Yamaha R6 2013 Series Service Manual
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Yamaha R6 2013 Series Service Manual

Yamaha R6 2013 Series Service Manual

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2013-2016
SERVICE MANUAL
YZFR6G
YZFR6GC
LIT-11616-29-23
2CX-28197-10

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Summary of Contents for Yamaha R6 2013 Series

  • Page 1 2013-2016 SERVICE MANUAL YZFR6G YZFR6GC LIT-11616-29-23 2CX-28197-10...
  • Page 2 EAS20002 YZFR6G/YZFR6GC SERVICE MANUAL ©2015 by Yamaha Motor Corporation, U.S.A. First edition, August 2015 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-29-23...

  • Page 3: Important Manual Information

    If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 4: How To Use This Manual

    EAS20004 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 EAS20005 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

    EAS10003 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 YCC-T (Yamaha Chip Controlled Throttle)/YCC-I (Yamaha Chip Controlled Intake) ............. 1-2 INSTRUMENT FUNCTIONS ..............1-6 IMPORTANT INFORMATION ............... 1-10 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-10 REPLACEMENT PARTS.................1-10 GASKETS, OIL SEALS AND O-RINGS ..........1-10 LOCK WASHERS/PLATES AND COTTER PINS ........

  • Page 10: Identification

    IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped on the right side of the steering head pipe. EAS30003 MODEL LABEL The model label “1” is affixed to the frame under the passenger seat. This information will be needed to order spare parts.

  • Page 11: Features

    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 12 FEATURES Aims and advantages of using YCC-I system • Improvement of the engine power characteristics The high power design in all ranges is now provided by having both two features of the short intake function to ensure the power at the high speed revolution of engine, and the long intake function to ensure the power in the practical use range.
  • Page 13 FEATURES YCC-T/YCC-I system outline 1. Throttle position sensor (for throttle cable pulley) 2. Throttle servo motor 3. Throttle position sensor (for throttle valves) 4. ECU (Engine Control Unit) 5. ETV main CPU (32 bit) 6. ETV sub CPU (16 bit) 7.
  • Page 14 FEATURES YCC-T/YCC-I control outline 1. Throttle position sensor (for throttle cable 16. ECU (Engine Control Unit) pulley) 17. Base map 2. Throttle position sensor (for throttle valves) 18. Idle speed control 3. Crankshaft position sensor 19. Calculated throttle valve opening angle 4.

  • Page 15: Instrument Functions

    FEATURES • To switch the multi-function meter unit be- EAS30682 INSTRUMENT FUNCTIONS tween kilometers and miles, press the “SE- LECT” button for one second. Multi-function meter unit Speedometer The speedometer shows the vehicle’s traveling speed. Tachometer 1. Clock 2. Speedometer 3.
  • Page 16 FEATURES To set the clock: 1. Turn the key to “ON”. To reset a tripmeter, push the “SELECT” button 2. Push both the “SELECT” button and “RE- to change the display to the tripmeter you want SET” button for two seconds. The hour digits to reset, and then push the “RESET”...
  • Page 17 FEATURES Coolant temperature display • When the air intake temperature display is se- lected, “A” is displayed for one second, and then “A” and the air intake temperature are dis- played. Self-diagnosis device 1. Coolant temperature display The coolant temperature display indicates the temperature of the coolant.
  • Page 18 FEATURES • Display brightness: [To set the shift timing indicator light activa- This function allows you to adjust the bright- tion function] ness of the displays and tachometer. • Shift timing indicator light activity function: The shift timing indicator light activation function This function allows you to set the indicator can be set between 10000 r/min and 18000 light to on, flash, or off.

  • Page 19: Important Information

    5. Keep all parts away from any source of fire. EAS30007 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 20: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS30010 EAS30012 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.

  • Page 21: Basic Service Information

    BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30013 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.

  • Page 22: Electrical System

    BASIC SERVICE INFORMATION ECA16760 EAS30014 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
  • Page 23 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA16630 ECA14371 NOTICE NOTICE...
  • Page 24 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
  • Page 25 BASIC SERVICE INFORMATION • As a quick remedy, use a contact revitalizer available at most part stores. 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, push both sections of the coupler or connector to- gether until they are connected securely.
  • Page 26 BASIC SERVICE INFORMATION 1-17...

  • Page 27: Special Tools

    SPECIAL TOOLS EAS20012 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 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-26 90890-01426 Oil filter wrench YU-38411 Oil pressure gauge set 3-27 90890-03120 Oil pressure adapter H 3-27 90890-03139 Fork spring compressor 4-47, 4-52 90890-01441 Fork spring compressor YM-01441 Rod holder 4-47, 4-52 90890-01434 Damper rod holder double ended...
  • Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller attachment (M10) 4-50, 4-52 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Ring nut wrench 4-56 90890-01268 Spanner wrench YU-01268 Ring nut wrench 4-64, 4-66 90890-01507 Ring nut wrench YM-01507 Damper rod holder (24 mm) 4-64, 4-65...
  • Page 30 Valve guide reamer (ø4.5) 5-25 90890-04118 Valve guide reamer (4.5 mm) YM-04118 Rotor holding tool 5-30, 5-31, 5-33, 90890-04166 5-33 YM-04166 Flywheel puller 5-30 90890-01404 Flywheel puller YM-01404 Yamaha bond No. 1215 5-31, 5-33, 5-58 90890-85505 (Three bond No.1215®) 1-21...
  • Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Digital circuit tester 5-37 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Universal clutch holder 5-43, 5-47 90890-04086 Universal clutch holder YM-91042 Piston pin puller set 5-61 90890-01304 Piston pin puller YU-01304 YU-01304 Radiator cap tester 6-3, 6-3 90890-01325...
  • Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 6-3, 6-3 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-12 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-12 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Pressure gauge 7-13...

  • Page 33: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-17 LUBRICATION POINTS AND LUBRICANT TYPES ........2-21 ENGINE....................2-21 CHASSIS....................2-22 LUBRICATION SYSTEM CHART AND DIAGRAMS........

  • Page 34: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model 2CXS (YZFR6G_U49) 2CXT (YZFR6GC_CAL) 2CXW (YZFR6G_U49) 2CXX (YZFR6GC_CAL) Dimensions Overall length 2040 mm (80.3 in) Overall width 705 mm (27.8 in) Overall height 1095 mm (43.1 in) Seat height 850 mm (33.5 in) Wheelbase 1375 mm (54.1 in) Ground clearance...

  • Page 35: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 599 cm³ Cylinder arrangement Inline Number of cylinders 4-cylinder Bore × stroke 67.0 × 42.5 mm (2.64 × 1.67 in) Compression ratio 13.1 : 1 Compression pressure 1392–1792 kPa/400 r/min (13.9–17.9 kgf/cm²/400 r/min, 198.0–254.9 psi/400 r/min)
  • Page 36 ENGINE SPECIFICATIONS Thermostat Valve opening temperature 69.0–73.0 °C (156.20–163.40 °F) Valve full open temperature 85.0 °C (185.00 °F) Valve lift (full open) 8.0 mm (0.31 in) Water pump Water pump type Single suction centrifugal pump Impeller shaft tilt limit 0.15 mm (0.006 in) Spark plug(s) Manufacturer/model NGK/CR10EK...
  • Page 37 ENGINE SPECIFICATIONS Limit 35.79 mm (1.41 in) Spring tilt (intake) 1.6 mm (0.06 in) Spring tilt (exhaust) 1.6 mm (0.06 in) Cylinder Bore 67.000–67.010 mm (2.6378–2.6382 in) Taper limit 0.006 mm (0.0002 in) Out of round limit 0.050 mm (0.0020 in) Piston Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in)
  • Page 38 ENGINE SPECIFICATIONS Plate quantity 9 pcs Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in) Plate quantity 8 pcs Warpage limit 0.10 mm (0.004 in) Clutch spring free length 55.00 mm (2.17 in) Limit 54.00 mm (2.13 in) Spring quantity 6 pcs Drivetrain Primary reduction ratio 2.073 (85/41)
  • Page 39 ENGINE SPECIFICATIONS Fuel line pressure (at idle) 300.0–390.0 kPa (3.00–3.90 kgf/cm², 43.5–56.6 psi) Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) EXUP cable slack (at the EXUP valve pulley) 1.0–2.0 mm (0.04–0.08 in) Air induction system 18–22 Ω Solenoid resistance...

  • Page 40: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 24.0° Trail 97 mm (3.8 in) Front wheel Wheel type Cast wheel Rim size 17M/CxMT3.50 Rim material Aluminum Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Rear wheel Wheel type...
  • Page 41 261.3 mm (10.29 in) Limit 256.1 mm (10.08 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil M1 Quantity (left) 456.0 cm³ (15.42 US oz, 16.08 Imp.oz) Quantity (right) 456.0 cm³ (15.42 US oz, 16.08 Imp.oz) Level (left) 124 mm (4.9 in)
  • Page 42 CHASSIS SPECIFICATIONS Spring Coil spring Shock absorber Gas-hydraulic damper Rear shock absorber assembly travel 60.0 mm (2.36 in) Wheel travel 120 mm (4.7 in) Spring preload Adjusting system Mechanical adjustable type Unit for adjustment Cam position Adjustment value (Soft) Adjustment value (STD) Adjustment value (Hard) Rebound damping Adjusting system...

  • Page 43: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Engine control unit Model/manufacturer TBDFB7/DENSO Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 10.0°/1300 r/min 248.0–372.0 Ω Pickup coil resistance Ignition coil 0.85–1.15 Ω Primary coil resistance Secondary coil resistance 5.01–6.78 kΩ...
  • Page 44 ELECTRICAL SPECIFICATIONS Shift timing indicator light Starter motor Power output 0.60 kW 0.0012–0.0022 Ω Armature coil resistance Brush overall length 6.0 mm (0.24 in) Limit 3.50 mm (0.14 in) Brush spring force 7.16–9.52 N (730–971 gf, 25.77–34.27 oz) Commutator diameter 28.0 mm (1.10 in) Limit 27.0 mm (1.06 in)

  • Page 45: Tightening Torques

    TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30015 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 46: Engine Tightening Torques

    TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Camshaft cap bolt (intake and ex- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) haust) Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kgf, 11 ft·lbf) pipe assembly) Cylinder head nut (1st) 25 Nm (2.5 m·kgf, 18 ft·lbf) Cylinder head nut (final) 42 Nm (4.2 m·kgf, 30 ft·lbf)
  • Page 47 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Throttle body joint clamp 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Intake funnel joint bolt 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Intake funnel joint bolt 2 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf) Locknut (throttle cable) 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Exhaust pipe assembly nut...
  • Page 48 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Crankshaft position sensor bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Crankcase stud bolt See TIP. Clutch spring bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Stake Clutch boss nut 115 Nm (11.5 m·kgf, 83 ft·lbf) Clutch boss plate stud bolt 25 Nm (2.5 m·kgf, 18 ft·lbf) Stake...
  • Page 49 TIGHTENING TORQUES Crankcase stud bolt Install the crankcase stud bolts (M10) so that their installed length is 68.2 mm (2.69 in). Cylinder head tightening sequence: Crankcase tightening sequence: 23 22 2-16...

