Yamaha FZ6-SS Service Manual

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  • Page 2 EAS00010 FZ6-SS/FZ6-SSC SERVICE MANUAL 2003 by Yamaha Motor Corporation, U.S.A. First edition, November 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-17-50...
  • Page 3: Important Manual Information

    If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 4: How To Use This Manual

    EAS00007 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. 1 The manual is divided into chapters.
  • Page 5: Specifications

    EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system COOL 7 Fuel injection system 8 Electrical system...
  • Page 6: Table Of Contents

    EAS00012 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 7 CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ......VEHICLE IDENTIFICATION NUMBER ......MODEL LABEL .
  • Page 8 ENGINE OIL LUBRICATION CHART ......2-29 LUBRICATION DIAGRAMS ........2-30 CABLE ROUTING .
  • Page 9 CHASSIS ........... . 3-41 ADJUSTING THE FRONT BRAKE .
  • Page 10 FRONT AND REAR BRAKES ........4-16 FRONT BRAKE PADS .
  • Page 11 SWINGARM AND DRIVE CHAIN ....... 4-68 REMOVING THE SWINGARM ....... 4-70 REMOVING THE DRIVE CHAIN .
  • Page 12 SHIFT SHAFT ..........5-39 SHIFT SHAFT AND STOPPER LEVER .
  • Page 13 CONNECTING RODS AND PISTONS ......5-67 REMOVING THE CONNECTING RODS AND PISTONS ..5-68 REMOVING THE CRANKSHAFT ASSEMBLY .
  • Page 14 CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM ........WIRING DIAGRAM .
  • Page 15: Troubleshooting

    ELECTRIC STARTING SYSTEM ....... . 8-14 CIRCUIT DIAGRAM ........8-14 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .
  • Page 16 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ... . ENGINE ..........FUEL SYSTEM .
  • Page 17: Gen Info

    MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
  • Page 18: Features

    FEATURES INFO EAS00896 FEATURES OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
  • Page 19: Fi System

    FEATURES INFO EAS00897 FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 250 kPa (2.5 kg/cm ). Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
  • Page 20: Instrument Function

    FEATURES INFO INSTRUMENT FUNCTION Multi-function display The multi-function display is equipped with the following: S a speedometer (which shows the riding speed) S an odometer (which shows the total distance traveled) S two tripmeters (which show the distance traveled since they were last set to zero) S a fuel reserve tripmeter (which shows the 1 Multi-function display distance traveled since the bottom segment...
  • Page 21 FEATURES INFO Clock mode To set the clock: 1. Push the “SELECT” button and “RESET” button together for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button to set the hours. 3. Push the “SELECT” button, and the minute digits will start flashing. 4.
  • Page 22: Important Information

    5. Keep all parts away from any source of fire. EAS00021 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 23: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the...
  • Page 24: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead S coupler S connector 2. Check: S lead S coupler S connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect sev- eral times.
  • Page 25: Special Tools

    SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 26 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Oil filter wrench 90890-01426 YU-38411 This tool is needed to loosen or tighten the oil filter cartridge. Fork seal driver Fork seal driver weight 90890-01367 Fork seal driver attachment YM-33963 Fork seal driver attachment This tool is used to install the front fork’s oil 90890-01374...
  • Page 27 This tool is used to check the ignition system components. Vacuum/pressure pump gauge set 90890-06756 YB-35956 This tool used to measure the vacuum pres- sure. Yamaha bond No. 1215 90890-85505 ACC-11001- 05-01 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces). 1-11...
  • Page 28: Spec

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5VX3 (USA except for CAL) 5VX4 (CAL) Dimensions Overall length 2,095 mm (82.5 in) Overall width 750 mm (29.5 in) Overall height 1,215 mm (47.8 in) Seat height 795 mm (31.3 in) Wheelbase 1,440 mm (56.7 in) Minimum ground clearance...
  • Page 29: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC Displacement 600 cm (36.61 cu.in) Cylinder arrangement Forward-inclined parallel 4-cylinder Bore stroke 65.5 44.5 mm (2.58 1.75 in) Compression ratio 12.2 : 1 1,250 X 1,350 r/min Engine idling speed Vacuum pressure at engine idling 29 kPa (218 mmHg, 8.6 inHg)
  • Page 30 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Formed 80 X 120 kPa (0.8 X 1.2 kg/cm Bypass valve opening pressure 0.8 X 1.2 bar, 11.6 X 17.4 psi) Oil pump Oil pump type Trochoid 0.03 X 0.09 mm Inner-rotor-to-outer-rotor-tip 0.15 mm (0.0012 X 0.0035 in)
  • Page 31 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) 23.008 X 23.029 mm (0.9058 X 0.9067 in) Camshaft cap inside diameter 22.967 X 22.980 mm (0.9042 X 0.9047 in) Camshaft journal diameter 0.028 X 0.062 mm (0.0011 X 0.0024 in) Camshaft-journal-to-camshaft- 0.08 mm cap clearance...
  • Page 32 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links 92RH2015 /120 Tensioning system Automatic Valves, valve seats, valve guides Valve clearance (cold) 0.13 X 0.20 mm (0.0051 X 0.0079 in) Intake 0.23 X 0.30 mm (0.0091 X 0.0118 in) Exhaust Valve dimensions Head Diameter...
  • Page 33 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Free length Intake (inner) 37.0 mm (1.46 in) 35.2 mm (1.39 in) Intake (outer) 38.4 mm (1.51 in) 36.5 mm (1.44 in) Exhaust 41.8 mm (1.65 in) 39.7 mm (1.56 in) Installed length (valve closed) Intake (inner) 30 mm (1.18 in) Intake...
  • Page 34 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston 0.010 X 0.035 mm (0.0004 X 0.0014 in) Piston-to-cylinder clearance 0.055 mm (0.0022 in) 65.475 X 65.490 mm (2.5778 X 2.5783 in) Diameter D Height H 4 mm (0.16 in) Piston pin bore (in the piston) 16.002 X 16.013 mm Diameter 16.043 mm...
  • Page 35 SPEC ENGINE SPECIFICATIONS Item Standard Limit Connecting rods 0.028 X 0.052 mm (0.0011 X 0.0020 in) Crankshaft-pin-to-big-end-bearing 0.08 mm clearance (0.0032 in) Bearing color code 1 = Blue 2 = Black 3 = Brown 4 = Green Crankshaft 51.85 X 52.55 mm (2.04 X 2.06 in) Width A 268.8 X 270.0 mm (10.58 X 10.63 in) Width B...
  • Page 36 SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Transmission type Constant mesh, 6-speed Primary reduction system Spur gear Primary reduction ratio 86/44 (1.955) Secondary reduction system Chain drive Secondary reduction ratio 46/16 (2.875) Operation Left-foot operation Gear ratios 1st gear 37/13 (2.846) 2nd gear 37/19 (1.947) 3rd gear...
  • Page 37: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond Caster angle Trail 97.5 mm (3.84 in) Front wheel Wheel type Cast wheel Size 17 M/C MT3.50 Material Aluminum Wheel travel 130 mm (5.12 in) Wheel runout Max. radial wheel runout 1 mm (0.04 in) Max.
  • Page 38 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless Size 180/55 ZR17 M/C (73W) Model (manufacturer) BT020R GG (BRIDGESTONE) D252 (DUNLOP) Tire pressure (cold) 0 X 90 kg (0 X 198 lb) 250 kPa (2.5 kgf/cm , 2.5 bar, 35.6 psi) 90 X 190 kg (198 X 419 lb) 290 kPa (2.9 kgf/cm , 2.9 bar, 41.3 psi)
  • Page 39 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Suspension type Telescopic fork Front fork type Coil spring/oil damper Front fork travel 130 mm (5.12 in) Spring Free length 354.0 mm (13.94 in) 347 mm (13.66 in) Spacer length 131.5 mm (5.18 in) Installed length 347.0 mm (13.66 in) Spring rate (K1)
  • Page 40 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Angular bearing Rear suspension Suspension type Swingarm (monocross) Rear shock absorber assembly Coil spring/gas-oil damper type Rear shock absorber assembly 50 mm (1.97 in) travel Spring Free length 185.0 mm (7.28 in) Installed length 172.0 mm (6.77 in) Spring rate (K1)
  • Page 41: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V Ignition system Ignition system type DC. T.C.I. Ignition timing 5_ BTDC at 1,300 r/min Advancer type Digital 248 X 372 Ω at 20_C (68_F)/Gy-B Crankshaft position sensor resistance/color T.C.I.
  • Page 42 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Indicator light (voltage /wattage quantity) Neutral indicator light High beam indicator light Oil level warning light Turn signal indicator light Engine trouble warning light Electric starting system System type Constant mesh Starter motor Model (manufacturer) SM-14 (MITSUBA) Power output 0.6 kW...
  • Page 43 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuses (amperage quantity) Main fuse 30 A Fuel injection system fuse 10 A Headlight fuse 20 A Signaling system fuse 10 A Ignition fuse 10 A Radiator fan motor fuse 20 A Backup fuse (odometer and clock) 10 A Taillight fuse 10 A...
  • Page 44: Conversion Table

    CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are SPECIFICATIONS listed in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC dard fasteners with a standard ISO thread unit data to IMPERIAL unit data.
  • Page 45: Tightening Torques

