABS. How- ever, the ABS ECU input has unstable factors. (For details, refer to “ABS TROUBLESHOOTING OUTLINE”...
Page 29: Abs Warning Light And Operation
FEATURES EAS2S31088 ABS WARNING LIGHT AND OPERATION ABS warning light • When the main switch is turned to “ON”, the ABS warning light comes on for 2 seconds, then goes off. • The ABS warning light comes on while the start switch is being pushed. •...
Page 30 FEATURES ABS function EWA2S31036 WARNING • When hydraulic control is performed by the ABS, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal. When the ABS is activated, the grip between the road surface and tires is close to the limit.
Page 31: Ycc-T (Yamaha Chip Controlled Throttle)/Ycc-I (Yamaha Chip Controlled Intake)
Electronic control throttle systems have been used on automobiles, but Yamaha has de- veloped a faster, more compact system specifically for the needs of a sports motorcycle. The Yamaha- developed system has a high-speed calculating capacity that produces computations of running con- ditions every 1/1000th of a second.
Page 32 FEATURES Aims and advantages of using YCC-I system • Improved power band. By using a dual intake funnel system, YCC-I optimizes the effectiveness of the fuel injection system to deliver an incredibly precise air/fuel mixture to the combustion chamber. This degree of intake vol- ume control gives both improved low to mid-range power, as well as improved power in the higher rpm range.
Page 33 FEATURES YCC-T/YCC-I system outline 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. ECU (engine control unit) 5. ETV main CPU (32 bit) 6. ETV sub CPU (16 bit) 7. FI CPU (32 bit) 8. Throttle servo motor driver 9.
Page 34 FEATURES YCC-T/YCC-I control outline 1. Accelerator position sensor 16. ECU (engine control unit) 2. Throttle position sensor 17. Base map 3. Crankshaft position sensor 18. Idle speed control 4. Speed sensor 19. Calculated throttle valve opening angle 5. Coolant temperature sensor 20.
Page 35: Instrument Functions
FEATURES • a transmission gear indicator EAS2S31097 INSTRUMENT FUNCTIONS • a coolant temperature display • a self-diagnosis device 1. Multi-function display EWA2S31030 1. Odometer WARNING 2. Clock Be sure to stop the vehicle before making 3. Trip/Fuel any setting changes to the multi-function 4.
Page 36 FEATURES 2. Push “RESET”, then push “SELECT” to scroll through the functions and to highlight an item. • The transmission must be in neutral to change settings in this mode. • Shifting the transmission into gear saves all settings made, then cancels the Select mode and displays the Normal mode in all screens.
Page 37 FEATURES 2. Push “RESET”. 3. Push “SELECT” to highlight “Operation se- lection”. The indicator light flashes once every two sec- onds to show that it has been deactivated. The 4. Push “RESET”. indicator light goes off after this menu is exited. Push “SELECT”...
Page 38 FEATURES 1. Push “SELECT” to highlight “All”. 2. Push “RESET” and the r/min digits for the highlighted gear start flashing, then perform steps 4-8 under “To set all gears to the same r/min:” in order to set the r/min for the individ- ual gears.
Page 39 FEATURES 1. Push “SELECT” to highlight “Display”. 2. Push “RESET”. 3. Push “SELECT” to highlight “All reset”. 2. Push “RESET”; the following screen is dis- 4. Push “RESET”, then push “SELECT” to high- played. light “Yes”. 3. Push “RESET” and the hour digits start flash- 5.
Page 40 FEATURES 2. Push “RESET”. 1. Push “SELECT” to highlight “Stopwatch”. 3. Push “SELECT” to highlight “Stopwatch”. 2. Push “RESET”. 3. Push “SELECT” to highlight “Countdown”. 4. Push “RESET”. The multi-function display changes to the 4. Push “RESET”. The multi-function display Normal mode and the stopwatch is displayed changes to the Normal mode, the stopwatch in place of the clock.
Page 41 FEATURES • If, when the engine is running while the system • Pushing “RESET” displays the Normal mode status menu is displayed, the fuel level warning for five seconds. Pushing “SELECT” and “RE- light or coolant temperature warning light SET” for at least three seconds, changes the comes on, the Normal mode is automatically display to the Normal mode.
Page 42 FEATURES 1. Use the code re-registering key to start the engine. Make sure there are no other immobilizer keys close to the main switch, and do not keep more than one immobilizer key on the same key ring! Immobilizer system keys may cause signal inter- ference, which may prevent the engine from starting.
Page 43: Important Information
5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 44: Bearings And Oil Seals
IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.
Page 45: 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 46: 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 inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 47 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-12 90890-01426 YU-38411 Oil pressure gauge set 3-13 90890-03120 Oil pressure adapter B 3-13 90890-03124 Steering nut wrench 3-27, 4-81 90890-01403 Exhaust flange nut wrench YU-A9472 Damper rod holder (24 mm) 4-23, 4-27, 90890-01328 4-48, 4-50...
Page 48 90890-04159 Pinion bearing retainer & remover YM-04159 Rotor holding tool 5-14, 5-17, 90890-01235 5-18, 5-21 Universal magneto & rotor holder YU-01235 Yamaha bond No. 1215 5-24, 5-42, 90890-85505 5-77 (Three bond No.1215®) Valve spring compressor 5-30, 5-35 90890-04019 YM-04019 Valve spring compressor attachment...
Page 49 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide installer (ø5) 5-32 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5) 5-32 90890-04099 Valve guide reamer (5.0 mm) YM-04099 Sheave holder 5-40, 5-41, 90890-01701 5-42 Primary clutch holder YS-01880-A Flywheel puller 5-40...
Page 50 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston pin puller set 5-82 90890-01304 Piston pin puller YU-01304 YU-01304 Damper spring compressor 5-109, 5-111 90890-04090 Middle drive shaft nut wrench (55 mm) 5-110 90890-04054 Offset wrench 55 mm YM-04054 YM-04054 Middle gear backlash tool 5-113 90890-04080...
Page 51 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-13 90890-04132 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-13 90890-04058 Bearing driver 40 mm YM-04058 Pressure gauge 7-5, 7-13...
Page 52 SPECIAL TOOLS 1-43...
Page 53: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................ 2-10 ELECTRICAL SPECIFICATIONS ..............2-13 TIGHTENING TORQUES ................2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-16 ENGINE TIGHTENING TORQUES............2-17 CHASSIS TIGHTENING TORQUES............2-23 LUBRICATION POINTS AND LUBRICANT TYPES ........2-29 ENGINE....................
Page 54: General Specifications
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 2S34 (B) (F) 2S35 (Europe except (F)) (ZA) 2S36 (AUS) Dimensions Overall length 2395 mm (94.3 in) Overall width 820 mm (32.3 in) Overall height 1190 mm (46.9 in) Seat height 775 mm (30.5 in) Wheelbase 1700 mm (66.9 in) Ground clearance...
Page 55: Engine Specifications
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 1679.0 cm³ Cylinder arrangement V-type 4-cylinder Bore × stroke 90.0 × 66.0 mm (3.54 × 2.60 in) Compression ratio 11.30 :1 Minimum–maximum 1250–1650 kPa (12.5–16.5 kgf/cm², 177.8– 234.7 psi) Starting system Electric starter...
Page 56 ENGINE SPECIFICATIONS Coolant reservoir capacity (up to the maximum level mark) 0.27 L (0.29 US qt, 0.24 Imp.qt) Radiator cap opening pressure 107.9–137.3 kPa (1.08–1.37 kgf/cm², 15.6–19.9 psi) Radiator core Width 400.0 mm (15.75 in) Height 200.2 mm (7.88 in) Depth 24.0 mm (0.94 in) Sub radiator core...
Page 57 ENGINE SPECIFICATIONS Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.10–0.17 mm (0.0039–0.0067 in) Exhaust 0.22–0.29 mm (0.0087–0.0114 in) Valve dimensions Valve head diameter A (intake) 33.90–34.10 mm (1.3346–1.3425 in) Valve head diameter A (exhaust) 29.90–30.10 mm (1.1772–1.1850 in) Valve face width B (intake)
Page 58 ENGINE SPECIFICATIONS Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in) Limit 4.945 mm (0.1947 in) Valve stem diameter (exhaust) 4.960–4.975 mm (0.1953–0.1959 in) Limit 4.930 mm (0.1941 in) Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in) Limit 5.050 mm (0.1988 in) Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 in) Limit...
Page 59 ENGINE SPECIFICATIONS Piston Piston-to-cylinder clearance 0.025–0.050 mm (0.0010–0.0020 in) Limit 0.10 mm (0.0039 in) Diameter D 89.960–89.975 mm (3.5417–3.5423 in) Height H 10.0 mm (0.39 in) Offset 0.00 mm (0.0000 in) Piston pin bore inside diameter 19.004–19.015 mm (0.7482–0.7486 in) Limit 19.045 mm (0.7498 in) Piston pin outside diameter...
Page 60 ENGINE SPECIFICATIONS Connecting rod Oil clearance 0.032–0.056 mm (0.0013–0.0022 in) Bearing color code 1.Blue 2.Black 3.Brown 4.Green Crankshaft Width A 83.92–83.97 mm (3.304–3.306 in) Width B 242.72–243.17 mm (9.56–9.57 in) Runout limit C 0.030 mm (0.0012 in) Big end side clearance D 0.320–0.474 mm (0.0126–0.0187 in) Big end radial clearance E 0.032–0.056 mm (0.0013–0.0022 in)
Page 61 ENGINE SPECIFICATIONS 29/26 (1.115) 29/31 (0.935) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0.025 mm (0.0010 in) Shift fork C thickness 6.26–6.39 mm (0.2465–0.2516 in) Shift fork L, R thickness...
Page 62 ENGINE SPECIFICATIONS Shaft drive Middle gear backlash 0.05–0.10 mm (0.002–0.004 in) Ring-gear-to-thrust-washer clearance 0.15–0.25 mm (0.006–0.010 in) Final gear backlash 0.1–0.2 mm (0.004–0.008 in)
Page 63: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 31.00° Trail 148.0 mm (5.83 in) Front wheel Wheel type Cast wheel 18M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 64 CHASSIS SPECIFICATIONS Front disc brake Disc outside diameter × thickness 320.0 × 5.5 mm (12.60 × 0.22 in) Brake disc thickness limit 5.0 mm (0.20 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (outer)
Page 65 CHASSIS SPECIFICATIONS Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum 17 click(s) out* Standard 12 click(s) out* Maximum 1 click(s) out* Compression damping adjusting positions Minimum 20 click(s) out* Standard 12 click(s) out* Maximum 1 click(s) out* Rear suspension Type Swingarm (link suspension)
Page 66: 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.) 3.0°/900 r/min Engine control unit Model/manufacturer TBDF94/DENSO (B) (F) TBDF95/DENSO (Europe except (F)) (AUS) (ZA) Ignition coil Minimum ignition spark gap...
Page 67 ELECTRICAL SPECIFICATIONS Fuel level warning light Coolant temperature warning light Engine trouble warning light ABS warning light Immobilizer system indicator light Electric starting system System type Constant mesh Starter motor Power output 0.90 kW 0.0081–0.0099 Ω Armature coil resistance Brush overall length 11.3 mm (0.44 in) Limit 7.60 mm (0.30 in)
Page 68 ELECTRICAL SPECIFICATIONS Fuel injection system fuse 15.0 A ABS motor fuse 30.0 A ABS ECU fuse 7.5 A ABS solenoid fuse 15.0 A Backup fuse 7.5 A Electronic throttle valve fuse 7.5 A Spare fuse 20.0 A 15.0 A × 2 Spare fuse Spare fuse 7.5 A...
Page 69: Tightening Torques
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
Page 70: Engine Tightening Torques
TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Throttle body joint bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Cylinder head bolt See TIP. Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Cylinder head stud bolt...
Page 71 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Thermostat bracket bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil cooler union bolt 63 Nm (6.3 m·kgf, 45 ft·lbf) Engine oil drain bolt 43 Nm (4.3 m·kgf, 31 ft·lbf) Oil strainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil pipe 2 and oil strainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Page 72 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front exhaust pipe and exhaust 20 Nm (2.0 m·kgf, 14 ft·lbf) chamber bolt Rear exhaust pipe protector bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Exhaust chamber bracket bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) (front side) Exhaust chamber bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Page 73 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Crankcase cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) l=70 mm Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) (2.76 in) l=25 mm Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) (0.98 in) Plate bolt 20 Nm (2.0 m·kgf, 14 ft·lbf)
Page 74 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder identification sensor bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Upper radiator bracket bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Lower radiator bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Upper/lower radiator bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Coolant reservoir and right lower 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Page 75 TIGHTENING TORQUES Crankcase tightening sequence 16 17 35 40 36 A. Lower crankcase B. Upper crankcase 2-22...
Page 76: Chassis Tightening Torques
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine bracket bolt (front side) 60 Nm (6.0 m·kgf, 43 ft·lbf) Engine mounting bolt (front side) 60 Nm (6.0 m·kgf, 43 ft·lbf) Engine mounting nut (front side) 60 Nm (6.0 m·kgf, 43 ft·lbf) Engine bracket bolt (left and right 60 Nm (6.0 m·kgf, 43 ft·lbf)
Page 77 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear shock absorber assembly 45 Nm (4.5 m·kgf, 32 ft·lbf) lower bolt Swingarm damper bolt 16 Nm (1.6 m·kgf, 11 ft·lbf) Torque stop pin 115 Nm (11.5 m·kgf, 85 ft·lbf) Rebound damping adjusting 7 Nm (0.7 m·kgf, 5.1 ft·lbf) hose guide bolt Rebound damping adjusting...
Page 78 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Reflector bracket nut (for AUS) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Battery box bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Brake hose holder and bracket of 7 Nm (0.7 m·kgf, 5.1 ft·lbf) the upper radiator bolt Brake hose flare nut 21 Nm (2.1 m·kgf, 15 ft·lbf)
Page 79 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake caliper retaining bolt 27 Nm (2.7 m·kgf, 19 ft·lbf) Rear brake caliper bleed screw 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Brake pedal pinch bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Brake pedal bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Rear brake light switch bracket...
Page 80 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Meter assembly 1 bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Headlight lower bracket and 10 Nm (1.0 m·kgf, 7.2 ft·lbf) headlight side cover bolt Headlight lower bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Meter assembly 2 cover bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Top cover bolt...
Page 81 TIGHTENING TORQUES 1. First, tighten the lower ring nut to approximately 52 Nm (5.2 m·kgf, 37 ft·lbf) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 18 Nm (1.8 m·kgf, 13 ft·lbf) with a torque wrench. Front wheel axle pinch bolt 1.
Page 82: Lubrication Points And Lubricant Types
LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Camshaft lobes and camshaft journals Valve lifters Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Crankshaft big ends Piston surfaces Piston pins Crankshaft journals...
Page 83 Shaft drive gear oil Ring gear thrust washer (9079E-SH001-00) Ring gear splines Shaft drive gear oil Ring gear bearing (9079E-SH001-00) Yamaha bond Cylinder head cover mating surface No.1215 (Three bond No.1215®) Yamaha bond Cylinder head cover gasket No.1215 (Three bond No.1215®)
Page 84: Chassis
LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Engine bracket bolt thread (front center, front right and front left) Engine mounting bolt thread (front and rear) Steering bearings and upper bearing cover lip Lower bearing dust seal lip Steering nut thread (upper and lower) Front wheel oil seal lips (right and left) Front wheel axle bolt...
Page 85 LUBRICATION POINTS AND LUBRICANT TYPES 2-32...
Page 86: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-33...
Page 87 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pan 2. Oil strainer 3. Oil pump 4. Relief valve 5. Oil cooler 6. Bypass valve 7. Oil filter cartridge 8. Crankcase oil gallery 9. Balancer 10. Balancer journal 11. Oil nozzle #4 12.
Page 88: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-35...
Page 89 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner (rear cylinders) 2. Exhaust camshaft (rear cylinders) 3. Intake camshaft (rear cylinders) 4. Oil pipe 1 5. Timing chain tensioner (front cylinders) 6. Intake camshaft (front cylinders) 7. Exhaust camshaft (front cylinders) 8.
Page 90 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
Page 91 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Balancer shaft 2. Main axle 3. Drive axle 4. Intake camshaft 5. Exhaust camshaft 2-38...