  • Page 50: Chassis Tightening Torques

    TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front right 45 Nm (4.5 m·kgf, 33 ft·lbf) side) Engine mounting bolt (front left side) 45 Nm (4.5 m·kgf, 33 ft·lbf) Engine mounting nut (rear upper 64 Nm (6.4 m·kgf, 46 ft·lbf) side) Engine mounting nut (rear lower...
  • Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cap bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Damper rod locknut 15 Nm (1.5 m·kgf, 11 ft·lbf) Damper rod assembly bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Front fender bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Relay arm and frame nut 40 Nm (4.0 m·kgf, 29 ft·lbf) Connecting arm and relay arm nut...
  • Page 52 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Battery box and frame 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Rear upper cowling damper plate 7 Nm (0.7 m·kgf, 5.1 ft·lbf) and frame License plate light assembly bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Rider footrest (left and right) assem- 28 Nm (2.8 m·kgf, 20 ft·lbf) bly bolt...
  • Page 53 TIGHTENING TORQUES Lower bracket pinch bolt Tighten each bolt to 23 Nm (2.3 m·kgf, 17 ft·lbf) in the order pinch bolt “1” → pinch bolt “2” → pinch bolt “1” → pinch bolt “2”. 2-20...

  • Page 54: Lubrication Points And Lubricant Types

    Shift forks and shift fork guide bars Shift shaft Cylinder head cover mating surface Bond TB1541C Cylinder head cover gasket Bond TB1215B Yamaha bond No.1215 (Three Bond Crankcase mating surface No.1215®) Three Bond No.1280B Yamaha bond No.1215 Crankshaft position sensor lead grommet (Three Bond No.1215®)

  • Page 55: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS30019 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing cover lip Lower bearing dust seal lip Tube guide (throttle grip) inner surface and throttle cables Brake lever pivoting point and metal-to-metal moving parts Brake caliper piston seal Brake caliper piston dust seal Clutch cable end Clutch lever pivoting point and metal-to-metal moving parts...

  • Page 56: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-23...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil filter 5. Oil cooler 6. Main gallery 7. Oil nozzle 8. Timing chain tensioner 9. Intake camshaft 10. Exhaust camshaft 11. Oil pipe 12. Main axle 13.

  • Page 58: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS 2-25...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Ventilation chamber cover 2. Relief valve 3. Ventilation chamber oil drain pipe 4. Oil cooler 2-26...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Oil check bolt 5. Oil strainer 6. Ventilation chamber oil drain pipe 7. Oil pipe 8. Oil pump 2-28...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil filter 3. Oil pipe 4. Oil pump 5. Oil strainer 2-30...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil pump 3. Oil pipe 4. Ventilation chamber oil drain pipe 5. Relief valve 2-32...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Oil nozzle 2-34...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pipe 2. Main axle 3. Drive axle 2-36...

  • Page 70: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-37...
  • Page 71 COOLING SYSTEM DIAGRAMS 1. Radiator inlet hose 2. Radiator inlet pipe 3. Thermostat outlet hose 4. Radiator 2-38...
  • Page 72 COOLING SYSTEM DIAGRAMS 2-39...
  • Page 73 COOLING SYSTEM DIAGRAMS 1. Water pump breather hose 2. Coolant reservoir hose 3. Coolant reservoir 4. Radiator 5. Radiator outlet hose 6. Oil cooler outlet hose 7. Radiator outlet pipe 8. Water jacket joint inlet hose 9. Water pump outlet pipe 10.

  • Page 74: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front view) 2-41...
  • Page 75 CABLE ROUTING 1. Clutch cable 2. Main switch lead 3. Handlebar switch lead (left) 4. Horn lead 5. Horn 6. Front brake hose 7. Throttle cable (decelerator cable) 8. Throttle cable (accelerator cable) 9. Handlebar switch lead (right) 10. Steering cover 11.
  • Page 76 CABLE ROUTING Engine (right side view) 2-43...
  • Page 77 CABLE ROUTING 1. Coolant reservoir breather hose M. Fasten the main harness with a plastic locking tie, making sure to align the positioning tape of the 2. Clutch cable main harness with the holes and groove of the 3. Hose clamp guide bar.
  • Page 78 CABLE ROUTING Engine (left side view) 2-45...
  • Page 79 CABLE ROUTING 1. Main switch lead S. For U49 and California, the coupler is without a bullet terminal, so insertion is unnecessary. 2. Handlebar switch lead (left) Connection point should be the same as for 3. Radiator fan motor lead (left) Europe (position shown in this illustration) (this 4.
  • Page 80 CABLE ROUTING Frame (top view) 2-47...
  • Page 81 CABLE ROUTING 1. Clutch cable 2. Throttle cable (decelerator cable) 3. Throttle cable (accelerator cable) 4. Handlebar switch lead (right) 5. Radiator cover (right) 6. Upper side cowling (right) 7. Coupler holder (right) 8. Radiator fan motor lead (right) 9. TPS lead 10.
  • Page 82 CABLE ROUTING Frame (top view) 2-49...
  • Page 83 CABLE ROUTING 1. Crankshaft position sensor lead O. Route each lead under the frame plate. There is no order for placing each lead. Insert the plastic 2. Ignition coil lead locking tie from upper part of the frame and direct 3.
  • Page 84 CABLE ROUTING Headlight (left side and rear view) 2-51...
  • Page 85 CABLE ROUTING 1. Headlight sub-wire harness 2. Headlight lead (low beam) 3. Headlight relay lead (on/off) 4. Headlight relay lead (dimmer) 5. Headlight lead (high beam) 6. Intake air temperature sensor lead 7. Atmospheric pressure sensor lead A. Secure the headlight sub-wire harness with the air duct hook.
  • Page 86 CABLE ROUTING Rear fender (top view) 2-53...
  • Page 87 CABLE ROUTING 1. Battery 2. Battery negative lead 3. Main fuse lead 4. Starting circuit cut-off relay lead 5. Fuse box lead 6. ECU (Engine Control Unit) 7. Turn signal relay lead 8. Rear turn signal light lead (left) 9. Rear turn signal light lead (right) 10.
  • Page 88 CABLE ROUTING Fuel tank (except for California) (left side and bottom view) 2-55...
  • Page 89 CABLE ROUTING 1. Fuel tank breather hose 2. Fuel tank drain hose 3. Main harness 4. Fuel hoses 5. Fuel tank breather hose 6. Fuel tank drain hose 7. Clamp 2-56...
  • Page 90 CABLE ROUTING Fuel tank (for California) (left side and bottom view) 2-57...
  • Page 91 CABLE ROUTING 1. Rollover valve 2. Fuel tank breather hose (fuel tank to rollover valve) 3. Fuel hose (fuel tank side) 4. Fuel tank overflow hose (fuel tank to hose joint) 5. Fuel tank overflow hose 6. Canister 7. Canister purge hose (3-way joint to canister) A.
  • Page 92 CABLE ROUTING 2-59...

  • Page 93: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ............. 3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5 CHECKING THE CRANKCASE BREATHER HOSE ........3-8 SYNCHRONIZING THE THROTTLE BODIES..........
  • Page 94 CHECKING THE BRAKE LIGHT SWITCHES.........3-30 ADJUSTING THE REAR BRAKE LIGHT SWITCH .........3-30 CHECKING AND LUBRICATING THE CABLES ........3-31 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-31 CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......3-31 CHECKING AND CHARGING THE BATTERY........3-32 CHECKING THE FUSES ................3-32 REPLACING THE HEADLIGHT BULBS ..........

  • Page 96: Periodic Maintenance

    • From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. • Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service.
  • Page 97 PERIODIC MAINTENANCE INITIAL ODOMETER READINGS 8000 mi 12000 mi 16000 mi 20000 mi 600 mi 4000 mi ITEM ROUTINE (13000 (19000 (25000 (31000 (1000 km) (7000 km) 1 month 6 months 12 months 18 months 24 months 30 months 1 * Air filter element •...
  • Page 98 Front and rear √ √ √ √ √ √ 26 * • Check operation. brake switches • Apply Yamaha cable lubricant √ √ √ √ √ √ 27 * Control cables or other suitable cable lubri- cant thoroughly. • Check operation.

  • Page 99: Checking The Fuel Line

    PERIODIC MAINTENANCE EAS30057 ECA13320 CHECKING THE FUEL LINE NOTICE The following procedure applies to all of the fuel, Before removing the spark plugs, blow away vacuum and breather hoses. any dirt accumulated in the spark plug wells 1. Remove: with compressed air to prevent it from falling •...

  • Page 100: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE 8. Install: 4. Measure: • Air induction system solenoid • Valve clearance Out of specification → Adjust. Refer to “AIR INDUCTION SYSTEM” on page 7-15. Valve clearance (cold) • Air filter case Intake Refer to “AIR FILTER CASE” on page 7-4. 0.12–0.19 mm (0.0047–0.0075 in) •...
  • Page 101 PERIODIC MAINTENANCE B. Cylinder Thickness gauge C. Combustion cycle 90890-03180 Feeler gauge set Cylinder #2 180° YU-26900-9 Cylinder #4 360° Cylinder #3 540° • If the valve clearance is incorrect, note the ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
  • Page 102 PERIODIC MAINTENANCE Last digit Rounded value 3, 4, 5, 6 7, 8, 9 Refer to the following table for the available valve pads. Valve pad range Nos. 150–240 1.50–2.40 mm Valve pad thickness b. Calculate the difference between the speci- (0.0591–0.0945 in) fied valve clearance and the measured valve 25 thicknesses in 0.05...

  • Page 103: Checking The Crankcase Breather Hose

    PERIODIC MAINTENANCE • Turn the crankshaft clockwise several full turns 1. Stand the vehicle on a level surface. to seat the parts. Place the vehicle on a suitable stand. h. Measure the valve clearance again. i. If the valve clearance is still out of specifica- 2.

  • Page 104: Checking The Exhaust System

    PERIODIC MAINTENANCE b. Turn the bypass air screw “1” with a white Engine idling speed paint mark out a little, and then turn it in fully. 1250–1350 r/min b. Turn all of the bypass air screws in fully. c. Using the throttle body with the lowest vacu- um pressure as the standard, turn out the by- pass air screws of the other throttle bodies to adjust them.

  • Page 105: Checking The Canister (For California Only)

    PERIODIC MAINTENANCE 1. Remove: • Side cowling assembly Refer to “GENERAL CHASSIS” on page 4-1. 2. Check: • Exhaust pipe assembly “1” • Muffler “2” Cracks/damage → Replace. • Gaskets “3” Exhaust gas leaks → Replace. 3. Check: Tightening torque •...

  • Page 106: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE • Upper air filter case b. Fold the air filter “1” forward and then fit into Refer to “AIR FILTER CASE” on page 7-4. the air filter case. 2. Remove: • Air filter element “1” ▲ ▲▲▲ ▲ ▲▲▲ ▲...

  • Page 107: Checking The Brake Operation

    PERIODIC MAINTENANCE EAS30074 CHECKING THE BRAKE FLUID LEVEL 1. Stand the vehicle on a level surface. • Place the vehicle on a suitable stand. • Make sure the vehicle is upright. 2. Check: • Brake fluid level Below the minimum level mark “a” → Add the specified brake fluid to the proper level.

  • Page 108: Adjusting The Front Disc Brake

    PERIODIC MAINTENANCE • When refilling, be careful that water does EWA13050 WARNING not enter the brake fluid reservoir. Water A soft or spongy feeling in the brake lever will significantly lower the boiling point of can indicate the presence of air in the brake the brake fluid and could cause vapor lock.

  • Page 109: Checking The Rear Brake Pads

    PERIODIC MAINTENANCE c. Tighten the locknut “1” to specification. EAS30077 CHECKING THE FRONT BRAKE HOSES Rear brake pedal adjusting lock- The following procedure applies to all of the brake hoses and brake hose holders. 16 Nm (1.6 m·kgf, 12 ft·lbf) 1.

  • Page 110: Bleeding The Hydraulic Brake System

    PERIODIC MAINTENANCE 3. Hold the vehicle upright and apply the brake several times. 4. Check: • Brake hoses Brake fluid leakage → Replace the damaged hose. Refer to “REAR BRAKE” on page 4-30. EAS30084 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA13100 WARNING Bleed the hydraulic brake system whenever: •...

