Yamaha YZFR1W 2007 Service Manual
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Yamaha YZFR1W 2007 Service Manual

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Table of Contents

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2007
MOTORCYCLE
SERVICE MANUAL
Model : YZFR1W
4C8281972000
*4C8281972000*

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Table of Contents
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Summary of Contents for Yamaha YZFR1W 2007

  • Page 1 2007 MOTORCYCLE SERVICE MANUAL Model : YZFR1W 4C8281972000 *4C8281972000*...
  • Page 2 EAS20040 YZFR1W SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. First edition, October 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3 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

    EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20100 16.Replace the part SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6.

  • Page 6: Table Of Contents

    GENERAL INFORMATION IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER...........1-1 MODEL LABEL..................1-1 FEATURES ....................1-2 FI SYSTEM .....................1-3 IMPORTANT INFORMATION ..............1-12 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-12 REPLACEMENT PARTS...............1-12 GASKETS, OIL SEALS AND O-RINGS..........1-12 LOCK WASHERS/PLATES AND COTTER PINS .........1-12 BEARINGS AND OIL SEALS ...............1-13 CIRCLIPS .....................1-13 CHECKING THE CONNECTIONS .............1-14 SPECIAL TOOLS..................1-15...

  • Page 7: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.

  • Page 8: Features

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

  • Page 9: Fi System

    FEATURES EAS4C81010 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm , 46.1 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus- ing the fuel to be injected into the intake manifold only during the time the passage remain open.
  • Page 10 YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake) Mechanism characteristics Yamaha developed the YCC-T and YCC-I system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a faster, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
  • Page 11 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 12 FEATURES YCC-T/YCC-I system outline 19.Intake funnel servo motor driver 1. Throttle position sensor (for throttle cable pulley) 20.Intake funnel servo motor 2. Throttle servo motor 3. Throttle position sensor (for throttle valves) 4. ECU (engine control unit) 5. ETV main CPU (32 bit) 6.
  • Page 13 FEATURES YCC-T/YCC-I control outline 15.Throttle servo motor 1. Throttle position sensor (for throttle cable pulley) 16.ECU (engine control unit) 2. Throttle position sensor (for throttle valves) 17.Base map 3. Crankshaft position sensor 18.Idle speed control 4. Speed sensor 19.Calculated throttle valve opening angle 5.
  • Page 14 FEATURES EAS4C81024 • To switch the speedometer and odometer/ INSTRUMENT FUNCTIONS tripmeter displays between kilometers and miles, press the “SELECT” button for at least Multi-function meter unit one second. Tachometer 1. Clock 2. Speedometer 3. “SELECT” button 4. “RESET” button 1.
  • Page 15 FEATURES 4. Push the “RESET” button to set the min- 3. Push the “SELECT” button again to reset utes. the stopwatch. 5. Push the “SELECT” button and then Split-time measurement release it to start the clock. 1. Push the “RESET” button to start the stop- watch.
  • Page 16 • When the key is turned to “ON”, the coolant re-registering key and both standard keys temperature is automatically displayed, even to a Yamaha dealer and have the standard if the air intake temperature was displayed keys re-registered. prior to turning the key to “OFF”.
  • Page 17 FEATURES This mode cycles through five control func- setting is selected when the indicator light tions, allowing you to make the following set- flashes once every two seconds.) tings in the order listed below. 2. Push the “SELECT” button to confirm the Display brightness: selected indicator light activity.

  • Page 18: Important Information

    EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 19: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

  • Page 20: Checking The Connections

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

  • Page 21: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-28, 4-61 90890-01403 Spanner wrench YU-33975 Damper rod holder 4-53, 4-54 90890-01423 Damping rod holder YM-01423 Oil filter wrench 3-12 90890-01426 YU-38411 Rod holder 4-52, 4-57 90890-01434 Damper rod holder double ended YM-01434 Rod puller 4-56, 4-57...
  • Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller attachment (M12) 4-56, 4-57 90890-01435 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Fork spring compressor 4-52, 4-57 90890-01441 YM-01441 Fork seal driver 4-55 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Vacuum gauge 90890-03094...
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Extension 3-10 90890-04136 Valve spring compressor 5-23, 5-29 90890-04019 YM-04019 Valve spring compressor attachment 5-23, 5-29 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Middle driven shaft bearing driver 6-11 90890-04058 Bearing driver 40 mm YM-04058 Mechanical seal installer 6-11...
  • Page 25 Valve guide reamer (ø4.5) 5-25 90890-04118 Valve guide reamer (4.5 mm) YM-04118 Ignition checker 8-92 90890-06754 Opama pet-4000 spark checker YU-34487 Yamaha bond No. 1215 5-67, 6-11 (Three bond No. 1215®) 90890-85505 Pivot shaft wrench 90890-01471 Frame spanner socket YM-01471 1-19...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pivot shaft wrench adapter 90890-01476 Pocket tester 1-14, 5-41, 8- 90890-03112 83, 8-84, 8-85, Analog pocket tester 8-88, 8-89, 8- YU-03112-C 90, 8-91, 8-92, 8-93, 8-94, 8- 95, 8-96, 8-97, 8-97, 8-98, 8- 99, 8-100 Oil pressure adapter H 3-13...
  • Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Ring nut wrench 4-68, 4-70 90890-01507 YM-01507 Damper rod holder (22 mm) 4-69, 4-70 90890-01365 1-21...
  • Page 28 SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-8 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 ........2-20 ENGINE ....................2-20 CHASSIS ....................2-20 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-23 ENGINE OIL LUBRICATION CHART ...........2-23 LUBRICATION DIAGRAMS ..............2-25 COOLING SYSTEM DIAGRAMS ...............2-35...

  • Page 29: Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 4C86 Dimensions Overall length 2060 mm (81.1 in) Overall width 720 mm (28.3 in) Overall height 1110 mm (43.7 in) Seat height 835 mm (32.9 in) Wheelbase 1415 mm (55.7 in) Ground clearance 135 mm (5.31 in) Minimum turning radius 3400 mm (133.9 in)

  • Page 30: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 998.0 cm³ Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in) Compression ratio 12.70 :1 Standard compression pressure (at sea level) 1480 kPa/350 r/min (210.5 psi/350 r/min) (14.8 kgf/cm²/350 r/min) Starting system...
  • Page 31 ENGINE SPECIFICATIONS Cylinder head Volume 14.00–14.80 cm³ (0.85–0.90 cu.in) Warpage limit 0.10 mm (0.0039 in) Camshaft Drive system Chain drive (right) Camshaft cap inside diameter 24.500–24.521 mm (0.9646–0.9654 in) Camshaft journal diameter 24.459–24.472 mm (0.9630–0.9635 in) Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) Camshaft lobe dimensions Intake A 34.450–34.550 mm (1.3563–1.3602 in)
  • Page 32 ENGINE SPECIFICATIONS Valve face width B (intake) 1.200–2.480 mm (0.0472–0.0976 in) Valve face width B (exhaust) 1.625–2.900 mm (0.0640–0.1142 in) Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve margin thickness D (intake) 1.10–1.50 mm (0.0433–0.0591 in) Valve margin thickness D (exhaust) 0.50–0.90 mm (0.0197–0.0354 in)
  • Page 33 ENGINE SPECIFICATIONS Installed compression spring force (intake) 171–197 N (38.44–44.29 lbf) (17.44–20.09 kgf) at 35.50 mm (1.398 in) Installed compression spring force (exhaust) 202–232 N (45.41–52.15 lbf) (20.60–23.66 kgf) at 33.00 mm (1.299 in) 2.5 °/1.7 mm Spring tilt (intake) 2.5 °/1.7 mm Spring tilt (exhaust) Winding direction (intake)
  • Page 34 ENGINE SPECIFICATIONS Oil ring Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in) End gap (installed) 0.10–0.40 mm (0.0039–0.0157 in) Connecting rod Oil clearance (using plastigauge®) 0.034–0.058 mm (0.0013–0.0023 in) Bearing color code 1.Blue 2.Black 3.Brown 4.Green Crankshaft Width A 55.20–56.60 mm (2.173–2.228 in)
  • Page 35 ENGINE SPECIFICATIONS Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0.100 mm (0.0039 in) Shift fork thickness 5.80–5.88 mm (0.2283–0.2315 in) Air filter Air filter element Oil-coated paper element Fuel pump Pump type Electrical Model/manufacturer 4C8/DENSO...

  • Page 36: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 24.00 ° Caster angle Trail 102.0 mm (4.02 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 37 CHASSIS SPECIFICATIONS 24.05 mm × 3 (0.95 in × 3) Caliper cylinder inside diameter Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Brake pedal free play 4.3–9.3 mm (0.17–0.37 in) Rear disc brake Disc outside diameter × thickness 220.0 ×...

  • Page 38: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) 5.0 °/1050 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer TBDF43/DENSO Ignition coil Model/manufacturer F6T568/MITSUBISHI Minimum ignition spark gap 6.0 mm (0.24 in) 0.85–1.15 Ω...
  • Page 39 ELECTRICAL SPECIFICATIONS Electric starting system System type Constant mesh Starter motor Model/manufacturer 5VY/YAMAHA Power output 0.90 kW 0.0090–0.0110 Ω Armature coil resistance Brush overall length 10.8 mm (0.43 in) Limit 7.19 mm (0.28 in) Brush spring force 5.28–7.92 N (19.01–28.51 oz) (538–808 gf) Commutator diameter 24.5 mm (0.96 in)

  • Page 40: Tightening Torques

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

  • Page 41: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Spark plugs 13 Nm (1.3 m·kg, 9.4 ft·lb) Cylinder head nut (2pieces) See NOTE Cylinder head nut (8pieces) See NOTE Cylinder head bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft cap bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head cover bolt...
  • Page 42 TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Exhaust pipe and muffler bolt 20 Nm (2.0 m·kg, 14 ft·lb) Exhaust pipe and EXUP valve 12 Nm (1.2 m·kg, 8.7 ft·lb) bolt Exhaust valve pipe bracket bolt 20 Nm (2.0 m·kg, 14 ft·lb) EXUP pulley and shaft arm nut 6.5 Nm (0.65 m·kg, 4.7 ft·lb) EXUP valve pulley cover bolt...
  • Page 43 TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Oil return pipe bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil return plug 24 Nm (2.4 m·kg, 17 ft·lb) AC magneto lead bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Stator coil screw 14 Nm (1.4 m·kg, 10 ft·lb) Generator rotor cover screw 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 44 TIGHTENING TORQUES 3. Final, tighten the bolts to 40 Nm (4.0 m·kg, 29 ft·lb) with a torque wrench following the tighten- ing order. • Crankcase bolt (main journal) 1. First, tighten the bolts to approximately 20 Nm (2.0 m·kg, 14 ft·lb) with a torque wrench follow- ing the tightening order.

  • Page 45: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Upper bracket pinch bolt 26 Nm (2.6 m·kg, 19 ft·lb) Steering stem nut 113 Nm (11.3 m·kg, 82 ft·lb) Handlebar pinch bolt 17 Nm (1.7m·kg, 12 ft·lb) Handlebar bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) Cap bolt...
  • Page 46 TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Connecting arm nut (connecting 44 Nm (4.4 m·kg, 32 ft·lb) arm and frame) Relay arm nut (relay arm and 44 Nm (4.4 m·kg, 32 ft·lb) connecting arm) Relay arm nut (relay arm and 44 Nm (4.4 m·kg, 32 ft·lb) swingarm) Rear shock absorber assembly...
  • Page 47 TIGHTENING TORQUES • Engine mounting adjust bolt and engine mount self locking nut Refer to "INSTALLING THE ENGINE" on page 5-7. • Front wheel axle pinch bolt 1. Insert the front wheel axle from the right side and tighten it with the flange bolt from the left side to 91 Nm (9.1 m·kg, 65.8 ft·lb).

  • Page 48: Lubrication Points And Lubricant Types

    Starter clutch assembly Primary driven gear Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Yamaha bond No. Cylinder head cover mating surface 1215 Yamaha bond No. Cylinder head cover semicircular 1215 Yamaha bond No.
  • Page 49 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Engine mount bolts (rear upper and lower) Relay arm, connecting rod and rear shock absorber collar Pivot shaft Swingarm pivot bearing Swingarm head pipe end, oil seal and bush...
  • Page 50 LUBRICATION POINTS AND LUBRICANT TYPES 2-22...

  • Page 51: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-23...
  • Page 52 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter 6. Main gallery 7. AC magneto drive gear shower 8. Shift fork (upper) 9. Main axle 10.Mission shower 11.Drive axle 12.AC magneto axle 13.Piston cooler 14.Chain tensioner...

  • Page 53: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-25...
  • Page 54 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Oil filter cartridge 4. Oil level switch 2-26...
  • Page 55 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 56 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil cooler 5. Relief valve 6. Oil pipe 7. Oil strainer 8. Oil pump 2-28...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil level switch 3. Oil pump 4. Oil strainer 5. Oil pipe 6. Oil cooler 2-30...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil delivery pipe 3. Drive axle 2-32...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Crankshaft 2-34...