Page 92 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
Page 93 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Crankshaft 2. Main gallery bolt 3. Oil pipe 2 4. Oil strainer 2-40...
Page 94 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-41...
Page 95 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil nozzle 3. Oil pump 4. Oil strainer 5. Oil pan 6. Relief valve assembly 7. Oil cooler 8. Oil pipe 1 2-42...
Page 96: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-43...
Page 97 COOLING SYSTEM DIAGRAMS 1. Thermostat inlet pipe (rear cylinder side) 2. Thermostat inlet hose (rear cylinder side) 3. Thermostat housing 4. Radiator cap 5. Thermostat inlet hose 2 (front cylinder side) 6. Coolant reservoir hose 7. Thermostat inlet pipe 2 (front cylinder side) 8.
Page 98 COOLING SYSTEM DIAGRAMS 2-45...
Page 99 COOLING SYSTEM DIAGRAMS 1. Thermostat outlet hose 2. Upper radiator inlet pipe 3. Upper radiator inlet hose 4. Left lower radiator inlet hose 5. Right lower radiator inlet hose 6. Coolant reservoir hose 7. Lower radiator outlet hose 8. Water pump inlet pipe 9.
Page 100: Cable Routing
CABLE ROUTING EAS20430 CABLE ROUTING 2-47...
Page 101 CABLE ROUTING 1. Front brake light switch lead O. Route the throttle cables between the wire harness mounting panel and the meter assembly 2 lead. 2. Brake hose (front brake master cylinder to hydraulic unit) P. Route the throttle cables between the wire harness mounting panel and the SELECT/RESET button 3.
Page 102 CABLE ROUTING 2-49...
Page 103 CABLE ROUTING 1. Throttle cables 2. Brake hose (front brake master cylinder to hydraulic unit) 3. Clutch hose 4. Meter assembly 1 5. Left handlebar switch lead 6. Meter assembly 1 lead 7. Headlight coupler 8. Auxiliary light coupler A. Route the throttle cables as shown in the illustration.
Page 104 CABLE ROUTING 2-51...
Page 105 CABLE ROUTING 1. Meter assembly 2 coupler M. Insert the projection on the intake funnel servo motor coupler into the hole in the thermostat 2. Ignition coil sub-wire harness 2 coupler housing bracket. 3. Front wheel sensor coupler N. Insert the projection on the immobilizer unit 4.
Page 106 CABLE ROUTING G 14 2-53...
Page 107 CABLE ROUTING 1. Radiator fan motor relay 2. Headlight relay 3. Relay unit 4. Fuse box 1 5. Turn signal/hazard relay 6. Rear wheel sensor coupler 7. Wire harness 8. Gas cylinder hose (rear shock absorber assembly) 9. O sensor lead 10.
Page 108 CABLE ROUTING 23 24 2-55...
Page 109 CABLE ROUTING 1. Meter assembly 2 O. Route the radiator fan motor sub-wire harness to the inside of the brake hose (hydraulic unit to left 2. Main switch couplers front brake caliper) and brake hose (front brake 3. Radiator fan motor sub-wire harness master cylinder to hydraulic unit).
Page 110 CABLE ROUTING 2-57...
Page 111 CABLE ROUTING 1. ABS test coupler 2. Fuel tank breather hose (fuel tank to rollover valve) 3. Fuel overflow hose 4. Fuel tank breather hose 5. Rollover valve A. Install the hose onto the hose fitting of the rollover valve, making sure that the hose contacts the valve.
Page 112 CABLE ROUTING 2-59...
Page 113 CABLE ROUTING 1. Meter assembly 1 lead Q. Route the wire harness under the intake air pressure sensor and fuel hose. 2. Upper radiator inlet pipe R. Point the end of the plastic locking tie outward, and 3. Meter assembly couplers –...
Page 114 CABLE ROUTING 2-61...
Page 115 CABLE ROUTING 1. Fuel pump coupler 2. Rear left turn signal light coupler 3. Tail/brake light coupler 4. Rear right turn signal light coupler 5. Tail/brake light lead 6. Rear right turn signal light lead 7. License plate light lead 8.
Page 116 CABLE ROUTING 2-63...
Page 117 CABLE ROUTING 1. ECU (engine control unit) 2. Wire harness 3. Lean angle sensor 4. Positive battery lead (to positive battery terminal) 5. Main fuse lead 6. Starter relay lead 7. Battery 8. Main fuse 9. Starter relay 10. Brake hose (hydraulic unit to left front brake caliper) 11.
Page 118 CABLE ROUTING 2-65...
Page 119 CABLE ROUTING 1. Accelerator position sensor 2. Throttle servo motor coupler 3. Sub-wire harness couplers 4. Intake air pressure sensor 5. Throttle position sensor 6. Throttle cable (accelerator cable) 7. Throttle cable (decelerator cable) 8. Injector #2 coupler 9. Injector #1 coupler 10.
Page 120 CABLE ROUTING 2-67...
Page 121 CABLE ROUTING 1. Brake hose (hydraulic unit to left front brake caliper) 2. Brake hose (hydraulic unit to rear brake caliper) 3. Brake hose (rear brake master cylinder to hydraulic unit) 4. Hydraulic unit assembly 5. Brake hose (front brake master cylinder to hydraulic unit) –...
Page 122 CABLE ROUTING 2-69...
Page 123 CABLE ROUTING 1. Clutch hose 2. Brake hose (hydraulic unit to left front brake caliper) 3. Brake hose (front brake master cylinder to hydraulic unit) 4. Brake hose (left front brake caliper to right front brake caliper) 5. Front wheel sensor lead 6.
Page 124 CABLE ROUTING 2-71...
Page 125: 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 ENGINE ......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODIES.......... 3-7 ADJUSTING THE EXHAUST GAS VOLUME ........... 3-9 ADJUSTING THE THROTTLE CABLE FREE PLAY ........
Page 126 CHASSIS ....................... 3-22 ADJUSTING THE FRONT DISC BRAKE..........3-22 CHECKING THE BRAKE FLUID LEVEL..........3-22 CHECKING THE FRONT BRAKE PADS ..........3-23 CHECKING THE REAR BRAKE PADS ..........3-23 CHECKING THE BRAKE HOSES............3-23 CHECKING THE BRAKE LIGHT SWITCHES......... 3-23 ADJUSTING THE REAR BRAKE LIGHT SWITCH .........
Page 128: Periodic Maintenance
UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 129 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Brake pedal pivot • Lubricate with lithium-soap- √ √ √ √...
Page 130 PERIODIC MAINTENANCE • Hydraulic brake and clutch service • Regularly check and, if necessary, correct the brake fluid and clutch fluid levels. • Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master and release cylinders, and change the brake and clutch fluids. •...
Page 131: Engine
ENGINE EAS20472 ENGINE EAS20530 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or A.
Page 132 ENGINE b. Turn the crankshaft almost 1/2 of a turn (167 c. Measure the valve clearance with a thickness degrees) counterclockwise until the “R” mark gauge. “a” on the generator rotor is aligned with the Thickness gauge stationary pointer “b” on the generator cover. 90890-03180 Feeler gauge set YU-26900-9...
Page 133 ENGINE • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. • Make a note of the position of each valve lifter “1” and valve pad “2” so that they can be in- stalled in the correct place.
Page 134: Synchronizing The Throttle Bodies
ENGINE 2. Remove: • Caps “1” g. Install the exhaust and intake camshafts, tim- ing chain and camshaft caps. Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Refer to “CAMSHAFTS” on page 5-9. • Lubricate the camshaft lobes and camshaft journals.
Page 135 ENGINE b. Check the vacuum pressure. The difference in vacuum pres- sure between the throttle bodies should not exceed 1.33 kPa (10 mmHg). If out of specification → Adjust the throttle body synchronization. L LLL L LLL L LLL L LLL L LLL Adjusting the throttle body synchronization 1.
Page 136: Adjusting The Exhaust Gas Volume
ENGINE EAS20600 ADJUSTING THE EXHAUST GAS VOLUME The selected cylinder number appears on the clock LCD. Be sure to set the CO density level to standard, • To decrease the selected cylinder number, and then adjust the exhaust gas volume. press the “RESET”...
Page 137: Checking The Spark Plugs
ENGINE ECA13320 NOTICE Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 4. Check: • Spark plug type Incorrect → Change. Manufacturer/model Throttle cable free play NGK/CR9EIA 3.0–5.0 mm (0.12–0.20 in) Manufacturer/model...
Page 138: Checking The Engine Oil Level
ENGINE ECA2S31003 NOTICE Before installing the spark plug, clean the spark • Engine oil also lubricates the clutch and the plug and gasket surface. wrong oil types or additives could cause 9. Connect: clutch slippage. Therefore, do not add any •...
Page 139: Measuring The Engine Oil Pressure
ENGINE Oil filter cartridge 17 Nm (1.7 m·kgf, 12 ft·lbf) L LLL L LLL L LLL L LLL L LLL 6. Check: • Engine oil drain bolt gasket Damage → Replace. 7. Install: • Engine oil drain bolt (along with the gasket) 4.
Page 140: Adjusting The Clutch Lever
ENGINE 2. Start the engine, warm it up for several min- Engine oil pressure Possible causes utes, and then turn it off. • Leaking oil passage ECA13410 NOTICE • Faulty oil filter Above specification • Oil viscosity too When the engine is cold, the engine oil will high have a higher viscosity, causing the engine oil pressure to increase.
Page 141: Bleeding The Hydraulic Clutch System
ENGINE EAS20900 BLEEDING THE HYDRAULIC CLUTCH Recommended fluid SYSTEM DOT 4 EWA13000 WARNING 3. Remove: Bleed the hydraulic clutch system whenever: • Clutch master cylinder reservoir cap • the system was disassembled, • Clutch master cylinder reservoir diaphragm • a clutch hose was loosened or removed, holder •...
Page 142: Replacing The Air Filter Element
ENGINE d. Place the other end of the hose into a con- 3. Remove: tainer. • Air filter element “1” e. Slowly squeeze the clutch lever several times. f. Fully squeeze the clutch lever without releas- ing it. g. Loosen the bleed screw. This will release the tension and cause the clutch lever to contact the handlebar grip.
Page 143: Checking The Throttle Body Joints
ENGINE • Top cover Refer to “GENERAL CHASSIS” on page 4-1. EAS21010 CHECKING THE THROTTLE BODY JOINTS 1. Remove: • Top cover • Intake duct assemblies Refer to “GENERAL CHASSIS” on page 4-1. • Lower air filter case Refer to “AIR FILTER CASE” on page 7-6. •...
Page 144: Checking The Exhaust System
ENGINE • Front exhaust pipe and exhaust chamber bolts “14” • Exhaust chamber and muffler bolts “15” • Rear exhaust pipe and exhaust chamber bolts “16” • Muffler bolts “17” • Exhaust chamber bolts “18” • Exhaust chamber bracket (front side) bolt “19”...
Page 145: Adjusting The Exup Cables
ENGINE 16 5 2. Check: • EXUP system operation M MMM M MMM M MMM M MMM M MMM a. Activate the diagnostic mode and select the diagnostic code No. D: 53. Refer to “FUEL INJECTION SYSTEM” on page 8-33. b.
Page 146: Checking The Coolant Level
ENGINE • Use only distilled water. However, if dis- Locknut (EXUP cable adjusting tilled water is not available, soft water may bolt) be used. 6 Nm (0.6 m·kgf, 4.3 ft·lbf) 3. Start the engine, warm it up for several min- utes, and then turn it off.
Page 147: Changing The Coolant
ENGINE • Right intake duct assembly Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: • Radiator cap “1” EWA13030 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury.
Page 148: Checking The Air Induction System
ENGINE ECA13480 NOTICE • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.
Page 149: Chassis
CHASSIS 4. Check: EAS21140 CHASSIS • Brake fluid level Below the minimum level mark “a” → Add the EAS21160 recommended brake fluid to the proper level. ADJUSTING THE FRONT DISC BRAKE 1. Adjust: Front brake • Brake lever position Recommended fluid (distance “a”...
Page 150: Checking The Front Brake Pads
CHASSIS EAS2S31010 CHECKING THE BRAKE HOSES In order to ensure a correct reading of the brake The following procedure applies to all of the fluid level, make sure the top of the brake fluid brake hoses and brake hose holders. reservoir is horizontal.
Page 151: Bleeding The Hydraulic Brake System (Abs)
CHASSIS 1. Bleed: Direction “a” • ABS Brake light comes on sooner. M MMM M MMM M MMM M MMM M MMM Direction “b” a. Fill the brake master cylinder reservoir or Brake light comes on later. brake fluid reservoir to the proper level with the recommended brake fluid.
Page 152: Adjusting The Shift Pedal
CHASSIS b. Turn the adjusting bolt “2” in direction “a” or ECA2S31005 NOTICE “b” until the specified installed shift rod length Make sure that the main switch is turned to is obtained. “OFF” before checking the operation of the Direction “a” hydraulic unit.
Page 153: Changing The Final Gear Oil
CHASSIS 6. Fill: Type • Final drive case Shaft drive gear oil (Part No.: (with the specified amount of the recom- 9079E-SH001–00) mended final gear oil) 4. Tighten: Quantity • Final gear oil check bolt 0.30 L (0.32 US qt, 0.26 Imp.qt) Final gear oil check bolt Refer to “CHECKING THE FINAL GEAR OIL 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Page 154: Checking The Front Fork
CHASSIS Refer to “STEERING HEAD” on page 4-78. e. Install the rubber washer “3”. f. Install the upper ring nut “2”. g. Finger tighten the upper ring nut, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned.
Page 155: Checking The Rear Suspension
CHASSIS Spring preload ECA13570 NOTICE • Grooves are provided to indicate the ad- justment position. • Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • Spring preload M MMM M MMM M MMM M MMM M MMM a.
Page 156: Adjusting The Rear Shock Absorber Assembly
CHASSIS Rebound damping Direction “a” ECA13590 NOTICE Compression damping is increased (suspension is harder). Never go beyond the maximum or minimum Direction “b” adjustment positions. Compression damping is decreased 1. Adjust: (suspension is softer). • Rebound damping M MMM M MMM M MMM M MMM M MMM...
Page 157 CHASSIS Direction “a” Direction “a” Spring preload is increased (suspen- Rebound damping is increased (sus- sion is harder). pension is harder). Direction “b” Direction “b” Spring preload is decreased (suspen- Rebound damping is decreased (sus- sion is softer). pension is softer). Rebound damping adjusting posi- tions Minimum...
Page 158: Checking The Tires
CHASSIS Compression damping adjusting Tire air pressure (measured on positions cold tires) Minimum Loading condition 12 click(s) out* 0–90 kg (0–198 lb) Standard Front 10 click(s) out* 250 kPa (2.50 kgf/cm², 36 psi) Maximum Rear 1 click(s) out* 290 kPa (2.90 kgf/cm², 42 psi) Loading condition * With the adjusting knob fully turned in 90–190 kg (198–419 lb)
Page 159: Checking The Wheels
After a tire or wheel has been changed or re- approved by Yamaha is used on this vehicle. placed, always balance the wheel. 2. Measure: Front tire •...
Page 160: Checking The Sidestand
CHASSIS 3. Check: EAS21720 LUBRICATING THE SIDESTAND • Wheel bearings Lubricate the pivoting point and metal-to-metal Refer to “CHECKING THE FRONT WHEEL” moving parts of the sidestand. on page 4-14 and “CHECKING THE REAR WHEEL” on page 4-24. Recommended lubricant Lithium-soap-based grease EAS2S31015 CHECKING THE SIDESTAND...
Page 161: Electrical System
ELECTRICAL SYSTEM EAS21750 EWA13320 ELECTRICAL SYSTEM WARNING Since the headlight bulb gets extremely hot, EAS21760 keep flammable products and your hands CHECKING AND CHARGING THE BATTERY away from the bulb until it has cooled down. Refer to “ELECTRICAL COMPONENTS” on page 8-125.
Page 162: Checking The Switches, Lights And Signals
ELECTRICAL SYSTEM M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw “1” in direction “a” or “b”. Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. L LLL L LLL L LLL L LLL...
Page 163 CHASSIS GENERAL CHASSIS..................4-1 INSTALLING THE ABS TEST COUPLER..........4-4 INSTALLING THE TOP COVER ............... 4-8 INSTALLING THE BATTERY..............4-10 FRONT WHEEL..................... 4-12 REMOVING THE FRONT WHEEL............4-14 DISASSEMBLING THE FRONT WHEEL..........4-14 CHECKING THE FRONT WHEEL ............4-14 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR ................