  • Page 111: Checking The Wheels

    PERIODIC MAINTENANCE h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bub- bles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. Front brake master cylinder bleed screw 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
  • Page 112 No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. Front tire Size 120/70 ZR17M/C (58W)

  • Page 113: Checking The Wheel Bearings

    PERIODIC MAINTENANCE EAS30641 CHECKING THE WHEEL BEARINGS Drive chain slack (on a suitable The following procedure applies to all of the stand) wheel bearings. 30.0–45.0 mm (1.18–1.77 in) 1. Check: • Wheel bearings Refer to “CHECKING THE FRONT WHEEL” Measure the drive chain slack halfway between on page 4-8 and “CHECKING THE REAR the drive axle and the rear wheel axle.

  • Page 114: Lubricating The Drive Chain

    PERIODIC MAINTENANCE e. Tighten the drive chain adjusting bolts in di- 3. Remove: rection “a” to specification. • Upper bracket Refer to “STEERING HEAD” on page 4-54. Drive chain adjusting bolt 4. Adjust: 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) • Steering head ▼...

  • Page 115: Lubricating The Steering Head

    PERIODIC MAINTENANCE EAS30720 LUBRICATING THE LEVERS Lower ring nut (final tightening Lubricate the pivoting point and metal-to-metal torque) moving parts of the levers. 14 Nm (1.4 m·kgf, 10 ft·lbf) Recommended lubricant d. Check the steering head for looseness or Lithium-soap-based grease binding by turning the front fork all the way in both directions.

  • Page 116: Adjusting The Front Fork Legs

    PERIODIC MAINTENANCE The spring preload setting is determined by measuring the distance “c” shown in the illustra- tion. The shorter distance “c” is, the higher the spring preload; the longer distance “c” is, the lower the spring preload. Direction “a” Spring preload is increased (suspen- sion is harder).
  • Page 117 PERIODIC MAINTENANCE 1. Adjust: Direction “a” • Rebound damping Compression damping is increased ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ (suspension is harder). a. Turn the adjusting screw “1” in direction “a” or Direction “b”...

  • Page 118: Checking The Rear Shock Absorber Assembly

    PERIODIC MAINTENANCE b. Turn the adjusting ring “1” in direction “a” or Slow compression damping “b”. Adjustment value from the start c. Align the desired position on the adjusting position (Soft) ring with the position indicator “2”. Adjustment value from the start Direction “a”...
  • Page 119 PERIODIC MAINTENANCE Rebound damping Fast compression damping Adjustment value from the start Adjustment value from the start position (Soft) position (Soft) Adjustment value from the start Adjustment value from the start position (STD) position (STD) Adjustment value from the start Adjustment value from the start position (Hard) position (Hard)

  • Page 120: Checking The Connecting Arm And Relay Arm

    PERIODIC MAINTENANCE • The adjustment value is the number of clicks that the adjusting screw is turned in direction “b” from the start position. • The start position is the position with the ad- justing screw fully turned in direction “a”. Recommended brand YAMALUBE SAE viscosity grades...
  • Page 121 PERIODIC MAINTENANCE 5. Remove: d. Lubricate the O-ring “7” of the new oil filter • Engine oil drain bolt “1” cartridge with a thin coat of engine oil. (along with the gasket) ECA23090 NOTICE Make sure the O-ring “7” is positioned cor- rectly in the groove of the oil filter cartridge.

  • Page 122: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE 8. Check: EWA12980 WARNING • Engine oil drain bolt gasket Damage → Replace. The engine, muffler and engine oil are ex- tremely hot. 9. Install: • Engine oil drain bolt (along with the gasket) Engine oil drain bolt 43 Nm (4.3 m·kgf, 31 ft·lbf) 10.Fill: •...

  • Page 123: Checking The Coolant Level

    PERIODIC MAINTENANCE Main gallery bolt Before checking the coolant level, wait a few 8 Nm (0.8 m·kgf, 5.8 ft·lbf) minutes until it settles. 8. Install: • Side cowling assembly EAS30067 CHECKING THE COOLING SYSTEM Refer to “GENERAL CHASSIS” on page 4-1. 1.

  • Page 124: Changing The Coolant

    PERIODIC MAINTENANCE 3. Install: • Exhaust pipe assembly Refer to “ENGINE REMOVAL” on page 5-3. • Side cowling assembly Refer to “GENERAL CHASSIS” on page 4-1. EAS30068 CHANGING THE COOLANT 1. Remove: • Side panel • Upper side cowling 5. Drain: •...

  • Page 125: Checking The Brake Light Switches

    PERIODIC MAINTENANCE Coolant is potentially harmful and should be handled with special care. Before checking the coolant level, wait a few EWA13040 minutes until the coolant has settled. WARNING 17.Install: • If coolant splashes in your eyes, thorough- • Side cowling assembly ly wash them with water and consult a doc- •...

  • Page 126: Checking And Lubricating The Cables

    PERIODIC MAINTENANCE 2. Adjust: ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ • Throttle cable free play EAS30114 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 127: Checking And Charging The Battery

    PERIODIC MAINTENANCE EAS30120 EWA13320 CHECKING AND CHARGING THE BATTERY WARNING Refer to “ELECTRICAL COMPONENTS” on Since the headlight bulb gets extremely hot, page 8-71. keep flammable products and your hands away from the bulb until it has cooled down. EAS30121 CHECKING THE FUSES 5.
  • Page 128 PERIODIC MAINTENANCE A. Headlight (left) B. Headlight (right) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • Headlight beam (horizontally) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

  • Page 129: Chassis

    CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEEL....................4-6 REMOVING THE FRONT WHEEL............4-8 DISASSEMBLING THE FRONT WHEEL..........4-8 CHECKING THE FRONT WHEEL ............4-8 ASSEMBLING THE FRONT WHEEL............4-9 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-9 CHECKING THE FRONT BRAKE DISCS..........4-10 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ....
  • Page 130 REAR BRAKE ....................4-30 INTRODUCTION ..................4-35 CHECKING THE REAR BRAKE DISC............4-35 REPLACING THE REAR BRAKE PADS..........4-35 REMOVING THE REAR BRAKE CALIPER ..........4-36 DISASSEMBLING THE REAR BRAKE CALIPER ........4-36 CHECKING THE REAR BRAKE CALIPER..........4-37 ASSEMBLING THE REAR BRAKE CALIPER ........4-37 INSTALLING THE REAR BRAKE CALIPER...........4-38 REMOVING THE REAR BRAKE MASTER CYLINDER ......
  • Page 131 CHAIN DRIVE....................4-67 REMOVING THE DRIVE CHAIN............. 4-68 CHECKING THE DRIVE CHAIN ............. 4-68 CHECKING THE DRIVE SPROCKET.............4-69 CHECKING THE REAR WHEEL SPROCKET........4-69 CHECKING THE REAR WHEEL DRIVE HUB ........4-69 INSTALLING THE DRIVE CHAIN ............4-69...

  • Page 132: General Chassis

    GENERAL CHASSIS EAS20026 GENERAL CHASSIS Removing the seat and battery 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 133 GENERAL CHASSIS Removing the tail/brake light assembly 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) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
  • Page 134 GENERAL CHASSIS Removing the tail/brake light assembly 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) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
  • Page 135 GENERAL CHASSIS Removing the side cowlings and front cowling assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • ’ Order Job/Parts to remove Remarks Side panel Side cowling assembly Front turn signal light coupler Disconnect.
  • Page 136 GENERAL CHASSIS Removing the front cowling assembly 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • 0.8 Nm (0.08 m kgf, 0.58 ft Ibf) •...

  • Page 137: Front Wheel

    FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 35 Nm (3.5 m kgf, 25 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 138 FRONT WHEEL Disassembling the front wheel ’ Order Job/Parts to remove Remarks Oil seal Wheel bearing Spacer...

  • Page 139: Removing The Front Wheel

    FRONT WHEEL EAS30145 EAS30147 REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL 1. Stand the vehicle on a level surface. 1. Check: EWA13120 • Wheel axle WARNING Roll the wheel axle on a flat surface. Bends → Replace. Securely support the vehicle so that there is no danger of it falling over.

  • Page 140: Assembling The Front Wheel

    FRONT WHEEL Place the front wheel on a suitable balancing stand. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Spin the front wheel. b. When the front wheel stops, put an “X ”...

  • Page 141: Checking The Front Brake Discs

    FRONT WHEEL EAS31327 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) The following procedure applies to both of the brake discs. 1. Install: • Front brake disc Front brake disc bolt 18 Nm (1.8 m·kgf, 13 ft·lbf) LOCTITE® b. Turn the front wheel 90° so that the heavy spot is positioned as shown.
  • Page 142 FRONT WHEEL • Front wheel axle pinch bolts Front brake caliper bolt 35 Nm (3.5 m·kgf, 25 ft·lbf) Front wheel axle 91 Nm (9.1 m·kgf, 66 ft·lbf) EWA13500 Front wheel axle pinch bolt WARNING 21 Nm (2.1 m·kgf, 15 ft·lbf) Make sure the brake hose is routed properly.

  • Page 143: Rear Wheel

    REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 22 Nm (2.2 m kgf, 16 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 110 Nm (11 m kgf, 80 ft lbf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...
  • Page 144 REAR WHEEL Removing the rear brake disc and rear wheel sprocket 30 Nm (3.0 m kgf, 22 ft Ibf) • • 100 Nm (10 m kgf, 72 ft lbf) • • ’ Order Job/Parts to remove Remarks Rear brake disc Rear wheel sprocket Collar Oil seal...
  • Page 145 REAR WHEEL Disassembling the rear wheel ’ Order Job/Parts to remove Remarks Collar Wheel bearing (left side) Spacer Oil seal Circlip Wheel bearing (right side) 4-14...

  • Page 146: Removing The Rear Wheel

    REAR WHEEL EAS30156 EAS30159 REMOVING THE REAR WHEEL CHECKING THE REAR WHEEL 1. Stand the vehicle on a level surface. 1. Check: EWA13120 • Rear wheel axle WARNING • Rear wheel Securely support the vehicle so that there is • Wheel bearings no danger of it falling over.

  • Page 147: Assembling The Rear Wheel

    REAR WHEEL EAS30164 ADJUSTING THE REAR WHEEL STATIC BALANCE • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1.
  • Page 148 REAR WHEEL 4. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-18. Drive chain slack (on a suitable stand) 30.0–45.0 mm (1.18–1.77 in) 5. Install: • Rear brake caliper Rear brake caliper bolt (M12) 27 Nm (2.7 m·kgf, 20 ft·lbf) Rear brake caliper bolt (M8) 22 Nm (2.2 m·kgf, 16 ft·lbf)

  • Page 149: Front Brake

    FRONT BRAKE EAS20030 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) • • ’...
  • Page 150 FRONT BRAKE Removing the front brake master cylinder 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • ’ Order Job/Parts to remove Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 151 FRONT BRAKE Disassembling the front brake master cylinder 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • ’ Order Job/Parts to remove Remarks Brake master cylinder kit Bleed screw Brake master cylinder body 4-20...
  • Page 152 FRONT BRAKE Removing the front brake calipers 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove ’...
  • Page 153 FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • ’ Order Job/Parts to remove 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 154: Introduction

    FRONT BRAKE d. Hold the dial gauge at a right angle against EAS30168 INTRODUCTION the brake disc surface. EWA14101 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.