  • Page 63: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-35...
  • Page 64 COOLING SYSTEM DIAGRAMS 1. Water pump 2. Radiator 3. Radiator fan 2-36...
  • Page 65 COOLING SYSTEM DIAGRAMS 2-37...
  • Page 66 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat 2-38...

  • Page 67: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-39...
  • Page 68 CABLE ROUTING 1. Ground lead 2. Meter lead 3. Headlight stay 4. Right headlight lead (high beam) 5. Right auxiliary light lead 6. Intake air temperature sensor coupler 7. Headlight lead 8. Left Auxiliary light lead 9. Left headlight lead (high beam) 10.Right console panel 11.Right intake air duct 12.Left intake air duct...
  • Page 69 CABLE ROUTING 2-41...
  • Page 70 CABLE ROUTING 1. Right handlebar switch lead 2. Clutch cable 3. Main switch lead 4. Left handlebar switch lead 5. Horn lead 6. Horn 7. Throttle cables 8. Brake hose 9. Throttle cable (return side) 10.Throttle cable (pull side) A. Route the clutch cable so as to get along the front side of the main switch after pass- ing it through the guide.
  • Page 71 CABLE ROUTING 2-43...
  • Page 72 CABLE ROUTING J. Cut the clamp tip leaving 2 to 4 mm (0.08 1. Wire harness to 0.16 in). 2. Crankshaft position sensor lead K. Route the rear brake light switch lead by 3. Bracket the outer side of the vehicle than the O 4.
  • Page 73 CABLE ROUTING 2-45...
  • Page 74 CABLE ROUTING I. 40 to 60mm (1.57 to 2.36 in) 1. Left radiator fan motor lead J. Route the sidestand switch lead by the 2. Heat protector inside of the water hose and water pipe. 3. Immobilizer lead K. Route the oil level switch lead by the inside 4.
  • Page 75 CABLE ROUTING 2-47...
  • Page 76 CABLE ROUTING N. All hoses and leads should be routed over 1. Throttle cables the vehicle’s upper side above the heat 2. Rectifier/regulator protector. 3. Rectifier/regulator lead O. To the fuel pump 4. Right air outlet grille P. To the speed sensor 5.
  • Page 77 CABLE ROUTING 2-49...
  • Page 78 CABLE ROUTING 1. Starter relay lead 2. Starter motor lead 3. Battery positive lead 4. Lean angle sensor 5. Turn signal relay 6. Main fuse 7. Turn signal light/license plate light lead 8. Tail/brake light lead 9. Tail/brake light bracket 10.Lower tail cover 11.Seat lock cable 12.Anti safety alarm coupler...
  • Page 79 CABLE ROUTING 2-51...
  • Page 80 CABLE ROUTING 1. Fuel tank 2. O-ring 3. Fuel hose 4. Fuel tank drain hose 5. Fuel tank breather hose 6. Air filter stay 7. Clip 8. Fuel tank bracket 9. Fuel hose clamp 10.Fuel pump assembly A. Install the lip of O-ring facing upward. B.
  • Page 81 CABLE ROUTING 2-53...
  • Page 82 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 ENGINE......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODIES ........3-7 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-8 CHECKING THE SPARK PLUGS............3-9 MEASURING THE COMPRESSION PRESSURE .......3-10 CHECKING THE ENGINE OIL LEVEL ..........3-11...
  • Page 83 LUBRICATING THE SIDESTAND............3-35 LUBRICATING THE REAR SUSPENSION ..........3-35 ELECTRICAL SYSTEM................3-36 CHECKING AND CHARGING THE BATTERY........3-36 CHECKING THE FUSES..............3-36 REPLACING THE HEADLIGHT BULBS..........3-36 ADJUSTING THE HEADLIGHT BEAMS ..........3-37...

  • Page 84: Periodic Maintenance

    √ √ • Replace any damaged parts if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAS4C81029 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS...
  • Page 85 PERIODIC MAINTENANCE INITIAL ODOMETER READINGS 1000 km 7000 km 13000 km 19000 km 25000 km 31000 km ITEM ROUTINE (600 mi) (4000 mi) (8000 mi) (12000 mi) (16000 mi) (20000 mi) 1 month 6 months 12 months 18 months 24 months 30 months •...
  • Page 86 28 * and switches • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 37000 km (24000 mi) or 36 months, repeat the maintenance intervals starting from 13000 km (8000 mi) or 12 months.

  • Page 87: Engine

    ENGINE EAS20470 ENGINE EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead 4.
  • Page 88 ENGINE • When removing the timing chain and cam- Valve clearance measuring sequence shafts, fasten the timing chain with a wire to Cylinder #1 → #2 → #4 → #3 retrieve it if it falls into the crankcase. 6. Adjust: •...
  • Page 89 ENGINE NOTE: • The thickness “a” of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. • Since valve pads of various sizes are origi- nally installed, the valve pad number must be rounded in order to reach the closest equiva- lent to the original.

  • Page 90: Synchronizing The Throttle Bodies

    ENGINE EAS20570 5. Install: SYNCHRONIZING THE THROTTLE BODIES • Fuel tank NOTE: Refer to "FUEL TANK" on page 7-1. Prior to synchronizing the throttle bodies, the 6. Start the engine and let it warm up for sev- valve clearance should be properly adjusted eral minutes.

  • Page 91: Adjusting The Throttle Cable Free Play

    ENGINE • If an air screw was removed, turn the screw NOTE: 3/4 turn in and be sure to synchronize the • If more than one throttle body has a bypass throttle body. air screw with a white paint mark, use the one with the lowest vacuum pressure as the Intake vacuum standard.

  • Page 92: Checking The Spark Plugs

    ENGINE 4. Remove: Throttle cable free play • Spark plugs 3.0–5.0 mm (0.12–0.20 in) ECA13320 CAUTION: 2. Adjust: Before removing the spark plugs, blow • Throttle cable free play away any dirt accumulated in the spark ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ plug wells with compressed air to prevent it from falling into the cylinders.

  • Page 93: Measuring The Compression Pressure

    ENGINE 10. Install: • Radiator upper bolts • Radiator lower bolt Refer to "RADIATOR" on page 6-1. 11. Install: • Side cowlings • Lower cowlings Refer to "GENERAL CHASSIS" on page 4- EAS20710 MEASURING THE COMPRESSION PRES- 6. Measure: SURE •...

  • Page 94: Checking The Engine Oil Level

    ENGINE Compression pressure (with oil applied into Type the cylinder) YAMALUBE 4, SAE 10W30 or Reading Diagnosis SAE 20W40 Recommended engine oil grade Higher than without Piston ring(s) wear or damage → Repair. API service, SG type or higher, JASO standard MA Same as without oil Piston, valves, cylin- der head gasket or...
  • Page 95 ENGINE c. Tighten the new oil filter cartridge to speci- fication with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 m·kg, 12 ft·lb) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Check: • Engine oil drain bolt gasket 8. Install: • Engine oil drain bolt 5.

  • Page 96: Measuring The Engine Oil Pressure

    ENGINE 13. Check: Pressure gauge • Engine oil level 90890-03153 Refer to "CHECKING THE ENGINE OIL YU-03153 LEVEL" on page 3-11. Oil pressure adapter H 90890-03139 EAS20820 MEASURING THE ENGINE OIL PRESSURE 1. Check: • Engine oil level Below the minimum level mark ”a” → Add the recommended engine oil to the proper level.

  • Page 97: Adjusting The Clutch Cable Free Play

    ENGINE EAS20870 ADJUSTING THE CLUTCH CABLE FREE Locknut PLAY 7 Nm (0.7 m·kg, 5.1 ft·lb) 1. Check: c. Tighten the locknuts “1”. • Clutch cable free play “a” Out of specification → Adjust. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 2.

  • Page 98: Checking The Throttle Body Joints

    ENGINE NOTE: When installing the air filter element into the air filter case cover, make sure that the sealing surfaces are aligned to prevent any air leaks. 6. Install: • Fuel tank • Fuel tank side covers Refer to "FUEL TANK" on page 7-1. •...

  • Page 99: Checking The Crankcase Breather Hose

    ENGINE NOTE: Before removing the fuel hoses, place a few rags in the area under where it will be remov- ing. ECA14940 CAUTION: Make sure the fuel tank breather hose is routed correctly. 3. Install: • Fuel tank • Fuel tank side covers Refer to "FUEL TANK"...

  • Page 100: Adjusting The Exup Cables

    ENGINE EAS21100 Exhaust pipe nut ADJUSTING THE EXUP CABLES 20 Nm (2.0 m·kg, 14 ft·lb) 1. Remove: Exhaust pipe and exhaust valve • Lower cowlings pipe bolt Refer to "GENERAL CHASSIS" on page 4- 12 Nm (1.2 m·kg, 8.7 ft·lb) Exhaust valve pipe and catalist 2.

  • Page 101: Checking The Exup Servo Motor

    ENGINE NOTE: • Place the vehicle on a suitable stand. • Make sure the vehicle is upright. 2. Remove: • Lower cowlings • Right side cowling Refer to "GENERAL CHASSIS" on page 4- 3. Check: • Coolant level ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ The coolant level should be between the 6.

  • Page 102: Checking The Cooling System

    ENGINE EAS21120 • Side cowlings CHECKING THE COOLING SYSTEM • Lower cowlings 1. Remove: Refer to "GENERAL CHASSIS" on page 4- • Lower cowlings • Side cowling Refer to "GENERAL CHASSIS" on page 4- EAS21130 CHANGING THE COOLANT 1. Remove: 2.
  • Page 103 ENGINE Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Radiator capacity (including all routes) 2.76 L (2.92 US qt) (2.43 Imp.qt) 7. Drain: Coolant reservoir capacity (up • Coolant to the maximum level mark) (from the engine and radiator) 0.25 L (0.26 US qt) (0.22 8.
  • Page 104 ENGINE 15. Install: • Coolant reservoir cap 16. Start the engine, warm it up for several minutes, and then stop it. 17. Check: • Coolant level Refer to "CHECKING THE COOLANT LEVEL" on page 3-18. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled.

  • Page 105: Chassis

    CHASSIS EAS21140 (distance “a” from the center of the footrest CHASSIS bracket bolt to the center of the brake pedal) EAS21160 Out of specification → Adjust. ADJUSTING THE FRONT DISC BRAKE 1. Adjust: Brake pedal position • Brake lever position 25.2 mm (0.99 in) (distance “a”...

  • Page 106: Checking The Brake Fluid Level

    CHASSIS EWA13050 WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce braking performance.

  • Page 107: Checking The Rear Brake Pads

    CHASSIS 3. Hold the vehicle upright and apply the brake several times. 4. Check: • Brake hose Brake fluid leakage → Replace the dam- aged hose. Refer to "FRONT BRAKE" on page 4-20. EAS21290 CHECKING THE REAR BRAKE HOSE 1. Check: •...

  • Page 108: Bleeding The Hydraulic Brake System

    CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Fill the brake fluid reservoir to the proper a. Hold the main body “1” of the rear brake level with the recommended brake fluid. light switch so that it does not rotate and b. Install the brake fluid reservoir diaphragm. turn the adjusting nut “2”...

  • Page 109: Adjusting The Shift Pedal

    CHASSIS g. Loosen the bleed screw. EAS21410 ADJUSTING THE DRIVE CHAIN SLACK NOTE: NOTE: Loosening the bleed screw will release the The drive chain slack must be checked at the pressure and cause the brake lever to contact tightest point on the chain. the throttle grip or the brake pedal to fully extend.

  • Page 110: Lubricating The Drive Chain

    CHASSIS Direction “a” Recommended lubricant Drive chain is tightened. Engine oil or chain lubricant Direction “b” suitable for O-ring chains Drive chain is loosened. EAS21500 CHECKING AND ADJUSTING THE STEER- ING HEAD 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there...
  • Page 111 CHASSIS Steering nut wrench 90890-01403 Spanner wrench YU-33975 Lower ring nut (initial tightening torque) 52 Nm (5.2 m·kg, 38 ft·lb) c. Loosen the lower ring nut “4” completely, then tighten it to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EWA13140 5. Install: WARNING • Upper bracket Do not overtighten the lower ring nut.

  • Page 112: Checking The Front Fork

    CHASSIS 4. Check: • Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to "FRONT FORK" on page 4-50. e. Repeat the above procedure on the oppo- site handlebar.
  • Page 113 CHASSIS Rebound damping adjust posi- tions Minimum 26 click(s) out* Standard 10 click(s) out* Maximum 1 click(s) out* * With the adjusting screw fully turned in. Spring preload adjusting posi- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ tions Minimum Compression damping ECA13590 Standard CAUTION: Never go beyond the maximum or minimum Maximum adjustment positions.

  • Page 114: Adjusting The Rear Shock Absorber Assembly

    CHASSIS Spring preload adjusting posi- tions Minimum Standard Maximum ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping ECA13590 EAS21610 CAUTION: ADJUSTING THE REAR SHOCK Never go beyond the maximum or minimum ABSORBER ASSEMBLY adjustment positions. EWA13120 WARNING 1. Adjust: Securely support the vehicle so that there •...