Page 164 REAR BRAKE ....................4-41 INTRODUCTION ..................4-47 CHECKING THE REAR BRAKE DISC............ 4-47 REPLACING THE REAR BRAKE PADS..........4-47 REMOVING THE REAR BRAKE CALIPER ..........4-48 DISASSEMBLING THE REAR BRAKE CALIPER ........4-49 CHECKING THE REAR BRAKE CALIPER..........4-49 ASSEMBLING THE REAR BRAKE CALIPER ........4-49 INSTALLING THE REAR BRAKE CALIPER...........
Page 165 SWINGARM....................4-88 REMOVING THE SWINGARM..............4-89 CHECKING THE SWINGARM ..............4-89 INSTALLING THE SWINGARM .............. 4-89 SHAFT DRIVE ....................4-91 TROUBLESHOOTING ................4-95 CHECKING THE FINAL GEAR OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS ......4-96 MEASURING THE FINAL GEAR BACKLASH ........4-96 ADJUSTING THE FINAL GEAR BACKLASH .........
Page 166: General Chassis
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats, side covers, and rear fender 7 Nm (0.7 m kgf, 5.1 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • Order Job/Parts to remove Q’ty Remarks Rider seat Passenger seat Left side cover Right side cover...
Page 167 GENERAL CHASSIS Removing the side cover inner panels, tail/brake light assembly, and rear turn signal light assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 168 GENERAL CHASSIS Removing the side cover inner panels, tail/brake light assembly, and rear turn signal light assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 169: Installing The Abs Test Coupler
GENERAL CHASSIS EAS2S31092 INSTALLING THE ABS TEST COUPLER 1. Install: • ABS test coupler “1” • Route the ABS test coupler lead through the slot “a” in the left side cover inner panel. • Make sure that the ABS test coupler clasp fac- es inward, toward the left side cover inner pan-...
Page 170 GENERAL CHASSIS Removing the passenger footrests and mudguard 2 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 26 Nm (2.6 m kgf, 19 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 171 GENERAL CHASSIS Removing the top cover, intake duct assemblies, and meter assembly 2 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 172 GENERAL CHASSIS Disassembling the intake duct assemblies 4 Nm (0.4 m kgf, 2.9 ft Ibf) • • 4 Nm (0.4 m kgf, 2.9 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Left intake duct Left intake duct inner plate Left intake grill Left intake dust filter Right intake duct...
Page 173: Installing The Top Cover
GENERAL CHASSIS EAS2S31033 INSTALLING THE TOP COVER 1. Install: • Top cover brackets Top cover bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) LOCTITE® First, tighten the bolts on the front side of the top cover bracket, and then on the rear side. 2.
Page 174 GENERAL CHASSIS Removing the battery 10 Nm (1.0 m kgf, 7.2 ft Ibf) 2 Nm (0.2 m kgf, 1.4 ft Ibf) • • • • Order Job/Parts to remove Q’ty Remarks Refer to “Removing the top cover, intake Top cover duct assemblies, and meter assembly 2”.
Page 175: Installing The Battery
GENERAL CHASSIS EAS2S31032 INSTALLING THE BATTERY 1. Install: • Battery seat “1” (to the battery “2”) Install the battery seat as shown in the illustra- tion. 2. Install: • Positive battery lead “1” • Negative battery lead “2” ECA2S31067 NOTICE First, connect the positive battery lead “1”, then the negative battery lead “2”.
Page 176 GENERAL CHASSIS Removing the meter assembly 1 and headlight 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 177: Front Wheel
FRONT WHEEL EAS21880 FRONT WHEEL Removing the front wheel, brake discs, wheel sensor and sensor housing 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 178 FRONT WHEEL Disassembling the front wheel 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil seal Oil seal Front wheel sensor rotor Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-13...
Page 179: Removing The Front Wheel
FRONT WHEEL b. Remove the oil seals “1” with a flat head EAS21900 REMOVING THE FRONT WHEEL screwdriver. ECA2S31007 NOTICE To prevent damaging the wheel or wheel sensor Keep magnets (including magnetic pick-up rotor, place a rag “2” between the screwdriver tools, magnetic screwdrivers, etc.) away and the surface of the wheel or rotor.
Page 180: Maintenance Of The Front Wheel Sensor And Sensor Rotor
FRONT WHEEL • Front wheel • Keep magnets (including magnetic pick-up Damage/wear → Replace. tools, magnetic screwdrivers, etc.) away Refer to “CHECKING THE TIRES” on page from the wheel sensor rotor. 3-31 and “CHECKING THE WHEELS” on • Do not drop or shock the wheel sensor or page 3-32.
Page 181: Assembling The Front Wheel
FRONT WHEEL M MMM M MMM M MMM M MMM M MMM • If any solvent gets on the wheel sensor ro- a. Hold the dial gauge at a right angle against tor, wipe it off immediately. the wheel sensor rotor surface. 1.
Page 182: Adjusting The Front Wheel Static Balance
FRONT WHEEL ECA2S31010 NOTICE Replace the wheel sensor rotor bolts with new ones. 3. Measure: • Wheel sensor rotor deflection Out of specification → Correct the wheel sen- sor rotor deflection or replace the wheel sen- sor rotor. Refer to “MAINTENANCE OF THE FRONT f.
Page 183: Installing The Front Wheel (Front Brake Discs)
FRONT WHEEL M MMM M MMM M MMM M MMM M MMM a. Turn the front wheel and make sure it stays at Align the slot in the front wheel sensor housing each position shown. with the projection of the front fork before as- sembly.
Page 184 FRONT WHEEL d. In the order pinch bolt “3” → pinch bolt “4” → pinch bolt “3”, tighten each bolt to 21 Nm (2.1 • When installing the front wheel sensor, check m·kgf, 15 ft·lbf) without performing temporary the wheel sensor lead for twists and the sensor tightening.
Page 185: Rear Wheel
REAR WHEEL EAS22030 REAR WHEEL Removing the rear wheel, brake disc, wheel sensor, and sensor housing 16 Nm (1.6 m kgf, 11 ft Ibf) • • 98 Nm (9.8 m kgf, 71 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
Page 186 REAR WHEEL Removing the rear wheel, brake disc, wheel sensor, and sensor housing 16 Nm (1.6 m kgf, 11 ft Ibf) • • 98 Nm (9.8 m kgf, 71 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
Page 187 REAR WHEEL Disassembling the rear wheel 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 188: Removing The Rear Wheel (Disc)
REAR WHEEL EAS22050 REMOVING THE REAR WHEEL (DISC) ECA2S31015 NOTICE Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel hub “1”, otherwise the wheel sensor rotor equipped in the wheel hub may be damaged, resulting in improper performance of the ABS system.
Page 189: Checking The Rear Wheel
REAR WHEEL • Lateral wheel runout Hexagon wrench (41) Refer to “CHECKING THE FRONT WHEEL” 90890-01525 on page 4-14. YM-01525 Radial wheel runout limit ECA2S31017 1.0 mm (0.04 in) NOTICE Lateral wheel runout limit The bearing retainer has left-handed 0.5 mm (0.02 in) threads.
Page 190 REAR WHEEL 1. Install: 4. Install: • Bearing “1” • Bearing retainer M MMM M MMM M MMM M MMM M MMM Installed depth of bearing “a” a. Tighten the bearing retainer “1” with a hexa- 9.6–10.6 mm (0.38–0.42 in) gon wrench (41) “2”.
Page 191: Adjusting The Rear Wheel Static Balance
REAR WHEEL 2. Check: 6. Measure: • Rear brake disc • Wheel sensor rotor deflection Refer to “CHECKING THE REAR BRAKE Out of specification → Correct the wheel sen- DISC” on page 4-47. sor rotor deflection or replace the wheel sen- 3.
Page 192 REAR WHEEL b. In the order pinch bolt “3” → pinch bolt “4” → pinch bolt “3”, tighten each bolt to 16 Nm (1.6 m·kgf, 11 ft·lbf) without performing temporary tightening. L LLL L LLL L LLL L LLL L LLL 6.
Page 193 REAR WHEEL Distance “a” (between the wheel sensor rotor and wheel sensor housing) 29.2–29.5 mm (1.15–1.16 in) 8. Install: • Rear wheel sensor Rear wheel sensor bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) ECA2S31021 NOTICE To route the rear wheel sensor lead, refer to “CABLE ROUTING”...
Page 194: Front Brake
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty...
Page 195 FRONT BRAKE Removing the front brake master cylinder 14 Nm (1.4 m kgf, 10 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”...
Page 196 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. 4-31...
Page 197 FRONT BRAKE Removing the front brake calipers 30 Nm (3.0 m kgf, 22 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
Page 198 FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Front brake pad Brake caliper piston...
Page 199: Introduction
FRONT BRAKE e. Measure the deflection 1.5 mm (0.06 in) be- EAS22220 INTRODUCTION low the edge of the brake disc. EWA14100 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.
Page 200: Replacing The Front Brake Pads
FRONT BRAKE 2. Install: d. Measure the brake disc deflection. • Brake pads e. If out of specification, repeat the adjustment • Brake pad springs steps until the brake disc deflection is within specification. Always install new brake pads and new brake f.
Page 201: Removing The Front Brake Calipers
FRONT BRAKE • Brake hose (hydraulic unit to left front brake caliper) Put the end of the brake hoses into a container and pump out the brake fluid carefully. EAS22350 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers.
Page 202: Checking The Front Brake Calipers
FRONT BRAKE • Whenever a brake caliper is disassembled, EAS22390 CHECKING THE FRONT BRAKE CALIPERS replace the brake caliper piston dust seals Recommended brake component replace- and brake caliper piston seals. ment schedule Recommended fluid Brake pads If necessary DOT 4 Piston seals Every two years Piston dust seals...
Page 203: Removing The Front Brake Master Cylinder
FRONT BRAKE • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. • When refilling, be careful that water does not enter the brake fluid reservoir.
Page 204: Checking The Front Brake Master Cylinder
FRONT BRAKE EAS22530 INSTALLING THE FRONT BRAKE MASTER To collect any remaining brake fluid, place a CYLINDER container under the master cylinder and the end 1. Install: of the brake hose. • Brake master cylinder “1” • Brake master cylinder holder “2” Brake master cylinder holder bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) •...
Page 205 FRONT BRAKE 3. Fill: 6. Check: • Brake master cylinder reservoir • Brake lever operation (with the specified amount of the recom- Soft or spongy feeling → Bleed the brake sys- mended brake fluid) tem. Refer to “BLEEDING THE HYDRAULIC Recommended fluid BRAKE SYSTEM (ABS)”...
Page 206: Rear Brake
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 27 Nm (2.7 m kgf, 19 ft Ibf) • • 27 Nm (2.7 m kgf, 19 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty...
Page 207 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 4 Nm (0.4 m kgf, 2.9 ft Ibf) •...
Page 208 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 4 Nm (0.4 m kgf, 2.9 ft Ibf) •...
Page 209 REAR BRAKE Disassembling the rear brake master cylinder 16 Nm (1.6 m kgf, 11 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake master cylinder joint Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
Page 210 REAR BRAKE Removing the rear brake caliper 98 Nm (9.8 m kgf, 71 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 16 Nm (1.6 m kgf, 11 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 211 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 212: Introduction
REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 5.5 mm (0.22 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...
Page 213: Removing The Rear Brake Caliper
REAR BRAKE • Brake pads Always install new brake pads, brake pad shims, brake pad insulator, and brake pad supports as a set. M MMM M MMM M MMM M MMM M MMM a. Connect a clear plastic hose “1” tightly to the bleed screw “2”.
Page 214: Disassembling The Rear Brake Caliper
REAR BRAKE EAS22640 CHECKING THE REAR BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston dust seal Every two years Piston seal Every two years Brake hoses Every four years Every two years and Brake fluid whenever the brake EAS22600 DISASSEMBLING THE REAR BRAKE is disassembled...
Page 215: Installing The Rear Brake Caliper
REAR BRAKE • Never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal.
Page 216 REAR BRAKE • Rear wheel sensor lead holder Brake caliper retaining bolt 27 Nm (2.7 m·kgf, 19 ft·lbf) Rear wheel sensor lead holder bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 5. Fill: • Brake fluid reservoir (with the specified amount of the recom- mended brake fluid) L LLL L LLL...
Page 217: Removing The Rear Brake Master Cylinder
REAR BRAKE 2. Check: • Brake master cylinder kit Damage/scratches/wear → Replace. 3. Check: • Brake fluid reservoir Cracks/damage → Replace. • Brake fluid reservoir diaphragm Cracks/damage → Replace. 4. Check: • Brake hoses Cracks/damage/wear → Replace. 8. Check: • Brake pedal operation EAS22730 Soft or spongy feeling →...
Page 218 REAR BRAKE 2. Install: 4. Fill: • Brake fluid reservoir • Brake hose gaskets (with the specified amount of the recom- • Brake hose (rear brake master cylinder to hy- mended brake fluid) draulic unit) “1” • Brake hose union bolt “2” Recommended fluid DOT 4 Brake hose union bolt...
Page 219 REAR BRAKE 7. Check: • Brake pedal operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-24. 8. Adjust: • Rear brake light operation timing Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”...
Page 220: Abs (Anti-Lock Brake System)
ABS (ANTI-LOCK BRAKE SYSTEM) EAS22760 ABS (ANTI-LOCK BRAKE SYSTEM) EAS2S31022 ABS COMPONENTS CHART 1. ABS test coupler 2. Hydraulic unit assembly 3. Brake hose (hydraulic unit to left front brake caliper) 4. Brake hose (front brake master cylinder to hydraulic unit) 5.
Page 221 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 16 Nm (1.6 m kgf, 11 ft Ibf) • • 16 Nm (1.6 m kgf, 11 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 222: Removing The Hydraulic Unit Assembly
ABS (ANTI-LOCK BRAKE SYSTEM) EAS2S31023 REMOVING THE HYDRAULIC UNIT Do not operate the brake lever and brake pedal ASSEMBLY while removing the brake hoses. ECA2S31024 NOTICE ECA2S31031 Unless necessary, avoid removing and in- NOTICE stalling the brake pipes of the hydraulic unit When removing the brake hoses, cover the assembly.
Page 223: Installing The Hydraulic Unit Assembly
ABS (ANTI-LOCK BRAKE SYSTEM) Brake hose flare nut 16 Nm (1.6 m·kgf, 11 ft·lbf) Brake hose holder bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) ECA2S31027 NOTICE If the brake hose flare nut does not turn eas- ily, replace the hydraulic unit assembly, brake hoses, and related parts as a set.
Page 224: Hydraulic Unit Operation Tests
ABS (ANTI-LOCK BRAKE SYSTEM) 9. Delete the fault codes. (Refer to “[D-1] DE- LETING THE FAULT CODES” on page 8-122.) 10.Perform a trial run. (Refer to “TRIAL RUN” on page 4-62.) EAS22800 HYDRAULIC UNIT OPERATION TESTS The reaction-force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is 6.
Page 225 ABS (ANTI-LOCK BRAKE SYSTEM) 5. Connect the test coupler adapter “1” to the ECA2S31028 NOTICE ABS test coupler “2”. • Check that the pulse is felt in the brake le- Test coupler adapter ver, brake pedal, and again in the brake le- 90890-03149 ver, in this order.
Page 226 ABS (ANTI-LOCK BRAKE SYSTEM) 9. After releasing the start switch, operate the 5. Connect the test coupler adapter “1” to the brake lever and the brake pedal simulta- ABS test coupler “2”. neously. Test coupler adapter 90890-03149 10.A reaction-force pulsating action is generated in the brake lever “1”...
Page 227: Trial Run
ABS (ANTI-LOCK BRAKE SYSTEM) • Be sure to continue operating the brake lever and brake pedal even after the pulsating action has stopped. 12.After the pulsating action has stopped in the brake pedal, it is generated in the brake lever 0.5 second later and continues for approxi- mately 1.5 seconds.