    Bolt Camshaft caps Bolt Cylinder head cover Bolt Camshaft cap oil check bolt Bolt Air indication system reed valve Bolt Yamaha bond No.1215 cover Air-cut valve stay Bolt Camshaft sprockets Bolt Connecting rod caps (except for CAL) 15 + 150_ 1.5 + 150_...
  • Page 46 Crankcase Bolt Crankcase Bolt Crankcase Bolt Generator rotor cover Bolt Clutch cover Bolt Clutch cover Bolt Yamaha bond No.1215 Pickup coil rotor cover Bolt Clutch cable holder Bolt Pickup coil rotor cover Bolt Shift shaft cover Bolt Breather plate Screw...
  • Page 47 SPEC TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence. 2-20...
  • Page 48: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Thread Item Item Remarks Remarks size mSkg ftSlb Upper bracket pinch bolt Steering stem nut Upper bracket and upper handlebar holder Under bracket pinch bolt – Lower ring nut See NOTE 1 Front fork cap bolt Damper rod assembly bolt Pinch bolt (front wheel axle) Front brake master cylinder and master cylinder...
  • Page 49 SPEC TIGHTENING TORQUES Tightening Thread Item Item Remarks Remarks size mSkg ftSlb Side cover and rear frame Rear mud guard and rear frame Engine stop switch and frame Coolant reserver tank bracket and stay 1, 2 Stay 1, 2 and frame Coolant reserver tank bracket and coolant reserver tank Canister and canister bracket (for CAL)
  • Page 50: Lubrication Points And Lubricant Types

    Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Yamaha bond Cylinder head cover mating surface No.1215 Yamaha bond Cylinder head cover semicircular No.1215 Yamaha bond Crankcase mating surface No.1215...
  • Page 51: Chassis

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Sidestand pivoting point and metal-to-metal moving parts Link and sidestand switch contact point...
  • Page 52: Cooling System Diagrams

    SPEC COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS Radiator Oil cooler 2-25...
  • Page 53 SPEC COOLING SYSTEM DIAGRAMS Water pump Oil cooler Radiator 2-26...
  • Page 54 SPEC COOLING SYSTEM DIAGRAMS Oil cooler Water pump 2-27...
  • Page 55 SPEC COOLING SYSTEM DIAGRAMS Radiator Thermostat 2-28...
  • Page 56: Engine Oil Lubrication Chart

    SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART 2-29...
  • Page 57: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Oil level switch Oil cooler Relief valve 2-30...
  • Page 58 SPEC LUBRICATION DIAGRAMS Oil pump Exhaust camshaft Intake camshaft Oil strainer 2-31...
  • Page 59 SPEC LUBRICATION DIAGRAMS Oil cooler Oil strainer Oil level switch Oil pump 2-32...
  • Page 60 SPEC LUBRICATION DIAGRAMS Main axle Oil pump Relief valve 2-33...
  • Page 61 SPEC LUBRICATION DIAGRAMS Cylinder head Intake camshaft Exhaust camshaft Crankshaft 2-34...
  • Page 62 SPEC LUBRICATION DIAGRAMS Main axle Drive axle 2-35...
  • Page 63: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Left handlebar switch lead A Clamp the right and left handlebar switch leads and Main switch lead handlebars. Point the tip of the clamp downward in Clutch cable front of the handlebars. Throttle cables B Clamp the horn lead and main switch lead to the in- Right handlebar switch lead ner tube.
  • Page 64 SPEC CABLE ROUTING F Clamp the brake hose to the inner tube. Point the binding section to the outside of the vehicle body and cut the tip down to the length of 1 to 5 mm (0.04 to 0.20 in). G Pass the throttle cables through the wire guide.
  • Page 65 SPEC CABLE ROUTING Right handlebar switch lead D Route the radiator hoses (2 pieces) under the cover Rear brake light switch lead Neutral switch lead E Route the crank shaft position sensor lead inner Fuel tank breather hose side of the radiator hose. Crankshaft position sensor lead F Pull down the mark-painted sections of the fuel tank breather hose, fuel tank drain hose and coolant res-...
  • Page 66 SPEC CABLE ROUTING I Pass the neutral switch lead between the engine and coolant reservoir tank bracket. J To the starter motor. K Install the right handlebar switch lead coupler through the hole of the bracket 2 from the downside. L Route the starter motor lead by the inner side of the air cut-off valve hose.
  • Page 67 SPEC CABLE ROUTING Main switch lead License plate light lead Stay assembly Rear turn signal light lead (right) Left handlebar switch lead Rear turn signal light lead (left) Clutch cable Speed sensor lead Throttle cables Side stand switch lead Battery negative lead coupler Oil level switch lead Starter relay lead A.C.
  • Page 68 SPEC CABLE ROUTING A Route the throttle cables above the stay assy 1. K Clamp the rear turn signal lead and license plate B Route the main switch lead above the clutch cable. light lead to the frame. Hook the clamp to the brack- C Line up the left handlebar switch lead coupler and et.
  • Page 69 SPEC CABLE ROUTING R To the rear turn signal light (left) X Make sure to pass the neutral switch lead through S Pass the fuel tank drain hose through the clamp lo- the hole of the flap. cated under the coolant reservoir tank. Y Clamp the seat lock wire to the frame as shown in T Route it behind the starter motor lead.
  • Page 70 SPEC CABLE ROUTING Right handlebar switch lead Seat lock cable Throttle cables Rectifier/regulator Battery positive lead E.C.U Coolant reservoir tank hose Fuel tank drain hose Battery cover Cover Connecter cover Starter relay lead Fuel tank breather hose Battery negative lead Brake fluid reservoir hose Battery negative lead coupler Lean angle cut-off switch...
  • Page 71 SPEC CABLE ROUTING A Either right or left side arrangement for the left han- H Set the 4-pin coupler in the connector cover after dlebar switch lead coupler and radiator fan motor wiring it. coupler can be accepted. I To the sidestand switch. B Point the L-shape terminal to the front side of the ve- J To the speed sensor.
  • Page 72 SPEC CABLE ROUTING S To the license plate light. AD Press the battery negative lead into the space be- T To the tail/brake light. tween the ribs of the frame. U Insert the enwinding clamp of the wire harness into AE Pass the spark plug leads #1 and #4 through the the hole of the rear frame.
  • Page 73 SPEC CABLE ROUTING AL Route the spark plug lead #4 by the front side of the spark plug leads #2 and #3. AM Route the spark plug leads #2 and #3 behind the air cut-off valve hose. 2-46...
  • Page 74 SPEC CABLE ROUTING Fuel pump assembly a Fuel piping connector attachment directions. (fuel Fuel tank breather hose (except for CAL) pump side) Fuel tank drain hose 1. It is inserted until it makes a click sound the connec- Fuel hose tor, and it checks that a connector does not fail out.
  • Page 75 SPEC CABLE ROUTING except for CAL A Front side. Coolant breather hose B Pass the coolant reservoir tank hose hangs down Coolant reservoir tank downward from back of the bolt. Coolant reservoir tank hose C Insert this portion securely. Clamp D Spittle is turned back.
  • Page 76 SPEC CABLE ROUTING for CAL A Front side. Clip B Point the paint marking upward. Roll over valve C Pass the canister hose and balance hose behind Canister hoes the bolt. Balance hose D Pass the canister hose outside, pass the balance Coolant reservoir tank hose inside.
  • Page 77 SPEC CABLE ROUTING K Insert the clamp certainly. L It may open and close to direction of which. All notches gear at the time of attachment. M Pass the coolant reservoir tank hose and the fuel tank drain hose inside of the clamp. N Point the knob of clamp downward.
  • Page 78: Chk Adj

    Air induction system hose for damage. (See page 7-32) S Replace any damaged parts if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL...
  • Page 79 (See page 3-20) Lubricate the throttle grip housing and cable. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.
  • Page 80: Seat

    SEAT EAS00038 SEAT Order Job/Part Q’ty Remarks Removing the seat Remove the parts in the order listed. Seat For installation, reverse the removal procedure.
  • Page 81: Fuel Tank

    FUEL TANK EAS00040 FUEL TANK 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Disconnect. Seat Refer to “SEAT”. Front cowling inner panel (left and Refer to “COWLINGS”.
  • Page 82 FUEL TANK 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Roll over valve (for CAL) For installation, reverse the removal procedure. Refer to the CABLE ROUTING for how to attach a hose.
  • Page 83: Removing The Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: S fuel hose CAUTION: S Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools.
  • Page 84: Installing The Fuel Pump

    FUEL TANK INSTALLING THE FUEL PUMP 1. Install: S fuel pump 4 Nm (0.4 mSkg, 2.9 ftSlb) NOTE: S Do not damage the installation surfaces of the fuel tank when installing the fuel pump. S Always use a new fuel pump gasket. S Install the fuel pump as shown in the illustra- tion.
  • Page 85: Cowlings

    COWLINGS COWLINGS 23 Nm (2.3 mSkg, 17 ftSlb) 33 Nm (3.3 mSkg, 24 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 5 Nm (0.5 mSkg, 3.6 ftSlb) Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed. Seat Refer to “SEAT”.
  • Page 86: Air Filter Case