  • Page 115: Checking The Tires

    CHASSIS Compression damping (fast compression ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ damping) a. Turn the adjusting knob “1” in direction “a” ECA13590 or “b”. CAUTION: Direction “a” Never go beyond the maximum or minimum Compression damping increased adjustment positions. (suspension is harder). 1. Adjust: Direction “b” Compression damping decreased...
  • Page 116 CHASSIS Damage/wear → Replace the tire. EWA13180 WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.

  • Page 117: Checking The Wheels

    EWA13260 concerning handling characteristics can be WARNING given if a tire combination other than one Never attempt to make any repairs to the approved by Yamaha is used on this vehi- wheel. cle. NOTE: Front tire After a tire or wheel has been changed or Size replaced, always balance the wheel.

  • Page 118: Lubricating The Pedal

    CHASSIS EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. Recommended lubricant Lithium-soap-based grease EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium-soap-based grease EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension.

  • Page 119: Electrical System

    ELECTRICAL SYSTEM EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to "ELECTRICAL COMPONENTS" on page 8-77. EAS21770 CHECKING THE FUSES Refer to "ELECTRICAL COMPONENTS" on page 8-77. 5. Remove: EAS21790 • Headlight bulb REPLACING THE HEADLIGHT BULBS EWA13320 The following procedure applies to both of the WARNING headlight bulbs.
  • Page 120 ELECTRICAL SYSTEM • Headlight bulb coupler (high beam) 11. Install: • Intake air duct panel Refer to "GENERAL CHASSIS" on page 4- EAS21810 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Remove: Front cowling inner panels ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 121 CHASSIS GENERAL CHASSIS..................4-1 CHECKING THE INTAKE FUNNEL............4-5 CHECKING THE INTAKE FUNNEL............4-5 CHECKING THE INTAKE FUNNEL OPERATION ........4-5 REMOVING THE COVER...............4-7 INSTALLING THE COVER ..............4-7 FRONT WHEEL ....................4-8 REMOVING THE FRONT WHEEL ............4-10 CHECKING THE FRONT WHEEL............4-10 ADJUSTING THE FRONT WHEEL STATIC BALANCE .......4-11 INSTALLING THE FRONT WHEEL ............4-12 REAR WHEEL ....................4-14 REMOVING THE REAR WHEEL ............4-17...
  • Page 122 HANDLEBARS ...................4-45 REMOVING THE HANDLEBAR ............4-47 CHECKING THE HANDLEBARS ............4-47 INSTALLING THE HANDLEBARS............4-47 CHECKING THE STEERING DAMPER ..........4-48 FRONT FORK.....................4-50 REMOVING THE FRONT FORK LEGS ..........4-52 DISASSEMBLING THE FRONT FORK LEGS ........4-52 CHECKING THE FRONT FORK LEGS..........4-53 ASSEMBLING THE FRONT FORK LEGS ...........4-54 INSTALLING THE FRONT FORK LEGS ..........4-58 STEERING HEAD..................4-59 REMOVING THE LOWER BRACKET ..........4-61...
  • Page 123 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery Order Job/Parts to remove Q’ty Remarks Rider seat Passenger seat Battery negative lead Battery positive lead ECU (engine control unit) ECU lead coupler Disconnect. ECU cover Battery band Battery Battery seat For installation, reverse the removal proce- dure.
  • Page 124 GENERAL CHASSIS Removing the front cowling and side cowlings Order Job/Parts to remove Q’ty Remarks Side cowling inner panel Side cowling Front turn signal light lead coupler Disconnect. Lower cowling Lower cowling front cover Intake air duct panel Intake air temperature coupler Disconnect.
  • Page 125 GENERAL CHASSIS Removing the rear fender Order Job/Parts to remove Q’ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Muffler Refer to "ENGINE REMOVAL" on page 5-1. Upper tail cover Tail/brake light lead coupler Disconnect.
  • Page 126 GENERAL CHASSIS Removing the air filter case Order Job/Parts to remove Q’ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Air filter case cover Air filter Intake funnel servo motor rod assembly Intake funnel joint Intake funnel Intake funnel rod...

  • Page 127: General Chassis

    GENERAL CHASSIS EAS4C81025 surface between upper stopper and lower CHECKING THE INTAKE FUNNEL seating position when it is moved by 1. Check: hand. • Intake funnel • Make sure that the intake funnel smoothly Cracks/damage → Replace. strokes from the upper position to the •...
  • Page 128 GENERAL CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Activate the diagnostic mode and select the diagnostic code number “34”. Refer to "FUEL INJECTION SYSTEM" on page 8-29. b. Set the engine stop switch to “ ”. c. Check that the intake funnel operate smoothly strokes from the upper position to the lower seating position.

  • Page 129: Removing The Cover

    GENERAL CHASSIS EAS21840 REMOVING THE COVER 1. Remove: • Tail cover • Rear fender NOTE: To remove the quick fastener, push its center with a screwdriver, then pull the fastener out. EAS21850 INSTALLING THE COVER 1. Install: • Rear fender •...

  • Page 130: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Reflector Reflector bracket Left brake hose holder Right brake hose holder Left front brake caliper Right front brake caliper Front wheel axle pinch bolt Front wheel axle bolt Front wheel axle Collar (left and right)
  • Page 131 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly pro- cedure.

  • Page 132: Removing The Front Wheel

    FRONT WHEEL EAS21900 Refer to "CHECKING THE TIRES" on page REMOVING THE FRONT WHEEL 3-32 and "CHECKING THE WHEELS" on 1. Stand the vehicle on a level surface. page 3-34. EWA13120 3. Measure: WARNING • Radial wheel runout “1” Securely support the vehicle so that there •...

  • Page 133: Adjusting The Front Wheel Static Balance

    FRONT WHEEL • Adjust the front wheel static balance with the brake disc installed. 1. Remove: • Balancing weight(s) 2. Find: • Front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ c. Remove the wheel bearings “3” with a gen- a.

  • Page 134: Installing The Front Wheel

    FRONT WHEEL EAS22000 NOTE: INSTALLING THE FRONT WHEEL Start with the lightest weight. The following procedure applies to both of the brake discs. 1. Lubricate: • Wheel axle • Oil seal lips Recommended lubricant Lithium-soap-based grease 2. Lift the wheel up between the fork legs. 3.
  • Page 135 FRONT WHEEL EWA13490 WARNING Make sure the brake cable is routed prop- erly. NOTE: Make sure that there is enough space between the brake pads before installing the brake cali- pers on to the brake discs. 4-13...

  • Page 136: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Rear brake caliper Locknut (left and right) Loosen. Adjusting bolt (left and right) Loosen. Rear wheel axle nut Washer Rear wheel axle Left adjusting block Right adjusting block Rear wheel Rear brake caliper bracket...
  • Page 137 REAR WHEEL Removing the brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar Dust cover Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel For installation, reverse the removal proce- dure.
  • Page 138 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly pro- cedure. 4-16...

  • Page 139: Removing The Rear Wheel

    REAR WHEEL EAS22040 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 140: Checking The Rear Wheel Drive Hub

    REAR WHEEL EAS22110 NOTE: CHECKING THE REAR WHEEL DRIVE HUB Tighten the self-locking nuts in stages and in a 1. Check: crisscross pattern. • Rear wheel drive hub “1” Cracks/damage → Replace. • Rear wheel drive hub dampers “2” Damage/wear → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 141 REAR WHEEL Rear wheel axle nut 150 Nm (15.0 m·kg, 108 ft·lb) Rear brake caliper bolt (front side) 27 Nm (2.7 m·kg, 20 ft·lb) Rear brake caliper bolt (rear side) 22 Nm (2.2 m·kg, 16 ft·lb) EWA13500 WARNING Make sure the brake hose is routed prop- erly.

  • Page 142: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks Brake hose holder Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw For installation, reverse the removal proce- dure.
  • Page 143 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-25. Stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Brake lever...
  • Page 144 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Bleed screw Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-22...
  • Page 145 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-25. Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal proce- dure.
  • Page 146 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure. 4-24...

  • Page 147: Introduction

    FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 148: Replacing The Front Brake Pads

    FRONT BRAKE Front brake disc bolt 18 Nm (1.8 m·kg, 13 ft·lb) LOCTITE® 3. Remove: • Brake pads “1” d. Measure the brake disc deflection. e. If out of specification, repeat the adjust- ment steps until the brake disc deflection is within specification.

  • Page 149: Removing The Front Brake Calipers

    FRONT BRAKE Below the minimum level mark “a” → Add NOTE: the recommended brake fluid to the proper Always install new brake pads and a new level. brake pad spring as a set. Refer to "CHECKING THE BRAKE FLUID ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ LEVEL"...

  • Page 150: Disassembling The Front Brake Calipers

    FRONT BRAKE EAS22360 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ DISASSEMBLING THE FRONT BRAKE CALIPERS EAS22390 CHECKING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. Recommended brake component replace- 1. Remove: ment schedule • Brake caliper pistons “1” Brake pads If necessary •...

  • Page 151: Installing The Front Brake Calipers

    FRONT BRAKE • Whenever a brake caliper is disassem- bled, replace the brake caliper piston seals. Recommended fluid DOT 4 EAS22450 INSTALLING THE FRONT BRAKE CALI- PERS The following procedure applies to both of the 3. Fill: brake calipers. • Brake fluid reservoir 1.

  • Page 152: Removing The Front Brake Master Cylinder

    FRONT BRAKE EAS22510 CHECKING THE FRONT BRAKE MASTER CYLINDER 1. Check: • Brake master cylinder Damage/scratches/wear → Replace. • Brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. 6. Check: • Brake lever operation Soft or spongy feeling →...

  • Page 153: Assembling The Front Brake Master Cylinder

    FRONT BRAKE 2. Install: EAS22520 ASSEMBLING THE FRONT BRAKE MAS- • Copper washers TER CYLINDER • Brake hose EWA13520 • Union bolt WARNING Front brake hose union bolt • Before installation, all internal brake com- 30 Nm (3.0 m·kg, 22 ft·lb) ponents should be cleaned and lubricated with clean or new brake fluid.
  • Page 154 FRONT BRAKE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake perfor- mance.

  • Page 155: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad Bleed screw Brake pad spring For installation, reverse the removal proce- dure.
  • Page 156 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-25. Footrest plate Brake fluid reservoir cap Rear brake fluid reservoir diaphragm holder Rear brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Hose joint...

  • Page 157: Rear Brake

    REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Hose joint Bush Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-35...

  • Page 158: Rear Brake

    REAR BRAKE Removing the rear brake calipers Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-25. Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal proce- dure.
  • Page 159 REAR BRAKE Disassembling the rear brake calipers Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Brake pad Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.

  • Page 160: Introduction

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 4.5 mm (0.18 in) WARNING 5. Adjust: Disc brake components rarely require dis- • Brake disc deflection assembly. Therefore, always follow these Refer to "CHECKING THE FRONT BRAKE preventive measures: DISCS" on page 4-25. •...
  • Page 161 REAR BRAKE 3. Measure: c. Tighten the bleed screw. • Brake pad wear limit “a” Out of specification → Replace the brake Bleed screw 6 Nm (0.6 m·kg, 4.3 ft·lb) pads as a set. d. Install a new brake pad shim “3” onto each Brake lining thickness...

  • Page 162: Removing The Rear Brake Caliper

    REAR BRAKE EAS22590 • Never try to pry out the brake caliper pis- REMOVING THE REAR BRAKE CALIPER ton. NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • Union bolt “1” •...

  • Page 163: Assembling The Rear Brake Caliper

    REAR BRAKE EWA13610 ECA14170 WARNING CAUTION: Whenever a brake caliper is disassembled, When installing the brake hose onto the replace the brake caliper piston seals. brake caliper “1”, make sure the brake pipe “a” touches the projection “b” on the brake 2.

  • Page 164: Removing The Rear Brake Master Cylinder

    REAR BRAKE • When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. ECA13540 CAUTION: Brake fluid may damage painted surfaces and plastic parts.

  • Page 165: Assembling The Rear Brake Master Cylinder

    REAR BRAKE EWA13530 WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to "CABLE ROUTING" on page 2-39. ECA14160 CAUTION: When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection “a” as shown. 4.
  • Page 166 REAR BRAKE • When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. ECA13540 CAUTION: Brake fluid may damage painted surfaces and plastic parts.
  • Page 167 HANDLEBARS EAS22850 HANDLEBARS Removing the handlebars Order Job/Parts to remove Q’ty Remarks Front cowling Refer to "GENERAL CHASSIS" on page 4-1. Side cowling Refer to "GENERAL CHASSIS" on page 4-1. Grip end Handlebar grip Clutch switch connector Disconnect. Left handlebar switch Clutch cable Clutch lever holder Throttle cable housing...
  • Page 168 HANDLEBARS Removing the handlebars Order Job/Parts to remove Q’ty Remarks Upper bracket bolt Loosen. Upper bracket pinch bolt Loosen. Steering stem nut Loosen. Upper bracket Left handlebar Right handlebar For installation, reverse the removal proce- dure. 4-46...