  • Page 155: Replacing The Front Brake Pads

    FRONT BRAKE ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ Front brake disc bolt a. Connect a clear plastic hose “1” tightly to the 18 Nm (1.8 m·kgf, 13 ft·lbf) bleed screw “2”.

  • Page 156: Removing The Front Brake Calipers

    FRONT BRAKE 5. Check: ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the brake hose joint • Brake lever operation Soft or spongy feeling → Bleed the brake sys- opening “a”...

  • Page 157: Assembling The Front Brake Calipers

    FRONT BRAKE • Brake caliper cylinders “2” Front brake hose union bolt Scratches/wear → Replace the brake caliper 30 Nm (3.0 m·kgf, 22 ft·lbf) assembly. • Brake caliper body “3” EWA13531 Cracks/damage → Replace the brake caliper WARNING assembly. Proper brake hose routing is essential to in- •...

  • Page 158: 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 To collect any remaining brake fluid, place a may result in a harmful chemical reaction, container under the master cylinder and the end leading to poor brake performance.

  • Page 159: Installing The Front Brake Master Cylinder

    FRONT BRAKE EAS30182 INSTALLING THE FRONT BRAKE MASTER 15.8˚ CYLINDER 1. Install: • Front brake master cylinder “1” • Front brake master cylinder holder “2” Front brake master cylinder bolt 13 Nm (1.3 m·kgf, 9.4 ft·lbf) 3. Fill: • Install the brake master cylinder holder with the •...
  • Page 160 FRONT BRAKE 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. 4-29...

  • Page 161: Rear Brake

    REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf)
  • Page 162 REAR BRAKE Removing the rear brake master cylinder 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 163 REAR BRAKE Disassembling the rear brake master cylinder ’ Order Job/Parts to remove Remarks Brake master cylinder kit Brake hose joint Brake master cylinder body 4-32...
  • Page 164 REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kgf, 22 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • ’ Order Job/Parts to remove Remarks Drain.
  • Page 165 REAR BRAKE Disassembling the rear brake caliper 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • ’ Order Job/Parts to remove Remarks Screw plug Brake pad pin...

  • Page 166: Introduction

    REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit EWA14101 4.5 mm (0.18 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 167: Removing The Rear Brake Caliper

    REAR BRAKE ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container.

  • Page 168: Checking The Rear Brake Caliper

    REAR BRAKE • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. EWA13611 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston dust seals and brake caliper piston seals.

  • Page 169: Installing The Rear Brake Caliper

    REAR BRAKE EAS30190 INSTALLING THE REAR BRAKE CALIPER Specified brake fluid 1. Install: DOT 4 • Rear brake caliper “1” (temporarily) EWA13090 WARNING • Copper washers • Use only the designated brake fluid. Other • Rear brake hose “2” brake fluids may cause the rubber seals to •...

  • Page 170: Removing The Rear Brake Master Cylinder

    REAR BRAKE EAS30193 EAS30195 REMOVING THE REAR BRAKE MASTER ASSEMBLING THE REAR BRAKE MASTER CYLINDER CYLINDER EWA13520 WARNING Before removing the rear brake master cylinder, • Before installation, all internal brake com- drain the brake fluid from the entire brake sys- ponents should be cleaned and lubricated tem.
  • Page 171 REAR BRAKE 7. Adjust: EWA13090 WARNING • Rear brake light operation timing • Use only the designated brake fluid. Other Refer to “ADJUSTING THE REAR BRAKE brake fluids may cause the rubber seals to LIGHT SWITCH” on page 3-30. deteriorate, causing leakage and poor brake performance.

  • Page 172: Handlebars

    HANDLEBARS EAS20033 HANDLEBARS Removing the handlebars 13 Nm (1.3 m kgf, 9.4 ft Ibf) 13 Nm (1.3 m kgf, 9.4 ft Ibf) 115 Nm (11.5 m kgf, 83 ft lbf) • • • • • • 26 Nm (2.6 m kgf, 19 ft Ibf) •...
  • Page 173 HANDLEBARS Removing the handlebars 13 Nm (1.3 m kgf, 9.4 ft Ibf) 13 Nm (1.3 m kgf, 9.4 ft Ibf) 115 Nm (11.5 m kgf, 83 ft lbf) • • • • • • 26 Nm (2.6 m kgf, 19 ft Ibf) •...

  • Page 174: Removing The Handlebars

    HANDLEBARS • Align the mating surfaces of the brake master EAS30203 REMOVING THE HANDLEBARS cylinder holder with the punch mark “b” on the 1. Stand the vehicle on a level surface. handlebar. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
  • Page 175 HANDLEBARS • Grip end (left) “2” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ There should be 1–3 mm (0.04–0.12 in) of clear- a. Apply a thin coat of rubber adhesive onto the ance “a”...

  • Page 176: Front Fork

    FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 26 Nm (2.6 m kgf, 19 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf)
  • Page 177 FRONT FORK Disassembling the front fork legs 15 Nm (1.5 m kgf, 11 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front fork legs.

  • Page 178: Removing The Front Fork Legs

    FRONT FORK EAS30206 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ REMOVING THE FRONT FORK LEGS a. Press down on the spacer with the fork spring The following procedure applies to both of the compressor “5”.

  • Page 179: Checking The Front Fork Legs

    FRONT FORK EAS30208 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • Inner tube • Outer tube Bends/damage/scratches → Replace. EWA13650 WARNING Do not attempt to straighten a bent inner 3.

  • Page 180: Assembling The Front Fork Legs

    FRONT FORK Recommended oil Yamaha Suspension Oil M1 3. Tighten: • Damper rod assembly bolt “1” Damper rod assembly bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) EAS30209 While holding the damper rod assembly with the ASSEMBLING THE FRONT FORK LEGS damper rod holder “2”, tighten the damper rod...
  • Page 181 FRONT FORK 8. Install: • Dust seal “1” (with the fork seal driver weight “2”) Fork seal driver 90890-01442 Adjustable fork seal driver (36–46 YM-01442 5. Install: • Outer tube (to the inner tube) 6. Install: • Washer • Oil seal “1” (with the fork seal driver “2”) Fork seal driver 90890-01442...
  • Page 182 456.0 cm³ (15.42 US oz, 16.08 Imp.oz) Quantity (right) 456.0 cm³ (15.42 US oz, 16.08 Imp.oz) Recommended oil Yamaha Suspension Oil M1 ECA14230 NOTICE • Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.
  • Page 183 FRONT FORK h. Remove the rod puller and rod puller attach- ment. Install the spring with the smaller pitch “a” facing i. Install the damper rod locknut “1” and position up “A”. it as specified “b”. Distance “b” 12 mm (0.47 in) d.

  • Page 184: Installing The Front Fork Legs

    FRONT FORK EAS30210 INSTALLING THE FRONT FORK LEGS Upper bracket pinch bolt The following procedure applies to both of the 26 Nm (2.6 m·kgf, 19 ft·lbf) front fork legs. 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts.

  • Page 185: Steering Head

    STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 52 Nm (5.2 m kgf, 38 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
  • Page 186 STEERING HEAD Removing the lower bracket 52 Nm (5.2 m kgf, 38 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...

  • Page 187: Removing The Lower Bracket

    STEERING HEAD 3. Replace: EAS30213 REMOVING THE LOWER BRACKET • Bearings 1. Stand the vehicle on a level surface. • Bearing races EWA13120 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼...
  • Page 188 STEERING HEAD Recommended lubricant Route the right brake pipe “a” through the projec- Lithium-soap-based grease tions “b” of the front brake hose joint bracket. 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” •...

  • Page 189: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 40 Nm (4.0 m kgf, 29 ft Ibf) • • 44 Nm (4.4 m kgf, 32 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) •...

  • Page 190: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Connecting arm bolts “1” the rear shock absorber, read and make sure •...

  • Page 191: Checking The Connecting Arm And Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY • Rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. • Spring Damage/wear → Replace the rear shock ab- sorber assembly. • Bushing Damage/wear → Replace. • Collar Damage/scratches → Replace. • Bolts Bends/damage/wear →...
  • Page 192 REAR SHOCK ABSORBER ASSEMBLY 4. Tighten: • Spacer bolt Rear shock absorber assembly spacer bolt 16 Nm (1.6 m·kgf, 12 ft·lbf) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 40 Nm (4.0 m·kgf, 29 ft·lbf) •...

  • Page 193: Swingarm

    SWINGARM EAS20037 SWINGARM Removing the swingarm 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 95 Nm (9.5 m kgf, 69 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) •...
  • Page 194 SWINGARM Removing the swingarm 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 95 Nm (9.5 m kgf, 69 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) •...

  • Page 195: Removing The Swingarm

    SWINGARM 4. Remove: EAS30226 REMOVING THE SWINGARM • Swingarm pivot shaft ring nut “1” 1. Stand the vehicle on a level surface. EWA13120 WARNING Loosen the swingarm pivot shaft ring nut with the ring nut wrench “2”. Securely support the vehicle so that there is no danger of it falling over.

  • Page 196: Installing The Swingarm

    SWINGARM EWA13770 WARNING Do not attempt to straighten a bent pivot shaft. 3. Wash: • Pivot shaft • Dust covers • Collars • Washers • Bearings Recommended cleaning solvent 5. Swingarm Kerosene 6. Swingarm pivot shaft 7. Bolt 4. Check: A.
  • Page 197 SWINGARM Swingarm pivot shaft ring nut 95 Nm (9.5 m·kgf, 69 ft·lbf) • Lubricate the swingarm pivot ring nut threads and mating surfaces with lithium-soap-based grease. • Tighten the swingarm pivot shaft ring nut with the ring nut wrench “2”. Ring nut wrench 90890-01507 Ring nut wrench...

  • Page 198: Chain Drive

    CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive sprocket and drive chain 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 85 Nm (8.5 m kgf, 61 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 199: Removing The Drive Chain

    CHAIN DRIVE EAS30229 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
  • Page 200 CHAIN DRIVE Bent teeth → Replace the drive sprockets as a set. b. Correct 1. Drive chain roller 2. Drive sprocket EAS30232 CHECKING THE REAR WHEEL SPROCKET Refer to “CHECKING AND REPLACING THE REAR WHEEL SPROCKET” on page 4-15. EAS30233 ▲...
  • Page 201 CHAIN DRIVE 4-70...
  • Page 202 CHAIN DRIVE 4-71...

  • Page 203: Engine

    ENGINE ENGINE INSPECTION ..................5-1 MEASURE THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-3 INSTALLING THE ENGINE............... 5-8 ADJUSTING THE SHIFT PEDAL.............. 5-8 ADJUSTING THE EXUP CABLES ............5-9 CAMSHAFTS....................5-11 REMOVING THE CAMSHAFTS..............5-13 CHECKING THE CAMSHAFTS ..............5-13 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES ...............5-14 CHECKING THE TIMING CHAIN TENSIONER........
  • Page 204 CLUTCH ......................5-39 REMOVING THE CLUTCH ..............5-43 CHECKING THE FRICTION PLATES.............5-43 CHECKING THE CLUTCH PLATES ............5-43 CHECKING THE CLUTCH SPRINGS.............5-44 CHECKING THE CLUTCH HOUSING ............5-45 CHECKING THE CLUTCH BOSS............5-45 CHECKING THE PRESSURE PLATE ............5-45 CHECKING THE PRIMARY DRIVE GEAR..........5-45 CHECKING THE PRIMARY DRIVEN GEAR ..........5-45 CHECKING THE PULL LEVER SHAFT AND PULL ROD ......5-46 CHECKING THE OIL PUMP DRIVE SPROCKET AND...
  • Page 205 TRANSMISSION.................... 5-72 REMOVING THE TRANSMISSION ............5-77 CHECKING THE SHIFT FORKS............. 5-77 CHECKING THE SHIFT DRUM ASSEMBLY..........5-78 CHECKING THE TRANSMISSION ............5-78 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ......5-78 INSTALLING THE TRANSMISSION ............5-79...