    AIR FILTER CASE EAS00043 AIR FILTER CASE 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Seat Refer to “SEAT”. Front cowling inner panel (left and Refer to “COWLINGS”. right) Fuel tank Refer to “FUEL TANK”.
  • Page 87: Battery Box And Battery Box Bracket

    BATTERY BOX AND BATTERY BOX BRACKET BATTERY BOX AND BATTERY BOX BRACKET 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Remove the parts in the order listed. Battery box NOTE: This part has to be set properly.
  • Page 88: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 89 ADJUSTING THE VALVE CLEARANCE 4. Measure: S valve clearance Out of specification ! Adjust. Valve clearance (cold) Intake valve 0.13 X 0.20 mm (0.0051 X 0.0079 in) Exhaust valve 0.23 X 0.30 mm (0.0091 X 0.0118 in) a. Turn the crankshaft counterclockwise. b.
  • Page 90 ADJUSTING THE VALVE CLEARANCE 5. Remove: S camshafts NOTE: S Refer to “CAMSHAFTS” in chapter 5. S When removing the timing chain and cam- shafts, fasten the timing chain with a wire to re- trieve it if it falls into the crankcase. 6.
  • Page 91 ADJUSTING THE VALVE CLEARANCE c. Round off the original valve pad number ac- cording to the following table. Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm (0.058 in)) Rounded value = 150 d.
  • Page 92 ADJUSTING THE VALVE CLEARANCE NOTE: S Refer to “CAMSHAFTS” in chapter 5. S Lubricate the camshaft bearings, camshaft lobes and camshaft journals. S First, install the exhaust camshaft. S Align the camshaft marks with the camshaft cap marks. S Turn the crankshaft counterclockwise several full turns to seat the parts.
  • Page 93 ADJUSTING THE VALVE CLEARANCE INTAKE INSTALLED PAD NUMBER MEASURED 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 CLEARANCE 0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.08 X 0.12...
  • Page 94: Synchronizing The Throttle Bodies

    ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE THROTTLE BODIES 7. Install: S all removed parts NOTE: For installation, reverse the removal procedure. SYNCHRONIZING THE THROTTLE BODIES NOTE: Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition tim- ing should be checked.
  • Page 95 SYNCHRONIZING THE THROTTLE BODIES 6. Measure: S engine idling speed Out of specification ! Adjust. Refer to “ADJUSTING THE ENGINE IDLING SPEED”. Engine idling speed 1,250 X 1,350 r/min 7. Adjust: S throttle body synchronization a. With throttle body #1 as standard, adjust throttle bodies #2, #3, and #4 using the air screws 1 .
  • Page 96: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED EAS00052 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the throttle bodies synchronization should be ad- justed properly, the air filter element should be clean, and the engine should have adequate compression.
  • Page 97: Adjusting The Throttle Cable Free Play

    ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00055 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and throttle bodies synchro- nization should be adjusted properly. 1. Check: S throttle cable free play a Out of specification ! Adjust.
  • Page 98 ADJUSTING THE THROTTLE CABLE FREE PLAY Handlebar side a. Loosen the locknut 1 . b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. Throttle cable free play is Direction increased.
  • Page 99: Checking The Spark Plugs

    CHECKING THE SPARK PLUGS EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: S radiator lower bolt 1 S radiator lower hose bracket bolt 2 2. Remove: S spark plug caps S spark plugs A Right side #1 and #2 and #3 B Left side #4 CAUTION:...
  • Page 100: Measuring The Compression Pressure

    CHECKING THE SPARK PLUGS/ MEASURING THE COMPRESSION PRESSURE 7. Install: S spark plug 18 Nm (1.8 mSkg, 13 ftSlb) S spark plug caps NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Install: S radiator lower hose bracket bolt S radiator lower bolt EAS00065 MEASURING THE COMPRESSION...
  • Page 101 MEASURING THE COMPRESSION PRESSURE CAUTION: Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 5. Install: S compression gauge 1 S adapter Compression gauge 90890-03081, YU-33223...
  • Page 102 MEASURING THE COMPRESSION PRESSURE d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and mea- sure again. Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than...
  • Page 103: Checking The Engine Oil Level

    CHECKING THE ENGINE OIL LEVEL EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure the motorcycle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 104: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for several min- utes, and then turn it off. 5.
  • Page 105 CHANGING THE ENGINE OIL 5. If the oil filter cartridge is also to be replaced, perform the following procedure. a. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench 90890-01426, YU-38411 b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil.
  • Page 106: Measuring The Engine Oil Pressure

    CHANGING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE 9. Install: S engine oil filler cap 10. Start the engine, warm it up for several min- utes, and then turn it off. 11. Check: S engine (for engine oil leaks) 12.
  • Page 107 MEASURING THE ENGINE OIL PRESSURE 5. Measure: S engine oil pressure (at the following conditions) Engine oil pressure 240 kPa (2.4 kg/cm , 2.4 bar, 34.1 psi) Engine speed Approx. 6,600 r/min Engine oil temperature 96_C (205_F) NOTE: Regarding the oil pressure as its own data may fluctuate depending on the oil temperature and viscosity, the oil pressure may fluctuate when measuring.
  • Page 108: Adjusting The Clutch Cable Free Play

    ADJUSTING THE CLUTCH CABLE FREE PLAY EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm (0.39 X 0.59 in) 2.
  • Page 109: Cleaning The Air Filter Element

    ADJUSTING THE CLUTCH CABLE FREE PLAY/ CLEANING THE AIR FILTER ELEMENT 4. Install: S air filter case Refer to “AIR FILTER CASE”. S fuel tank Refer to “FUEL TANK”. S front cowling inner panel (left and right) Refer to “COWLINGS”. S seat Refer to “SEAT”.
  • Page 110: Checking The Throttle Body Joints

    CLEANING THE AIR FILTER ELEMENT/ CHECKING THE THROTTLE BODY JOINTS NOTE: When installing the air filter element into the air filter case cover, make sure their sealing sur- faces are aligned to prevent any air leaks. 6. Install: S fuel tank Refer to “FUEL TANK”.
  • Page 111: Checking The Fuel And Breather Hoses

    CHECKING THE FUEL AND BREATHER HOSES/ CHECKING THE CRANKCASE BREATHER HOSE EAS00096 CHECKING THE FUEL AND BREATHER HOSES The following procedure applies to all of the fuel and breather hoses. 1. Remove: S rider seat Refer to “SEAT”. S front cowling inner panel (left and right) Refer to “COWLINGS”...
  • Page 112: Checking The Exhaust System

    CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM 3. Install: S fuel tank Refer to “FUEL TANK”. S front cowling inner panel (left and right) Refer to “COWLINGS”. S rider seat Refer to “SEAT”. EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipes and gaskets.
  • Page 113: Checking The Coolant Level

    CHECKING THE COOLANT LEVEL EAS00102 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure the motorcycle is upright. 2. Check: S coolant level The coolant level should be between the maximum level mark a and minimum level mark b .
  • Page 114: Checking The Cooling System

    CHECKING THE COOLING SYSTEM/ CHANGING THE COOLANT EAS00104 CHECKING THE COOLING SYSTEM 1. Check: S radiator 1 S radiator inlet hose 2 S radiator outlet hose 3 S oil cooler 4 S oil cooler inlet hose 5 S oil cooler outlet hose 6 S water jacket outlet joint 7 S water jacket hose 8 S water pump outlet pipe 9...
  • Page 115: Changing The Coolant

    CHANGING THE COOLANT 3. Disconnect: S coolant reservoir cap 1 4. Drain: S coolant (from the coolant reservoir tank) 5. Remove: S radiator cap lock bolt 1 S radiator cap 2 CAUTION: A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot.
  • Page 116 CHANGING THE COOLANT 10. Install: S coolant reservoir tank 11. Connect: S coolant reservoir hose 12. Fill: S cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity...
  • Page 117 CHANGING THE COOLANT S Use only distilled water. However, if dis- tilled water is not available, soft water may be used. S If coolant comes into contact with painted surfaces, immediately wash them with wa- ter. S Do not mix different types of antifreeze. 13.
  • Page 118: Chassis

    ADJUSTING THE FRONT BRAKE EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) NOTE: S While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position.
  • Page 119: Adjusting The Rear Brake

    ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Check: S brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification ! Adjust. Brake pedal position (below the top of the rider footrest) 25.8 mm (1.02 in) 2.
  • Page 120: Checking The Brake Fluid Level

    ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL 3. Adjust: S rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure the motorcycle is upright.
  • Page 121: Checking The Front And Rear Brake Pads

    CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE FRONT AND REAR BRAKE PADS CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal.
  • Page 122: Adjusting The Rear Brake Light Switch

    ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT AND REAR BRAKE HOSES EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by move- ment of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.
  • Page 123 BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00135 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system whenev- S the system is disassembled. S a brake hose is loosened, disconnected or replaced. S the brake fluid level is very low. S brake operation is faulty.
  • Page 124: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.
  • Page 125: Adjusting The Drive Chain Slack

    ADJUSTING THE DRIVE CHAIN SLACK EAS00140 ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swin- garm or cause an accident.
  • Page 126: Lubricating The Drive Chain