Page 228: Handlebar
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 28 Nm (2.8 m kgf, 20 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 229 HANDLEBAR Removing the handlebar 28 Nm (2.8 m kgf, 20 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 230: Removing The Handlebar
HANDLEBAR EAS22860 ECA2S31030 REMOVING THE HANDLEBAR NOTICE 1. Stand the vehicle on a level surface. First, tighten the bolts on the front side of the EWA13120 handlebar holder, and then on the rear side. WARNING Securely support the vehicle so that there is no danger of it falling over.
Page 231 HANDLEBAR L LLL L LLL L LLL L LLL L LLL 7. Install: 5. Install: • Throttle grip • Left handlebar switch “1” • Throttle cables • Throttle cable housings “1” Align the projection “a” on the left handlebar switch with the hole “b” in the handlebar. Align the projection “a”...
Page 232 HANDLEBAR • Align the mating surfaces of the brake master cylinder holder with the punch mark “a” on the handlebar. • First, tighten the upper bolt, then the lower bolt. 10.Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CA- BLE FREE PLAY”...
Page 233: Front Fork
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 26 Nm (2.6 m kgf, 19 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf)
Page 234 FRONT FORK Removing the front fork legs 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 26 Nm (2.6 m kgf, 19 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 235 FRONT FORK Disassembling the front fork legs 22 Nm (2.2 m kgf, 16 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs.
Page 236 FRONT FORK Disassembling the front fork legs 22 Nm (2.2 m kgf, 16 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil seal Washer Outer tube bushing Inner tube bushing Outer tube For assembly, reverse the disassembly pro- cedure.
Page 237: Removing The Front Fork Legs
FRONT FORK 1. Hold the locknut “1” and loosen the cap bolt EAS22960 REMOVING THE FRONT FORK LEGS “2”. 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.
Page 238: Checking The Front Fork Legs
FRONT FORK 1. Check: • Inner tube While holding the damper rod with the damper • Outer tube rod holder “1”, loosen the damper rod assembly Bends/damage/scratches → Replace. bolt. EWA13650 WARNING Damper rod holder Do not attempt to straighten a bent inner 90890-01447 tube as this may dangerously weaken it.
Page 239 FRONT FORK EWA13660 WARNING • Make sure the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor han- dling and a loss of stability. • When assembling the front fork leg, be sure to replace the following parts: –Inner tube bushing 3.
Page 240 FRONT FORK Adjust the oil seal clip so that it fits into the outer tube’s groove. 6. Install: • Oil seal “1” (with the fork seal driver “2”) 8. Install: Fork seal driver 90890-01502 • Dust seal “1” YM-A0948 (with the fork seal driver “2”) ECA14220 Fork seal driver NOTICE...
Page 241 FRONT FORK 10.After filling the front fork leg, slowly stroke the damper rod assembly “1” up and down (at least ten times) to distribute the fork oil. Be sure to stroke the damper rod assembly slowly because the fork oil may spurt out. 14.Install: •...
Page 242: Installing The Front Fork Legs
FRONT FORK Lower bracket pinch bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Turn signal light pinch nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Cap bolt 25 Nm (2.5 m·kgf, 18 ft·lbf) Upper bracket pinch bolt 26 Nm (2.6 m·kgf, 19 ft·lbf) EWA13680 WARNING a.
Page 243: Steering Head
STEERING HEAD EAS23090 STEERING HEAD Removing the coupler holder and brake hose holder 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 244 STEERING HEAD Removing the coupler holder and brake hose holder 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty...
Page 245 STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kgf, 85 ft lbf) • • 1st 52 Nm (5.2 m kgf, 37 ft lbf) • • 2nd 18 Nm (1.8 m kgf, 13 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Steering stem nut...
Page 246: Removing The Lower Bracket
STEERING HEAD M MMM M MMM M MMM M MMM M MMM EAS23110 REMOVING THE LOWER BRACKET a. Remove the bearing races from the steering 1. Stand the vehicle on a level surface. head pipe “1” with a long rod “2” and hammer. EWA13120 b.
Page 247 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 3-26. 3. Install: • Upper bracket •...
Page 248: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 48 Nm (4.8 m kgf, 35 ft Ibf) 48 Nm (4.8 m kgf, 35 ft Ibf) • • • • 48 Nm (4.8 m kgf, 35 ft Ibf) •...
Page 249 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 48 Nm (4.8 m kgf, 35 ft Ibf) 48 Nm (4.8 m kgf, 35 ft Ibf) • • • • 48 Nm (4.8 m kgf, 35 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf)
Page 250: Handling The Rear Shock Absorber And Gas Cylinder
REAR SHOCK ABSORBER ASSEMBLY EAS23170 EAS23230 HANDLING THE REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER AND GAS CYLINDER ASSEMBLY 1. Stand the vehicle on a level surface. EWA13750 WARNING EWA13120 WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Be- Securely support the vehicle so that there is fore handling the rear shock absorber or gas no danger of it falling over.
Page 251: Installing The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY 3. Check: Installed depth “a” • Spacers 4.6–5.6 mm (0.18–0.22 in) • Collars Installed depth “b” Damage/scratches → Replace. 3.0–4.0 mm (0.12–0.16 in) Installed depth “c” EAS23310 INSTALLING THE REAR SHOCK 1.0 mm (0.04 in) ABSORBER ASSEMBLY Installed depth “d”...
Page 252 REAR SHOCK ABSORBER ASSEMBLY • Hold the connecting arm and relay arm bolt so When installing the rear shock absorber assem- that it does not turn while tightening the con- bly, lift up the swingarm. necting arm and relay arm nut. 6.
Page 253: Swingarm
SWINGARM EAS23330 SWINGARM Removing the swingarm 100 Nm (10.0 m kgf, 72 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 254: Removing The Swingarm
SWINGARM EAS23350 EAS23360 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: • Swingarm EWA13120 WARNING Bends/cracks/damage → Replace. Securely support the vehicle so that there is 2. Check: no danger of it falling over. •...
Page 255 SWINGARM d. Tighten the pivot bolt locknut. Pivot bolt locknut 100 Nm (10.0 m·kgf, 72 ft·lbf) L LLL L LLL L LLL L LLL L LLL 4-90...
Page 256: Shaft Drive
SHAFT DRIVE EAS23551 SHAFT DRIVE Removing the final drive assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 42 Nm (4.2 m kgf, 30 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf)
Page 257 SHAFT DRIVE Disassembling the final drive assembly 85 Nm (8.5 m kgf, 61 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 19 Nm (1.9 m kgf, 13 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 258 SHAFT DRIVE Disassembling the final drive assembly 85 Nm (8.5 m kgf, 61 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 19 Nm (1.9 m kgf, 13 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 259 SHAFT DRIVE Disassembling the final drive assembly 85 Nm (8.5 m kgf, 61 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 19 Nm (1.9 m kgf, 13 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 260: Troubleshooting
SHAFT DRIVE EAS23560 TROUBLESHOOTING Symptom Possible cause 1. A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration or sus- B. Improper gear backlash tained speeds (not to be confused with en- C. Damaged gear teeth gine surging or transmission-related D.
Page 261: Checking The Final Gear Oil For Contamination And Checking The Shaft Drive For Leaks
SHAFT DRIVE NO → 2. Place the vehicle on a suitable Rear wheel bearings and shaft drive bear- stand so that the rear wheel is ele- ings are probably not damaged. Repeat vated and then spin the rear wheel. the test or remove and check the compo- Is the wheel bearing damaged? nents.
Page 262: Adjusting The Final Gear Backlash
SHAFT DRIVE 4. Measure: h. Reinstall the ring gear fix bolt, and dial gauge. • Final gear backlash i. Repeat steps (d) to (h) three more times (for Out of specification → Adjust. a total of four measurements). j. If any of the readings are over specification, Final gear backlash adjust the final gear backlash.
Page 263: Disassembling The Final Drive Assembly
SHAFT DRIVE 3. Adjust: • Final gear backlash M MMM M MMM M MMM M MMM M MMM a. Select the suitable ring gear shim(s) and thrust washer with the following chart. Final gear backlash is in- Thinner shim creased. Final gear backlash is de- Thicker shim creased.
Page 264: Removing And Installing The Bearing
SHAFT DRIVE EAS2S31031 REMOVING AND INSTALLING THE BEARING 1. Check: • Bearing Damage → Replace. 2. Remove: • Dowel pin “1” • Bearing “2” M MMM M MMM M MMM M MMM M MMM a. Heat the final drive case to approximately 4.
Page 265: Aligning The Final Drive Pinion Gear And Ring Gear
SHAFT DRIVE • Install the final drive case stud bolts so that the specified installed length “a” is obtained. a. 30–31 mm (1.18–1.22 in) EAS23640 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR Aligning the final drive pinion gear and ring gear is necessary when any of the following parts are replaced: b.
Page 266 SHAFT DRIVE f = the ring gear bearing thickness constant. Final drive pinion gear shims Thickness (mm) Ring gear bearing thickness 0.30 0.40 0.50 15.90 mm (0.63 in) Since the final drive pinion gear shims are Example: only available in 0.10 mm increments, round If the ring gear bearing housing is marked off to the hundredths digit.
Page 267 SHAFT DRIVE ECA14350 NOTICE The bearing retainer has left-hand threads. To tighten the bearing retainer, turn it coun- terclockwise. Bearing retainer wrench 90890-04159 Pinion bearing retainer & remov- YM-04159 5. Stake the coupling gear nut “1” at a cutout “a” in the final drive pinion gear.
Page 268: Checking The Drive Shaft
SHAFT DRIVE e. Measure the width of the flattened Plasti- EAS2S31030 INSTALLING THE FINAL DRIVE ASSEMBLY gauge® “1”. 1. Install: • Drive shaft Ring-gear-to-thrust-washer clear- (to the universal joint) ance 2. Install: 0.15–0.25 mm (0.006–0.010 in) • Universal joint (final drive side) M MMM M MMM M MMM...
Page 269 SHAFT DRIVE Lift the universal joint “1” and make sure that it falls freely when released. 7. Install: • Rear wheel Refer to “REAR WHEEL” on page 4-20. 8. Fill: 4. Install: • Final gear case • Final drive assembly Refer to “CHECKING THE ENGINE OIL LEVEL”...
Page 270 SHAFT DRIVE 4-105...
Page 271: Engine
ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE............... 5-7 INSTALLING THE EXUP CABLES ............5-8 CAMSHAFTS....................5-9 REMOVING THE CAMSHAFTS.............. 5-13 CHECKING THE CAMSHAFTS .............. 5-14 CHECKING THE CAMSHAFT SPROCKETS ......... 5-15 CHECKING THE CAMSHAFT GEARS ........... 5-16 CHECKING THE DECOMPRESSION SYSTEM........5-16 CHECKING THE TIMING CHAIN GUIDES..........
Page 272 CLUTCH ......................5-48 REMOVING THE CLUTCH ..............5-56 CHECKING THE FRICTION PLATES............. 5-56 CHECKING THE CLUTCH PLATES ............5-57 CHECKING THE CLUTCH SPRING PLATE........... 5-58 CHECKING THE CLUTCH HOUSING ............ 5-58 CHECKING THE CLUTCH BOSS............5-58 CHECKING THE PRESSURE PLATE ............ 5-58 CHECKING THE CLUTCH PUSH RODS ..........
Page 273 CRANKSHAFT AND BALANCER ..............5-92 REMOVING THE BALANCER SHAFT JOURNAL BEARINGS ....5-93 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ...... 5-93 CHECKING THE TIMING CHAINS ............5-93 CHECKING THE CRANKSHAFT ............5-93 CHECKING THE BALANCER ..............5-95 INSTALLING THE CRANKSHAFT ............5-96 INSTALLING THE BALANCER SHAFT ..........
Page 274: Engine Removal
ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the exhaust chamber and exhaust pipes 45 Nm (4.5 m kgf, 32 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • •...
Page 275 ENGINE REMOVAL Removing the exhaust chamber and exhaust pipes 45 Nm (4.5 m kgf, 32 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
Page 276 ENGINE REMOVAL Disconnecting the leads and hose 28 Nm (2.8 m kgf, 20 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Right rider footrest assembly Refer to “REAR BRAKE” on page 4-41. Drive shaft Refer to “SHAFT DRIVE”...
Page 277 ENGINE REMOVAL Disconnecting the leads and hose 28 Nm (2.8 m kgf, 20 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Crankshaft position sensor coupler Disconnect. Left rider footrest assembly Sidestand switch coupler Disconnect.
Page 278 ENGINE REMOVAL Removing the engine 60 Nm (6.0 m kgf, 43 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 279 ENGINE REMOVAL Removing the engine 60 Nm (6.0 m kgf, 43 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 280: Installing The Engine
ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE Engine bracket bolt (front center 1. Install: side) • Engine mounting collar (inside) “1” 60 Nm (6.0 m·kgf, 43 ft·lbf) • Engine mounting collar (outside) “2” Engine bracket bolt (front left side) • Engine mounting collar (inside) “3” 60 Nm (6.0 m·kgf, 43 ft·lbf) •...
Page 281: Installing The Exup Cables
ENGINE REMOVAL M MMM M MMM M MMM M MMM M MMM a. Install the EXUP cable 1 “1” onto the servo motor pulley, and then install the cable onto the right side of the EXUP bracket. • The correct installation position for the EXUP cable 1 is identified by the casting mark “a”...
Page 282: Camshafts
CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head covers 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) •...
Page 283 CAMSHAFTS Removing the cylinder head covers 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) •...
Page 284 CAMSHAFTS Removing the camshafts (16) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) • • (16) 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 285 CAMSHAFTS Removing the camshafts (16) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) • • (16) 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 286: Removing The Camshafts
CAMSHAFTS EAS23820 REMOVING THE CAMSHAFTS The identification marks on the camshaft caps are the same for both the front and rear cylin- Rear cylinders ders; therefore, be sure to identify the cylinder of 1. Position: each camshaft cap so that it can be reinstalled in •...
Page 287: Checking The Camshafts
CAMSHAFTS While holding the camshaft sprocket and cam- shaft gear with the rotor holding tool “1”, loosen the camshaft sprocket bolts and camshaft gear bolts. Rotor holding tool 90890-01235 Universal magneto & rotor holder YU-01235 L LLL L LLL L LLL L LLL L LLL EAS23850...
Page 288: Checking The Camshaft Sprockets
CAMSHAFTS • Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge®. Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 3.
Page 289: Checking The Camshaft Gears
CAMSHAFTS EAS23960 CHECKING THE TIMING CHAIN TENSIONERS The following procedure applies to both of the timing chain tensioners. 1. Disassemble: • Timing chain tensioner Squeeze timing chain tensioner clip 2 “5”, and then remove the timing chain tensioner spring and timing chain tensioner rod. a.
Page 290: Installing The Camshafts
CAMSHAFTS b. Install the timing chain tensioner spring, tim- L LLL L LLL L LLL L LLL L LLL ing chain tensioner spring seat, and timing EAS24020 chain tensioner rod. INSTALLING THE CAMSHAFTS c. Squeeze timing chain tensioner clip 2 “1”, and then push the timing chain tensioner rod Front cylinders-intake side “3”...
Page 291 CAMSHAFTS M MMM M MMM M MMM M MMM M MMM a. Make sure that piston #2 is at TDC. b. Turn the crankshaft about 2/3 of a turn (223 degrees) counterclockwise until the “F” mark “a” on the generator rotor is aligned with the stationary pointer “b”...
Page 292 CAMSHAFTS 8. Rotate the crankshaft counterclockwise a few 5. Install: times to release the timing chain tensioner • Intake camshaft cap bolts rod. Intake camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) If the timing chain tensioner rod does not re- lease, rotate the crankshaft clockwise.
Page 293 CAMSHAFTS L LLL L LLL L LLL L LLL L LLL 3. Install: 2. Install: • Exhaust camshaft cap bolts • Exhaust camshaft “1” • Exhaust camshaft caps “2” Exhaust camshaft cap bolt ECA2S31034 10 Nm (1.0 m·kgf, 7.2 ft·lbf) NOTICE Do not turn the crankshaft when installing ECA2S31035...
Page 294 CAMSHAFTS Intake camshaft gear bolt Rotor holding tool 24 Nm (2.4 m·kgf, 17 ft·lbf) 90890-01235 Universal magneto & rotor holder YU-01235 • Install the camshaft gear onto the left side of the camshaft. • Install the camshaft gear so that the bolt hole next to the “R”...