  • Page 206: Engine Inspection

    ENGINE INSPECTION 6. Measure: EAS20041 ENGINE INSPECTION • Compression pressure Out of specification → Refer to steps (c) and EAS30249 (d). MEASURE THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- Compression pressure inders. 1392–1792 kPa/400 r/min (13.9– 17.9 kgf/cm²/400 r/min, 198.0–...
  • Page 207 ENGINE INSPECTION 8. Install: • Radiator Refer to “RADIATOR” on page 6-1. • Side cowling assembly Refer to “GENERAL CHASSIS” on page 4-1.

  • Page 208: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the exhaust pipe assembly 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 45 Nm (4.5 m kgf, 33 ft Ibf)
  • Page 209 ENGINE REMOVAL Removing the exhaust pipe assembly 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 45 Nm (4.5 m kgf, 33 ft Ibf) •...
  • Page 210 ENGINE REMOVAL Disconnecting the leads and hoses 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 211 ENGINE REMOVAL Disconnecting the leads and hoses 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 212 ENGINE REMOVAL Removing the engine 45 Nm (4.5 m kgf, 33 ft Ibf) • • 64 Nm (6.4 m kgf, 46 ft Ibf) • • 45 Nm (4.5 m kgf, 33 ft Ibf) • • 64 Nm (6.4 m kgf, 46 ft Ibf) •...

  • Page 213: Installing The Engine

    ENGINE REMOVAL EAS30251 INSTALLING THE ENGINE 1. Install: • Engine “1” • Engine mounting bolt (rear lower side) “2” • Engine mounting bolt (rear upper side) “3” • Engine mounting collars (inside) “4” • Engine mounting collar (center) “5” • Engine mounting collars (outside) “6” •...

  • Page 214: Adjusting The Exup Cables

    ENGINE REMOVAL Installed shift rod length 267.2–269.2 mm (10.52–10.60 in) 2. Check: • EXUP system operation ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Activate the diagnostic mode and select the 3.
  • Page 215 ENGINE REMOVAL 4. Adjust: g. Repeat steps (2) and (3). • EXUP cable free play ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 216: Camshafts

    CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • ’ Order Job/Parts to remove Remarks Radiator...
  • Page 217 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 218: Removing The Camshafts

    CAMSHAFTS EAS30256 ECA13720 REMOVING THE CAMSHAFTS NOTICE 1. Remove: To prevent damage to the cylinder head, • Pickup rotor cover camshafts or camshaft caps, loosen the Refer to “PICKUP ROTOR” on page 5-32. camshaft cap bolts in stages and in a criss- 2.

  • Page 219: Checking The Timing Chain, Camshaft Sprockets, And Timing Chain Guides

    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 (intake and ex- haust) 3.

  • Page 220: Checking The Timing Chain Tensioner

    CAMSHAFTS 2. Check: • Timing chain tensioner rod • Camshaft sprocket More than 1/4 tooth wear “a” → Replace the Prior to installing the timing chain tensioner rod, camshaft sprocket and the timing chain as a drain the engine oil from the timing chain ten- set.

  • Page 221: Installing The Camshafts

    CAMSHAFTS 2. Install: • Timing chain “1” • Exhaust camshaft “2” • Intake camshaft “3” (with the camshaft sprockets temporarily tightened) • Make sure the match marks “a” on the cam- shaft sprockets are aligned with the cylinder head edge “b”. •...
  • Page 222 CAMSHAFTS 6. Rotate the crankshaft a few times to release the timing chain tensioner rod. 4. Install: • Camshaft cap bolts Camshaft cap bolt (intake and ex- If the engine is not disassembled, set the engine haust) stop switch to “ ”, and then crank the engine a 10 Nm (1.0 m·kgf, 7.2 ft·lbf) few times by pressing the start switch for approx- imately 0.5–1.0 second each time.
  • Page 223 CAMSHAFTS 9. Measure: • Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-5. 10.Install: • Cylinder head cover gasket • Cylinder head cover Cylinder head cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) •...

  • Page 224: Cylinder Head

    CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 1st 25 Nm (2.5 m kgf, 18 ft Ibf) 1st 30 Nm (3.0 m kgf, 22 ft Ibf) • • • • 2nd 60 Nm (6.0 m kgf, 43 ft Ibf) 2nd 42 Nm (4.2 m kgf, 30 ft Ibf)

  • Page 225: Removing The Cylinder Head

    CYLINDER HEAD 3. Measure: EAS30276 REMOVING THE CYLINDER HEAD • Cylinder head warpage 1. Remove: Out of specification → Resurface the cylinder • Cylinder head bolts head. • Cylinder head nuts Warpage limit 0.05 mm (0.0020 in) • Loosen the nuts, cap nuts, and bolts in de- creasing numerical order (refer to the numbers in the illustration).
  • Page 226 CYLINDER HEAD Cylinder head nut (1st) 25 Nm (2.5 m·kgf, 18 ft·lbf) Cylinder head nut (final) 42 Nm (4.2 m·kgf, 30 ft·lbf) • Cylinder head cap nuts “8”, “9” Cylinder head cap nut (1st) 30 Nm (3.0 m·kgf, 22 ft·lbf) Cylinder head cap nut (final) 60 Nm (6.0 m·kgf, 43 ft·lbf) •...

  • Page 227: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs ’ Order Job/Parts to remove Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-19. Valve lifter Valve pad Valve cotter Upper spring seat Intake valve spring Exhaust valve spring Intake valve Exhaust valve...

  • Page 228: Removing The Valves

    VALVES AND VALVE SPRINGS EAS30283 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 229 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) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”...

  • Page 230: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 2. Check: Valve guide remover (ø4.5) • Valve seat 90890-04116 Pitting/wear → Replace the cylinder head. Valve guide remover (4.5 mm) 3. Measure: YM-04116 • Valve seat width C “a” Valve guide installer (ø4.5) Out of specification → Replace the cylinder 90890-04117 head.

  • Page 231: Checking The Valve Springs

    VALVES AND VALVE SPRINGS ECA23100 NOTICE This model uses titanium intake and exhaust valves. Titanium valves that have been used to lap the valve seats must not be used. Always re- place lapped valves with new valves. • When replacing the cylinder head, replace the valves without lapping the valve seats and e.

  • Page 232: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 1. Deburr: Free length (intake) • Valve stem end 37.47 mm (1.48 in) (with an oil stone) Limit 35.60 mm (1.40 in) Free length (exhaust) 37.67 mm (1.48 in) Limit 35.79 mm (1.41 in) 2. Lubricate: •...
  • Page 233 VALVES AND VALVE SPRINGS 6. Lubricate: b. Smaller pitch • Valve lifter 4. Install: (with the recommended lubricant) • Valve cotters Recommended lubricant Engine oil Install the valve cotters by compressing the valve spring with the valve spring compressor 7. Install: “1”...

  • Page 234: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS20047 GENERATOR AND STARTER CLUTCH Removing the generator and starter clutch 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 235: Removing The Generator

    GENERATOR AND STARTER CLUTCH 2. Check: EAS30295 REMOVING THE GENERATOR • Starter clutch idle gear 1. Remove: • Starter clutch gear • Generator rotor bolt “1” Burrs/chips/roughness/wear → Replace the • Washer defective part(s). 3. Check: While holding the generator rotor “2” with the ro- •...

  • Page 236: Installing The Generator

    While holding the generator rotor “2” with the ro- tor holding tool “3”, tighten the generator rotor bolt. Rotor holding tool 90890-04166 YM-04166 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 5-31...

  • Page 237: Pickup Rotor

    PICKUP ROTOR EAS20147 PICKUP ROTOR Removing the pickup rotor 35 Nm (3.5 m kgf, 25 ft Ibf) • • 15 Nm (1.5 m kgf, 11 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 238: Removing The Pickup Rotor

    When installing the pickup rotor, align the groove “a” in the crankshaft with the projection “b” on the pickup rotor. 3. Apply: • Sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 5-33...
  • Page 239 PICKUP ROTOR 5-34...

  • Page 240: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS” on page Rider seat 4-1. Air filter case Refer to “AIR FILTER CASE” on page 7-4. Fuel tank Refer to “FUEL TANK”...
  • Page 241 ELECTRIC STARTER Disassembling the starter motor 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks O-ring Starter motor front cover Lock washer Oil seal Bearing Washer set Starter motor yoke Armature assembly Gasket Washer set Brush holder (along with the brushes) Starter motor rear cover...

  • Page 242: Checking The Starter Motor

    ELECTRIC STARTER EAS30325 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 “1” Out of specification → Replace the starter Armature coil resistance motor.

  • Page 243: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing • Oil seal Damage/wear → Replace the defective part(s). EAS30326 ASSEMBLING THE STARTER MOTOR 1. Install: • Starter motor yoke “1” Align the tab “a” on the brush holder with the slot “b”...

  • Page 244: Clutch

    CLUTCH EAS20055 CLUTCH Removing the clutch cover 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS”...
  • Page 245 CLUTCH Removing the pull lever shaft ’ Order Job/Parts to remove Remarks Circlip Pull lever shaft Oil seal Bearing Bearing 5-40...
  • Page 246 CLUTCH Removing the clutch 115 Nm (11.5 m kgf, 83 ft lbf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
  • Page 247 CLUTCH Removing the clutch 115 Nm (11.5 m kgf, 83 ft lbf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...

  • Page 248: Removing The Clutch

    CLUTCH EAS30346 REMOVING THE CLUTCH Remove the spacer and bearing from the main 1. Remove: axle, then remove the oil pump drive chain from • Oil strainer the oil pump driven sprocket, and then remove Refer to “OIL PUMP” on page 5-51. the clutch housing and oil pump drive chain from •...

  • Page 249: Checking The Clutch Springs

    CLUTCH 1. Check: • Clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • Clutch plate warpage (with a surface plate and thickness gauge “1”) Out of specification → Replace the clutch plates as a set. Thickness gauge ▼...

  • Page 250: Checking The Clutch Housing

    CLUTCH 1. Check: • Clutch spring Pitting on the clutch boss splines will cause er- Damage → Replace the clutch springs as a ratic clutch operation. set. 2. Measure: • Clutch spring free length “a” Out of specification → Replace the clutch springs as a set.

  • Page 251: Checking The Pull Lever Shaft And Pull Rod

    CLUTCH • Install the oil pump drive chain onto the clutch housing, and then install the chain onto the oil pump driven sprocket while installing the clutch housing onto the main axle. • Make sure that the oil pump drive chain passes through the oil pump drive chain guide.
  • Page 252 CLUTCH • Install the last friction plate “1” offset from the other friction plates “2”, making sure to align a projection on the friction plate with the punch mark “a” on the clutch housing. 4. Tighten: • Clutch boss nut “1” Clutch boss nut 115 Nm (11.5 m·kgf, 83 ft·lbf) 7.
  • Page 253 CLUTCH 9. Install: 11.Adjust: • Dowel pins • Clutch cable free play Refer to “ADJUSTING THE CLUTCH LEVER • Clutch cover gasket FREE PLAY” on page 3-11. • Clutch cover “1” Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) •...

  • Page 254: Shift Shaft

    SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kgf, 16 ft Ibf) • • ’ Order Job/Parts to remove Remarks Shift arm Refer to “ENGINE REMOVAL” on page 5-3. Clutch housing Refer to “CLUTCH” on page 5-39. Circlip Washer Shift shaft...