    ADJUSTING THE DRIVE CHAIN SLACK/ LUBRICATING THE DRIVE CHAIN f. Tighten both locknuts to specification. Locknut 16 Nm (1.6 mSkg, 12 ftSlb) g. Tighten the wheel axle nut to specification. Wheel axle nut 120 Nm (12 mSkg, 87 ftSlb) EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts.
  • Page 127: Checking And Adjusting The Steering Head

    CHECKING AND ADJUSTING THE STEERING HEAD EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 128 CHECKING AND ADJUSTING THE STEERING HEAD c. Loosen the lower ring nut 6 completely, then tighten it to specification. WARNING Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 18 Nm (1.8 mSkg, 13 ftSlb) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions.
  • Page 129: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK Steering head tension 200 X 500 g e. Repeat the above procedure on the opposite handlebar. f. If the steering head tension is out of specifi- cation (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut.
  • Page 130: Adjusting The Rear Shock Absorber Assembly

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EAS00156 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1.
  • Page 131: Checking The Tires

    CHECKING THE TIRES WARNING S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. S The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories) and the anticipated riding speed.
  • Page 132 Ltd. for this model. The front and rear tires should always be by the same manufactur- er and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. 3-55...
  • Page 133 CHECKING THE TIRES/CHECKING THE WHEELS Front tire Manufacturer Size Model BRIDGESTONE 120/70ZR 17 BT020F M/C (58W) DUNLOP 120/70ZR 17 D252F M/C (58W) Rear tire Manufacturer Size Model BRIDGESTONE 180/55ZR 17 BT020R M/C (73W) DUNLOP 180/55ZR 17 D252 M/C (73W) WARNING New tires and wheels have a relatively low grip on the road surface until they have been slightly worn.
  • Page 134: Checking And Lubricating The Cables

    CHECKING AND LUBRICATING THE CABLES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE CENTERSTAND EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in- ner and outer cables. WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement.
  • Page 135: Lubricating The Rear Suspension

    LUBRICATING THE REAR SUSPENSION EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Molybdenum disulfide grease 3-58...
  • Page 136: Electrical System

    CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries.
  • Page 137 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 138 CHECKING AND CHARGING THE BATTERY 5. Charge: Charging Ambient temperature 20_C S battery (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause bat-...
  • Page 139 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charged and NOTE: AMP meter to the battery Set the charging voltage at 16 X 17 V.
  • Page 140 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
  • Page 141 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charging method using a constant voltage charger 6. Install: S battery 7. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1 , and then the negative battery lead 2 .
  • Page 142: Checking The Fuses

    CHECKING THE FUSES EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Remove: S right side cover Refer to “COWLINGS”.
  • Page 143 CHECKING THE FUSES WARNING Never use a fuse with an amperage rating other than that specified. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.
  • Page 144: Replacing The Headlight Bulbs

    REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Remove: S front cowling inner panels Refer to “COWLINGS”. 2. Disconnect: S headlight bulb cover S headlight coupler 1 3. Remove: S headlight bulb holder 1 4.
  • Page 145: Adjusting The Headlight Beams

    ADJUSTING THE HEADLIGHT BEAMS EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: S headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or Direction Headlight beam is raised. Headlight beam is Direction lowered.
  • Page 146: Chas

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 6 Nm (0.6 mSkg, 4.3 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 4 Nm (0.4 mSkg, 2.9 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb)
  • Page 147 CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 Order Job/Part Q’ty Remarks Disassembling the front wheel Disassemble the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly procedure.
  • Page 148: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 149 CHAS FRONT WHEEL AND BRAKE DISCS 2. Check: S tire S front wheel Damage/wear ! Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Measure: S radial wheel runout 1 S lateral wheel runout 2 Over the specified limits ! Replace.
  • Page 150: Checking The Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS c. Remove the wheel bearings 3 with a gener- al bearing puller. d. Install the new wheel bearings and oil seals in the reverse order of disassembly. CAUTION: Do not contact the wheel bearing inner race 1 or balls 2 .
  • Page 151: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: S brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification ! Replace. Brake disc thickness limit (minimum) Front: 4.5 mm (0.18 in) Rear: 4.5 mm (0.18 in) 4.
  • Page 152: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISCS 3. Insert the wheel axle. NOTE: Install the tire and wheel with the mark 1 point- ing in the direction of wheel rotation. 4. Lower the front wheel so that it is on the ground.
  • Page 153 CHAS FRONT WHEEL AND BRAKE DISCS a. Spin the front wheel. b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. c. Turn the front wheel 90_ so that the “X ” mark is positioned as shown.
  • Page 154: Rear Wheel And Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC EAS00551 REAR WHEEL AND BRAKE DISC REAR WHEEL 22 Nm (2.2 mSkg, 16 ftSlb) 27 Nm (2.7 mSkg, 20 ftSlb) 120 Nm (12 mSkg, 87 ftSlb) Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed.
  • Page 155: Rear Brake Disc And Rear Wheel Sprocket

    CHAS REAR WHEEL AND BRAKE DISC EAS00556 REAR BRAKE DISC AND REAR WHEEL SPROCKET 30 Nm (3.0 mSkg, 22 ftSlb) 100 Nm (10 mSkg, 72 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake disc and Remove the parts in the order listed. rear wheel sprocket Rear brake disc Rear wheel sprocket...
  • Page 156 CHAS REAR WHEEL AND BRAKE DISC EAS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed. Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly procedure. 4-11...
  • Page 157: Removing The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 158: Checking The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EAS00565 CHECKING THE REAR WHEEL 1. Check: S wheel axle S rear wheel S wheel bearings S oil seals Refer “CHECKING FRONT WHEEL”. 2. Check: S tire S rear wheel Damage/wear ! Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS”...
  • Page 159: Installing The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC 2. Replace: S rear wheel sprocket a. Remove the self-locking nuts and the rear wheel sprocket. b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. c.
  • Page 160: Adjusting The Rear Wheel Static Balance

    CHAS REAR WHEEL AND BRAKE DISC EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. S Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1.
  • Page 161: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 10 Nm (1.0 mSkg, 7.2 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed.
  • Page 162 CHAS FRONT AND REAR BRAKES REAR BRAKE PADS 3 Nm (0.3 mSkg, 2.2 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 27 Nm (2.7 mSkg, 20 ftSlb) 22 Nm (2.2 mSkg, 16 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake pads.
  • Page 163 CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: WARNING S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.
  • Page 164: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00582 REPLACING THE FRONT BRAKE PADS The following procedure applies to both brake calipers. NOTE: When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1.
  • Page 165 CHAS FRONT AND REAR BRAKES a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger.
  • Page 166: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00583 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. Remove: S screw plug 1 S brake pad pin 2 S brake caliper 3 S brake pad spring 4 2.
  • Page 167 CHAS FRONT AND REAR BRAKES b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. Bleed screw 6 Nm (0.6 mSkg, 4.3 ftSlb) d. Install a new brake pad shim 3 onto each new brake pad 4 .
  • Page 168: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 2 Nm (0.2 mSkg, 1.4 ftSlb) 10 Nm (1.0 mSkg, 72 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain.
  • Page 169 CHAS FRONT AND REAR BRAKES 2 Nm (0.2 mSkg, 1.4 ftSlb) 10 Nm (1.0 mSkg, 72 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Master cylinder assembly For installation, reverse the removal procedure. 4-24...
  • Page 170: Disassembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder Push rod For assembly, reverse the disassembly procedure. 4-25...
  • Page 171 CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 30 Nm (3.0 mSkg, 22 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder Brake fluid Drain.
  • Page 172: Disassembling The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake master Disassemble the parts in the order listed. cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder body For assembly, reverse the disassembly procedure. 4-27...
  • Page 173: Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: S brake light switch coupler 1 (from the brake light switch) 2.
  • Page 174 CHAS FRONT AND REAR BRAKES 3. Check: S rear brake fluid reservoir 1 Cracks/damage ! Replace. S rear brake fluid reservoir diaphragm 2 Cracks/damage ! Replace. 4. Check: S front brake master cylinder reservoir 1 Cracks/damage ! Replace. S front brake master cylinder reservoir dia- phragm 2 Damage/wear ! Replace.
  • Page 175 CHAS FRONT AND REAR BRAKES EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents.
  • Page 176 CHAS FRONT AND REAR BRAKES NOTE: S While holding the brake hose, tighten the union bolt as shown. S Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary.
  • Page 177 CHAS FRONT AND REAR BRAKES EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: S brake master cylinder kit S circlip S dust boot 2. Install: S copper washers S brake hoses S union bolt 30 Nm (3.0 mSkg, 22 ftSlb) WARNING Proper brake hose routing is essential to in- sure safe motorcycle operation.
  • Page 178 CHAS FRONT AND REAR BRAKES CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.
  • Page 179 CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 4 Nm (0.4 mSkg, 2.9 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 10 Nm (1.0 mSkg, 72 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty Remarks...
  • Page 180 CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. calipers NOTE: The following procedure applies to both of the front brake calipers. Brake pad Brake caliper piston Brake caliper piston seal...
  • Page 181 CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 22 Nm (2.2 mSkg, 16 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 27 Nm (2.7 mSkg, 20 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain.
  • Page 182: Disassembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 mSkg, 4.3 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 3 Nm (0.3 mSkg, 2.2 ftSlb) Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Disassemble the parts in the order listed. Screw plug Brake pad pin Brake pad...
  • Page 183: Calipers

    CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE:...
  • Page 184: Caliper

    CHAS FRONT AND REAR BRAKES EAS00627 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 S brake caliper 4 NOTE: Put the end of the brake hose into a container...
  • Page 185 CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is disas- sembled 1.
  • Page 186 CHAS FRONT AND REAR BRAKES EAS00638 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
  • Page 187 CHAS FRONT AND REAR BRAKES 2. Fill: S brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 188 CHAS FRONT AND REAR BRAKES EAS00642 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
  • Page 189 CHAS FRONT AND REAR BRAKES WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S 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 190: Front Fork

    CHAS FRONT FORK EAS00647 FRONT FORK FRONT FORK LEGS 30 Nm (3.0 mSkg, 22 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
  • Page 191 CHAS FRONT FORK EAS00648 24 Nm (2.4 mSkg, 17 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Disassembling the front fork legs Disassemble the parts in the order listed. NOTE: The following the procedure applies to both of the front fork legs. Cap bolt O-ring Spacer...
  • Page 192 CHAS FRONT FORK 24 Nm (2.4 mSkg, 17 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Inner tube Outer tube bushing Inner tube bushing Oil flow stopper Outer tube For assembly, reverse the disassembly procedure. 4-47...
  • Page 193: Removing The Front Fork Legs

    CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 194 CHAS FRONT FORK 3. Remove: S dust seal 1 S oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 4. Remove: S damper rod assembly bolt NOTE: While holding the damper rod assembly with the damper rod holder 1 and T-handle 2 , loosen the damper rod assembly bolt.
  • Page 195: Checking The Front Fork Legs

    CHAS FRONT FORK EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: S inner tube 1 S outer tube 2 Bends/damage/scratches ! Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.
  • Page 196: Assembling The Front Fork Legs

    CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING S Make sure the oil levels in both front fork legs are equal. S Uneven oil levels can result in poor han- dling and a loss of stability.
  • Page 197 CHAS FRONT FORK Damper rod holder 90890-01294 T-handle 90890-01326 4. Install: S outer tube bushing 1 (with the fork seal driver weight 2 and fork seal driver attachment 3 ) Fork seal driver weight 90890-01367 Fork seal driver attachment 90890-01374 5.
  • Page 198 CHAS FRONT FORK 7. Install: S dust seal 1 (with the fork seal driver weight) Fork seal driver weight 90890-01367 8. Fill: S front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.467 L (0.41 Imp qt, 0.49 US qt) Recommended oil Suspension oil “01”...
  • Page 199: Installing The Front Fork Legs

    CHAS FRONT FORK 10. Install: S spring 1 S spring seat 2 S spacer 3 S cap bolt NOTE: S Install the spring with the smaller pitch a fac- ing up. S Before installing the cap bolt, lubricate its O- ring with grease.
  • Page 200: Handlebar

    CHAS HANDLEBAR EAS00664 HANDLEBAR 26 Nm (2.6 mSkg, 19 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Grip end Handlebar grip (left) Clutch switch connector...
  • Page 201: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S grip end S handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
  • Page 202: Installing The Handlebar

    CHAS HANDLEBAR EAS00672 INSTALLING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Install: S handlebar 1 S upper handlebar holders 2 23 Nm (2.3 mSkg, 17 ftSlb) S upper handlebar holder caps 3 CAUTION: S First, tighten the bolts on the front side of...
  • Page 203 CHAS HANDLEBAR 5. Install: S grip end 26 Nm (2.6 mSkg, 19 ftSlb) 6. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm (0.12 X 0.20 in) 7.
  • Page 204: Steering Head

    CHAS STEERING HEAD EAS00676 STEERING HEAD UNDER BRACKET 110 Nm (11 mSkg, 80 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Removing the under bracket Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
  • Page 205 CHAS STEERING HEAD 110 Nm (11 mSkg, 80 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Upper ring nut Rubber washer Lower ring nut Under bracket Bearing cover Bearing inner race Upper bearing Lower bearing Dust seal...
  • Page 206: Removing The Under Bracket

    CHAS STEERING HEAD EAS00677 REMOVING THE UNDER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S steering stem nut S washer S upper bracket S lock washer S rubber washer S ring nut 1...
  • Page 207: Installing The Steering Head

    CHAS STEERING HEAD 3. Replace: S bearing balls S bearing races a. Remove the bearing races 1 from the steer- ing head pipe with a long rod 2 and hammer. b. Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer. c.
  • Page 208 CHAS STEERING HEAD 3. Install: S upper bracket S washer S steering stem nut 110 Nm (11 mSkg, 80 ftSlb) 4. Install: S front fork legs Refer to “INSTALLING THE FRONT FORK LEGS”. 4-63...
  • Page 209: Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 40 Nm (4.0 mSkg, 29 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Rear wheel Refer to “REAR WHEEL AND BRAKE DISC”.
  • Page 210: Removing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00694 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 211: Handling The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00686 HANDLING THE REAR SHOCK ABSORBER WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsi- ble for property damage or personal injury that may result from improper handling of the rear shock absorber.
  • Page 212: Installing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY S spring Damage/wear ! Replace the rear shock ab- sorber assembly. S bushings Damage/wear ! Replace. S dust seals Damage/wear ! Replace. S bolts Bends/damage/wear ! Replace. EAS00697 INSTALLING THE REAR SHOCK ABSORB- ER ASSEMBLY 1.
  • Page 213: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN SWINGARM AND DRIVE CHAIN 16 Nm (1.6 mSkg, 12 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 120 Nm (12 mSkg, 87 ftSlb) Order Job/Part Q’ty Remarks Removing the swingarm and drive Remove the parts in the order listed. chain Muffler assembly Catalyst assembly...
  • Page 214 CHAS SWINGARM AND DRIVE CHAIN 16 Nm (1.6 mSkg, 12 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 120 Nm (12 mSkg, 87 ftSlb) Order Job/Part Q’ty Remarks Drive chain guide Dust cover Bearing Spacer For installation, reverse the removal procedure. 4-69...
  • Page 215: Removing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN EAS00703 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 216: Removing The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00704 REMOVING THE DRIVE CHAIN 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 217: Installing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN 4. Check: S dust covers 1 S spacer 2 Damage/wear ! Replace. S bearings Damage/pitting ! Replace. AS00711 INSTALLING THE SWINGARM 1. Lubricate: S bearings S spacer S dust covers S pivot shaft Recommended lubricant Lithium-soap-based grease 2.
  • Page 218: Checking The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: S ten-link section a of the drive chain Out of specification ! Replace the drive chain. Ten-link drive chain section limit (maximum) 150.1 mm (5.91 in) NOTE: S While measuring the ten-link section, push down on the drive chain to increase its tension.
  • Page 219 CHAS SWINGARM AND DRIVE CHAIN 4. Check: S O-rings 1 Damage ! Replace the drive chain. S drive chain rollers 2 Damage/wear ! Replace the drive chain. S drive chain side plates 3 Damage/wear ! Replace the drive chain. Cracks ! Replace the drive chain and make sure that the battery breather hose is proper- ly routed away from the drive chain and be- low the swingarm.
  • Page 220: Eng

    ENGINE EAS00188 ENGINE ENGINE DRIVE SPROCKET 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) Order Job/Part Q’ty Remarks Removing the drive sprocket Drive chain Loosen.
  • Page 221: Exhaust Pipe

    ENGINE EAS00189 EXHAUST PIPE 20 Nm (2.0 mSkg, 15 ftSlb) 9 Nm (0.9 mSkg, 6.5 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 34 Nm (3.4 mSkg, 26 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 16 Nm (1.6 mSkg, 11.6 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb)
  • Page 222: Leads And Hoses

    ENGINE EAS00191 LEADS AND HOSES Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Front cowling inner panel (left and right) Refer to “COWLINGS” in chapter 3. Fuel tank Refer to “FUEL TANK”...
  • Page 223 ENGINE Order Job/Part Q’ty Remarks Radiator Refer to “COOLING SYSTEM” in chapter 6. Starter motor Refer to “STARTER MOTOR” in chapter 8. Battery negative lead Battery positive lead Clutch cable Ground lead Stator coil assembly coupler Disconnect. Crankshaft position sensor coupler Disconnect.
  • Page 224 ENGINE EAS00191 ENGINE 55 Nm (5.5 mSkg, 40 ftSlb) 55 Nm (5.5 mSkg, 40 ftSlb) 55 Nm (5.5 mSkg, 40 ftSlb) 55 Nm (5.5 mSkg, 40 ftSlb) Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine.
  • Page 225: Installing The Engine

    ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: S rear engine mounting bolts 1 NOTE: Lubricate the rear engine mounting bolt threads with lithium-soap-based grease. 2. Install: S right front engine mounting bolt 2 S left front engine mounting bolts 3 NOTE: Do not fully tighten the bolts.
  • Page 226 ENGINE 5. Tighten S right front engine mounting bolts 6 55 Nm (5.5 mSkg, 40 ftSlb) 6. Install: S shift arm 7 10 Nm (1.0 mSkg, 7.2 ftSlb) NOTE: S Align the punch mark a in the shift shaft with the slot in the shift arm.
  • Page 227: Camshafts