  • Page 169: Handlebars

    HANDLEBARS EAS22870 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” NOTE: EAS22900 Blow compressed air between the handlebar INSTALLING THE HANDLEBARS and the handlebar grip, and gradually push the 1.

  • Page 170: Checking The Steering Damper

    HANDLEBARS 4. Install: 7. Install: • Handlebar grip • Throttle grip • Throttle cable housing “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto • Throttle cables the end of the left handlebar. NOTE: b. Slide the handlebar grip over the end of the Align the projection “a”...
  • Page 171 HANDLEBARS 4-49...

  • Page 172: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks Front wheel Refer to "FRONT WHEEL" on page 4-8. Front brake caliper Refer to "FRONT BRAKE" on page 4-20. Side cowling Refer to "GENERAL CHASSIS" on page 4-1. Front fender Handlebar pinch bolt Loosen.
  • Page 173 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Damper adjusting rod Damper adjusting rod locknut Washer Spacer Fork spring Dust seal Oil seal clip Oil seal Washer Damper rod assembly bolt Copper washer Damper rod assembly Inner tube Outer tube...

  • Page 174: Removing The Front Fork Legs

    FRONT FORK EAS22970 • Front fork leg REMOVING THE FRONT FORK LEGS The following procedure applies to both of the EAS22990 DISASSEMBLING THE FRONT FORK LEGS front fork legs. The following procedure applies to both of the 1. Stand the vehicle on a level surface. front fork legs.

  • Page 175: Checking The Front Fork Legs

    FRONT FORK 1. Check: • Inner tube “1” • Outer tube “2” Bends/damage/scratches → Replace. EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 3. Remove: • Dust seal • Oil seal clip “1” (with a flat-head screwdriver) •...

  • Page 176: Assembling The Front Fork Legs

    FRONT FORK 4. Check: • Cap bolt O-ring “1” Damage/wear → Replace. 2. Lubricate: • Inner tube’s outer surface Recommended oil Suspension oil 01 or equiva- lent 3. Tighten: • Damper rod assembly bolt “1” Damper rod assembly bolt 23 Nm (2.3 m·kg, 17 ft·lb) LOCTITE®...
  • Page 177 FRONT FORK 4. Install: • Dust seal “1” • Oil seal clip “2” • Oil seal “3” • Washer “4” ECA14220 CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: 6. Install: • Before installing the oil seal, lubricate its lips •...
  • Page 178 FRONT FORK Rod puller 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M12) 90890-01435 Universal damping rod bleeding tool set YM-A8703 11. Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.
  • Page 179 FRONT FORK a. Remove the rod puller attachment. b. Install the nut. c. Install the fork spring and spacer. NOTE: Install the spring with the smaller pitch “a” fac- ing up “A”. g. Remove the rod puller and the rod puller attachment.

  • Page 180: Installing The Front Fork Legs

    FRONT FORK EWA4C81003 WARNING • The fork spring is compressed. • Always use a new cap bolt O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: 3. Adjust: •...

  • Page 181: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Front cowling Refer to "GENERAL CHASSIS" on page 4-1. Side cowling Refer to "GENERAL CHASSIS" on page 4-1. Front wheel Refer to "FRONT WHEEL" on page 4-8. Front fork legs Refer to "FRONT BRAKE"...
  • Page 182 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Bearing cover Bearing inner race Upper bearing Lower bearing Dust seal Bearing outer race For installation, reverse the removal proce- dure. 4-60...

  • Page 183: Removing The Lower Bracket

    STEERING HEAD EAS23110 • Bearings REMOVING THE LOWER BRACKET • Bearing races 1. Stand the vehicle on a level surface. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EWA13120 a. Remove the bearing races “1” from the WARNING steering head pipe with a long rod “2” and Securely support the vehicle so that there hammer.
  • Page 184 STEERING HEAD • Bearing races Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to "CHECKING AND ADJUSTING THE STEERING HEAD" on page 3-27. 3.

  • Page 185: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK"...

  • Page 186: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 2. Remove: HANDLING THE REAR SHOCK ABSORBER • Rear shock absorber assembly lower bolt EWA13740 “1” WARNING • Relay arm-to-swingarm bolt “2” This rear shock absorber contains highly NOTE: compressed nitrogen gas. Before handling While removing the rear shock absorber the rear shock absorber, read and make assembly lower bolt, hold the swingarm so that sure you understand the following informa-...

  • Page 187: Checking The Connecting Arm And Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY • Dust seals Installed depth “a” Damage/wear → Replace. 1.0 mm (0.04 in) • Bolts Installed depth “b” Bends/damage/wear → Replace. 4.0 mm (0.16 in) EAS23260 A. Left side CHECKING THE CONNECTING ARM AND B. Right side RELAY ARM 1.

  • Page 188: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to "REAR WHEEL" on page 4-14. Refer to "REAR SHOCK ABSORBER Rear shock absorber assembly ASSEMBLY" on page 4-63. Drive sprocket Refer to "ENGINE REMOVAL" on page 5-1. Right footrest bracket Drive chain adjusting bolt/locknut Drive chain guard...
  • Page 189 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 4-67...

  • Page 190: Removing The Swingarm

    SWINGARM EAS23350 REMOVING THE SWINGARM Swingarm side play (at the end 1. Stand the vehicle on a level surface. of the swingarm) EWA13120 1.0 mm (0.04 in) WARNING d. Check the swingarm vertical movement “B” Securely support the vehicle so that there by moving the swingarm up and down.

  • Page 191: Checking The Swingarm

    SWINGARM • Washers NOTE: • Bearings Loosen the swingarm pivot shaft with the damper rod holder (22 mm) “2”. Recommended cleaning solvent Kerosene Damper rod holder (22 mm) 4. Check: 90890-01365 • Dust covers “1” • Spacer “2” • Washer “3” Damage/wear →...
  • Page 192 SWINGARM 5. Swingarm 6. Pivot shaft A. Left side B. Right side 3. Install: • Pivot shaft “1” Pivot shaft 7 Nm (0.7 m·kg, 5.1 ft·lb) NOTE: 5. Install: Tighten the pivot shaft with the damper rod • Pivot shaft nut “1” holder (22 mm) “2”.

  • Page 193: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks Swingarm Refer to "SWINGARM" on page 4-66. Drive chain guard Drive chain For installation, reverse the removal proce- dure. 4-71...

  • Page 194: Removing The Drive Chain

    CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: 2. Check: Place the vehicle on a suitable stand so that •...

  • Page 195: Checking The Rear Wheel Sprocket

    CHAIN DRIVE b. Correct 1. Drive chain roller 2. Drive chain sprocket EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to "CHECKING AND REPLACING THE REAR WHEEL SPROCKET" on page 4-18 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to "CHECKING THE REAR WHEEL DRIVE HUB"...
  • Page 196 CHAIN DRIVE ECA14300 CAUTION: Never install a new drive chain onto worn drive chain sprockets; this will dramatically shorten the drive chain’s life. 3. Adjust: • Drive chain slack Refer to "ADJUSTING THE DRIVE CHAIN SLACK" on page 3-26 Drive chain slack 30.0–40.0 mm (1.18–1.57 in) ECA13550 CAUTION:...
  • Page 197 CHAIN DRIVE 4-75...
  • Page 198 ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-7 CAMSHAFTS....................5-9 REMOVING THE CAMSHAFTS ............5-11 CHECKING THE CAMSHAFTS ............5-12 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET..5-13 CHECKING THE TIMING CHAIN GUIDES ..........5-13 CHECKING THE TIMING CHAIN TENSIONER ........5-13 INSTALLING THE CAMSHAFTS ............5-15 CYLINDER HEAD..................5-18 REMOVING THE CYLINDER HEAD ............5-19 CHECKING THE CYLINDER HEAD ............5-19...
  • Page 199 CHECKING THE CLUTCH PLATES.............5-48 CHECKING THE CLUTCH SPRINGS ..........5-49 CHECKING THE CLUTCH HOUSING ..........5-49 CHECKING THE CLUTCH BOSS ............5-49 CHECKING THE PRESSUR PLATE 2 ..........5-50 CHECKING THE PRESSURE PLATE 1 ..........5-50 CHECKING THE PUSH LEVER SHAFT AND PUSH ROD....5-50 INSTALLING THE CLUTCH..............5-50 SHIFT SHAFT .....................5-54 REMOVING THE SHIFT SHAFT ............5-55 CHECKING THE SHIFT SHAFT ............5-55...
  • Page 200 CHECKING THE TRANSMISSION ............5-90 INSTALLING THE TRANSMISSION.............5-91...
  • Page 201 ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the drive sprocket Order Job/Parts to remove Q’ty Remarks Lower cowlings Refer to "GENERAL CHASSIS" on page 4-1. Loosen. Drive chain Refer to "ADJUSTING THE DRIVE CHAIN SLACK" on page 3-26. Locknut Shift rod Sift arm Drive sprocket cover Drive sprocket nut...
  • Page 202 ENGINE REMOVAL Removing the exhaust pipe Order Job/Parts to remove Q’ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Side cowlings Refer to "GENERAL CHASSIS" on page 4-1. Lower cowlings Refer to "GENERAL CHASSIS"...
  • Page 203 ENGINE REMOVAL Removing the exhaust pipe Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure.
  • Page 204 ENGINE REMOVAL Disassembling the exhaust valve pipe Order Job/Parts to remove Q’ty Remarks Washer Pulley Collar Plate Spring EXUP pulley bracket Housing Gasket Collar Shaft arm Exhaust valve pipe For assembly, reverse the disassembly pro- cedure.
  • Page 205 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to "FUEL TANK" on page 7-1. Air filter case Refer to "GENERAL CHASSIS" on page 4-1. Throttle body Refer to "THROTTLE BODIES" on page 7-4. Drain.
  • Page 206 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Engine mounting bolt (front right side) Engine mount collar (outer) Engine mount collar (center) Engine mount collar (inner) Engine mounting bolt (front left side) Locknut Engine mounting bolt (rear lower side) Locknut Engine mounting bolt (rear upper side) Engine mounting adjust bolt...

  • Page 207: Engine Removal

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Engine mounting adjust bolts (temporary tighten) 2. Install: • Engine 3. Install: • Engine mounting bolt (rear lower side) “1” • Engine mounting bolt (rear upper side) “2” • Locknuts 6. Tighten: NOTE: •...
  • Page 208 ENGINE REMOVAL Upper locknut Engine mounting bolt (front 51 Nm (5.1 m·kg, 37 ft·lb) right side) Lower locknut 45 Nm (4.5 m·kg, 33 ft·lb) 51 Nm (5.1 m·kg, 37 ft·lb) NOTE: First tighten the lower locknut, and then tighten the upper locknut. 8.

  • Page 209: Camshafts

    CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to "FUEL TANK" on page 7-1. Side cowlings Refer to "GENERAL CHASSIS" on page 4-1. Lower cowlings Refer to "GENERAL CHASSIS" on page 4-1. Throttle body Refer to "THROTTLE BODIES"...
  • Page 210 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Refer to "CRANKSHAFT POSITION SEN- Pickup rotor cover SOR" on page 5-37. Camshaft sprocket bolt Loosen. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft Exhaust camshaft...

  • Page 211: Removing The Camshafts

    CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: • Pickup rotor cover Refer to "CRANKSHAFT POSITION SEN- SOR" on page 5-37. 2. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. b.

  • Page 212: Checking The Camshafts

    CAMSHAFTS 3. Measure: • Camshaft runout EAS23850 CHECKING THE CAMSHAFTS Out of specification → Replace. 1. Check: • Camshaft lobes Camshaft runout limit Blue discoloration/pitting/scratches → 0.030 mm (0.0012 in) Replace the camshaft. 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification →...

  • Page 213: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFTS 2. Check: • Camshaft sprocket More than 1/4 tooth wear “a” → Replace the camshaft sprocket and the timing chain as a set. a. 1/4 tooth ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Correct 5. Measure: 1. Timing chain roller • Camshaft journal diameter “a” 2.
  • Page 214 CAMSHAFTS NOTE: NOTE: Squeeze the timing chain tensioner clip, and When the timing chain tensioner rod “3” is then remove the timing chain tensioner spring pushed while holding the grip of the timing and timing chain tensioner rod. chain tensioner clip “2”, make sure not to release the timing chain tensioner rod “3”...

  • Page 215: Installing The Camshafts

    CAMSHAFTS EAS24000 INSTALLING THE CAMSHAFTS 1. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b. When position #1 is at TDC, align the “T” mark “a” with the crankcase mating surface “b”.
  • Page 216 CAMSHAFTS ECA4C81004 CAUTION: • Lubricate the camshaft cap bolts with the engine oil. • The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. • Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing.
  • Page 217 CAMSHAFTS 11. Measure: • Valve clearance Out of specification → Adjust. Refer to "ADJUSTING THE VALVE CLEARANCE" on page 3-4. 12. Install: • Pickup coil rotor cover "CRANKSHAFT POSITION SENSOR" on page 5-37. 5-17...