  • Page 255: Checking The Shift Shaft

    SHIFT SHAFT EAS30377 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS30378 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.

  • Page 256: Oil Pump

    OIL PUMP EAS20054 OIL PUMP Removing the oil pan and oil pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
  • Page 257 OIL PUMP Removing the oil pan and oil pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 43 Nm (4.3 m kgf, 31 ft Ibf) 10 Nm (1.0 m...
  • Page 258 OIL PUMP Disassembling the oil pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • ’ Order Job/Parts to remove Remarks Oil pump housing cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump housing Oil pump driven sprocket 5-53...

  • Page 259: Removing The Oil Pan

    OIL PUMP EAS30333 REMOVING THE OIL PAN 1. Remove: • Oil level switch lead holder • Bottom cowling brackets • Oil pan • Oil pan gasket 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 260: Installing The Oil Pan

    OIL PUMP Recommended lubricant Engine oil 2. Install: • Oil pump driven sprocket • Oil pump housing “1” • Washer “2” • Pin “3” • Oil pump inner rotor “4” • Oil pump outer rotor When installing the inner rotor, align the pin “3” in the oil pump shaft with the groove “a”...

  • Page 261: Crankcase

    CRANKCASE EAS20059 CRANKCASE Separating the crankcase 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
  • Page 262 CRANKCASE Separating the crankcase 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...

  • Page 263: Disassembling The Crankcase

    • Sealant • M6 × 30 mm bolt: “28” (onto the crankcase mating surfaces) 24 23 22 Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.
  • Page 264 CRANKCASE ECA13980 Crankcase bolt (M8 × 115 mm, M8 NOTICE × 85 mm) Before tightening the crankcase bolts, make 1st: 20 Nm (2.0 m·kgf, 14 ft·lbf) sure the transmission gears shift correctly *2nd: 12 Nm (1.2 m·kgf, 8.7 when the shift drum assembly is turned by ft·lbf) hand.

  • Page 265: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 1st 15 Nm (1.5 m kgf, 11 ft Ibf) • • 2nd Specified angle 175 -185 ’ Order Job/Parts to remove Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-56. Connecting rod cap Big end lower bearing Piston pin clip...

  • Page 266: Removing The Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS30745 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 so that it can be reinstalled in its original place. 4.

  • Page 267: Checking The Piston Rings

    CONNECTING RODS AND PISTONS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Bore 67.000–67.010 mm (2.6378–...

  • Page 268: Checking The Piston Pins

    CONNECTING RODS AND PISTONS EAS30749 CHECKING THE PISTON PINS The following procedure applies to all of the pis- ton pins. 1. Check: • Piston pin Blue discoloration/grooves → Replace the piston pin and then check the lubrication sys- tem. 2. Measure: •...

  • Page 269: Checking The Connecting Rods

    CONNECTING RODS AND PISTONS • Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter “b” - Piston pin outside diameter “a” Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 EAS30750 CHECKING THE CONNECTING RODS d. Assemble the connecting rod halves. 1. Measure: • Crankshaft-pin-to-big-end-bearing clearance •...

  • Page 270: Installing The Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS For example, if the connecting rod P and the crankshaft web P numbers are 5 and 1 re- spectively, then the bearing size for P (connecting rod) - P (crankshaft) 5 - 1 = 4 (green) Bearing color code Code 1 Blue...
  • Page 271 CONNECTING RODS AND PISTONS • Install the piston pin clips, so that the clip ends 5. Lubricate: are 3 mm (0.12 in) “c” or more from the cutout • Bolt threads in the piston. • Nut seats • Reinstall each piston into its original cylinder (with the recommended lubricant) (numbering order starting from the left: #1 to Recommended lubricant...
  • Page 272 CONNECTING RODS AND PISTONS EWA13400 WARNING If the connecting rod nut is tightened more than the specified angle, do not loosen the nut and then retighten it. Instead, replace the connecting rod bolt and nut with a new one and perform the procedure again. ECA13950 NOTICE Do not use a torque wrench to tighten the...

  • Page 273: Crankshaft

    CRANKSHAFT EAS20061 CRANKSHAFT Removing the crankshaft ’ Order Job/Parts to remove Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-56. Refer to “CONNECTING RODS AND PIS- Connecting rod caps TONS” on page 5-60. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Oil nozzle 5-68...

  • Page 274: Removing The Crankshaft Journal Bearings

    CRANKSHAFT 3. Measure: EAS30419 REMOVING THE CRANKSHAFT JOURNAL • Crankshaft-journal-to-crankshaft-journal- BEARINGS bearing clearance 1. Remove: Out of specification → Replace the crank- • Crankshaft journal lower bearings shaft journal bearings. (from the lower crankcase) • Crankshaft journal upper bearings Journal oil clearance (from the upper crankcase) 0.044–0.020 mm (0.0017–0.0008 Identify the position of each crankshaft journal...
  • Page 275 CRANKSHAFT 4. Select: • Crankshaft journal bearings (J –J • The numbers “A” stamped into the crankshaft web and the numbers “B” stamped into the lower crankcase are used to determine the re- placement crankshaft journal bearing sizes. • J –J refer to the bearings shown in the crank- shaft illustration.

  • Page 276: Installing The Crankshaft

    CRANKSHAFT Bearing color code Code 0 White Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green EAS30791 INSTALLING THE CRANKSHAFT 1. Install: • Crankshaft journal upper bearings (into the upper crankcase) • Crankshaft journal lower bearings (into the lower crankcase) •...
  • Page 277 TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 278 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’...
  • Page 279 TRANSMISSION Disassembling the main axle assembly ’ Order Job/Parts to remove Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd/4th pinion gear Circlip Washer 5th pinion gear Collar Bearing housing Bearing Main axle/1st pinion gear 5-74...
  • Page 280 TRANSMISSION Disassembling the drive axle assembly ’ Order Job/Parts to remove Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 5-75...
  • Page 281 TRANSMISSION Disassembling the drive axle assembly ’ Order Job/Parts to remove Remarks 6th wheel gear Circlip Washer 2nd wheel gear Collar Bearing Drive axle 5-76...

  • Page 282: Transmission

    TRANSMISSION EAS30430 REMOVING THE TRANSMISSION 1. Remove: • Main axle assembly “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the main axle assembly bearing housing bolts “2” 2.

  • Page 283: Checking The Shift Drum Assembly

    TRANSMISSION EAS30432 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • Shift drum groove Damage/scratches/wear → Replace the shift drum assembly. • Shift drum segment “1” Damage/wear → Replace the shift drum as- sembly. • Shift drum bearing “2” Damage/pitting → Replace the shift drum as- 3.

  • Page 284: Installing The Transmission

    TRANSMISSION • Install the circlip so that both ends “b” rest on the sides of a spline “c” with both axles aligned. Face the seal side of the bearing to the outside and install it close to the right side end of the crankcase.
  • Page 285 TRANSMISSION • Install the shift drum retainer with its “OUT” mark “c” facing outward. • Make sure that the drive axle bearing circlip “4” is inserted into the grooves “d” in the upper crankcase. 6. Main axle assembly 4. Install: •...
  • Page 286 TRANSMISSION 5-81...

  • Page 287: Cooling System

    COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 OIL COOLER....................6-5 CHECKING THE OIL COOLER ..............6-6 INSTALLING THE OIL COOLER .............. 6-6 THERMOSTAT ....................6-7 CHECKING THE THERMOSTAT.............. 6-8 INSTALLING THE THERMOSTAT............6-8 WATER PUMP....................6-9 DISASSEMBLING THE WATER PUMP..........6-11 CHECKING THE WATER PUMP ............

  • Page 288: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) •...
  • Page 289 RADIATOR Removing the radiator 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) •...

  • Page 290: Checking The Radiator

    RADIATOR EAS30439 CHECKING THE RADIATOR 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 291 RADIATOR b. Apply 100 kPa (14.50 psi) (1.0 kg/cm ) of pressure. c. Measure the indicated pressure with the gauge. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲...

  • Page 292: Oil Cooler

    OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kgf, 7.2 ft Ibf) 63 Nm (6.3 m kgf, 46 ft Ibf) • • • • ’ Order Job/Parts to remove Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-25.

  • Page 293: Checking The Oil Cooler

    OIL COOLER • Crankcase EAS30441 CHECKING THE OIL COOLER (with the specified amount of the recom- 1. Check: mended engine oil) • Oil cooler Refer to “CHANGING THE ENGINE OIL” on Cracks/damage → Replace. page 3-25. 2. Check: 4. Check: •...

  • Page 294: Thermostat

    THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • ’ Order Job/Parts to remove Remarks Air filter case Refer to “AIR FILTER CASE” on page 7-4. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-29.

  • Page 295: Checking The Thermostat

    THERMOSTAT 2. Check: EAS30443 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage → Replace. • Thermostat Does not open at 71–85 °C (159.8–185.0 °F) EAS30939 INSTALLING THE THERMOSTAT → Replace. 1. Install: • Thermostat Install the thermostat with its breather hole “a” facing up.

  • Page 296: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • ’ Order Job/Parts to remove Remarks...
  • Page 297 WATER PUMP Disassembling the water pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 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 Remarks Water pump housing cover Gasket...

  • Page 298: Disassembling The Water Pump

    WATER PUMP 5. Remove: EAS30446 DISASSEMBLING THE WATER PUMP • Mechanical seal (impeller side) “1” 1. Remove: (from the impeller, with a thin, flat-head • Circlip screwdriver) • Impeller shaft 2. Remove: Do not scratch the impeller shaft. • Mechanical seal (housing side) “1” Remove the mechanical seal (housing side) from the outside of the water pump housing.

  • Page 299: Installing The Water Pump

    WATER PUMP 2. Install: 4. Measure: • Impeller shaft tilt • Mechanical seal (housing side) “1” Out of specification → Repeat steps (3) and (into the water pump housing “2”) (4). ECA20330 NOTICE ECA20340 NOTICE Never lubricate the mechanical seal (hous- Make sure the mechanical seal (impeller ing side) surface with oil or grease.
  • Page 300 WATER PUMP 2. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-29. 3. Check: • Cooling system Leaks → Repair or replace the faulty part. 6-13...

  • Page 301: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 CHECKING THE FUEL PUMP OPERATION..........7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-3 AIR FILTER CASE ..................7-4 REMOVING THE FUEL HOSE (PRIMARY INJECTOR FUEL RAIL SIDE AND SECONDARY INJECTOR FUEL RAIL SIDE) ....
  • Page 302 FUEL TANK EAS20067 FUEL TANK Removing the fuel tank and fuel pump 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...

  • Page 303: Fuel Tank

    FUEL TANK • Do not touch the base section of the fuel EAS30450 REMOVING THE FUEL TANK sender. 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. EAS30454 2. Remove: CHECKING THE FUEL PUMP BODY •...

  • Page 304: Installing The Fuel Tank

    FUEL TANK EAS30457 INSTALLING THE FUEL TANK 1. Connect: • Fuel tank breather hose (fuel tank to hose joint) “1” • Fuel tank overflow hose (fuel tank to hose joint) “2” • Fuel tank breather hose “3” • Fuel tank overflow hose “4” 3.

  • Page 305: Air Filter Case

    AIR FILTER CASE EAS20068 AIR FILTER CASE Removing the air filter case and secondary injectors 5 Nm (0.5 m kgf, 3.6 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • •...
  • Page 306 AIR FILTER CASE Removing the air filter case and secondary injectors 5 Nm (0.5 m kgf, 3.6 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • • • • •...