    CAMSHAFTS EAS00194 CAMSHAFTS CYLINDER HEAD COVER 12 Nm (1.2 mSkg, 8.7 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Battery Refer to “CHECKING AND CHARGING THE BATTERY”...
  • Page 228 CAMSHAFTS EAS00196 CAMSHAFTS 10 Nm (1.0 mSkg, 7.2 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed.
  • Page 229 CAMSHAFTS 10 Nm (1.0 mSkg, 7.2 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Exhaust camshaft Timing chain guide (intake side) Cam sprocket For installation, reverse the removal procedure.
  • Page 230: Removing The Camshafts

    CAMSHAFTS EAS00198 REMOVING THE CAMSHAFTS 1. Remove: S pickup rotor cover Refer to “CRANKSHAFT POSITION SEN- SOR AND PICKUP ROTOR”. 2. Align: S “T” mark a on the pickup rotor (with the crankcase mating surface b ) a. Turn the crankshaft clockwise. b.
  • Page 231: Checking The Camshafts

    CAMSHAFTS 7. Remove: S intake camshaft 1 S exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire a . 8. Remove: S camshaft sprockets EAS00204 CHECKING THE CAMSHAFTS 1. Check: S camshaft lobes Blue discoloration/pitting/scratches ! Re- place the camshaft.
  • Page 232 CAMSHAFTS 3. Measure: S camshaft runout Out of specification ! Replace. Camshaft runout limit 0.06 mm (0.0024 in) 4. Measure: S camshaft-journal-to-camshaft-cap clear- ance Out of specification ! Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.028 X 0.062 mm (0.0011 X 0.0024 in) <Limit>: 0.08 mm (0.0032 in) a.
  • Page 233: Checking The Timing Chain, Camshaft Sprockets

    CAMSHAFTS EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: S timing chain 1 Damage/stiffness ! Replace the timing chain and camshaft sprockets as a set. 2.
  • Page 234: Installing The Camshafts

    CAMSHAFTS b. Remove the screwdriver and slowly release the timing chain tensioner rod. c. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough move- ment, replace the timing chain tensioner. 3.
  • Page 235 CAMSHAFTS 3. Install: S dowel pins S exhaust camshaft caps S intake camshaft caps NOTE: S Make sure each camshaft cap is installed in its original place. S Make sure the arrow mark a on each cam- shaft cap points towards the right side of the engine.
  • Page 236 CAMSHAFTS 6. Install: S timing chain tensioner a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod ful- ly clockwise with a thin screwdriver 1 . b. With the timing chain tensioner rod turned all the way into the timing chain tensioner hous- ing (with the thin screwdriver still installed), install the gasket and the timing chain ten-...
  • Page 237 CAMSHAFTS 10. Measure: S valve clearance Out of specification ! Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” in chapter 3. 5-18...
  • Page 238: Cylinder Head

    CYLINDER HEAD EAS00221 CYLINDER HEAD 19 Nm (1.9 mSkg, 14 ftSlb) 50 Nm (5.0 mSkg, 36 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Intake and exhaust camshaft Refer to “CAMSHAFTS”.
  • Page 239: Removing The Cylinder Head

    CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remove: S cylinder head bolts NOTE: S Loosen the bolts in the proper sequence as shown. S Loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them.
  • Page 240: Installing The Cylinder Head

    CYLINDER HEAD EAS00233 INSTALLING THE CYLINDER HEAD 1. Install: S gasket S dowel pins 2 2. Install: S cylinder head NOTE: Pass the timing chain through the timing chain cavity. 3. Tighten: S cylinder head bolts 1 X 19 Nm (1.9 mSkg, 14 ftSlb) 50 Nm (5.0 mSkg, 36 ftSlb) S cylinder head bolts 12 Nm (1.2 mSkg, 8.7 ftSlb)
  • Page 241: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Remove the valves and valve springs Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring outer Intake valve spring inner...
  • Page 242 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Exhaust valve upper spring seat Exhaust valve spring Refer to “REMOVING/INSTALLING Exhaust valve stem seal THE VALVES”. Exhaust valve lower spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal procedure.
  • Page 243: Removing The Valves

    VALVES AND VALVE SPRINGS EAS00238 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 244: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019, YM-04019 Valve spring compressor attachment 90890-04108, YM-01253 4. Remove: S upper spring seat 1 S valve spring outer 2 S valve spring inner (intake only) 3 S valve 4 S valve stem seal 5 S lower spring seat 6 NOTE: Identify the position of each part very carefully...
  • Page 245 VALVES AND VALVE SPRINGS 2. Replace: S valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100_C (212_F) in an oven. a. Remove the valve guide with the valve guide remover 1 .
  • Page 246: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 5. Measure: S valve margin thickness a Out of specification ! Replace the valve. Valve margin thickness 0.6 X 0.8 mm (0.0236 X 0.0315 in) <Limit>: 0.5 mm (0.02 in) 6. Measure: S valve stem runout Out of specification ! Replace the valve.
  • Page 247 VALVES AND VALVE SPRINGS NOTE: Where the valve seat and valve face contacted one another, the blueing will have been re- moved. 4. Lap: S valve face S valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.
  • Page 248: Checking The Valve Springs

    VALVES AND VALVE SPRINGS j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat. EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.
  • Page 249 VALVES AND VALVE SPRINGS 3. Measure: S valve spring tilt a Out of specification ! Replace the valve spring. Spring tilt limit Intake valve spring (inner) 2.5_/1.6 mm (0.06 in) (outer) 2.5_/1.7 mm (0.07 in) Exhaust valve spring 2.5_/1.8 mm (0.07 in) EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the...
  • Page 250 VALVES AND VALVE SPRINGS NOTE: S Make sure that each valve is installed in its original place. S Install the valve springs with the larger pitch a facing up. b Smaller pitch 4. Install: S valve cotters 1 NOTE: Install the valve cotters by compressing the valve springs with the valve spring compressor 2 and the valve spring compressor attachment Valve spring compressor...
  • Page 251: Starter Clutch And Generator

    STARTER CLUTCH AND GENERATOR EAS00341 STARTER CLUTCH AND GENERATOR STATOR COIL ASSEMBLY 10 Nm (1.0 mSkg, 7.2 ftSlb) 32 Nm (3.2 mSkg, 23 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty...
  • Page 252 STARTER CLUTCH AND GENERATOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 32 Nm (3.2 mSkg, 23 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Stator coil assembly Generator rotor bolt Refer to “REMOVING/INSTALLING Washer...
  • Page 253: Removing The Generator

    STARTER CLUTCH AND GENERATOR EAS00347 REMOVING THE GENERATOR 1. Remove: S seat Refer to “SEAT” in chapter 3. S front cowling inner panel (left and right) Refer to “COWLINGS” in chapter 3. S fuel tank Refer to “FUEL TANK” in chapter 3. 2.
  • Page 254: Removing The Starter Clutch

    STARTER CLUTCH AND GENERATOR 5. Remove: S generator rotor 1 (with the flywheel puller 2 and flywheel pull- er attachment) S woodruff key CAUTION: To protect the end of the crankshaft, place an appropriate sized socket between the fly- wheel puller set’s center bolt and the crank- shaft.
  • Page 255: Checking The Starter Clutch

    STARTER CLUTCH AND GENERATOR EAS00351 CHECKING THE STARTER CLUTCH 1. Check: S starter clutch rollers 1 Damage/wear ! Replace. 2. Check: S starter clutch idle gear 1 S starter clutch drive gear 2 Burrs/chips/roughness/wear ! Replace the defective part(s). 3. Check: S starter clutch gear’s contacting surfaces a Damage/pitting/wear ! Replace the starter clutch gear.
  • Page 256: Installing The Generator

    Sheave holder 90890-01701, YS-01880-A 3. Apply: S sealant (onto the stator coil assembly lead grommet) Yamaha bond No.1215 90890-85505, ACC-11001-05-01 4. Install: S stator coil 5. Install: S generator rotor cover 12 Nm (1.2 mSkg, 8.7 ftSlb)
  • Page 257 STARTER CLUTCH AND GENERATOR NOTE: Tighten the generator rotor cover bolts in stages and in a crisscross pattern. 6. Fill: S engine oil Refer to “CHANGING THE ENGINE OIL” in chapter 3. S coolant Refer to “CHANGING THE COOLANT” in chapter 3.
  • Page 258: Shift Shaft

    SHIFT SHAFT EAS00327 SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER 22 Nm (2.2 mSkg, 16 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the shift shaft and stopper Remove the parts in the order listed. lever Drain.
  • Page 259 SHIFT SHAFT 22 Nm (2.2 mSkg, 16 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Stopper lever Collar Washer Shift shaft spring stopper For installation, reverse the removal procedure. 5-40...
  • Page 260: Checking The Shift Shaft

    SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 Bends/damage/wear ! Replace. S shift shaft spring 2 Damage/wear ! Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: S stopper lever 1 Bends/damage ! Replace. Roller turns roughly ! Replace the stopper lever.
  • Page 261: Crankshaft Position Sensor And Pickup Rotor

    CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) Order Job/Part Q’ty Remarks Removing the crankshaft position Remove the parts in the order listed.
  • Page 262 CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) Order Job/Part Q’ty Remarks Crankshaft position sensor Pickup rotor Plug screw For installation, reverse the removal procedure.
  • Page 263: Removing The Pickup Rotor

    CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR REMOVING THE PICKUP ROTOR 1. Remove: S pickup rotor cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.
  • Page 264 3 , tighten the pickup rotor bolt. Sheave holder 90890-01701, YS-01880-A 3. Apply: S sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No.1215 90890-85505, ACC-11001-5-01 4. Install: S pickup rotor cover S gasket NOTE: S When installing the pickup rotor cover, align the timing chain guide (intake side) pin 1 with the hole 2 in the pickup rotor cover.
  • Page 265: Clutch

    CLUTCH EAS00273 CLUTCH CLUTCH COVER : YAMAHA BOND No. 1215 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Engine oil Drain.
  • Page 266 CLUTCH Order Job/Part Q’ty Remarks Disassembling the clutch cover Disassemble the parts in the order listed. Circlip Washer Pull lever Pull lever spring Washer Oil seal Bearing Pull lever shaft Washer For assembly, reverse the disassembly procedure. 5-47...
  • Page 267 CLUTCH EAS00274 CLUTCH 90 Nm (9.0 mSkg, 65 ftSlb) 8 Nm (0.8 mSkg, 5.8 ftSlb) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Compression spring Pressure plate Pull rod Bearing Friction plate (Brown) Clutch plate (t=2.0 mm, 0.08 in) Friction plate Clutch plate (t=2.3 mm, 0.09 in) Clutch boss nut...
  • Page 268 CLUTCH EAS00276 REMOVING THE CLUTCH 1. Remove: S clutch cable holder 1 S clutch cover 2 S gasket NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
  • Page 269: Checking The Clutch Plates

    CLUTCH 2. Measure: S friction plate thickness Out of specification ! Replace the friction plates as a set. NOTE: Measure the friction plate at four places. Friction plate thickness 2.9 X 3.1 mm (0.114 X 0.122 in) <Limit>: 2.8 mm (0.110 in) EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the...
  • Page 270: Checking The Clutch Housing

    CLUTCH 2. Measure: S clutch spring free length a Out of specification ! Replace the clutch springs as a set. Clutch spring free length 55 mm (2.17 in) <Limit>: 52.3 mm (2.06 in) EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: S clutch housing dogs Damage/pitting/wear ! Deburr the clutch housing dogs or replace the clutch housing.
  • Page 271: Checking The Pull Lever Shaft And Pull Rod

    CLUTCH EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: S pull lever shaft pinion gear teeth a S pull rod teeth b Damage/wear ! Replace the pull rod and pull lever shaft pinion gear as a set. 2.
  • Page 272 CLUTCH 4. Install: S friction plates S clutch plates NOTE: First, install a clutch plate and then alternate be- tween a friction plate and a friction plate. a. Install the clutch plate and friction plate as shown in the illustration. Clutch plate 1 : t=2.3 mm (0.09 in) Clutch plate 2 : t=2.0 mm (0.08 in) Friction plate 3...
  • Page 273 CLUTCH 8. Install: S clutch cover S gasket S clutch cable holder NOTE: S Install the pull rod so that the teeth a face to- wards the rear of the motorcycle. Then, install the clutch cover. S Apply oil onto the bearing. S Apply molybdenum disulfide grease onto the pull rod.
  • Page 274: Oil Pan And Oil Pump

    OIL PAN AND OIL PUMP EAS00356 OIL PAN AND OIL PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 43 Nm (4.3 mSkg, 31 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order...
  • Page 275 OIL PAN AND OIL PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 43 Nm (4.3 mSkg, 31 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part...
  • Page 276 OIL PAN AND OIL PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Disassembling the oil pump Disassemble the parts in the order listed. assembly Oil pump cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump rotor housing Oil pump driver sprocket For assembly, reverse the disassembly procedure.
  • Page 277: Removing The Oil Pan

    OIL PAN AND OIL PUMP EAS00362 REMOVING THE OIL PAN 1. Remove: S oil level switch 1 S oil pan 2 S oil pan gasket S dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.
  • Page 278 OIL PAN AND OIL PUMP 3. Check: S oil pump operation Rough movement ! Repeat steps (1) and (2) or replace the defective part(s). EAS00365 CHECKING THE RELIEF VALVE 1. Check: S relief valve body 1 S relief valve 2 S spring 3 S O-ring 4 Damage/wear ! Replace the defective...
  • Page 279 OIL PAN AND OIL PUMP EAS00374 ASSEMBLING THE OIL PUMP 1. Lubricate: S inner rotor S outer rotor S oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: S oil pump housing 1 S oil pump shaft 2 S washer 3 S pin 4 S inner rotor 5...
  • Page 280: Installing The Oil Strainer

    OIL PAN AND OIL PUMP EAS00378 INSTALLING THE OIL STRAINER 1. Install: S oil strainer 1 S relief valve 2 NOTE: Make sure to check the arrow mark a located on the oil strainer housing for the front and rear direction of the engine and then install the oil strainer so that its arrow mark points to the front side of the engine.
  • Page 281: Crankcase

    CRANKCASE CRANKCASE 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Cylinder head Refer to “CYLINDER HEAD”. Starter clutch and generator Refer to “STARTER CLUTCH AND GENERATOR”.
  • Page 282 CRANKCASE 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Thrust plate Washer Plate For installation, reverse the removal procedure. 5-63...
  • Page 283 CRANKCASE EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside down. 2. Remove: S crankcase bolts NOTE: S Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. S Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration).
  • Page 284: Checking The Crankcase

    ASSEMBLING THE CRANKCASE 1. Lubricate: S crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: S sealant Yamaha bond No. 1215 90890-85505, ACC-1109-05-01 5-65...
  • Page 285 CRANKCASE NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings. 3. Install: S dowel pin 4.
  • Page 286: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS00252 CONNECTING RODS AND PISTONS 15 Nm (1.5 mSkg, 11 ftSlb) +120_ 15 Nm (1.5 mSkg, 11 ftSlb) +150_ Order Job/Part Q’ty Remarks Removing the connecting rods and Remove the parts in the order listed. pistons Lower crankcase Refer to “CRANKCASE”.
  • Page 287: Removing The Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS00393 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: S connecting rod cap 1 S big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
  • Page 288: Removing The Crankshaft Assembly

    CONNECTING RODS AND PISTONS EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: S crankshaft assembly S crankshaft journal upper bearings (from the upper crankcase) Refer to “CRANKSHAFT”. NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place.
  • Page 289: Checking The Piston Rings

    CONNECTING RODS AND PISTONS 65.50 X 65.51 mm Cylinder bore “C” (2.5787 X 2.5791 in) 65.56 mm Wear limit (2.5811 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.002 in) “C” = maximum of D “T”...
  • Page 290: Checking The Piston Pins

    CONNECTING RODS AND PISTONS Piston ring side clearance Top ring 0.030 X 0.065 mm (0.0012 X 0.0026 in) <Limit>: 0.115 mm (0.0045 in) 2nd ring 0.030 X 0.065 mm (0.0012 X 0.0026 in) <Limit>: 0.125 mm (0.0049 in) 2. Install: S piston ring (into the cylinder) NOTE:...
  • Page 291 CONNECTING RODS AND PISTONS 2. Measure: S piston pin outside diameter a Out of specification ! Replace the piston pin. Piston pin outside diameter 15.991 X 16.000 mm (0.6296 X 0.6299 in) <Limit>: 15.971 mm (0.6288 in) 3. Measure: S piston pin bore inside diameter b Out of specification ! Replace the piston.
  • Page 292: Checking The Big End Bearings (Except For Cal)

    CONNECTING RODS AND PISTONS CHECKING THE BIG END BEARINGS (except for CAL) 1. Measure: S crankshaft-pin-to-big-end-bearing clear- ance Out of specification ! Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance 0.028 X 0.052 mm (0.0011 X 0.0020 in) The following procedure applies to all of the connecting rods.
  • Page 293 CONNECTING RODS AND PISTONS e. Tighten the connecting rod nuts. Connecting rod nut 15 Nm (1.5 mSkg, 11 ftSlb) + 150_ f. Replace the connecting rod bolts with new ones. CAUTION: Tighten the connecting rod nuts using the plastic-region tightening angle method. Always install new bolts and nuts.
  • Page 294 CONNECTING RODS AND PISTONS 2. Select: S big end bearings (P1 X P4) NOTE: S The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. S “P1”...
  • Page 295: Checking The Big End Bearings (For Cal)