Page 295 CAMSHAFTS • Tighten the camshaft cap bolts in stages and in ECA2S31034 NOTICE a crisscross pattern. Do not turn the crankshaft when installing 6. Install: the camshaft to avoid damage or improper • Timing chain guide valve timing. 7. Install: •...
Page 296 CAMSHAFTS 9. Check that the timing chain is taut. If the • Make sure each camshaft cap is installed in its chain is slack, reinstall the timing chain ten- original place. Refer to the identification marks sioner. as follows: Exhaust-left side: “2S3-83” Rear cylinders-exhaust side Exhaust-right side: “2S3-78”...
Page 297 “T2” mark “a” on the generator rotor with the stationary pointer “b” on the generator cover. • Apply Yamaha bond No.1215 “1” onto the mat- ing surfaces of the cylinder head cover, cylin- der head cover gasket, and cylinder head.
Page 298 CAMSHAFTS 9. Install: • Ignition coils “1” When installing the ignition coils, make sure that the ignition coil couplers are positioned at the angles shown in the illustration. A. Front cylinders B. Rear cylinders 5-25...
Page 299: Cylinder Heads
CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads 1st 30 Nm (3.0 m kgf, 22 ft lbf) 1st 30 Nm (3.0 m kgf, 22 ft lbf) • • • • Final Specified angle 85–95˚ Final Specified angle 85–95˚ 20 Nm (2.0 m kgf, 14 ft Ibf) •...
Page 300: Removing The Cylinder Heads
CYLINDER HEADS EAS24140 REMOVING THE CYLINDER HEADS 1. Remove: • Cylinder head bolts • Loosen the bolts in the proper sequence as shown. • Loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. 2.
Page 301 CYLINDER HEADS Pass the timing chains through the timing chain cavity. 2. Tighten: • Cylinder head bolts EWA2S31032 WARNING Replace the bolts with new ones. Tighten the bolts using the following procedure. M MMM M MMM M MMM M MMM M MMM a.
Page 302 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 5-26. Valve lifter Valve pad Valve cotter Valve spring retainer...
Page 303: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.
Page 304 VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 mm (0.0004–0.0015 b. Install the new valve guide with the valve guide installer “2”...
Page 305: Checking The Valve Seats
VALVES AND VALVE SPRINGS Valve guide remover (ø5) Valve stem runout 90890-04097 0.010 mm (0.0004 in) Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5) 90890-04099 Valve guide reamer (5.0 mm) YM-04099 L LLL L LLL...
Page 306 VALVES AND VALVE SPRINGS For the best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hands. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion.
Page 307: Checking The Valve Springs
VALVES AND VALVE SPRINGS EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • Valve spring free length “a” Out of specification → Replace the valve spring. Free length (intake) 40.78 mm (1.61 in) Limit b.
Page 308 VALVES AND VALVE SPRINGS 2. Lubricate: • Valve stem “1” • Valve stem seal “2” (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil • Valve stem end (with the recommended lubricant) b. Smaller pitch Recommended lubricant Engine oil 4. Install: •...
Page 309 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil...
Page 310: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •...
Page 311 GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 312 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 32 Nm (3.2 m kgf, 23 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Generator rotor Washer Starter clutch Woodruff key Starter clutch gear...
Page 313: 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 and starter clutch bolts. •...
Page 314: Installing The Starter Clutch
GENERATOR AND STARTER CLUTCH 4. Check: • Starter clutch operation M MMM M MMM M MMM M MMM M MMM a. Install the starter clutch gear “1” and starter clutch onto the generator rotor “2” and hold the generator rotor. b.
Page 315 • Route the stator coil lead “2” to the inside of the rib “d” on the generator cover. 3. Apply: • Sealant (onto the crankshaft position sensor/stator assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 5. Install: • Generator cover gasket • Generator cover Generator cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Page 316 GENERATOR AND STARTER CLUTCH 5-43...
Page 317: Electric Starter
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Front exhaust pipes Refer to “ENGINE REMOVAL” on page 5-1. Starter motor lead Disconnect.
Page 318 ELECTRIC STARTER Disassembling the starter motor 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Circlip Pinion gear Starter motor front cover Bearing Oil seal Circlip Starter motor rear cover Brush seat (along with brushes) Brush spring Brush Bearing...
Page 319: Checking The Starter Motor
ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Digital circuit tester 1. Check: 90890-03174 • Commutator Model 88 Multimeter with ta- Dirt → Clean with 600 grit sandpaper. chometer YU-A1927 2. Measure: • Commutator diameter “a” Out of specification → Replace the starter Armature coil motor.
Page 320: Assembling The Starter Motor
ELECTRIC STARTER 3. Install: • Starter motor yoke “1” • Starter motor front cover “2” Align the match marks “a” on the starter motor yoke with the match mark “b” on the starter mo- tor front cover. 7. Check: • Pinion gear teeth Damage/wear →...
Page 321 CLUTCH EAS25061 CLUTCH Removing the clutch cover 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-11.
Page 322 CLUTCH Removing the clutch 25 Nm (2.5 m kgf, 18 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 95 Nm (9.5 m kgf, 68 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “REMOVING THE CLUTCH RE- Clutch release cylinder LEASE CYLINDER”...
Page 323 CLUTCH Removing the clutch 25 Nm (2.5 m kgf, 18 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 95 Nm (9.5 m kgf, 68 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Thrust washer Clutch housing Collar...
Page 324 CLUTCH Removing the clutch master cylinder 30 Nm (3.0 m kgf, 22 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM”...
Page 325 CLUTCH Removing the clutch master cylinder 30 Nm (3.0 m kgf, 22 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch master cylinder For installation, reverse the removal proce- dure.
Page 326 CLUTCH Disassembling the clutch master cylinder Order Job/Parts to remove Q’ty Remarks Clutch master cylinder push rod Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. 5-53...
Page 327: Clutch
CLUTCH Removing the clutch release cylinder 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain.
Page 328 CLUTCH Disassembling the clutch release cylinder 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Boot Clutch release cylinder piston Clutch release cylinder spring Clutch release cylinder piston seal Bleed screw For assembly, reverse the disassembling procedure.
Page 329: Removing The Clutch
CLUTCH 4. Loosen: EAS25070 REMOVING THE CLUTCH • Clutch boss nut “1” 1. Remove: • Clutch cover “1” While holding the clutch boss “2” with the univer- sal clutch holder “3”, loosen the clutch boss nut. Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern.
Page 330: Checking The Clutch Plates
CLUTCH EAS25110 CHECKING THE CLUTCH PLATES • This step should be performed only if the fric- The following procedure applies to all of the tion plates and clutch plates were replaced. clutch plates. • To measure the total width of the friction plates 1.
Page 331: Checking The Clutch Spring Plate
CLUTCH EAS25130 EAS25160 CHECKING THE CLUTCH SPRING PLATE CHECKING THE CLUTCH BOSS 1. Check: 1. Check: • Clutch spring plate • Clutch boss splines Damage → Replace. Damage/pitting/wear → Replace the clutch 2. Check: boss. • Clutch spring plate seat Damage →...
Page 332: Installing The Clutch
CLUTCH 3. Lubricate: EAS25260 INSTALLING THE CLUTCH • Friction plates 1. Install: • Clutch plates • Clutch boss plate “1” (with the recommended lubricant) • Clutch boss “2” Recommended lubricant Engine oil Assemble the clutch boss and clutch boss plate so that the rivets “a”...
Page 333: Disassembling The Clutch Master Cylinder
CLUTCH EAS25280 DISASSEMBLING THE CLUTCH MASTER CYLINDER ECA13840 NOTICE • Clutch components rarely require disas- sembly. • Therefore, always follow these preventive measures: • Never disassemble clutch components un- less absolutely necessary. • If any connection on the hydraulic clutch 6.
Page 334: Checking The Clutch Master Cylinder
CLUTCH EAS25290 CHECKING THE CLUTCH MASTER Clutch master cylinder holder CYLINDER bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Recommended clutch component replace- ment schedule Piston seals Every two years • Align the end of the clutch master cylinder Clutch hose Every four years holder with the punch mark “a”...
Page 335: Removing The Clutch Release Cylinder
CLUTCH 3. Fill: 6. Check: • Clutch master cylinder reservoir • Clutch lever operation (with the specified amount of the recom- Soft or spongy feeling → Bleed the clutch mended clutch fluid) system. Refer to “BLEEDING THE HYDRAULIC Recommended fluid CLUTCH SYSTEM”...
Page 336: Assembling The Clutch Release Cylinder
CLUTCH 1. Check: • Clutch hose union bolt “3” • Clutch release cylinder body Clutch hose union bolt Cracks/damage → Replace the clutch re- 30 Nm (3.0 m·kgf, 22 ft·lbf) lease cylinder. 2. Check: ECA2S31042 • Clutch release cylinder NOTICE •...
Page 337 CLUTCH 4. Bleed: • Clutch system Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-14. 5. Check: • Clutch fluid level Below the minimum level mark “a” → Add the recommended clutch fluid to the proper level. Refer to “CHECKING THE CLUTCH FLUID LEVEL”...
Page 338: Shift Shaft
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift arm and shift shaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) •...
Page 339 SHIFT SHAFT Removing the shift arm and shift shaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 340: Checking The Shift Shaft
SHIFT SHAFT 3. Install: EAS25420 CHECKING THE SHIFT SHAFT • Shift shaft “1” 1. Check: • Shift shaft Hook the end of the shift shaft spring onto the • Shift shaft spring shift shaft spring stopper “2”. Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1.
Page 341: Oil Pump
OIL PUMP EAS24921 OIL PUMP Removing the oil pan and oil pump assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (10) 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 342 OIL PUMP Removing the oil pan and oil pump assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (10) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
Page 343 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump driven gear Oil pump housing For assembly, reverse the disassembly pro- cedure. 5-70...
Page 344: Removing The Oil Pan
OIL PUMP EAS24930 REMOVING THE OIL PAN Inner-rotor-to-outer-rotor-tip 1. Remove: clearance • Oil level switch lead holder Less than 0.120 mm (0.0047 in) • Oil pan Limit 0.20 mm (0.0079 in) • Oil pan gasket Outer-rotor-to-oil-pump-housing clearance Loosen each bolt 1/4 of a turn at a time, in stag- 0.090–0.190 mm (0.0035–0.0075 es and in a crisscross pattern.
Page 345: Checking The Oil Pipe 2
OIL PUMP EAS2S31038 EAS25030 CHECKING THE OIL PIPE 2 INSTALLING THE OIL PUMP 1. Check: 1. Install: • Oil pipe 2 • Oil pump “1” Damage → Replace. Oil pump bolt Obstruction → Wash and blow out with com- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) pressed air.
Page 346: Crankcase
CRANKCASE EAS25540 CRANKCASE Separating the crankcase 30 Nm (3.0 m kgf, 22 ft lbf) 24 Nm (2.4 m kgf, 17 ft Ibf) • • • • 2nd 25 Nm (2.5 m kgf, 18 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 347 CRANKCASE Separating the crankcase 30 Nm (3.0 m kgf, 22 ft lbf) 24 Nm (2.4 m kgf, 17 ft Ibf) • • • • 2nd 25 Nm (2.5 m kgf, 18 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 348 CRANKCASE Removing the plate, oil pipe 3, and damper 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 349: Disassembling The Crankcase
CRANKCASE EAS25550 DISASSEMBLING THE CRANKCASE 1. Remove: • Crankcase bolts • Washers • Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. •...
Page 350: Checking The Timing Chain Guide Assembly
• Sealant (onto the upper crankcase “2”) (onto the crankcase mating surfaces) ECA13980 NOTICE Yamaha bond No. 1215 Before tightening the crankcase bolts, make 90890-85505 sure the transmission gears shift correctly (Three bond No.1215®) when the shift drum assembly is turned by ECA2S31066 hand.
Page 351 CRANKCASE • Lubricate the washers with engine oil. • Lubricate the bolts “1”–“8” thread and washers with engine oil. • Lubricate the bolts “9”–“42” thread part and mating surface with engine oil. • Finger tighten the crankcase bolts. × – •...
Page 352 CRANKCASE EWA2S31013 WARNING Crankcase bolt “9”–“27”, “31”– “39” If the bolt is tightened more than the speci- 24 Nm (2.4 m·kgf, 17 ft·lbf) fied angle, do not loosen the bolt and then re- Crankcase bolt “28”–“30”, “40”– tighten it. Instead, replace the bolt with a new “42”...
Page 353 CRANKCASE Install the main axle bearing retainer with its “OUT” mark “a” facing outward. 35 40 36 A. Lower crankcase B. Upper crankcase 9. Install: • Middle drive pinion gear bearing retainer “1” Middle drive pinion gear bearing retainer bolt 24 Nm (2.4 m·kgf, 17 ft·lbf) LOCTITE®...
Page 354: Connecting Rods And Pistons
CONNECTING RODS AND PISTONS EAS2S31041 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 1st 20 Nm (2.0 m kgf, 14 ft lbf) •...
Page 355: Removing The Connecting Rods And Pistons
CONNECTING RODS AND PISTONS EAS26030 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the con- necting rods and pistons. 1. Remove: • Connecting rod cap “1” Identify the position of each connecting rod cap so that it can be reinstalled in its original place. 2.
Page 356: Checking The Piston Rings
CONNECTING RODS AND PISTONS 1. Check: • Piston wall • Cylinder wall Vertical scratches → Replace the upper crankcase, and replace the piston and piston rings as a set. 2. Measure: • Piston-to-cylinder clearance M MMM M MMM M MMM M MMM M MMM a.
Page 357: Checking The Piston Pins
CONNECTING RODS AND PISTONS Piston ring Piston ring Top ring Top ring Ring side clearance End gap (installed) 0.030–0.070 mm (0.0012– 0.20–0.35 mm (0.0079–0.0138 0.0028 in) Limit Limit 0.120 mm (0.0047 in) 0.60 mm (0.0236 in) 2nd ring 2nd ring Ring side clearance End gap (installed) 0.020–0.060 mm (0.0008–...
Page 358: Checking The Connecting Rods
CONNECTING RODS AND PISTONS a. Clean the big end bearings, crankshaft pins, Piston pin bore inside diameter and the inside of the connecting rod halves. 19.004–19.015 mm (0.7482– b. Install the big end upper bearing into the con- 0.7486 in) necting rod and the big end lower bearing into Limit the connecting rod cap.
Page 359 CONNECTING RODS AND PISTONS ECA2S31044 NOTICE Tighten the connecting rod bolts using the plastic-region tightening angle method. Al- ways install new bolts. f. Clean the connecting rod bolts. g. After installing the big end bearing, assemble the connecting rod and connecting rod cap without installing them onto the crankshaft.
Page 360 CONNECTING RODS AND PISTONS EWA2S31038 L LLL L LLL L LLL L LLL L LLL WARNING 2. Select: • When a bolt is tightened more than the • Big end bearing (P –P specified angle, do not loosen the bolt and then retighten it.
Page 361: Installing The Connecting Rods And Pistons
CONNECTING RODS AND PISTONS For example, if the connecting rod “P ” and ECA2S31046 NOTICE the crankshaft web “P ” numbers are “4” and Tighten the connecting rod bolts using the “1” respectively, then the bearing size for “P ” plastic-region tightening angle method.
Page 362 CONNECTING RODS AND PISTONS Be sure to install the piston rings so that the manufacturer marks face up. c. More than 3 mm (0.12 in) 5. Lubricate: • Piston • Piston rings 4. Install: • Cylinder • Piston “1” (with the recommended lubricant) (onto its respective connecting rod “2”) •...
Page 363 CONNECTING RODS AND PISTONS Recommended lubricant Engine oil 9. Install: • Connecting rod assembly (into the cylinder and onto the crankshaft pin) • While compressing the piston rings with one hand, install the connecting rod assembly into the cylinder with the other hand. c.
Page 364 CONNECTING RODS AND PISTONS L LLL L LLL L LLL L LLL L LLL 5-91...
Page 365: Crankshaft And Balancer
CRANKSHAFT AND BALANCER EAS25950 CRANKSHAFT AND BALANCER Removing the crankshaft and balancer Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-73. Refer to “CONNECTING RODS AND PIS- Connecting rod caps TONS” on page 5-81. Balancer shaft Balancer shaft journal upper bearing Balancer shaft journal lower bearing Crankshaft...