  • Page 307: Removing The Fuel Hose (Primary Injector Fuel Rail Side And Secondary Injector Fuel Rail Side)

    AIR FILTER CASE EAS30459 EAS30462 REMOVING THE FUEL HOSE (PRIMARY CHECKING THE SECONDARY INJECTORS INJECTOR FUEL RAIL SIDE AND 1. Check: SECONDARY INJECTOR FUEL RAIL SIDE) • Injectors Damage → Replace. 1. Remove: • Fuel hose (primary injector fuel rail side and EAS30461 secondary injector fuel rail side) REMOVING THE INTAKE FUNNEL...

  • Page 308: Installing The Intake Funnel

    AIR FILTER CASE Upper air filter case to lower air filter case bolt 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Air filter bolt 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Tighten the upper air filter case to lower air filter case bolts and air filter bolt in proper sequence A.
  • Page 309 AIR FILTER CASE...

  • Page 310: Throttle Bodies

    THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the canister (for California only) 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 Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE”...
  • Page 311 THROTTLE BODIES Removing the throttle body assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-4. Refer to “AIR INDUCTION SYSTEM”...
  • Page 312 THROTTLE BODIES Removing the primary injectors 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) •...

  • Page 313: Checking The Throttle Body Joints

    THROTTLE BODIES EAS30792 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ CHECKING THE THROTTLE BODY JOINTS a. Wash the throttle bodies in a petroleum- The following procedure applies to all of the based solvent.

  • Page 314: Adjusting The Throttle Position Sensor (For Throttle Valves)

    THROTTLE BODIES d. Turn the main switch to “OFF” and set the en- gine stop switch to “ON”. e. Simultaneously press and hold the “SE- LECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the but- tons for 8 seconds more.
  • Page 315 THROTTLE BODIES e. Simultaneously press and hold the “SE- LECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the but- tons for 8 seconds more. “dIAG” appears on the odometer, tripmeter and fuel reserve trip LCD. f.

  • Page 316: Air Induction System

    AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 7-15...
  • Page 317 AIR INDUCTION SYSTEM 1. Lower air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to cylinder head cover) 5. Reed valve assembly 6.
  • Page 318 AIR INDUCTION SYSTEM Removing the air cut-off valve ’ Order Job/Parts to remove Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-4. Air induction system cover Air induction system solenoid coupler Disconnect.
  • Page 319 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 Remarks Reed valve cover Reed valve assembly Reed valve plate 7-18...

  • Page 320: Checking The Air Induction System

    AIR INDUCTION SYSTEM 2. Check: EAS30488 CHECKING THE AIR INDUCTION SYSTEM • Reed valve • Reed valve stopper Air injection • Reed valve seat The air induction system burns unburned ex- Cracks/damage → Replace the reed valve haust gases by injecting fresh air (secondary air) assembly.

  • Page 321: 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 ................8-11 CHARGING SYSTEM..................8-13 CIRCUIT DIAGRAM ................8-13 TROUBLESHOOTING ................8-15 LIGHTING SYSTEM ..................8-17 CIRCUIT DIAGRAM ................
  • Page 322 ELECTRICAL COMPONENTS..............8-71 CHECKING THE SWITCHES ..............8-75 CHECKING THE BULBS AND BULB SOCKETS ........8-77 CHECKING THE FUSES ................8-78 CHECKING AND CHARGING THE BATTERY........8-78 CHECKING THE RELAYS ..............8-81 CHECKING THE TURN SIGNAL RELAY ..........8-83 CHECKING THE RELAY UNIT (DIODE) ..........8-83 CHECKING THE IGNITION COILS............

  • Page 324: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 325 IGNITION SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 17.Sidestand switch 22.ECU (Engine Control Unit) 23.Spark plug 24.Ignition coil #1 25.Ignition coil #2 26.Ignition coil #3 27.Ignition coil #4 40.Crankshaft position sensor 47.Lean angle sensor...

  • Page 326: Engine Stopping Due To Sidestand Operation

    IGNITION SYSTEM EAS30491 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.

  • Page 327: Troubleshooting

    IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Air filter case 4. Side cowlings 5. Bottom cowlings NG → 1.
  • Page 328 IGNITION SYSTEM NG → 8. Check the engine stop switch. • The engine stop switch is faulty. Refer to “CHECKING THE • Replace the right handlebar switch. SWITCHES” on page 8-75. OK ↓ NG → 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch.
  • Page 329 IGNITION SYSTEM...

  • Page 330: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 331 ELECTRIC STARTING SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 8. Starter relay 10.Starter motor 11.Engine ground 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 17.Sidestand switch 62.Handlebar switch (right) 64.Engine stop switch 65.Start switch 67.Handlebar switch (left) 70.Clutch switch A.

  • Page 332: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS30494 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 333 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN 12. Starter relay NEUTRAL 13. Starter motor b. WHEN THE SIDESTAND IS UP AND THE 14. Engine ground CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4.

  • Page 334: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Air filter case 4. Side cowlings 5. Thermostat NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s).
  • Page 335 ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-75. OK ↓ NG → 9. Check the engine stop switch. • The engine stop switch is faulty. Refer to “CHECKING THE •...

  • Page 336: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-13...
  • Page 337 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 6. Main fuse 7. Battery 11.Engine ground 8-14...

  • Page 338: Troubleshooting

    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Bottom cowlings NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
  • Page 339 CHARGING SYSTEM 8-16...

  • Page 340: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-17...
  • Page 341 LIGHTING SYSTEM 3. Main switch 6. Main fuse 7. Battery 11.Engine ground 22.ECU (Engine Control Unit) 48.Meter assembly 57.High beam indicator light 60.Meter light 67.Handlebar switch (left) 68.Dimmer switch 75.Front turn signal/position light (right) 76.Front turn signal/position light (left) 77.Headlight (low beam) 78.Headlight (high beam) 79.License plate light 81.Tail/brake light...

  • Page 342: Troubleshooting

    LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light, taillight, position light, license plate light or meter light. • Before troubleshooting, remove the following part(s): 1. Rider seat 2.
  • Page 343 LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-17. OK ↓ Replace the ECU, meter assembly, headlight assembly, front turn/position light, license plate light or tail/brake light.

  • Page 344: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-21...
  • Page 345 SIGNALING SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 13.Relay unit 16.Neutral switch 19.Fuel sender 22.ECU (Engine Control Unit) 42.Coolant temperature sensor 46.Speed sensor 48.Meter assembly 49.Fuel level warning light 50.Oil level warning light 51.Neutral indicator light 52.Tachometer 53.Shift timing indicator light...

  • Page 346: Troubleshooting

    SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or indicator light. • The horn fails to sound. • The speedometer fail to operate • Before troubleshooting, remove the following part(s): 1. Rider seat 2.
  • Page 347 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-21. OK ↓ Replace the horn. The tail/brake light fails to come on. NG → 1.
  • Page 348 SIGNALING SYSTEM NG → 4. Check the entire signaling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-21. OK ↓ Replace the meter assembly or turn signal light. The neutral indicator light fails to come. NG →...
  • Page 349 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-21. OK ↓ Replace the meter assembly. The coolant temperature warning light fails to come. NG →...

  • Page 350: Cooling System

    COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-27...
  • Page 351 COOLING SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 22.ECU (Engine Control Unit) 42.Coolant temperature sensor 86.Radiator fan motor relay 87.Radiator fan motor fuse (right) 88.Radiator fan motor fuse (left) 89.Radiator fan motor (right) 90.Radiator fan motor (left) 8-28...

  • Page 352: Troubleshooting

    COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings NG → 1. Check the fuses. (Main, ignition and radiator fan mo- tor) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 353 COOLING SYSTEM 8-30...

  • Page 354: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-31...
  • Page 355 FUEL INJECTION SYSTEM 3. Main switch F. Secondary injector sub-wire harness 4. Ignition fuse 5. Backup fuse (odometer and clock) 6. Main fuse 7. Battery 9. Fuel injection system fuse 11.Engine ground 12.ETV fuse 13.Relay unit 14.Starting circuit cut-off relay 15.Fuel pump relay 16.Neutral switch 17.Sidestand switch...

  • Page 356: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS30505 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 357: Troubleshooting Method

    FUEL INJECTION SYSTEM EAS30506 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on. 1. Check: • Fault code number ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

  • Page 358: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS30507 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.

  • Page 359: Troubleshooting Details

    FUEL INJECTION SYSTEM EAS30508 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 have been completed, reset the meter display according to the reinstatement method.
  • Page 360 FUEL INJECTION SYSTEM Fault code No. 12 Fault code No. Crankshaft position sensor: no normal signals are received from the Item crankshaft position sensor. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. — Meter display —...
  • Page 361 FUEL INJECTION SYSTEM Fault code No. 13 Fault code No. Item Intake air pressure sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Meter display Displays the intake air pressure. Compare the actually measured atmospheric pressure with the meter Procedure display value without cranking the engine.
  • Page 362 FUEL INJECTION SYSTEM Fault code No. 15 Fault code No. Throttle position sensor (for throttle valves): open or short circuit Item detected. Able/Unable to start engine Fail-safe system Able/Unable to drive vehicle Diagnostic code No. 01, 13 Throttle position sensor (for throttle valves) signal 1 Meter display •...
  • Page 363 FUEL INJECTION SYSTEM Fault code No. 17 Fault code No. Item EXUP servo motor circuit: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Actuates the servo motor (turns to open side and to closed side). Illumi- Actuation nates the engine trouble warning light.
  • Page 364 FUEL INJECTION SYSTEM Fault code No. 18 Fault code No. Item EXUP servo motor: EXUP servo motor is stuck. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Actuates the servo motor (turns to open side and to closed side). Illumi- Actuation nates the engine trouble warning light.
  • Page 365 FUEL INJECTION SYSTEM Fault code No. 19 Fault code No. Sidestand switch: open circuit is detected in the input line from the Item sidestand switch to the ECU. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Sidestand switch Meter display •...
  • Page 366 FUEL INJECTION SYSTEM Fault code No. 20 Fault code No. Intake air pressure sensor or atmospheric pressure sensor: when Item the main switch is turned to “ON”, the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ greatly. Able to start engine Fail-safe system Able to drive vehicle...
  • Page 367 FUEL INJECTION SYSTEM Fault code No. 22 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. Meter display Displays the intake air temperature. Compare the actually measured intake air temperature with the meter Procedure display value.
  • Page 368 FUEL INJECTION SYSTEM Fault code No. 23 Fault code No. Item Atmospheric pressure sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Meter display Displays the atmospheric pressure. Compare the actually measured atmospheric pressure with the meter Procedure display value.
  • Page 369 FUEL INJECTION SYSTEM Fault code No. 24 Fault code No. sensor: no normal signals are received from the O sensor. Item Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Probable cause of malfunc- Confirmation of service com- Item...
  • Page 370 FUEL INJECTION SYSTEM Fault code No. 30 Fault code No. Item Latch up detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Lean angle sensor output voltage Meter display • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Procedure Remove the lean angle sensor and incline it more than 65 degrees.
  • Page 371 FUEL INJECTION SYSTEM Fault code No. 33 Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the prima- Item ry lead of the cylinder-#1 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 372 FUEL INJECTION SYSTEM Fault code No. 34 Fault code No. Cylinder-#2 ignition coil: open or short circuit detected in the prima- Item ry lead of the cylinder-#2 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 373 FUEL INJECTION SYSTEM Fault code No. 35 Fault code No. Cylinder-#3 ignition coil: open or short circuit detected in the prima- Item ry lead of the cylinder-#3 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 374 FUEL INJECTION SYSTEM Fault code No. 36 Fault code No. Cylinder-#4 ignition coil: open or short circuit detected in the prima- Item ry lead of the cylinder-#4 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 375 FUEL INJECTION SYSTEM Fault code No. 39 Fault code No. Item Primary injector: open or short circuit detected. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 376 FUEL INJECTION SYSTEM Fault code No. 40 Fault code No. Item Secondary injector: open circuit detected. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 377 FUEL INJECTION SYSTEM Fault code No. 41 Fault code No. Item Lean angle sensor: open or short circuit detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Lean angle sensor output voltage Meter display • 0.4–1.4 (upright) •...
  • Page 378 FUEL INJECTION SYSTEM Fault code No. 42 Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item Neutral switch: open circuit is detected in the neutral switch. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 379 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item Neutral switch: open circuit is detected in the neutral switch. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Neutral switch Meter display •...
  • Page 380 FUEL INJECTION SYSTEM Fault code No. 43 Fault code No. Fuel system voltage: power supply to the injectors and fuel pump is Item not normal. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Fuel system voltage (battery voltage) Meter display Approximately 12.0 Set the engine stop switch to “...
  • Page 381 FUEL INJECTION SYSTEM Fault code No. 44 Fault code No. Error in writing the amount of CO adjustment on EEPROM: an error Item is detected while reading or writing on EEPROM (CO adjustment val- ue). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 382 FUEL INJECTION SYSTEM Fault code No. 46 Fault code No. Vehicle system power supply (monitoring voltage): power supply is Item not normal. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure —...
  • Page 383 FUEL INJECTION SYSTEM Fault code No. 59 Fault code No. Throttle position sensor (for throttle cable pulley): open or short cir- cuit detected. Item Throttle position sensor (for throttle cable pulley): coupler connec- tion is loose. Able/Unable to start engine Fail-safe system Able/Unable to drive vehicle Diagnostic code No.
  • Page 384 FUEL INJECTION SYSTEM Fault code No. 60 Fault code No. Throttle servo motor: open or short circuit detected. Item Motor is defective or ECU internal malfunction. Able/Unable to start engine Fail-safe system Able/Unable to drive vehicle Diagnostic code No. 01, 13 Throttle position sensor (for throttle valves) signal 1 Meter display •...
  • Page 385 FUEL INJECTION SYSTEM Fault code No. Er-1 Fault code No. Er-1 ECU internal malfunction (output signal error): no signals are re- Item ceived from the ECU. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. — Meter display —...
  • Page 386 FUEL INJECTION SYSTEM Fault code No. Er-2 Fault code No. Er-2 ECU internal malfunction (output signal error): no signals are re- Item ceived from the ECU within the specified duration. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.
  • Page 387 FUEL INJECTION SYSTEM Fault code No. Er-3 Fault code No. Er-3 ECU internal malfunction (output signal error): data from the ECU Item cannot be received correctly. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. — Meter display —...
  • Page 388 FUEL INJECTION SYSTEM Fault code No. Er-4 Fault code No. Er-4 ECU internal malfunction (input signal error): non-registered data Item has been received from the meter. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. — Meter display —...
  • Page 389 FUEL INJECTION SYSTEM 8-66...