  • Page 218: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Engine Refer to "ENGINE REMOVAL" on page 5-1. Intake camshaft Refer to "CAMSHAFTS" on page 5-9. Exhaust camshaft Refer to "CAMSHAFTS" on page 5-9. Cylinder head Cylinder head gasket Dowel pin Coolant pipe...

  • Page 219: Removing The Cylinder Head

    CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD Warpage limit 1. Remove: 0.10 mm (0.0039 in) • Intake camshaft • Exhaust camshaft Refer to "REMOVING THE CAMSHAFTS" on page 5-11. 2. Remove: • Cylinder head nuts • Cylinder head bolts NOTE: •...
  • Page 220 CYLINDER HEAD NOTE: • First, tighten the nuts “1” – “10” to approxi- mately 10 Nm (1.0 m·kg, 7.2 ft·lb) with a torque wrench, and then tighten the 25 Nm (2.5 m·kg, 18 ft·lb). • Retighten the nuts “1” – “10” to 40 Nm (4.0 m·kg, 29 ft·lb) with a torque wrench.
  • Page 221 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to "CYLINDER HEAD" on page 5-18. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal Intake valve lower spring seat...

  • Page 222: Valves And Valve Springs

    VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-22...

  • Page 223: Removing The Valves

    VALVES AND VALVE SPRINGS EAS24280 • Valve cotters “1” REMOVING THE VALVES NOTE: The following procedure applies to all of the Remove the valve cotters by compressing the valves and related components. valve spring with the valve spring compressor NOTE: “2”...
  • Page 224 VALVES AND VALVE SPRINGS • 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 Valve-stem-to-valve-guide clear- b. Install the new valve guide with the valve ance (intake) guide installer “2”...

  • Page 225: Checking The Valve Seats

    VALVES AND VALVE SPRINGS Valve guide remover (ø4.5) 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide remover (ø5) 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø4.5) 90890-04117 Valve guide installer (4.5 mm) 6. Measure: YM-04117 • Valve stem runout Out of specification →...
  • Page 226 VALVES AND VALVE SPRINGS ECA4C81012 Valve seat width CAUTION: Valve seat width C (intake) This model uses titanium intake valves. 0.90–1.10 mm (0.0354–0.0433 Titanium valves that have been used to lap the valve seats must not be used. Always Valve seat width C (exhaust) replace lapped valves with new valves.

  • Page 227: Checking The Valve Springs

    VALVES AND VALVE SPRINGS Valve spring free length Free length (intake) 39.79 mm (1.57 in) Limit 37.80 mm (1.49 in) Free length (exhaust) 38.42 mm (1.51 in) Limit 36.50 mm (1.44 in) e. Apply a fine lapping compound to the valve face and repeat the above steps.

  • Page 228: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS • Valve stem seal “2” Spring tilt limit (with the recommended lubricant) Spring tilt (intake) 2.5 °/1.7 mm Recommended lubricant Spring tilt (exhaust) Molybdenum disulfide oil 2.5 °/1.7 mm 3. Install: • Valve “1” EAS24320 CHECKING THE VALVE LIFTERS •...
  • Page 229 VALVES AND VALVE SPRINGS NOTE: Valve spring compressor • The valve lifter must move smoothly when 90890-04019 rotated with a finger. YM-04019 • Each valve lifter and valve pad must be rein- Valve spring compressor stalled in its original position. attachment 90890-04108 Valve spring compressor...

  • Page 230: Generator

    GENERATOR EAS24480 GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Side cowlings Refer to "GENERAL CHASSIS" on page 4-1. Lower cowlings Refer to "GENERAL CHASSIS"...
  • Page 231 GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Stator coil assembly lead holder Idler gear Idler gear shaft Washer Bearing For installation, reverse the removal proce- dure. 5-31...

  • Page 232: Removing The Generator

    GENERATOR EAS24490 EAS24500 REMOVING THE GENERATOR INSTALLING THE GENERATOR 1. Remove: 1. Install: • Plug • Idle gear shaft • Generator rotor cover “1” • Idle gear “1” • Washer NOTE: • Idle gear shaft bolt “2” • While pushing generator rotor, remove the generator rotor cover.
  • Page 233 GENERATOR NOTE: • First tighten the M8 bolts and then tighten the M6 bolts. • Tighten the generator rotor cover bolts in stages and in a crisscross pattern. 5-33...

  • Page 234: Starter Clutch

    STARTER CLUTCH EAS24550 STARTER CLUTCH Removing the starter clutch Order Job/Parts to remove Q’ty Remarks Generator rotor Damper Driven gear Washer Starter clutch drive gear Collar Washer Spacer O-ring For assembly, reverse the removal proce- dure. 5-34...

  • Page 235: Removing The Starter Clutch

    STARTER CLUTCH EAS24560 REMOVING THE STARTER CLUTCH 1. Remove: • Spacer “1” • O-ring “2” • Washer “3” EAS24570 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch rollers “1” Damage/wear → Replace. 2. Remove: • Starter clutch drive gear “1” •...

  • Page 236: Installing The Starter Clutch

    STARTER CLUTCH b. When turning the starter clutch drive gear clockwise “A”, the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch drive gear counterclockwise “B”, it should turn freely, otherwise the starter clutch is faulty and must be replaced.

  • Page 237: Crankshaft Position Sensor

    CRANKSHAFT POSITION SENSOR EAS24520 CRANKSHAFT POSITION SENSOR Removing the crankshaft position sensor Order Job/Parts to remove Q’ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Side cowlings Refer to "GENERAL CHASSIS" on page 4-1. Lower cowlings Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK"...

  • Page 238: Removing The Crankshaft Position Sensor

    CRANKSHAFT POSITION SENSOR EAS24530 2. Connect REMOVING THE CRANKSHAFT POSITION • Crankshaft position sensor lead coupler SENSOR 1. Disconnect: • Crankshaft position sensor lead coupler 2. Remove: • Crankshaft position sensor • O-ring • Pickup coil rotor cover “1” NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.

  • Page 239: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Air filter case Refer to "GENERAL CHASSIS" on page 4-1. Throttle body Refer to "THROTTLE BODIES"...
  • Page 240 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Front cover Lock washer Washer Starter motor yoke Armature assembly Gasket Brush holder Rear cover For assembly, reverse the removal proce- dure. 5-40...

  • Page 241: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 1000 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “a” Armature coil Out of specification → Replace the starter Commutator resistance “1”...

  • Page 242: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Gear teeth 3. Install: Damage/wear → Replace the starter • Nut “1” motor. EAS24800 5 Nm (0.5 m·kg, 3.6 ft·lb) ASSEMBLING THE STARTER MOTOR 1. Install: • Brush holder • Armature ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Pull both the brush spring and the brush outside and hook the brush spring to the groove portion at the side of the brush.

  • Page 243: Installing The Starter Motor

    ELECTRIC STARTER EAS24810 INSTALLING THE STARTER MOTOR 1. Install: • Starter motor “1” • Starter motor bolts “2” Starter motor bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) 2. Connect: • Starter motor lead “3” Starter motor lead bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) 5-43...

  • Page 244: Clutch

    CLUTCH EAS25060 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Right side cowling Refer to "GENERAL CHASSIS" on page 4-1. Bottom cowlings Refer to "GENERAL CHASSIS" on page 4-1. Drain. Engine oil Refer to "CHANGING THE ENGINE OIL" on page 3-11.
  • Page 245 CLUTCH Removing the push lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the removal proce- dure. 5-45...
  • Page 246 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Compression spring Pressure plate 1 Push rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Clutch plate 2 Clutch plate 3 Friction plate 3 Clutch damper spring Clutch damper spring seat Muffler Spring Clutch boss...

  • Page 247: Removing The Clutch

    CLUTCH EAS25080 • Friction plate 2 REMOVING THE CLUTCH • Clutch plate 2 1. Remove: • Clutch plate 3 • Clutch cover “1” • Friction plate 3 • Gasket • Clutch damper spring NOTE: • Clutch damper spring seat Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.

  • Page 248: Checking The Friction Plates

    CLUTCH • Springs • Pressure plate 2 • Conical spring washer • Thrust plate 2 EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: • Friction plate 3. Measure: Damage/wear → Replace the friction •...

  • Page 249: Checking The Clutch Springs

    CLUTCH Clutch plate “2” EAS25150 CHECKING THE CLUTCH HOUSING Part No. Thickness 1. Check: 5VY-16325-00 2.0 mm (0.079 in) • Clutch housing dogs Damage/pitting/wear → Deburr the clutch 4B1-16325-00 2.3 mm (0.091 in) housing dogs or replace the clutch hous- ing.

  • Page 250: Checking The Pressur Plate 2

    CLUTCH EAS4C81005 2. Check: CHECKING THE PRESSUR PLATE 2 • Push rod bearing 1. Check: Damage/wear → Replace. • Pressure plate 2 Cracks / damage → Replace. EAS25170 EAS25240 CHECKING THE PRESSURE PLATE 1 INSTALLING THE CLUTCH 1. Check: 1. Install: •...
  • Page 251 CLUTCH 3. Install: • Spring “1” • Clutch boss nut “2” Clutch boss nut 115 Nm (11.5 m·kg, 83 ft·lb) NOTE: • Put the spring detent “a” into the groove of the pressure plate 2. Assemble so that each spring detent “a” is 4.
  • Page 252 CLUTCH NOTE: Clutch spring bolt Assemble the friction plates and clutch plates 10 Nm (1.0 m·kg, 7.2 ft·lb) according to the installation order. NOTE: Tighten the clutch spring bolts in stages and in a crisscross pattern. 7. Install: • Friction plate 1 “1” NOTE: 10.
  • Page 253 CLUTCH 12. Tighten: • Clutch cover bolts “1” • Clutch cover bolt “2” Clutch cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Clutch cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) LOCTITE® NOTE: Tighten the clutch cover bolts in a stages and in a crisscross pattern.

  • Page 254: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Shift arm Refer to "ENGINE REMOVAL" on page 5-1 Clutch assembly Refer to "CLUTCH" on page 5-44. Circlip Washer Shift shaft Collar Shift shaft spring Washer Stopper screw...

  • Page 255: Removing The Shift Shaft

    SHIFT SHAFT EAS4C81008 REMOVING THE SHIFT SHAFT 1. Remove: • Clutch assembly Refer to "CLUTCH" on page 5-44 2. Remove: • Shift arm • Shift rod Refer to "ENGINE REMOVAL" on page 5-1 3. Remove: • Circlip “1” • Washer “2” (left side of the engine) EAS25420 CHECKING THE SHIFT SHAFT...
  • Page 256 SHIFT SHAFT • Stopper lever spring “3” 4. Install: • Shift rod • Shift arm Refer to "ENGINE REMOVAL" on page 5- 5. Install: • Clutch assembly Refer to "CLUTCH" on page 5-44. 2. Install: • Washer • Collar • Shift shaft spring “1” •...

  • Page 257: Oil Pump

    OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Side cowlings Refer to "GENERAL CHASSIS" on page 4-1. Lower cowlings Refer to "GENERAL CHASSIS" on page 4-1. Drain. Engine oil Refer to "CHANGING THE ENGINE OIL" on page 3-11.
  • Page 258 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Oil strainer Oil pipe Oil delivery pipe Relief valve assembly Oil/water pump assembly drive chain guide Collar Oil/water pump assembly drive sprocket Washer Oil/water pump assembly drive chain Dowel pin Oil/water pump assembly For installation, reverse the removal proce-...
  • Page 259 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil/water pump driven sprocket Collar Oil pump housing Bearing Oil pump outer rotor Oil pump inner rotor For assembly, reverse the disassembly pro- cedure. 5-59...

  • Page 260: Removing The Oil Pan

    OIL PUMP EAS24930 EAS24960 REMOVING THE OIL PAN CHECKING THE OIL PUMP 1. Remove: 1. Check: • Oil level switch “1” • Oil pump driven gear “1” • Oil pan “2” • Oil pump housing “2” Cracks/damage/wear → Replace the •...

  • Page 261: Checking The Relief Valve

    OIL PUMP EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes. 1. Check: • Oil delivery pipe “1” • Oil pipe “2” Damage → Replace. Obstruction → Wash and blow out with compressed air.

  • Page 262: Assembling The Oil Pump

    OIL PUMP • O-ring “2” Oil/water pump driven sprocket Damage/wear → Replace. bolt • Oil nozzle passage 15 Nm (1.5 m·kg, 11 ft·lb) Obstruction → Blow out with compressed LOCTITE® air. NOTE: 5VY mark of the oil/water pump driven gear is installed at oil pump side.

  • Page 263: Installing The Oil Pan

    OIL PUMP NOTE: Install the oil/water pump assembly drive chain “1” onto the oil/water pump assembly drive sprocket “2”. ECA4C81007 CAUTION: After installing the oil/water pump assem- bly drive chain and drive sprocket, make sure the oil/water pump turns smoothly. 5.
  • Page 264 OIL PUMP • Engine oil drain bolt Engine oil drain bolt 43 Nm (4.3 m·kg, 31 ft·lb) EWA12820 WARNING Always use new copper washers. NOTE: • Tighten the oil pan bolts in stages and in a crisscross pattern. • Lubricate the oil level switch O-ring with engine oil.