Page 366: Removing The Balancer Shaft Journal Bearings
CRANKSHAFT AND BALANCER 2. Check: EAS2S31094 REMOVING THE BALANCER SHAFT • Crankshaft journal surfaces JOURNAL BEARINGS • Crankshaft pin surfaces 1. Remove: • Bearing surfaces • Balancer shaft journal upper bearings Scratches/wear → Replace the crankshaft. (from the upper crankcase) 3.
Page 367 CRANKSHAFT AND BALANCER Do not put the Plastigauge® over the oil hole in the crankshaft journal. L LLL L LLL L LLL L LLL L LLL 4. Select: • Crankshaft journal bearings (J –J e. Install the crankshaft journal lower bearings •...
Page 368: Checking The Balancer
CRANKSHAFT AND BALANCER b. Place the upper crankcase upside down on a bench. J1 J2 J3 J4 c. Install the balancer shaft journal upper bear- ings “1” and the balancer shaft into the upper crankcase. Align the projections “a” on the balancer shaft journal upper bearings with the notches “b”...
Page 369: Installing The Crankshaft
CRANKSHAFT AND BALANCER f. Oil groove f. Tighten the bolts to specification in the tight- J1 J2 J3 J4 ening sequence cast on the crankcase. Refer to “CRANKCASE” on page 5-73. g. Remove the lower crankcase and the balanc- B 8 8 8 7 er shaft journal lower bearings.
Page 370: Installing The Balancer Shaft
CRANKSHAFT AND BALANCER • Align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcase. • Be sure to install each crankshaft journal bear- ing in its original place. c. Oil groove 2. Install: •...
Page 371: Transmission
TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-73. Drive axle/middle drive pinion gear assembly Main axle assembly Shift drum retainer Long shift fork guide bar...
Page 372 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Bearing Circlip 2nd pinion gear Toothed lock washer Toothed lock washer retainer 5th pinion gear Toothed spacer Toothed washer Circlip 3rd pinion gear Circlip Toothed washer 4th pinion gear Collar Bearing Main axle/1st pinion gear...
Page 373 TRANSMISSION Disassembling the drive axle/middle drive pinion gear assembly Order Job/Parts to remove Q’ty Remarks Middle drive pinion gear assembly Refer to “MIDDLE GEAR” on page 5-105. Bearing Washer 1st wheel gear Collar 4th wheel gear Circlip Toothed washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer...
Page 374 TRANSMISSION Disassembling the drive axle/middle drive pinion gear assembly Order Job/Parts to remove Q’ty Remarks Drive axle For assembly, reverse the disassembly pro- cedure. 5-101...
Page 375: Checking The Shift Forks
TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks. • Shift drum groove Damage/scratches/wear → Replace the shift 1. Check: • Shift fork cam follower “1” drum assembly.
Page 376: Assembling The Main Axle And Drive Axle
TRANSMISSION 2. Install: 3. Check: • Toothed lock washer retainer “1” • Transmission gears Blue discoloration/pitting/wear → Replace • Toothed lock washer “2” the defective gear(s). • Transmission gear dogs • With the toothed lock washer retainer “1” in the Cracks/damage/rounded edges →...
Page 377: Installing The Transmission
TRANSMISSION 3. Check: • Transmission Rough movement → Repair. Oil each gear, shaft, and bearing thoroughly. A. Main axle B. Drive axle EAS26350 INSTALLING THE TRANSMISSION 1. Install: • Shift drum assembly • Shift fork-L • Shift fork-R • Short shift fork guide bar •...
Page 378 MIDDLE GEAR EAS25711 MIDDLE GEAR Removing the middle driven pinion gear 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Circlip Bearing Universal joint (middle gear side) Middle driven pinion gear assembly Refer to “ADJUSTING THE MIDDLE GEAR Middle driven pinion gear shim...
Page 379: Middle Gear
MIDDLE GEAR Removing the middle driven pinion gear 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Bearing race Middle driven pinion gear bearing housing For installation, reverse the removal proce- dure. 5-106...
Page 380 MIDDLE GEAR Removing the middle drive pinion gear 110 Nm (11.0 m kgf, 80 ft lbf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-73. Middle drive pinion gear bearing retainer Refer to “ALIGNING THE MIDDLE GEAR”...
Page 381 MIDDLE GEAR Removing the middle drive pinion gear 110 Nm (11.0 m kgf, 80 ft lbf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Middle drive pinion gear bearing housing For installation, reverse the removal proce- dure.
Page 382: Removing The Middle Driven Pinion Gear Assembly
MIDDLE GEAR • While holding the universal joint yoke “2” with EAS2S31047 REMOVING THE MIDDLE DRIVEN PINION the universal joint holder “3”, loosen the univer- GEAR ASSEMBLY sal joint yoke nut. 1. Remove: • Universal joint (middle gear side) Universal joint holder M MMM M MMM M MMM...
Page 383: Checking The Middle Driven Pinion Gear Assembly
MIDDLE GEAR EAS2S31053 ASSEMBLING THE MIDDLE DRIVE PINION Middle drive shaft nut wrench (55 GEAR ASSEMBLY 1. Install: 90890-04054 Offset wrench 55 mm • Middle drive pinion gear nut YM-04054 M MMM M MMM M MMM M MMM M MMM a.
Page 384: Assembling The Middle Driven Pinion Gear Assembly
MIDDLE GEAR While compressing the spring with the damper spring compressor “2”, install the washer and spring retainers. Damper spring compressor 90890-04090 3. Install: • Universal joint yoke nut (middle gear side) “1” M MMM M MMM M MMM M MMM M MMM a.
Page 385: Installing The Middle Driven Pinion Gear Assembly
MIDDLE GEAR EAS2S31056 INSTALLING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 1. Install: • Universal joint (middle gear side) M MMM M MMM M MMM M MMM M MMM a. Fit the universal joint into the yoke. b. Remove the universal joint holder, and then turn the nut with a torque wrench to check the starting torque.
Page 386: Measuring The Middle Gear Backlash
MIDDLE GEAR b. Make sure the dial gauge plunger contacts the measuring point on the centerline of the yoke bearing hole as shown. L LLL L LLL L LLL L LLL L LLL 2. Check: • Universal joint operation Rough operation → Replace the universal c.
Page 387: Aligning The Middle Gear
MIDDLE GEAR b. For example, the clearance between the crankcase and the middle driven pinion gear • Tighten the middle driven pinion gear bearing bearing housing is 0.46 mm. Therefore, the housing bolts carefully, one thread turn at a chart instructs you to round off the 6 to 5. time only.
Page 388 MIDDLE GEAR “b”= 57.70 “c”= a numeral on the upper crankcase, to be Select the middle driven pinion gear shim(s) “2” divided by 100 and added to “71.00” by calculating the middle drive pinion gear shim thickness and then measuring the middle gear backlash.
Page 389 MIDDLE GEAR Example: If the middle driven pinion gear bearing hous- ing is marked “+17” “d” is 54.72 (i.e., 54.55 + 0.17 = 54.72) If the middle driven pinion gear is marked “+03” “e” is 12.03 (i.e., 12.00 + 0.03 = 12.03) If the middle driven pinion gear is marked “- 02”...
Page 390 MIDDLE GEAR 5-117...
Page 391: Cooling System
COOLING SYSTEM RADIATORS....................6-1 CHECKING THE RADIATORS ..............6-4 INSTALLING THE RADIATOR ASSEMBLY ..........6-4 OIL COOLER....................6-5 CHECKING THE OIL COOLER ..............6-6 INSTALLING THE OIL COOLER .............. 6-6 THERMOSTAT ....................6-7 CHECKING THE THERMOSTAT.............. 6-9 INSTALLING THE THERMOSTAT ASSEMBLY ........6-9 WATER PUMP....................
Page 392: Radiators
RADIATORS EAS2S31078 RADIATORS Removing the radiator assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 4 Nm (0.4 m kgf, 2.9 ft Ibf) •...
Page 393 RADIATORS Removing the radiator assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 4 Nm (0.4 m kgf, 2.9 ft Ibf) •...
Page 394 RADIATORS Disassembling the radiators 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 395: Checking The Radiators
RADIATORS EAS26390 CHECKING THE RADIATORS 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
Page 396 OIL COOLER EAS26410 OIL COOLER Removing the oil cooler 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 63 Nm (6.3 m kgf, 45 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...
Page 397: Oil Cooler
OIL COOLER 5. Install: EAS26420 CHECKING THE OIL COOLER • Oil filter cartridge 1. Check: Refer to “CHANGING THE ENGINE OIL” on • Oil cooler page 3-11. Cracks/damage → Replace. 2. Check: Oil filter cartridge • Oil cooler inlet hose 17 Nm (1.7 m·kgf, 12 ft·lbf) •...
Page 398: Thermostat
THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 399 THERMOSTAT Removing the thermostat assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 400: Checking The Thermostat
THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat housing 1. Check: Cracks/damage → Replace. • Thermostat “1” 3. Check: Does not open at 69–73 °C (156.2–163.4 °F) • Thermostat hoses → Replace. • Thermostat pipes • Upper radiator inlet hose •...
Page 401 THERMOSTAT 4. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-20. 5. Check: • Cooling system Leaks → Repair or replace any faulty part. 6. Measure: • Radiator cap opening pressure Below the specified pressure →...
Page 402: Water Pump
WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 9 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (15) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 403 WATER PUMP Removing the water pump 10 9 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (15) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
Page 404: Disassembling The Water Pump
WATER PUMP EAS26510 EAS26570 DISASSEMBLING THE WATER PUMP ASSEMBLING THE WATER PUMP 1. Remove: 1. Install: • Water pump seal “1” • Oil seal “1” (into the crankcase cover) Remove the water pump seal from the inside of Installed depth “a” the crankcase cover “2”.
Page 405: Installing The Water Pump
WATER PUMP 4. Middle driven shaft bearing driver A. Push down 3. Install: • Impeller “1” • Washer • Water pump driven gear • Circlip After installation, check that the impeller shaft ro- tates smoothly. EAS26590 INSTALLING THE WATER PUMP 1.
Page 406 WATER PUMP 6-15...
Page 407: Fuel System
FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 CHECKING THE ROLLOVER VALVE ............7-3 INSTALLING THE FUEL PUMP..............7-3 INSTALLING THE FILLER NECK ............. 7-4 INSTALLING THE FUEL TANK..............
Page 408: Fuel Tank
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 41 Nm (4.1 m kgf, 30 ft Ibf) •...
Page 409 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 41 Nm (4.1 m kgf, 30 ft Ibf) •...
Page 410: Removing The Fuel Tank
FUEL TANK EAS26630 ECA14720 REMOVING THE FUEL TANK NOTICE 1. Extract the fuel in the fuel tank through the • Do not drop the fuel pump or give it a fuel tank cap with a pump. strong shock. 2. Disconnect: •...
Page 411: Installing The Filler Neck
FUEL TANK • Align the projection “b” on the fuel tank with the slot in the fuel pump bracket. Mount the fuel tank in the rear frame, and then • Tighten the fuel pump nuts in the proper tight- install the fuel tank and rear frame as a unit. ening sequence as shown.
Page 412 FUEL TANK c. Connect the pressure gauge “2” and adapter “3” to the fuel hose “1”. Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter 90890-03176 YM-03176 d. Start the engine. e. Measure the fuel pressure. Fuel line pressure 324.0 kPa (3.24 kgf/cm², 47.0 psi) Faulty →...
Page 413: Air Filter Case
AIR FILTER CASE EAS2S31001 AIR FILTER CASE Removing the air filter case and intake funnels 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • (10) 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) 6 Nm (0.6 m...
Page 414 AIR FILTER CASE Removing the air filter case and intake funnels 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • (10) 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) 6 Nm (0.6 m kgf, 4.3 ft Ibf)
Page 415: Checking The Intake Funnels
AIR FILTER CASE EAS2S31005 CHECKING THE INTAKE FUNNELS 1. Check: • Intake funnel servo motor operation M MMM M MMM M MMM M MMM M MMM a. Apply current to the intake funnel servo motor and check that the variable intake funnel seals mates with the fixed intake funnels (Il- lustration “A”).
Page 416: Installing The Air Filter Case And Intake Funnels
AIR FILTER CASE 3. Install: EAS2S31007 INSTALLING THE AIR FILTER CASE AND • Lower air filter case gaskets “1” INTAKE FUNNELS 1. Install: Make sure that the lower air filter case gaskets • Variable intake funnel lever shaft “1” are seated in the lower air filter case grooves. •...
Page 417 AIR FILTER CASE 5. Install: • Upper air filter case Upper air filter case screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Tighten the upper air filter case screws in proper sequence as shown. 7-10...
Page 418: Throttle Bodies
THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3 Nm (0.3 m kgf, 2.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
Page 419 THROTTLE BODIES Removing the injectors 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Throttle position sensor Accelerator position sensor...
Page 420: Checking The Injectors
THROTTLE BODIES EAS26980 EAS2S31098 CHECKING THE INJECTORS CHECKING THE INJECTOR PRESSURE EWA2S31037 WARNING • After installing the injectors, perform the follow- • Check the injectors in a well-ventilated area ing steps to check the injector pressure. free of combustible materials. Make sure •...
Page 421: Checking And Cleaning The Throttle Bodies
THROTTLE BODIES Pressure drops → Properly install or replace ECA2S31068 NOTICE the injector • Observe the following precautions; other- L LLL L LLL L LLL L LLL L LLL wise, the throttle bodies may not operate EAS2S31095 properly. CHECKING AND CLEANING THE THROTTLE •...
Page 422: Adjusting The Throttle Position Sensor
THROTTLE BODIES • Do not allow carbon deposits or other for- EWA2S31034 WARNING eign materials to enter any of the passages When cleaning the throttle bodies, be careful in each throttle body or in the space be- not to injure yourself on the throttle valves or tween the throttle valve shaft and the throt- other components of the throttle bodies.
Page 423: Adjusting The Accelerator Position Sensor
THROTTLE BODIES 2. Adjust: EAS29090 ADJUSTING THE ACCELERATOR POSITION • Throttle position sensor angle SENSOR M MMM M MMM M MMM M MMM M MMM EWA2S31017 a. Temporary tighten the throttle position sen- WARNING sor. • Handle the accelerator position sensor with b.
Page 424 THROTTLE BODIES L LLL L LLL L LLL L LLL L LLL 7-17...
Page 425 THROTTLE BODIES 7-18...
Page 426: Air Induction System
AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-19...
Page 427 AIR INDUCTION SYSTEM 1. Air induction system hose (air cut-off valve to rear reed valve cover) 2. Air induction system hose (air filter case to air chamber) 3. Air chamber 4. Air induction system hose (air chamber to air cut-off valve) 5.
Page 428 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Lower air filter case Refer to “AIR FILTER CASE”...
Page 429 AIR INDUCTION SYSTEM Removing the reed valves 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Cylinder head covers Refer to “CAMSHAFTS” on page 5-9. Reed valve cover Reed valve assembly Reed valve plate...
Page 430: Checking The Air Induction System
AIR INDUCTION SYSTEM • Reed valve stopper EAS27060 CHECKING THE AIR INDUCTION SYSTEM • Reed valve seat Cracks/damage → Replace the reed valve Air induction assembly. The air induction system burns unburned ex- 3. Check: haust gases by injecting fresh air (secondary air) •...
Page 431: Electrical System
ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM .................. 8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION....... 8-3 TROUBLESHOOTING ................8-4 ELECTRIC STARTING SYSTEM ..............8-7 CIRCUIT DIAGRAM .................. 8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......8-9 TROUBLESHOOTING ................8-10 CHARGING SYSTEM..................8-13 CIRCUIT DIAGRAM ................
Page 432 ABS (ANTI-LOCK BRAKE SYSTEM)............8-81 CIRCUIT DIAGRAM ................8-81 ABS COMPONENTS CHART ..............8-83 ABS COUPLER LOCATION CHART ............8-85 MAINTENANCE OF THE ABS ECU ............8-87 ABS TROUBLESHOOTING OUTLINE............ 8-87 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-88 BASIC PROCESS FOR TROUBLESHOOTING ........8-89 [A] CHECKING THE ABS WARNING LIGHT..........