  • Page 390: Fuel Pump System

    FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-67...
  • Page 391 FUEL PUMP SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 9. Fuel injection system fuse 11.Engine ground 13.Relay unit 15.Fuel pump relay 18.Fuel pump 22.ECU (Engine Control Unit) 62.Handlebar switch (right) 64.Engine stop switch 8-68...
  • Page 392 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 393 FUEL PUMP SYSTEM 8-70...

  • Page 394: Electrical Components

    ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-71...
  • Page 395 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Battery 5. Fuse box 1 6. Main fuse 7. Fuel injection system fuse 8. Starter relay 9. Neutral switch 10. EXUP servo motor 11. Rear brake light switch 12.
  • Page 396 ELECTRICAL COMPONENTS 8-73...
  • Page 397 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Atmospheric pressure sensor 3. Intake funnel servo motor 4. Coolant temperature sensor 5. Fuel pump 6. ECU (Engine Control Unit) 7. Lean angle sensor 8. Relay unit 9. Turn signal relay 10. Crankshaft position sensor 11.

  • Page 398: Checking The Switches

    ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES 1. Clutch switch 2. Main switch 3. Dimmer switch 4. Horn switch 5. Turn signal switch 6. Sidestand switch 7. Front brake light switch 8. Engine stop switch 9. Start switch 10. Neutral switch 11.
  • Page 399 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. ECA14371 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...
  • Page 400 ELECTRICAL COMPONENTS • Avoid touching the glass part of a headlight EAS30550 CHECKING THE BULBS AND BULB bulb to keep it free from oil, otherwise the SOCKETS transparency of the glass, the life of the bulb, and the luminous flux will be adverse- Do not check any of the lights that use LEDs.
  • Page 401 ELECTRICAL COMPONENTS Amperage Fuses Q’ty rating Check each bulb socket for continuity in the same manner as described in the bulb section; Main 50 A however, note the following. Ignition 15 A ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...
  • Page 402 ELECTRICAL COMPONENTS • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL • Skin — Wash with water. • Eyes — Flush with water for 15 minutes and get immediate medical attention.
  • Page 403 ELECTRICAL COMPONENTS • If the battery becomes hot to the touch at D. These values vary with the temperature, the condition of the battery plates, and the any time during the charging process, dis- electrolyte level. connect the battery charger and let the bat- tery cool before reconnecting it.

  • Page 404: Checking The Relays

    ELECTRICAL COMPONENTS 6. Install: • Standard charging current is reached • Battery Battery is good. • Standard charging current is not reached • Battery band Replace the battery. Refer to “GENERAL CHASSIS” on page 4-1. 7. Connect: d. Adjust the voltage so that the current is at the •...
  • Page 405 ELECTRICAL COMPONENTS Starter relay 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3” and “4”) Headlight relay (on/off) 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3”...

  • Page 406: Checking The Turn Signal Relay

    ELECTRICAL COMPONENTS Radiator fan motor relay b. Turn the main switch to “ON”. c. Measure the turn signal relay input voltage. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: •...

  • Page 407: Checking The Ignition Coils

    ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. Continuity d. Check the relay unit (diode) for no continuity. Positive tester probe → ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 408: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS d. Crank the engine by pushing the start switch Pocket tester “ ” and gradually increase the spark gap un- 90890-03112 til a misfire occurs. Analog pocket tester ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 409: Checking The Stator Coil

    ELECTRICAL COMPONENTS EWA13810 WARNING Lean angle sensor output voltage Operating angle • A wire that is used as a jumper lead must 65° have at least the same capacity of the bat- Output voltage up to operating tery lead, otherwise the jumper lead may angle burn.

  • Page 410: Checking The Rectifier/Regulator

    ELECTRICAL COMPONENTS d. Measure the charging voltage. • Positive tester probe → white “2” ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ • Negative tester probe → EAS30796 white “3” CHECKING THE OIL LEVEL SWITCH 1.

  • Page 411: Checking The Fuel Sender

    ELECTRICAL COMPONENTS EAS30573 CHECKING THE FUEL SENDER 1. Disconnect: • Fuel pump coupler (from the wire harness) • Fuel hose (from the fuel tank) 2. Remove: • Fuel tank Refer to “FUEL TANK” on page 7-1. 3. Remove: c. Measure the radiator fan motor movement. •...

  • Page 412: Checking The Fuel Pump

    ELECTRICAL COMPONENTS c. Connect the battery (DC 12 V) to the fuel pump terminal as shown. • Positive battery lead → red/blue “2” • Negative battery lead → black “3” ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 413: Checking The Cylinder Identification Sensor

    ELECTRICAL COMPONENTS • Positive tester probe → brown/red “1” • Negative tester probe → red/white “2” Br/R R/W b. Turn the main switch to “ON”. c. Rotate the crankshaft. d. Measure the voltage of white/black and black/blue. Turn the crankshaft twice and check that the output voltage rises to approx- c.
  • Page 414 ELECTRICAL COMPONENTS Make sure that the intake air temperature sensor terminals do not get wet. c. Place a thermometer “3” in the water. d. Slowly heat the water, then let it cool down to the specified temperature. e. Measure the intake air temperature sensor resistance.

  • Page 415: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ............... 9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED ............ 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING................ 9-2 SHIFT PEDAL DOES NOT MOVE ............9-2 JUMPS OUT OF GEAR................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............

  • Page 416: Troubleshooting

    TROUBLESHOOTING Electrical system EAS20090 TROUBLESHOOTING 1. Battery • Discharged battery EAS30599 • 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 417: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system EAS30605 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 418: Overcooling

    TROUBLESHOOTING 2. Engine oil • Worn brake disc • Incorrect oil level • Air in hydraulic brake system • Incorrect oil viscosity • Leaking brake fluid • Inferior oil quality • Faulty brake caliper kit • Faulty brake caliper seal Cooling system •...

  • Page 419: Faulty Lighting Or Signaling System

    TROUBLESHOOTING Rear shock absorber assembly Turn signal does not come on • Faulty rear shock absorber spring • Faulty turn signal switch • Leaking oil or gas • Faulty turn signal relay • Burnt-out turn signal bulb Tire(s) • Incorrect connection •...

  • Page 420: Self-Diagnostic Function And Diagnostic Code Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS20116 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS31118 SELF-DIAGNOSTIC FUNCTION TABLE For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-34. Fault code Item Cylinder identification sensor: no normal signals are received from the cylinder identification sensor when the engine is started or while the vehicle is being driven.

  • Page 421: Communication Error With The Meter

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault code Item Engine idling stop EAS31119 COMMUNICATION ERROR WITH THE METER For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-34. Fault code Item Er-1 ECU internal malfunction (output signal error): no signals are received from the ECU. ECU internal malfunction (output signal error): no signals are received from the ECU within the Er-2 specified duration.
  • Page 422 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Fuel system voltage (battery Approximately 12.0 Set the engine stop switch to voltage) “ ”, and then compare with the actually measured bat- tery voltage. (If the battery voltage is lower, recharge the battery.) Throttle position sensor (for...

  • Page 423: Diagnostic Code: Actuator Operation Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Malfunction history code — • No history • History exists Fault codes 11-60 • (If more than one code number is detected, the display changes every two seconds to show all the de- tected code numbers.
  • Page 424 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Actuation Procedure code No. Actuates the cylinder-#3 igni- tion coil five times at one- Check the spark five times. Cylinder-#3 ignition coil second intervals. • Connect an ignition check- Illuminates the engine trou- ble warning light.
  • Page 425 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Actuation Procedure code No. Actuates the air induction system solenoid five times at Check the operating sound Air induction system sole- one-second intervals. of the air induction system noid Illuminates the engine trou- solenoid five times.

  • Page 426: Wiring Diagram

    55. Engine trouble warning light EAS20091 EAS30613 WIRING DIAGRAM COLOR CODE 56. Coolant temperature warning Black light YZFR6G/YZFR6GC Brown 57. High beam indicator light 1. AC magneto Chocolate 58. Turn signal indicator light (left) 2. Rectifier/regulator Dark blue 59. Turn signal indicator light (right) 3.
  • Page 429 YZFR6G/YZFR6GC WIRING DIAGRAM Gy/R R/L R/B G/B O/G R/B O Gy/R Br/Y R/L Br/Y Y/L R/G Br/W Br/W G/W B/W Br/R Gy/G O/B B/L Gy/G Br/R Sb/W Br/B Br/B Sb/W B/R Y/B R/W Y/B B Ch Dg Sb/W Sb/W P/W L Sb/W Sb/W Sb/W...
  • Page 430 YZFR6G/YZFR6GC WIRING DIAGRAM (Gy) (Gy) (Dg) (Gy) (Gy) (Gy) FREE (Gy) PUSH (Gy) (Gy) (Dg) (Db) (Db) (Gy) (Gy) (Gy) (Gy)

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