  • Page 265: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Air filter case Refer to "GENERAL CHASSIS" on page 4-1. Throttle body assembly Refer to "THROTTLE BODIES" on page 7-4. Engine Refer to "ENGINE REMOVAL" on page 5-1 Cylinder head Refer to "CYLINDER HEAD"...
  • Page 266 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Lower crankcase Dowel pin Damper For installation, reverse the removal proce- dure. 5-66...

  • Page 267: Disassembling The Crankcase

    Engine oil 2. Apply: 3. Remove: • Sealant • Lower crankcase ECA13900 Yamaha bond No. 1215 CAUTION: (Three bond No. 1215®) Tap on one side of the crankcase with a 90890-85505 soft-face hammer. Tap only on reinforced portions of the crankcase, not on the NOTE: crankcase mating surfaces.
  • Page 268 CRANKCASE Crankcase bolt Bolt “1”–“10” 1st: 20 Nm (2.0 m·kg, 14 ft·lb) 2nd*: 20 Nm (2.0 m·kg, 14 ft·lb) 3rd: +60° Bolt “11”–“16” 24 Nm (2.4 m·kg, 17 ft·lb) Bolt “17”–“26” 10 Nm (1.0 m·kg, 7.2 ft·lb) *Following the tightening order, loosen the 3.

  • Page 269: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to "CRANKCASE" on page 5-65. Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring...
  • Page 270 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to "CRANKCASE" on page 5-65. Refer to "REMOVING THE CONNECTING Connecting rod and connecting rod caps RODS AND PISTONS" on page 5-71. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Washer Crankshaft drive gear...

  • Page 271: Removing The Connecting Rods And Pistons

    CRANKSHAFT EAS26030 REMOVING THE CONNECTING RODS AND Piston pin puller set PISTONS 90890-01304 The following procedure applies to all of the Piston pin puller connecting rods and pistons. YU-01304 1. Remove: • Connecting rod cap “1” • Big end bearings NOTE: •...

  • Page 272: Checking The Cylinder And Piston

    CRANKSHAFT b. If out of specification, rebore or replace the NOTE: cylinder, and replace the piston and piston Identify the position of each crankshaft journal rings as a set. upper bearing so that it can be reinstalled in its c. Measure piston skirt diameter “P” with the original place.

  • Page 273: Checking The Piston Pin

    CRANKSHAFT Piston ring side clearance Piston ring end gap Top ring Top ring 0.030–0.065 (0.0012– 0.15–0.25 mm (0.0059–0.0098 0.0026 in) Limit Limit 0.115 mm (0.0045 in) 0.50 mm (0.0197 in) 2nd ring 2nd ring 0.020–0.055 (0.0008– 0.30–0.45 mm (0.0118–0.0177 0.0022 in) Limit Limit 0.115 mm (0.0045 in)

  • Page 274: Checking The Big End Bearings

    CRANKSHAFT a. Clean the big end bearings, crankshaft pins, and the inside of the connecting rods halves. b. Install the big end upper bearing into the connecting rod and the big end lower bear- ing into the connecting rod cap. NOTE: Align the projections “a”...
  • Page 275 CRANKSHAFT j. Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi- tion. k. Tighten the connecting rod bolts. Connecting rod bolt e.
  • Page 276 CRANKSHAFT p. After the installation, check that the section 2. Select: shown “a” is flush with each other by touch- • Big end bearings (P1 – P4) ing the surface. NOTE: • Side machined face “a” • The numbers “A” stamped into the crank- EW2D1008 shaft wed and the numbers “1”...

  • Page 277: Installing The Connecting Rod And Piston

    CRANKSHAFT EAS26190 (with the recommended lubricant) INSTALLING THE CONNECTING ROD AND PISTON Recommended lubricant The following procedure applies to all of the Engine oil connecting rods and pistons. 4. Offset: 1. Install: • Piston ring end gaps • Top ring “1” •...
  • Page 278 CRANKSHAFT 7. Install: NOTE: • Cylinder gasket “2” • Install by carrying out the following proce- dures in order to assemble in the most suit- able condition. • First tighten the bolts to 15 Nm (1.5 m·kg, 11 ft·lb) • Retighten the bolts to 29.4 Nm (3.0 m·kg, 21 ft·lb) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 279 CRANKSHAFT ECA14980 CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. a. Clean the connecting rod bolts. b. Tighten the connecting rod bolts. c. Put a mark “1” on the connecting rod bolt “2” and the connecting rod cap “3”. 11.

  • Page 280: Checking The Crankshaft

    CRANKSHAFT • If they are not flush with each other, remove the connecting rod bolt and big end bearing and restart from step “9”. In this case, make sure to replace the con- necting rod bolt. ECA14680 CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle.
  • Page 281 CRANKSHAFT Crankcase bolt Bolt “1”–“10” 1st: 20 Nm (2.0 m·kg, 14 ft·lb) 2nd: 20 Nm (2.0 m·kg, 14 ft·lb) 3rd: +60° Bolt “11”–“16” 24 Nm (2.4m·kg, 17 ft·lb) Bolt “17”–“26” 10 Nm (1.0m·kg, 7.2 ft·lb) M9 × 105 mm (4.1 in) bolts: “1”–“10” d.

  • Page 282: Installing The Crankshaft

    CRANKSHAFT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Select: • Crankshaft journal bearings (J1–J5) NOTE: • The numbers “A” stamped into the crank- shaft web and the numbers “1” stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. • “J1–J5” refer to the bearings shown in the crankshaft illustration.
  • Page 283 CRANKSHAFT NOTE: • Align the projections “a” on the crankshaft journal upper bearings with the notches “b” in the upper crankcase. • Be sure to install each crankshaft journal upper bearing in its original place. 3. Install: • Crankshaft 4. Install: •...

  • Page 284: Transmission

    TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Lower crankcase Refer to "CRANKCASE" on page 5-65. Drive axle assembly Circlip Oil seal Bearing Washer Shift fork guide bar retainer Spring Shift fork guide bar Shift fork-L...
  • Page 285 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-85...
  • Page 286 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Main axle Bearing housing Bearing For assembly, reverse the disassembly pro- cedure.
  • Page 287 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty 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 6th wheel gear Circlip Washer Collar...
  • Page 288 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks For assembly, reverse the disassembly pro- cedure. 5-88...

  • Page 289: Removing The Transmission

    TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainers “2” • Shift fork guide bars • Shift fork “L” and “R” • Shift drum assembly • Shift fork “C” EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks.

  • Page 290: Checking The Shift Drum Assembly

    TRANSMISSION 3. Check: • Shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift forks and shift fork guide bar as a set. 2. Measure: • Drive axle runout EAS26270 (with a centering device and dial gauge “1”) CHECKING THE SHIFT DRUM ASSEMBLY Out of specification →...
  • Page 291 TRANSMISSION EAS26350 INSTALLING THE TRANSMISSION 1. Install: • Bearing “1” NOTE: Make the seal side of bearing face to the out- side and install it close to the right end face of the crankcase. • Oil pipe “2” 3. Install: •...
  • Page 292 TRANSMISSION 4. Check: • Transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly. 5-92...
  • Page 293 TRANSMISSION 5-93...
  • Page 294 COOLING SYSTEM RADIATOR....................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR ..............6-3 OIL COOLER ....................6-4 CHECKING THE OIL COOLER..............6-5 INSTALLING THE OIL COOLER ............6-5 THERMOSTAT ....................6-6 CHECKING THE THERMOSTAT............6-7 ASSEMBLING THE THERMOSTAT ASSEMBLY ........6-8 INSTALLING THE THERMOSTAT ASSEMBLY ........6-8 WATER PUMP ....................6-9 DISASSEMBLING THE WATER PUMP..........6-10 CHECKING THE WATER PUMP ............6-10 ASSEMBLING THE WATER PUMP............6-10...
  • Page 295 RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Side cowling Refer to "GENERAL CHASSIS" on page 4-1. Drain. Coolant Refer to "CHANGING THE COOLANT" on page 3-19. Fuel tank Refer to "FUEL TANK"...
  • Page 296 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Radiator fan motor For installation, reverse the removal proce- dure.

  • Page 297: Cooling System

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.

  • Page 298: Oil Cooler

    OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to "CHANGING THE ENGINE OIL" on page 3-11. Drain. Coolant Refer to "CHANGING THE COOLANT" on page 3-19. Oil cooler inlet hose Oil cooler bolt Loosen.

  • Page 299: Checking The Oil Cooler

    OIL COOLER EAS26420 3. Fill: CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage → Replace. Refer to "CHANGING THE COOLANT" on page 3-19. • Crankcase (with the specified amount of the recom- mended engine oil) Refer to "CHANGING THE ENGINE OIL"...

  • Page 300: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly Order Job/Parts to remove Q’ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Air filter case Refer to "GENERAL CHASSIS" on page 4-1. Refer to "CHANGING THE COOLANT"...

  • Page 301: Checking The Thermostat

    THERMOSTAT Disassembling the thermostat assembly Order Job/Parts to remove Q’ty Remarks Thermostat housing cover Thermostat Thermostat housing O-ring For assembly, reverse the disassembly pro- cedure. EAS26450 d. While stirring the water, observe the ther- CHECKING THE THERMOSTAT mostat and thermometer’s indicated tem- 1.

  • Page 302: Assembling The Thermostat Assembly

    THERMOSTAT EAS26480 INSTALLING THE THERMOSTAT ASSEM- A. Fully closed 1. Fill: B. Fully open • Cooling system NOTE: (with the specified amount of the recom- If the accuracy of the thermostat is in doubt, mended coolant) replace it. A faulty thermostat could cause seri- Refer to "CHANGING THE COOLANT"...

  • Page 303: Water Pump

    WATER PUMP EAS26500 WATER PUMP Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Oil/water pump assembly Refer to "OIL PUMP" on page 5-57. Oil pump rotor Refer to "OIL PUMP" on page 5-57. Water pump cover O-ring Impeller shaft (along with the impeller) Water pump seal Oil seal Bearing...

  • Page 304: Disassembling The Water Pump

    WATER PUMP EAS26520 DISASSEMBLING THE WATER PUMP 1. Remove: • Water pump seal “1” • Water pump housing “2” NOTE: Tap out the bearing and oil seal from the out- side of the water pump housing. EAS26540 CHECKING THE WATER PUMP 1.
  • Page 305 4. Measure: tools. • Impeller shaft tilt • Before installing the water pump seal, apply Out of specification → Repeat steps (3) Yamaha bond No. 1215 (Three bond No. and (4). 1215®) “2” to the water pump housing “3”. ECA14090 CAUTION:...
  • Page 306 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 THROTTLE BODIES..................7-4 CHECKING THE INJECTORS ...............7-6 CHECKING THE THROTTLE BODIES ..........7-6 CHECKING THE FUEL PRESSURE............7-6 ADJUSTING THE THROTTLE POSITION SENSOR...
  • Page 307 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank side cover Fuel sender coupler Fuel pump coupler Fuel tank drain hose Fuel tank breather hose...

  • Page 308: Fuel Tank

    FUEL TANK EAS26630 ECA14720 REMOVING THE FUEL TANK CAUTION: 1. Extract the fuel in the fuel tank through the • Do not drop the fuel pump or give it a fuel tank cap with a pump. strong shock. 2. Remove: •...

  • Page 309: Installing The Fuel Tank

    FUEL TANK EAS4C81002 INSTALLING THE FUEL TANK 1. Install: • Fuel hose • Fuel hose connector cover ECA14740 CAUTION: When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct posi- tion, otherwise the fuel hose will not be properly installed.

  • Page 310: Throttle Bodies

    THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty Remarks Rider seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Air filter case Refer to "GENERAL CHASSIS" on page 4-1. Sub-wire harness coupler Disconnect.
  • Page 311 THROTTLE BODIES Removing the injectors Order Job/Parts to remove Q’ty Remarks Intake air pressure sensor coupler Disconnect. Cylinder #1-injector coupler Disconnect. Cylinder #2-injector coupler Disconnect. Cylinder #3-injector coupler Disconnect. Cylinder #4-injector coupler Disconnect. Sub-wire harness Negative pressure hose Disconnect. Intake air pressure sensor Fuel distributor Injector Throttle position sensor (for throttle valves)

  • Page 312: Checking The Injectors

    THROTTLE BODIES EAS26980 CHECKING THE INJECTORS 1. Check: • Injectors Damage → Replace. c. Connect the pressure gauge “2” and adapter “3” to the fuel hose (fuel tank to pri- mary injector fuel rail). EAS26990 CHECKING THE THROTTLE BODIES Pressure gauge 1.

  • Page 313: Adjusting The Throttle Position Sensor (For Throttle Cable Pulley)

    THROTTLE BODIES ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Throttle position sensor (for throttle cable a. Temporary tighten the throttle position sen- pulley) sor (for throttle valves). Refer to "ADJUSTING THE THROTTLE b. Check that the throttle valves are fully POSITION SENSOR (FOR THROTTLE closed. CABLE PULLEY)"...
  • Page 314 THROTTLE BODIES ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 315: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses Order Job/Parts to remove Q’ty Remarks Air cut-off valve coupler Disconnect. Air cut-off valve hose 1 Disconnect. Air cut-off valve hose 2 Disconnect. Air cut-off valve hose 3 Disconnect.