Page 434: Ignition System
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
Page 435 IGNITION SYSTEM 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 15.Relay unit 20.Sidestand switch 21.Crankshaft position sensor 25.Lean angle sensor 31.ECU (engine control unit) 33.Cylinder-#1 ignition coil 34.Cylinder-#2 ignition coil 35.Cylinder-#3 ignition coil 36.Cylinder-#4 ignition coil 37.Spark plug 65.Gear position switch 86.Engine stop switch 93.Ignition fuse...
Page 436: Engine Stopping Due To Sidestand Operation
IGNITION SYSTEM EAS2S31057 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 gear position switch (neutral circuit) and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
Page 437: Troubleshooting
IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Top cover 2. Right side cover NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
Page 438 IGNITION SYSTEM NG → 9. Check the gear position switch. Refer to “CHECKING THE Replace the gear position switch. SWITCHES” on page 8-129. OK ↓ NG → 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. SWITCHES” on page 8-129. OK ↓...
Page 439 IGNITION SYSTEM...
Page 440: Electric Starting System
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
Page 441 ELECTRIC STARTING SYSTEM 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 13.Starter relay 14.Starter motor 15.Relay unit 16.Starting circuit cut-off relay 20.Sidestand switch 65.Gear position switch 70.Clutch switch 86.Engine stop switch 87.Start switch 93.Ignition fuse...
Page 442: 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 443: Troubleshooting
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Top cover 2. Right side cover NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
Page 444 ELECTRIC STARTING SYSTEM NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-129. OK ↓ NG → 10.Check the gear position switch. Refer to “CHECKING THE Replace the gear position switch. SWITCHES”...
Page 445 ELECTRIC STARTING SYSTEM 8-12...
Page 446: Charging System
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-13...
Page 447 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 6. Main fuse 8. Battery 9. Frame ground 8-14...
Page 448: Troubleshooting
CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Top cover 2. Passenger seat NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES” on page 8-133. OK ↓...
Page 449 CHARGING SYSTEM 8-16...
Page 450: Lighting System
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-17...
Page 451 LIGHTING SYSTEM 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 31.ECU (engine control unit) 55.Multi-function meter 60.Meter light 63.High beam indicator light 68.Headlight relay 71.Pass switch 72.Dimmer switch 82.Auxiliary light 83.Headlight 88.Tail/brake light 90.License plate light 91.Parking lighting fuse 93.Ignition fuse 94.Headlight fuse 8-18...
Page 452: Troubleshooting
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, auxiliary light or meter light. • Before troubleshooting, remove the following part(s): 1. Top cover 2. Right side cover 3. Rear fender NG →...
Page 453 LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 8-17. OK ↓ Replace the ECU or meter assembly 8-20...
Page 454: Signaling System
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21...
Page 455 SIGNALING SYSTEM 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 10.Backup fuse (odometer, clock, and immobilizer system) 15.Relay unit 19.Fuel sender 27.Coolant temperature sensor 31.ECU (engine control unit) 45.Rear wheel sensor 48.ABS ECU (electronic control unit) 51.Neutral indicator light 54.Shift timing indicator light 55.Multi-function meter 56.Oil level warning light...
Page 456: 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 shift indicator fails to come on. • The fuel meter fails to come on. •...
Page 457 SIGNALING SYSTEM NG → 2. Check the horn. Refer to “CHECKING THE HORN” Replace the horn. on page 8-142. OK ↓ NG → 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring.
Page 458 SIGNALING SYSTEM NG → 4. Check the turn signal/hazard relay. Refer to “CHECKING THE TURN Replace the turn signal/hazard relay. SIGNAL/HAZARD RELAY” on page 8-138. OK ↓ NG → 5. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM”...
Page 459 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-21. OK ↓ Replace the meter assembly 2. The oil level warning light fails to come on. NG →...
Page 460 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-21. OK ↓ Replace the ECU, meter assembly 1 or meter assembly 2. The shift timing indicator light fails to come on. NG →...
Page 461 SIGNALING SYSTEM 8-28...
Page 462: Cooling System
COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-29...
Page 463 COOLING SYSTEM 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 27.Coolant temperature sensor 31.ECU (engine control unit) 93.Ignition fuse 96.Radiator fan motor relay 97.Main radiator fan motor fuse 98.Main radiator fan motor 99.Sub radiator fan motor fuse 100.Sub radiator fan motor 8-30...
Page 464: Troubleshooting
COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Top cover 2. Right side cover 3. Rear fender NG → 1. Check the fuses. (Main, ignition, main radiator fan motor, and sub radiator fan motor) Replace the fuse(s).
Page 465 COOLING SYSTEM 8-32...
Page 466: Fuel Injection System
FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-33...
Page 467 FUEL INJECTION SYSTEM 3. Fuel injection system fuse 5. Electric throttle valve fuse 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 13.Starter relay 15.Relay unit 16.Starting circuit cut-off relay 17.Fuel pump relay 18.Fuel pump 20.Sidestand switch 21.Crankshaft position sensor 22.Atmospheric pressure sensor 23.Intake air pressure sensor 24.Cylinder identification sensor...
Page 468: 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 en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 469: Troubleshooting Method
FUEL INJECTION SYSTEM a. Main switch “OFF” d. Engine trouble warning light on for 1.4 seconds b. Main switch “ON” c. Engine trouble warning light off ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
Page 470: Diagnostic Mode
FUEL INJECTION SYSTEM The engine operation is not normal but the If a malfunction is detected in the sensors or engine trouble warning light does not come actuators, repair or replace all faulty parts. If no malfunction is detected in the sensors 1.
Page 471 FUEL INJECTION SYSTEM • To increase the selected diagnostic code number, press the “SELECT” button. Press the “SELECT” button for 1 second or longer to automatically increase the diagnostic code numbers. “D:01 D:70” “D:70 D:01” 6. Verify the operation of the sensor or actuator. •...
Page 472 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:07 Vehicle speed pulse 0–999 Check that the number in- creases when the rear wheel is rotated. The num- ber is cumulative and does not reset each time the wheel is stopped.
Page 473 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:60 EEPROM fault code dis- — play • No history • History exists 01–04 (Cylinder fault code) • (If more than one cylinder is defective, the display alter- nates every two seconds to show all the detected cylin- der numbers.
Page 474 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code D:70 Control number 0–254 [-] — Actuator operation table Diag- nostic Item Actuation Checking method code Actuates the cylinder-#1 igni- tion coil five times at one- Check the spark five times. D:30 Cylinder-#1 ignition coil second intervals.
Page 475 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the injector #4 five times at one-second inter- Check the operating sound D:39 Injector #4 vals. of the injector #4 five times. Illuminates the engine trou- ble warning light. Actuates the air induction system solenoid five times at Check the operating sound...
Page 476: Troubleshooting Details
FUEL INJECTION SYSTEM EAS27461 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the meter display ac- cording to the reinstatement method.
Page 477 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Diagnostic code No. — Meter display — Checking method — Probable cause of malfunction Check or maintenance job Installed condition of crankshaft position •...
Page 478 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure sensor. • Execute the diagnostic mode. (Code No. D:03) • Replace if defective. Refer to “CHECKING THE INTAKE AIR PRESSURE SENSOR” on page 8-147. Reinstatement method Turning the main switch to “ON”.
Page 479 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Throttle position sensor signal 2 Meter display • 15–16 (fully closed position) • 97–102 (fully opened position) D:13 • Check with throttle valve fully closed. Checking method •...
Page 480 FUEL INJECTION SYSTEM Fault code No. Item EXUP servo motor circuit: open or short circuit detected. Open or short circuit in wire harness. • Repair or replace if there is an open or short circuit. • Between EXUP servo motor coupler and ECU coupler.
Page 481 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the blue/yellow Item lead of the ECU is detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. D:20 Sidestand switch Meter display •...
Page 482 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor or atmospheric pressure sensor: when the main switch is turned to “ON”, the atmospheric pres- Item sure sensor voltage and intake air pressure sensor voltage dif- fer greatly. Defective intake air pressure sensor or •...
Page 483 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. D:05 Meter display Displays the intake air temperature. Compare the actually measured intake air temperature with the Checking method meter display value.
Page 484 FUEL INJECTION SYSTEM Fault code No. Item Atmospheric pressure sensor: open or short circuit detected. Open or short circuit in wire harness. • Repair or replace if there is an open or short circuit. • Between atmospheric pressure sensor coupler and ECU coupler.
Page 485 FUEL INJECTION SYSTEM Fault code No. Latch up detected. Item No normal signal is received from the lean angle sensor. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. D:08 Lean angle sensor Meter display • 0.4–1.4 (upright) •...
Page 486 FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#1 ignition coil. Open or short circuit in wire harness • Repair or replace if there is an open or short and/or ignition coil sub-wire harness 1.
Page 487 FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#2 ignition coil. Open or short circuit in wire harness • Repair or replace if there is an open or short and/or ignition coil sub-wire harness 2.
Page 488 FUEL INJECTION SYSTEM Fault code No. Cylinder-#3 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#3 ignition coil. Open or short circuit in wire harness • Repair or replace if there is an open or short and/or ignition coil sub-wire harness 1.
Page 489 FUEL INJECTION SYSTEM Fault code No. Cylinder-#4 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#4 ignition coil. Open or short circuit in wire harness • Repair or replace if there is an open or short and/or ignition coil sub-wire harness 2.
Page 490 FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Open or short circuit in wire harness • Repair or replace if there is an open or short and/or sub-wire harness. circuit. • Between injector coupler and sub-wire har- ness coupler.
Page 491 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Probable cause of malfunction Check or maintenance job Connections • Check the coupler for any pins that may be • Lean angle sensor coupler pulled out. •...
Page 492 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Gear position switch: open or short circuit is detected in the neutral circuit of the gear position switch. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 493 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Gear position switch: open or short circuit is detected in the neutral circuit of the gear position switch. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 494 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: the ECU is unable to monitor the battery Item voltage (an open or short circuit in the line to the ECU). Probable cause of malfunction Check or maintenance job Connections • Check the coupler for any pins that may be •...
Page 495 FUEL INJECTION SYSTEM Fault code No. Item Power supply to the fuel injection system is not normal. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Checking method — Probable cause of malfunction Check or maintenance job Connections •...
Page 496 FUEL INJECTION SYSTEM Fault code No. Faulty ECU memory. (When this malfunction is detected in the Item ECU, the fault code number might not appear on the meter.) Probable cause of malfunction Check or maintenance job Malfunction in ECU. • Replace the ECU. Do not perform this procedure with the main switch turned to “ON”.
Page 497 FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Defective accelerator position sensor. • Execute the diagnostic mode. (Code No. D:14 and/or D:15) • Replace if defective. Refer to “CHECKING THE ACCELERATOR POSITION SENSOR” on page 8-146. Reinstatement method Turning the main switch to “ON”.
Page 498 FUEL INJECTION SYSTEM Fault code No. Throttle servo motor: open or short circuit detected. Item Defective throttle servo motor. Malfunction in ECU (servo motor driving system). Reinstatement method Turning the main switch to “ON”. Fault code No. Engine idling stop: engine has been left idling. (The ECU auto- Item matically stops the engine after 20 minutes if it is left idling.) Able to start engine...
Page 499 FUEL INJECTION SYSTEM Fault code No. ER-2 ECU internal malfunction (output signal error): no signals are Item received from the ECU within the specified duration. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display —...
Page 500 FUEL INJECTION SYSTEM Fault code No. ER-3 ECU internal malfunction (output signal error): data from the Item ECU cannot be received correctly. Malfunction in ECU. • Replace the ECU. Reinstatement method Turning the main switch to “ON”. Fault code No. ER-4 ECU internal malfunction (input signal error): non-registered Item...
Page 501 FUEL INJECTION SYSTEM 8-68...
Page 502: Fuel Pump System
FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-69...
Page 503 FUEL PUMP SYSTEM 3. Fuel injection system fuse 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 15.Relay unit 17.Fuel pump relay 18.Fuel pump 31.ECU (engine control unit) 86.Engine stop switch 93.Ignition fuse 8-70...
Page 504: Troubleshooting
FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Top cover 2. Right side cover 3. Fuel tank NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
Page 505 FUEL PUMP SYSTEM 8-72...
Page 506: Immobilizer System
IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-73...
Page 507 IMMOBILIZER SYSTEM 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 10.Backup fuse (odometer, clock, and immobilizer system) 11.Immobilizer unit 31.ECU (engine control unit) 52.Immobilizer system indicator light 55.Multi-function meter 64.Meter assembly 2 93.Ignition fuse 8-74...
Page 508: General Information
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 509 IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration re- Accesso- bilizer unit Standard quirement ry lock* Main Immobiliz- and key switch er unit √ Standard key is lost New standard key All keys have been Code re-registering √ √...
Page 510 IMMOBILIZER SYSTEM c. LED on d. LED off e. Standby mode on f. Standby mode off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. Do not start the engine with a standard key that has not been registered.
Page 511: Troubleshooting
IMMOBILIZER SYSTEM Voiding the standard key code: If a standard key has been lost, it is possible to disable its use by re-registering the remaining standard key. Standard key registration erases the stored standard key code from the memory, thus disabling the lost standard key.
Page 512: Self-Diagnosis Fault Code Indication
IMMOBILIZER SYSTEM NG → 4. Check the entire immobilizer sys- tem wiring. Properly connect or repair the immobilizer Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-73. OK ↓ • Check the condition of the each im- mobilizer system circuits. •...
Page 513 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Codes transmitted Noise interference or 1. Register the UNIT between the ECU disconnected lead/ca- code re-register- and the immobilizer ble. ing key. unit do not match. 1. Interference due to 2. Check the wire radio wave noise.
Page 514: Abs (Anti-Lock Brake System)
ABS (ANTI-LOCK BRAKE SYSTEM) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27730 CIRCUIT DIAGRAM 8-81...
Page 515 ABS (ANTI-LOCK BRAKE SYSTEM) 4. ABS solenoid fuse 6. Main fuse 7. Main switch 8. Battery 9. Frame ground 12.ABS motor fuse 13.Starter relay 15.Relay unit 16.Starting circuit cut-off relay 31.ECU (engine control unit) 45.Rear wheel sensor 46.Front wheel sensor 47.ABS test coupler 48.ABS ECU (electronic control unit) 53.ABS warning light...
Page 516: Abs Components Chart
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27740 ABS COMPONENTS CHART 1. ABS ECU fuse 2. ABS test coupler 3. Hydraulic unit assembly 4. ABS solenoid fuse 5. ABS motor fuse 6. ABS warning light 7. Front wheel sensor 8. Front wheel sensor rotor 9.
Page 517 ABS (ANTI-LOCK BRAKE SYSTEM) 8-84...
Page 518: Abs Coupler Location Chart
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27750 ABS COUPLER LOCATION CHART Y Lg W Gy (BLACK) Sb/W (BLACK) B W Ch L/W W/Y Br/R Lg/W B/L B Lg/L L/W Ch G/Y (GRAY) Lg/W Lg/L W Gy (BLACK) (BLACK) 8-85...
Page 519 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Meter assembly 1 coupler 2. ABS ECU coupler 3. Rear wheel sensor coupler 4. ABS test coupler 5. Front wheel sensor coupler 8-86...
Page 520: Maintenance Of The Abs Ecu
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27770 MAINTENANCE OF THE ABS ECU If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air. Checking the ABS ECU 1. Check: • Terminals “1” of the ABS ECU Cracks/damages → Replace the hydraulic unit assembly and the brake hoses that are connected to the assembly as a set.
Page 521: Basic Instructions For Troubleshooting
ABS (ANTI-LOCK BRAKE SYSTEM) The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the lever and pedal, but these do not indicate a malfunction.
Page 522: Basic Process For Troubleshooting
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING [A] Turn the main switch to ON, and check the ABS warning light. The ABS warning light (LED) is defective. • The wire harness is grounded between the • [B-1] Does the ABS warning [C-1] Does only the ABS warning ABS ECU and the meter assembly 1.
Page 523: [A] Checking The Abs Warning Light
ABS (ANTI-LOCK BRAKE SYSTEM) EWA2S31022 WARNING When maintenance or checks have been performed on components related to the ABS, be sure to perform a final check before delivering the vehicle to the customer. (Refer to “[D-3] FINAL CHECK” on page 8-123.) EAS27830 [A] CHECKING THE ABS WARNING LIGHT Turn the main switch to “ON”.
Page 524: [B-5] Malfunction Are Currently Detected
ABS (ANTI-LOCK BRAKE SYSTEM) 2. The ABS warning light flashes every 0.5 second for more than 6 seconds. The ABS warning light flashes every 0.5 second if a fault code for a past malfunction is not stored in the memory of the ABS ECU. The ABS warning light flashes quicker if a fault code is displayed on the multi-function display.
Page 525: [C-3] The Abs Warning Light Remains On
ABS (ANTI-LOCK BRAKE SYSTEM) • If the battery is defective, clean the battery terminals and recharge it, or replace the battery. 3. Main fuse • Check the fuse for continuity. Refer to “CHECKING THE FUSES” on page 8-133. • If the main fuse is blown, replace the fuse. 4.
Page 526: [C-5] Diagnosis Using The Fault Codes
ABS (ANTI-LOCK BRAKE SYSTEM) • If the T/C terminal is not short-circuited to the ground, the internal circuit of the meter assembly 1 is defective. Replace the meter assembly 1. EAS2S31074 [C-5] DIAGNOSIS USING THE FAULT CODES Connect the test coupler adapter to the ABS test coupler, and then turn the main switch to “ON”. Information for the fault codes from the ABS ECU is contained in the following table.
Page 527 ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. Start switch signal is not received prop- • Wire harness ABS-22 erly (start switch circuit or start switch • Connection of the relay unit coupler and monitor circuit). ABS ECU coupler. Brake light signal is not received prop- erly while vehicle is traveling (brake •...
Page 528 ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. • Battery voltage • Connection of the ABS ECU coupler and starter relay coupler ABS-54 Power voltage is too low. • Wire harness • Refer to “CHARGING SYSTEM” on page 8-13.
Page 529 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-11 Symptom Front wheel sensor signal is not received prop- ABS-25 erly. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or •...
Page 530 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-12 Symptom Rear wheel sensor signal is not received proper- Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or • Turn the main replace the wheel sensor if nec- switch to “ON”...
Page 531 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-13 Symptom Incorrect signal from the front wheel sensor is ABS-26 detected. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or •...
Page 532 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-14 Symptom Incorrect signal from the rear wheel sensor is ABS-27 detected. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or •...
Page 533 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-15 Symptom No continuity in the front wheel sensor circuit. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Wire harness continuity. • Check for continuity between the white terminal “1” and the white terminal “3”...
Page 534 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-15 Symptom No continuity in the front wheel sensor circuit. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the ABS ECU coupler and front wheel sensor coupler, and then delete the fault...
Page 535 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-16 Symptom No continuity in the rear wheel sensor circuit. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Wire harness continuity. • Check for continuity between the white terminal “1” and the white terminal “3”...
Page 536 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-16 Symptom No continuity in the rear wheel sensor circuit. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the ABS ECU coupler and rear wheel sensor coupler, and then delete the fault...
Page 537 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-18 Symptom Missing pulses detected in the rear wheel sen- ABS-46 sor signal. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel bearings, Check the components for loose- •...
Page 538 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-22 Symptom Start switch signal is not received properly (start switch circuit or start switch monitor cir- cuit). Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Engine startability. Check the electric starting sys- •...
Page 539 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-24 Symptom Brake light signal is not received properly while vehicle is traveling (brake light circuit, or front or rear brake light switch circuit). Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method...
Page 540 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-31 Symptom Solenoid relay is defective. Power is not supplied to the solenoid relay. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Battery voltage Recharge or replace the battery. Turn the main Refer to “CHECKING AND switch to “ON”...
Page 541 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-32 Symptom Hydraulic unit solenoid relay is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Short circuit in solenoid relay. Replace the hydraulic unit as- • Turn the main sembly.
Page 542 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-33 Symptom ABS motor is defective. Power is not supplied to the ABS motor. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Battery voltage Recharge or replace the battery. •...
Page 543 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-34 Symptom Hydraulic unit ABS motor relay is short-circuit- Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Short circuit in ABS motor relay. Replace the hydraulic unit as- • Turn the main sembly.
Page 544 Brake lines • Check the brake lines for kinks and deterioration. EWA2S31023 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake...
Page 545 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-41 Symptom Front wheel will not recover from the locking tendency even though the signal is continuous- ly transmitted from the ABS ECU to release the hydraulic pressure (when the battery voltage is normal) Order Item/components and probable Check or maintenance job...
Page 546 (particularly between the hydraulic unit and the rear brake caliper). EWA2S31023 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake master cylinder to the hydraulic unit are correct.
Page 547 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-42 Symptom Rear wheel will not recover from the locking ten- ABS-47 dency even though the signal is continuously transmitted from the ABS ECU to release the hy- draulic pressure. Order Item/components and probable Check or maintenance job Reinstatement cause...
Page 548 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-43 Symptom Incorrect signal from the front wheel sensor is detected. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or •...
Page 549 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-44 Symptom Incorrect signal from the rear wheel sensor is detected. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or •...
Page 550 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-53 Symptom Power voltage is too low. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Battery voltage Recharge or replace the battery. • Turn the main Refer to “CHECKING AND switch to “ON”...
Page 551 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-54 Symptom Power voltage is too low. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Battery voltage Recharge or replace the battery. • Turn the main Refer to “CHECKING AND switch to “ON”...
Page 552 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-56 Symptom Hydraulic unit sensor power monitor circuit is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Defective internal monitor circuit (sen- Replace the hydraulic unit as- • Turn the main sor power).
Page 553 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-63 Symptom Front wheel sensor power is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Short circuit in wire harness. • Check that there is no short cir- Turn the main cuit between the white terminal switch to “ON”...
Page 554 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS-64 Symptom Rear wheel sensor power is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Short circuit in wire harness. • Check that there is no short cir- Turn the main cuit between the white terminal switch to “ON”...
Page 555: [D-1] Deleting The Fault Codes
ABS (ANTI-LOCK BRAKE SYSTEM) 8. Turn the main switch to “OFF”. EAS2S31075 [D-1] DELETING THE FAULT CODES 9. Disconnect the test coupler adapter from the 1. Connect the test coupler adapter “1” to the ABS test coupler, and then install the protec- ABS test coupler “2”.
Page 556: [D-3] Final Check
ABS (ANTI-LOCK BRAKE SYSTEM) b. Measure the ABS ECU voltage. 7. Check: • ABS ECU voltage L LLL L LLL L LLL L LLL L LLL Out of specification → Replace the right han- 6. Check: dlebar switch. • ABS-ECU-to-start-switch-lead continuity No continuity →...
Page 557 ABS (ANTI-LOCK BRAKE SYSTEM) 8-124...
Page 558: Electrical Components
ELECTRICAL COMPONENTS EAS27972 ELECTRICAL COMPONENTS 8-125...
Page 559 ELECTRICAL COMPONENTS 1. Main switch 2. Clutch switch 3. Battery 4. Main fuse 5. Starter relay 6. ABS motor fuse 7. Turn signal/hazard relay 8. Fuse box 1 9. Headlight relay 10.Radiator fan motor relay 11.Relay unit 12.Rear brake light switch 13.O sensor 14.Sidestand switch...
Page 560 ELECTRICAL COMPONENTS 8-127...
Page 561 ELECTRICAL COMPONENTS 1. Air induction system solenoid 2. Atmospheric pressure sensor 3. ECU (engine control unit) 4. Lean angle sensor 5. Hydraulic unit assembly 6. Fuse box 2 7. Rectifier/regulator 8. EXUP servo motor 9. Fuel pump assembly 10.Gear position switch 11.Oil level switch 12.Crankshaft position sensor 13.Coolant temperature sensor...
Page 562: Checking The Switches
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES Y L/B G Dg Br/W Ch Dg Br/W Ch R/Y Y B/Br Br B/Br L/B B G Br Br/W (BLACK) ( BLACK ) R/W R/L L/W B/W R Br/L Br/R Br/R Br/L Sb L 8-129...
Page 563 ELECTRICAL COMPONENTS 1. Pass switch 2. Dimmer switch 3. Hazard switch 4. Turn signal switch 5. Horn switch 6. Engine stop switch 7. Start switch 8. Front brake light switch 9. Rear brake light switch 10.Gear position switch 11.Sidestand switch 12.Main switch 13.Clutch switch 8-130...
Page 564 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 565: Checking The Bulbs And Bulb Sockets
ELECTRICAL COMPONENTS EAS27990 EWA2S31015 CHECKING THE BULBS AND BULB WARNING SOCKETS Since headlight bulbs get extremely hot, keep flammable products and your hands Do not check any of the lights that use LEDs. away from them until they have cooled down.
Page 566: Checking The Fuses
ELECTRICAL COMPONENTS Checking the condition of the bulb sockets b. If the pocket tester indicates “∞”, replace the The following procedure applies to all of the bulb fuse. sockets. L LLL L LLL L LLL L LLL L LLL 1. Check: 3.
Page 567: Checking And Charging The Battery
ELECTRICAL COMPONENTS • Right side cover Refer to “GENERAL CHASSIS” on page 4-1. Since VRLA (Valve Regulated Lead Acid) bat- teries are sealed, it is not possible to check the EAS28030 CHECKING AND CHARGING THE BATTERY charge state of the battery by measuring the EWA13290 specific gravity of the electrolyte.
Page 568 ELECTRICAL COMPONENTS • When charging a battery, be sure to remove Example it from the vehicle. (If charging has to be Open-circuit voltage = 12.0 V done with the battery mounted on the vehi- Charging time = 6.5 hours Charge of the battery = 20–30% cle, disconnect the negative battery lead from the battery terminal.) •...
Page 569 ELECTRICAL COMPONENTS c. Make sure that the current is higher than the standard charging current written on the bat- Voltage should be measured 30 minutes after tery. the engine is stopped. b. Connect a charger and ammeter to the bat- If the current is lower than the standard charging tery and start charging.
Page 570: Checking The Relays
ELECTRICAL COMPONENTS 10.Install: 2. Negative battery terminal • Top cover 3. Positive tester probe Refer to “GENERAL CHASSIS” on page 4-1. 4. Negative tester probe EAS28040 Result CHECKING THE RELAYS Continuity Check each switch for continuity with the pocket (between “3” and “4”) tester.
Page 571: Checking The Turn Signal/Hazard Relay
ELECTRICAL COMPONENTS Radiator fan motor relay b. Turn the main switch to “ON”. c. Measure the turn signal/hazard relay input 1. Positive battery terminal voltage. 2. Negative battery terminal 3. Positive tester probe L LLL L LLL L LLL L LLL L LLL 4.
Page 572: Checking The Ignition Coils
ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C The pocket tester and the analog pocket tester readings are shown in the following table. Continuity M MMM M MMM M MMM M MMM M MMM Positive tester probe → sky blue a.
Page 573: Checking The Ignition Spark Gap
ELECTRICAL COMPONENTS c. Measure the primary coil resistance. M MMM M MMM M MMM M MMM M MMM a. Disconnect the spark plug cap from the spark L LLL L LLL L LLL L LLL L LLL plug. 2. Check: b.
Page 574: Checking The Lean Angle Sensor
ELECTRICAL COMPONENTS • Positive tester probe → blue/yellow “1” • Negative tester probe → green/white “2” c. Turn the main switch to “ON”. d. Turn the lean angle sensor to 65°. e. Measure the lean angle sensor output volt- age. L LLL L LLL L LLL...
Page 575: Checking The Stator Coil
ELECTRICAL COMPONENTS EAS28150 CHECKING THE STATOR COIL Charging voltage 1. Disconnect: 14 V at 5000 r/min • Stator coil coupler (from the wire harness) M MMM M MMM M MMM M MMM M MMM a. Set the engine tachometer to the spark plug 2.
Page 576: Checking The Oil Level Switch
ELECTRICAL COMPONENTS 2. Remove: EAS28190 CHECKING THE OIL LEVEL SWITCH • Fuel pump 1. Drain: (from the fuel tank) • Engine oil 3. Check: 2. Remove: • Fuel sender resistance • Oil level switch Out of specification → Replace the fuel pump (from the oil pan) assembly.
Page 577: Checking The Fuel Level Warning Light
ELECTRICAL COMPONENTS EAS29040 EAS28250 CHECKING THE FUEL LEVEL WARNING CHECKING THE RADIATOR FAN MOTORS LIGHT The following procedure applies to both of the This model is equipped with a self-diagnosis de- radiator fan motors. vice for the fuel level detection circuit. 1.
Page 578: Checking The Throttle Position Sensor
ELECTRICAL COMPONENTS 2. Check: EWA2S31016 WARNING • Coolant temperature sensor resistance Out of specification → Replace. • Handle the throttle position sensor with special care. Coolant temperature sensor re- • Never subject the throttle position sensor sistance to strong shocks. If the throttle position 2.45 kΩ...
Page 579: Checking The Accelerator Position Sensor
ELECTRICAL COMPONENTS EAS29100 CHECKING THE ACCELERATOR POSITION When installing the accelerator position sensor, SENSOR adjust its angle properly. Refer to “ADJUSTING 1. Remove: THE ACCELERATOR POSITION SENSOR” on • Accelerator position sensor page 7-16. (from the throttle body) EWA2S31017 WARNING EAS28370 CHECKING THE AIR INDUCTION SYSTEM •...
Page 580: Checking The Cylinder Identification Sensor
ELECTRICAL COMPONENTS • Never subject the atmospheric pressure Cylinder identification sensor sensor to strong shocks. If the atmospheric output voltage (ON) pressure sensor is dropped, replace it. 4.8 V 1. Check: Cylinder identification sensor • Atmospheric pressure sensor output voltage output voltage (OFF) Out of specification →...
Page 581: Checking The Intake Air Temperature Sensor
ELECTRICAL COMPONENTS 1. Check: Intake air temperature sensor re- • Intake air pressure sensor output voltage sistance Out of specification → Replace. 290–390 Ω at 80 °C (176 °F) Intake air pressure sensor output M MMM M MMM M MMM M MMM M MMM voltage...
Page 582 ELECTRICAL COMPONENTS 8-149...
Page 583: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ............... 9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED ............ 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING................ 9-2 SHIFT PEDAL DOES NOT MOVE ............9-2 JUMPS OUT OF GEAR................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................
Page 584: Troubleshooting
TROUBLESHOOTING Electrical system EAS28451 TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.
Page 585: Poor Medium-And-High-Speed Performance
TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •...
Page 586: Overheating
TROUBLESHOOTING EAS28600 EAS28620 OVERHEATING POOR BRAKING PERFORMANCE • Worn brake pad Engine • Worn brake disc 1. Clogged coolant passages • Air in hydraulic brake system • Cylinder head(s) and piston(s) • Leaking brake fluid • Heavy carbon buildup • Faulty brake caliper kit 2.
Page 587: Faulty Lighting Or Signaling System
TROUBLESHOOTING 4. Swingarm Turn signal does not come on • Worn bearing or bushing • Faulty turn signal switch • Bent or damaged swingarm • Faulty turn signal/hazard relay 5. Rear shock absorber assembly(-ies) • Burnt-out turn signal bulb • Faulty rear shock absorber spring •...
Page 588 EAS28740 55. Multi-function meter EAS28750 WIRING DIAGRAM COLOR CODE 56. Oil level warning light Black 57. Engine trouble warning light VMX17(Y) 2009 Brown 58. Fuel level warning light 1. AC magneto Chocolate 59. Coolant temperature warning 2. Rectifier/regulator Dark green light 3.
Page 590 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
Page 591 VMX17(Y) 2009 VMX17(Y) 2009 VMX17(Y) 2009 VMX17(Y) 2009 VMX17(Y) 2009 WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO R/L3 R/L1 B/O1 B/O3 (GRAY) B/W B2 R L1 L/W1 IGNITION COIL R/L1 Sb/W Br/W WIRE HARNESS SUB-WIRE HARNESS 1 B/W P/W W2 W1 Lg/W W/B R/W Y/W L/Y B/W1 B/Y P/B Gy/G O/G Gy/R...
Page 592 VMX17(Y) 2009 VMX17(Y) 2009 VMX17(Y) 2009 VMX17(Y) 2009 VMX17(Y) 2009 WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO (GRAY) IGNITION COIL WIRE HARNESS SUB-WIRE HARNESS 1 (DARK BLUE) (BLACK) (BLACK) (BLACK) (BLACK) IGNITION COIL WIRE HARNESS SUB-WIRE HARNESS 2 (BLACK) (BLACK) METER ASSEMBLY 1...

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Yamaha VMAX 2009 Service Manual

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