  • Page 316: Checking The Air Induction System

    AIR INDUCTION SYSTEM EAS27060 A. From the air cleaner CHECKING THE AIR INDUCTION SYSTEM B. To the cylinder head 1. Check: Air injection • Hoses The air induction system burns unburned Loose connections → Connect properly. exhaust gases by injecting fresh air (second- Cracks/damage →...
  • Page 317 AIR INDUCTION SYSTEM 7-11...
  • Page 318 ELECTRICAL SYSTEM IGNITION SYSTEM..................8-1 CIRCUIT DIAGRAM................8-1 TROUBLESHOOTING ................8-3 ELECTRIC STARTING SYSTEM..............8-5 CIRCUIT DIAGRAM................8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-7 TROUBLESHOOTING ................8-9 CHARGING SYSTEM .................8-11 CIRCUIT DIAGRAM................8-11 TROUBLESHOOTING ................8-13 LIGHTING SYSTEM ...................8-15 CIRCUIT DIAGRAM................8-15 TROUBLESHOOTING ................8-17 SIGNALING SYSTEM.................8-19 CIRCUIT DIAGRAM................8-19 TROUBLESHOOTING ................8-21 COOLING SYSTEM..................8-25 CIRCUIT DIAGRAM................8-25 TROUBLESHOOTING ................8-26...
  • Page 319 ELECTRICAL COMPONENTS..............8-77 CHECKING THE SWITCHES...............8-81 CHECKING THE BULBS AND BULB SOCKETS.........8-84 CHECKING THE FUSES..............8-85 CHECKING AND CHARGING THE BATTERY........8-85 CHECKING THE RELAYS..............8-88 CHECKING THE TURN SIGNAL RELAY ..........8-89 CHECKING THE RELAY UNIT (DIODE) ..........8-90 CHECKING THE IGNITION COILS ............8-91 CHECKING THE CRANKSHAFT POSITION SENSOR .......8-92 CHECKING THE LEAN ANGLE SENSOR ...........8-92 CHECKING THE STARTER MOTOR OPERATION......8-93 CHECKING THE STATOR COIL............8-93...

  • Page 320: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 321 IGNITION SYSTEM 1. Main switch 4. Main fuse 8. Battery 12.Starting circuit cut-off relay 13.Neutral switch 14.Sidestand switch 19.ECU (engine control unit) 20.Ignition coil #1 21.Ignition coil #2 22.Ignition coil #3 23.Ignition coil #4 24.Spark plug 35.Crankshaft position sensor 40.Lean angle sensor 58.Engine stop switch 64.Clutch switch 79.Ignition fuse...
  • Page 322 IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1 Rider seat 2 Passenger seat 3 Fuel tank 4 Side cowlings 1 Check the fuses. NG→ (Main and ignition) Replace the fuse(s).
  • Page 323 IGNITION SYSTEM 8 Check the engine stop switch. NG→ Refer to "CHECKING THE Replace the right handlebar switch. SWITCHES" on page 8-81. OK↓ 9 Check the neutral switch. NG→ Refer to "CHECKING THE Replace the neutral switch. SWITCHES" on page 8-81. OK↓...

  • Page 324: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 325 ELECTRIC STARTING SYSTEM 1. Main switch 4. Main fuse 8. Battery 10.Starter relay 11.Starter motor 12.Starting circuit cut-off relay 13.Neutral switch 14.Sidestand switch 58.Engine stop switch 59.Start switch 64.Clutch switch 79.Ignition fuse 88.Ground 89.Battery negative lead...
  • Page 326 ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 327 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.
  • Page 328 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider seat 2 Passenger seat 3 Fuel tank 4 Air filter case 1 Check the fuses. NG→ (Main and ignition) Replace the fuse(s).
  • Page 329 ELECTRIC STARTING SYSTEM 8 Check the engine stop switch. NG→ Refer to "CHECKING THE Replace the right handlebar switch. SWITCHES" on page 8-81. OK↓ 9 Check the neutral switch. NG→ Refer to "CHECKING THE Replace the neutral switch. SWITCHES" on page 8-81. OK↓...

  • Page 330: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11...
  • Page 331 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Main fuse 8. Battery 88.Ground 89.Battery negative lead 8-12...
  • Page 332 CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider seat 2 Fuel tank 3 Air filter case NG→ 1 Check the fuse. (Main) Replace the fuse. Refer to "CHECKING THE FUSES" on page 8-85.
  • Page 333 CHARGING SYSTEM 8-14...

  • Page 334: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15...
  • Page 335 LIGHTING SYSTEM 1. Main switch 4. Main fuse 8. Battery 19.ECU (engine control unit) 51.High beam indicator light 54.Meter light 62.Dimmer switch 71.Headlight 72.Auxiliary light 74.License plate light 76.Tail/brake light 77.Headlight relay (on/off) 78.Headlight relay (dimmer) 81.Headlight fuse 88.Ground 89.Battery negative lead 8-16...
  • Page 336 LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider seat 2 Fuel tank 3 Side cowlings 1 Check the each bulbs and bulb NG→...
  • Page 337 LIGHTING SYSTEM 8 Check the headlight relay (dimmer). NG→ Refer to "CHECKING THE Replace the headlight relay. RELAYS" on page 8-88. OK↓ 9 Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to "LIGHTING SYSTEM" on system’s wiring.

  • Page 338: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19...
  • Page 339 SIGNALING SYSTEM 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 12.Starting circuit cut-off relay 13.Neutral switch 15.Fuel pump 19.ECU (engine control unit) 33.Speed sensor 43.Fuel level warning light 44.Oil level warning light 45.Neutral indicator light 46.Tacho meter 47.Shift timing indicator light 48.Multi-function meter...
  • Page 340 SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider seat 2 Passenger seat 3 Fuel tank 4 Side cowling NG→...
  • Page 341 SIGNALING SYSTEM 3 Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to "SIGNALING SYSTEM" on ing system’s wiring. page 8-19. OK↓ This circuit is OK. The tail/brake light fails to come on. NG→ 1 Check the tail/brake light bulb and socket.
  • Page 342 SIGNALING SYSTEM 3 Check the turn signal relay. NG→ The turn signal relay is faulty and must Refer to "CHECKING THE be replaced. RELAYS" on page 8-88. OK↓ 4 Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to "SIGNALING SYSTEM"...
  • Page 343 SIGNALING SYSTEM 2 Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to "SIGNALING SYSTEM" on ing system’s wiring. page 8-19. OK↓ This circuit is OK. The speedometer fails to operate. NG→ 1 Check the speed sensor. Refer to "CHECKING THE SPEED Replace the speed sensor.
  • Page 344 COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-25...
  • Page 345 COOLING SYSTEM 84.Right radiator fan motor fuse 1. Main switch 85.Left radiator fan motor fuse 4. Main fuse 86.Right radiator fan motor 8. Battery 87.Left radiator fan motor 19.ECU (engine control unit) 88.Ground 36.Coolant temperature sensor 89.Battery negative lead 79.Ignition fuse 83.Radiator fan motor relay EAS27320 TROUBLESHOOTING...
  • Page 346 COOLING SYSTEM 7 Check the entire cooling system’s NG→ wiring. Properly connect or repair the cooling Refer to "COOLING SYSTEM" on system’s wiring. page 8-25. OK↓ This circuit is OK. 8-27...
  • Page 347 COOLING SYSTEM 8-28...

  • Page 348: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-29...
  • Page 349 FUEL INJECTION SYSTEM 1. Main switch 4. Main fuse 5. Backup fuse 8. Battery 9. Fuel injection system fuse 12.Starting circuit cut-off relay 13.Neutral switch 14.Sidestand switch 15.Fuel pump 16.Throttle position sensor (for throttle valves) 17.Throttle position sensor (for throttle cable pulley) 18.O sensor...
  • Page 350 FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 351 FUEL INJECTION SYSTEM a. Main switch “OFF” b. Main switch “ON” c. Engine trouble warning light off d. Engine trouble warning light on for 1.4 sec- onds EAS27362 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.
  • Page 352 FUEL INJECTION SYSTEM Able / Able / Fault Item Symptom unable to unable to code No. start drive Intake air pressure sensor-open or Intake air pressure short circuit detected. sensor Defective values are detected due Able Able Atmospheric pressure to the internal malfunction of the sensor intake air pressure sensor or the Atmospheric pressure sensor.
  • Page 353 FUEL INJECTION SYSTEM Able / Able / Fault Item Symptom unable to unable to code No. start drive The ECU is unable to monitor the Fuel system voltage battery voltage Able Able (monitor voltage) (an open circuit in the line to the ECU).
  • Page 354 FUEL INJECTION SYSTEM EAS27400 The engine operation is not normal but the TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1. Check the operation of following sensors engine trouble warning light comes on. and actuators in the Diagnostic mode.
  • Page 355 FUEL INJECTION SYSTEM EAS27421 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ON”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.
  • Page 356 FUEL INJECTION SYSTEM NOTE: If the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ ” again. 9. Turn the main switch to “OFF” to cancel the diagnostic mode. Fault code table Fault Diagnostic code...
  • Page 357 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Atmospheric pressure sensor hose is clogged. When the main switch is • Intake air pressure sensor hose is clogged, turned to “ON”, the atmo- kinked, or pinched. spheric pressure sensor •...
  • Page 358 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Lean angle sensor: • Open or short circuit in wire harness. open or short circuit • Defective lean angle sensor. detected. • Malfunction in ECU. No normal signals are •...
  • Page 359 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Improper connection in wire harness. Data from the ECU cannot Er-3 • Malfunction in meter. — be received correctly. • Malfunction in ECU. Non-registered data has •...
  • Page 360 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Fuel system voltage Approximately 12.0 Set the engine stop switch (battery voltage) to “ ”, and then compare with the actually measured battery voltage. (If the bat- tery voltage is lower, recharge the battery.) Throttle position sensor (for throttle valves) signal 2...
  • Page 361 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction history code — • No history • History exists 11-60 (Fault detection code) • (If more than one code number is detected, the dis- play changes every two seconds to show all the detected code numbers.
  • Page 362 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the cylinder-#2 igni- tion coil five times at one-sec- Check the spark five times. Cylinder-#2 ignition coil ond intervals. • Connect an ignition Illuminates the engine trou- checker. ble warning light. Actuates the cylinder-#3 igni- tion coil five times at one-sec- Check the spark five times.
  • Page 363 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the fuel injection system relay five times at one-second intervals. Illuminates the engine trou- Check the operating sound ble warning light. Fuel injection system relay of the fuel injection system (The engine trouble warning relay five times.
  • Page 364 FUEL INJECTION SYSTEM No normal signals are received from the cylinder identifi- Fault code No. Symptom cation sensor when the engine is started or while the vehicle is being driven. Diagnostic code No. — — Orde Item/components and probable Reinstatement Check or maintenance job cause method...
  • Page 365 FUEL INJECTION SYSTEM No normal signals are received from the crankshaft posi- Fault code No. Symptom tion sensor. Diagnostic code No. — — Orde Item/components and probable Reinstatement Check or maintenance job cause method Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the tion sensor engine.
  • Page 366 FUEL INJECTION SYSTEM Intake air pressure sensor: hose system malfunction Fault code No. Symptom (clogged or detached hose). Diagnostic code No. Intake air pressure sensor Orde Item/components and probable Reinstatement Check or maintenance job cause method Intake air pressure sensor hose •...
  • Page 367 FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor circuit: open or short circuit detected. Diagnostic code No. EXUP servo motor Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections • Check the coupler for any pins Reinstated •...
  • Page 368 FUEL INJECTION SYSTEM Open circuit is detected in the input line from the side- Fault code No. Symptom stand switch to the ECU. Diagnostic code No. Sidestand switch Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections •...
  • Page 369 FUEL INJECTION SYSTEM Coolant temperature sensor: open or short circuit Fault code No. Symptom detected. Diagnostic code No. Coolant temperature sensor Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections • Check the coupler for any pins Reinstated •...
  • Page 370 FUEL INJECTION SYSTEM Atmospheric pressure sensor: open or short circuit Fault code No. Symptom detected. Diagnostic code No. Atmospheric pressure sensor Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections • Check the coupler for any pins Reinstated •...
  • Page 371 FUEL INJECTION SYSTEM Latch up detected. Fault code No. Symptom No normal signal is received from the lean angle sensor. Diagnostic code No. Lean angle sensor Orde Item/components and probable Reinstatement Check or maintenance job cause method The vehicle has overturned. Raise the vehicle upright.
  • Page 372 FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. Symptom #2 ignition coil. Diagnostic code No. Cylinder-#2 ignition coil Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections • Check the couplers for any pins Cranking the •...
  • Page 373 FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. Symptom #3 ignition coil. Diagnostic code No. Cylinder-#3 ignition coil Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections • Check the couplers for any pins Cranking the •...
  • Page 374 FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. Symptom #4 ignition coil. Diagnostic code No. Cylinder-#4 ignition coil Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections • Check the couplers for any pins Cranking the •...
  • Page 375 FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit detected in injector. Injector #1 Injector #2 Diagnostic code No. Injector #3 Injector #4 Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections • Check the couplers for any pins Cranking the •...
  • Page 376 FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections • Check the coupler for any pins Reinstated •...
  • Page 377 FUEL INJECTION SYSTEM ANo normal signals are received from the speed sensor. Fault code No. Symptom BOpen circuit is detected in the neutral switch. Speed sensor Diagnostic code No. Neutral switch Orde Item/components and probable Reinstatement Check or maintenance job cause method Installed state of speed sensor.
  • Page 378 FUEL INJECTION SYSTEM Power supply to the injectors and fuel pump is not nor- Fault code No. Symptom mal. Diagnostic code No. Fuel system voltage (battery voltage) Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections • Check the coupler for any pins Turning the •...
  • Page 379 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply is not normal. Diagnostic code No. — — Orde Item/components and probable Reinstatement Check or maintenance job cause method Malfunction in rectifier/regulator • Replace if defective. Starting the Refer to "CHARGING SYS- engine and TEM"...
  • Page 380 FUEL INJECTION SYSTEM Throttle position sensor (for throttle cable pulley): open or short circuit detected. Fault code No. Symptom Throttle position sensor (for throttle cable pulley): cou- pler connection is loose. Throttle position sensor (for throttle cable pulley) signal 1 Diagnostic code No.
  • Page 381 FUEL INJECTION SYSTEM Throttle servo motor: open or short circuit detected. Fault code No. Symptom Defective throttle servo motor. Malfunction in ECU (servo motor driving system). Throttle position sensor (for throttle valves) signal 1 Diagnostic code No. Throttle position sensor (for throttle valves) signal 2 Orde Item/components and probable Reinstatement...
  • Page 382 FUEL INJECTION SYSTEM No signals are received from the ECU within the specified Fault code No. Er-2 Symptom duration. Diagnostic code No. — — Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections • Check the coupler for any pins Turning the •...
  • Page 383 FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Diagnostic code No. — — Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •...

  • Page 384: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-65...
  • Page 385 FUEL PUMP SYSTEM 1. Main switch 4. Main fuse 8. Battery 9. Fuel injection system fuse 12.Starting circuit cut-off relay 15.Fuel pump 19.ECU (engine control unit) 48.Multi-function meter 58.Engine stop switch 79.Ignition fuse 88.Ground 89.Battery negative lead 8-66...
  • Page 386 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider seat 2 Passenger seat 3 Fuel tank 4 Side cowlings 1 Check the fuses. NG→ (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 387 FUEL PUMP SYSTEM 7 Check the entire fuel pump sys- NG→ tem’s wiring. Properly connect or repair the fuel Refer to "FUEL PUMP SYSTEM" pump system’s wiring. on page 8-65. OK↓ Replace the ECU. 8-68...

  • Page 388: Immobilizer System

    IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-69...
  • Page 389 IMMOBILIZER SYSTEM 1. Main switch 4. Main fuse 5. Backup fuse 6. Immobilizer unit 8. Battery 19.ECU (engine control unit) 42.Immobilizer system indicator light 48.Multi-function meter 79.Ignition fuse 88.Ground 89.Battery negative lead 8-70...
  • Page 390 IMMOBILIZER SYSTEM EAS27671 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that can be re-registered with new codes •...
  • Page 391 IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration Acces- bilizer unit Standard requirement sory lock* Main Immobi- and key switch lizer unit √ Standard key is lost New standard key All keys have been Code re-registering √ √ √...
  • Page 392 IMMOBILIZER SYSTEM e. Standby mode on f. Standby mode off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. NOTE: Do not start the engine with a standard key that has not been registered.
  • Page 393 IMMOBILIZER SYSTEM Voiding the standard key code: If a standard key has been lost, it is possible to disable its use by re-registering the remaining stan- dard key. Standard key registration erases the stored standard key code from the memory, thus dis- abling the lost standard key.To re-register, refer to “Standard key registration”.
  • Page 394 IMMOBILIZER SYSTEM 4 Check the entire immobilizer sys- NG→ tem wiring. Properly connect or repair the immobi- Refer to "IMMOBILIZER SYSTEM" lizer system wiring. on page 8-69. OK↓ • Check the condition of the each immobilizer system circuits. • Refer to "SELF-DIAGNOSIS FAULT CODE INDICATION"...
  • Page 395 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Codes transmitted Noise interference or dis- 1 Register the code UNIT between the ECU connected lead/cable. re-registering key. and the immobilizer 1 Interference due to 2 Check the wire unit do not match. radio wave noise.
  • Page 396 ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-77...
  • Page 397 ELECTRICAL COMPONENTS 1. Main switch 2. Immobilizer unit 3. Front brake light switch 4. Clutch switch 5. Fuel injection system fuse 6. Starter relay 7. Battery 8. Main fuse 9. Neutral switch 10.Rear brake light switch 11.EXUP servo motor 12.Sidestand switch 13.O sensor 14.Speed sensor...
  • Page 398 ELECTRICAL COMPONENTS 8-79...
  • Page 399 ELECTRICAL COMPONENTS 1. Air temperature sensor 2. Atmospheric pressure sensor 3. Fuel pump 4. Coolant temperature sensor 5. Starting circuit cut-off relay 6. Turn signal relay 7. ECU (engine control unit) 8. Lean angle sensor 9. Crankshaft position sensor 10.Intake air pressure sensor 11.Throttle servo motor 12.Throttle position sensor (for throttle cable pulley)

  • Page 400: Electrical Components

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-81...
  • Page 401 ELECTRICAL COMPONENTS 1. Main switch 2. Horn switch 3. Dimmer switch 4. Turn signal switch 5. Clutch switch 6. Sidestand switch 7. Engine stop switch 8. Front brake light switch 9. Start switch 10.Oil level switch 11.Neutral switch 12.Rear brake light switch 8-82...
  • Page 402 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
  • Page 403 ELECTRICAL COMPONENTS EAS27990 wise the transparency of the glass, the CHECKING THE BULBS AND BULB SOCK- life of the bulb, and the luminous flux will be adversely affected. If the headlight Check each bulb and bulb socket for damage bulb gets soiled, thoroughly it with a cloth or wear, proper connections, and also for conti- moistened with alcohol or lacquer thin- nuity between the terminals.
  • Page 404 ELECTRICAL COMPONENTS d. If the fuse immediately blows again, check NOTE: the electrical circuit. Check each bulb socket for continuity in the same manner as described in the bulb section; Amperage Fuses Q’ty however, note the following. rating Main 50 A ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 405 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 406 ELECTRICAL COMPONENTS • Do not use a high-rate battery charger NOTE: since it forces a high-amperage current Set the charging voltage at 16–17 V.If the set- into the battery quickly and can cause ting is lower, charging will be insufficient. If too battery overheating and battery plate high, the battery will be over-charged.
  • Page 407 ELECTRICAL COMPONENTS c. Make sure that the current is higher than Pocket tester the standard charging current written on 90890-03112 the battery. Analog pocket tester NOTE: YU-03112-C If the current is lower than the standard charg- 1. Disconnect the relay from the wire harness. ing current written on the battery, This type of 2.
  • Page 408 ELECTRICAL COMPONENTS Relay unit (fuel pump relay) 4. Negative tester probe Result Continuity/No continuity Radiator fan motor relay 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity/No continuity 1. Positive battery terminal Headlight relay (on/off) 2.
  • Page 409 ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C Continuity Positive tester probe → Sky b. Turn the main switch to “ON”. blue “1” → c. Measure the turn signal relay input voltage. Negative tester probe Black/Yellow “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ No continuity 2.
  • Page 410 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ c. Measure the primary coil resistance. a. Disconnect the relay unit coupler from the wire harness. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Connect the pocket tester (Ω × 1) to the 2. Check: relay unit terminal as shown. • Secondary coil resistance c.
  • Page 411 ELECTRICAL COMPONENTS Pocket tester Minimum ignition spark gap 90890-03112 6.0 mm (0.24 in) Analog pocket tester ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ YU-03112-C a. Disconnect the ignition coil from the spark plug. • Positive tester probe b. Connect the ignition checker/dynamic Gray “1” spark tester “2” as shown. •...
  • Page 412 ELECTRICAL COMPONENTS EAS28150 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the rectifier/regulator) 2. Check: • Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.14–0.18 Ω at 20°C (68°F) c. When turn the lean angle sensor to 65°. d.
  • Page 413 ELECTRICAL COMPONENTS • Positive tester probe Charging voltage Horn terminal “1” 14 V at 5000 r/min • Negative tester probe Horn terminal “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachometer to the ignition coil of cylinder #1. b. Connect the pocket tester (AC 20 V) to the rectifier/regulator coupler as shown.
  • Page 414 ELECTRICAL COMPONENTS 4. Check: Oil level switch • Fuel sender resistance Maximum level position resis- tance Fuel sender resistance 484–536 Ω at 20°C (68°F) 19–141Ω at 20°C (68°F) Minimum level position resis- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ tance a. Connect the pocket tester (Ω × 1) to the 114–126 Ω...
  • Page 415 ELECTRICAL COMPONENTS • Never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor is dropped, replace it. 2. Check: • Coolant temperature sensor resistance Out of specification → Replace. b. Set the main switch to “ON”. Coolant temperature sensor...
  • Page 416 ELECTRICAL COMPONENTS d. Slowly heat the coolant, and then let it cool b. Measure the throttle position sensor (for to the specified temperature indicated in throttle cable pulley) maximum resistance. the table. e. Check the coolant temperature sensor for ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ continuity at the temperatures indicated in 3.
  • Page 417 ELECTRICAL COMPONENTS c. Measure the air induction system solenoid resistance. b. Measure the throttle position sensor (for ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ throttle valves) maximum resistance. EAS28380 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE ATMOSPHERIC PRES- 3. Install: SURE SENSOR • Throttle position sensor (for throttle valves) 1. Check: •...
  • Page 418 ELECTRICAL COMPONENTS EAS28390 CHECKING THE CYLINDER IDENTIFICA- Intake air pressure sensor out- TION SENSOR put voltage 1. Check: 3.15–4.15 V • Cylinder identification sensor output volt- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the Out of specification → Replace. intake air pressure sensor coupler (wire Cylinder identification...
  • Page 419 ELECTRICAL COMPONENTS Intake pressure sensor resistance 2.21–2.69 kΩ at 20°C (68°F) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 100) to the intake air temperature sensor terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe Brown/White “1”...
  • Page 420 ELECTRICAL COMPONENTS 8-101...
  • Page 421 TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED ..........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING ..............9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ...................9-2 OVERHEATING ..................9-2 OVERCOOLING ..................9-3 POOR BRAKING PERFORMANCE ............9-3 FAULTY FRONT FORK LEGS ..............9-3 UNSTABLE HANDLING................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........9-4...

  • Page 422: Troubleshooting

    TROUBLESHOOTING EAS28450 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) NOTE: • Blown, damaged or incorrect fuse The following guide for troubleshooting does • Improperly installed fuse not cover all the possible causes of trouble. It 3.
  • Page 423 TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •...
  • Page 424 TROUBLESHOOTING • Incorrect oil viscosity • Oil or grease on the brake disc • Inferior oil quality • Oil or grease on the brake pad • Incorrect brake fluid level Cooling system 1. Coolant EAS28650 FAULTY FRONT FORK LEGS • Low coolant level 2.
  • Page 425 TROUBLESHOOTING 7. Wheel(s) • Incorrect turn signal bulb • Incorrect wheel balance Turn signal remains lit • Deformed cast wheel • Faulty turn signal relay • Damaged wheel bearing • Burnt-out turn signal bulb • Bent or loose wheel axle •...

  • Page 426: Wiring Diagram

    EAS28740 54. Meter light Br/G Brown/Green WIRING DIAGRAM 55. Oil level switch Br/L Brown/Blue 56. Right handlebar switch YZFR1W Br/R Brown/Red 57. Front brake light switch 1. Main switch Br/W Brown/White 58. Engine stop switch 2. AC magneto Green/Black 59. Start switch 3.
  • Page 427 YZFR1W 2007 YZFR1W 2007 WIRING DIAGRAM SCHEMA DE CABLAGE O/B L/B G/B R/B Gy/R Gy/R O R/BO/G Dg L/R B/W G/W Gy/G Br/R W/B Br/R L Gy/G L/W R/G Y/L Ch B Sb/W L/R Sb/W Dg Ch B Y/B Br...
  • Page 428 YZFR1W 2007 YZFR1W 2007 WIRING DIAGRAM SCHEMA DE CABLAGE REAR TURN SIGNAL HEADLIGHT WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS LIGHT LEAD COUPLER SUB-WIRE HARNESS FREE PUSH...
  • Page 429 Yamaha Motor Canada Ltd. 480 Gordon Baker Road Toronto, ON M2H 3B4...

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