    CONNECTING RODS AND PISTONS CHECKING THE BIG END BEARINGS (for CAL) 1. Measure: S crankshaft-pin-to-big-end-bearing clear- ance Out of specification ! Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance 0.028 X 0.052 mm (0.0011 X 0.0020 in) The following procedure applies to all of the connecting rods.
  • Page 296 CONNECTING RODS AND PISTONS e. Tighten the connecting rod bolts. NOTE: Install by carrying out the following procedures in order to assemble in the most suitable condi- tion. S connecting rod bolts Connecting rod bolt 24.5 Nm (2.5 mSkg, 17.7 ftSlb) f.
  • Page 297 CONNECTING RODS AND PISTONS k. Tighten the connecting rod bolts. Connecting rod bolt 15 Nm (1.5 mSkg, 11 ftSlb) + 120_ CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts. l. Clean the connecting rod bolts. m.
  • Page 298 CONNECTING RODS AND PISTONS q. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS AND PISTONS”.  r. Measure the compressed Plastigauge width on the crankshaft pin. crankshaft-pin-to-big-end-bearing clearance is out of specification, select re- placement big end bearings.
  • Page 299 CONNECTING RODS AND PISTONS INSTALLING THE CONNECTING ROD AND PISTON (except for CAL) The following procedure applies to all of the connecting rods and pistons. 1. Install: S top ring 1 S 2nd ring 2 S upper oil ring rail 3 S oil ring expander 4 S lower oil ring rail 5 NOTE:...
  • Page 300 CONNECTING RODS AND PISTONS 4. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring e Oil ring expander 5. Lubricate: S crankshaft pins S big end bearings S connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant...
  • Page 301 CONNECTING RODS AND PISTONS b. Clean the connecting rod bolts and nuts. c. Tighten the connecting rod nuts. d. Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod cap 3 . e. Tighten the nut further to reach the specified angle (150_).
  • Page 302 CONNECTING RODS AND PISTONS INSTALLING THE CONNECTING ROD AND PISTON (for CAL) The following procedure applies to all of the connecting rods and pistons. 1. Install: S top ring 1 S 2nd ring 2 S upper oil ring rail 3 S oil ring expander 4 S lower oil ring rail 5 NOTE:...
  • Page 303 CONNECTING RODS AND PISTONS 4. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring e Oil ring expander 5. Lubricate: S crankshaft pins S big end bearings S connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant...
  • Page 304 CONNECTING RODS AND PISTONS 7. Tighten: NOTE: Install by carrying out the following procedures in order to assemble in the most suitable condi- tion. S connecting rod bolts. 24.5 Nm (2.5 mSkg, 17.7 ftSlb) a. Replace the connecting rod bolts with new ones.
  • Page 305 CONNECTING RODS AND PISTONS 9. Tighten: S connecting rod bolts 15 Nm (1.5 mSkg, 11 ftSlb) + 120_ 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.
  • Page 306: Crankshaft

    CRANKSHAFT EAS00381 CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Connecting rod caps Refer to “CONNECTING RODS AND PISTONS”. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing For installation, reverse the removal procedure.
  • Page 307: Checking The Crankshaft

    CRANKSHAFT EAS00395 CHECKING THE CRANKSHAFT 1. Measure: S crankshaft runout Out of specification ! Replace the crank- shaft. Crankshaft runout Less than 0.03 mm (0.0012 in) 2. Check: S crankshaft journal surfaces S crankshaft pin surfaces S bearing surfaces Scratches/wear ! Replace the crankshaft. CHECKING THE CRANKSHAFT JOURNAL BEARINGS 1.
  • Page 308 CRANKSHAFT c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crank- case. NOTE: Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the up- per crankcase.  d. Put a piece of Plastigauge 2 on each crankshaft journal.
  • Page 309 CRANKSHAFT g. Remove the lower crankcase and the crank- shaft journal lower bearings.  h. Measure the compressed Plastigauge width c on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. 2.
  • Page 310: Installing The Crankshaft

    CRANKSHAFT EAS00407 INSTALLING THE CRANKSHAFT 1. Install: S crankshaft journal upper bearings 1 (into the upper crankcase) NOTE: S Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the upper crankcase. S Be sure to install each crankshaft journal up- per bearing in its original place.
  • Page 311: Transmission

    TRANSMISSION EAS00419 TRANSMISSION TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the part in the order listed.
  • Page 312 TRANSMISSION 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Main axle assembly Oil pipe Oil baffle plate Thrust plate Washer For installation, reverse the removal procedure.
  • Page 313 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle Disassemble the parts in the order listed. assembly Bearing 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 5-94...
  • Page 314 TRANSMISSION Order Job/Part Q’ty Remarks Bearing housing Bearing For installation, reverse the removal procedure. 5-95...
  • Page 315 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle Disassemble the parts in the order listed. assembly Washer 1st wheel gear Collar 5th wheel gear Circlip Washer Collar 3rd wheel gear Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip...
  • Page 316 TRANSMISSION Order Job/Part Q’ty Remarks 6th wheel gear Circlip Washer 2nd wheel gear Collar Collar Oil seal Bearing Circlip Drive axle For installation, reverse the removal procedure. 5-97...
  • Page 317: Removing The Transmission

    TRANSMISSION EAS00420 REMOVING THE TRANSMISSION 1. Remove: S main axle assembly 1  (with the Torx wrench T30) a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing. b. Tighten the bolts until they contact the crank- case surface.
  • Page 318: Checking The Shift Drum Assembly

    TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: S shift drum grooves Damage/scratches/wear ! Replace the shift drum assembly. S shift drum segment 1 Damage/wear ! Replace the shift drum as- sembly. S shift drum bearing 2 Damage/pitting ! Replace the shift drum assembly.
  • Page 319: Installing The Transmission

    TRANSMISSION 4. Check: S transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect ! Reassemble the transmission axle assemblies. 5. Check: S transmission gear movement Rough movement ! Replace the defective part(s). 6. Check: S circlips Bends/damage/looseness ! Replace. EAS00430 INSTALLING THE TRANSMISSION 1.
  • Page 320 TRANSMISSION 3. Install: S shift fork “R” 1 and “L” 2 S drive axle 3 S shift fork guide bar S shift drum retainer 10 Nm (1.0 mSkg, 7.2 ftSlb) NOTE: S Install shift fork “L” into the groove in the 6th wheel gear and shift fork “R”...
  • Page 321: Cool

    COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 7 Nm (0.7 mSkg, 5.1 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Front cowling inner panel (left and right) Refer to “COWLINGS”...
  • Page 322 COOL RADIATOR 7 Nm (0.7 mSkg, 5.1 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Radiator fan For installation, reverse the removal procedure.
  • Page 323: Checking The Radiator

    COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: S radiator fins Obstruction ! Clean. Apply compressed air to the rear of the radia- tor. Damage ! Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.
  • Page 324: Installing The Radiator

    COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Install: S radiator S coolant hoses 2. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 3. Check: S cooling system Leaks ! Repair or replace any faulty part.
  • Page 325: Oil Cooler

    COOL OIL COOLER EAS00457 OIL COOLER 10 Nm (1.0 mSkg, 7.2 ftSlb) 63 Nm (6.3 mSkg, 46 ftSlb) Order Job/Part Q’ty Remarks Removing the oil cooler Remove the parts in the order listed. Radiator assembly Refer to “RADIATOR”. Engine oil Drain.
  • Page 326 COOL OIL COOLER 10 Nm (1.0 mSkg, 7.2 ftSlb) 63 Nm (6.3 mSkg, 46 ftSlb) Order Job/Part Q’ty Remarks O-ring Water pump outlet hose Radiator outlet hose For installation, reverse the removal procedure.
  • Page 327: Checking The Oil Cooler

    COOL OIL COOLER EAS00458 CHECKING THE OIL COOLER 1. Check: S oil cooler Cracks/damage ! Replace. 2. Check: S oil cooler inlet hose S oil cooler outlet hose Cracks/damage/wear ! Replace. EAS00459 INSTALLING THE OIL COOLER 1. Clean: S mating surfaces of the oil cooler and the crankcase (with a cloth dampened with lacquer thinner) 2.
  • Page 328: Thermostat

    COOL THERMOSTAT EAS00460 THERMOSTAT 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Front cowling inner panel (left and right) Refer to “COWLINGS” Fuel tank Refer to “FUEL TANK”...
  • Page 329: Checking The Thermostat

    COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: S thermostat 1 Does not open at 71 X 85_C (160 X 185_F) ! Replace. a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d.
  • Page 330: Installing The Thermostat

    COOL THERMOSTAT EAS00466 INSTALLING THE THERMOSTAT 1. Install: S thermostat NOTE: Install the thermostat with its breather hole a facing up. 2. Install: S thermostat cover 12 Nm (1.2 mSkg, 8.7 ftSlb) NOTE: Before installing the thermostat cover to the cyl- inder head, lubricate the O-ring with a thin coat of lithium soap based grease.
  • Page 331: Water Pump

    COOL WATER PUMP EAS00468 WATER PUMP 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. NOTE: It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil.
  • Page 332 COOL WATER PUMP 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Disassembling the water pump Disassemble the parts in the order listed. Water pump cover O-ring Impeller shaft Circlip Water pump seal Oil seal Bearing Water pump housing O-ring Copper washer For assembly, reverse the disassembly...
  • Page 333: Disassembling The Water Pump

    COOL WATER PUMP EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: S water pump cover S O-ring S circlip S impeller shaft 2. Remove: S water pump seal 1 NOTE: Remove the water pump seal from the outside of the water pump housing. 2 Water pump housing 3.
  • Page 334: Checking The Water Pump

    Never lubricate the water pump seal surface with oil or grease. NOTE: S Install the water pump seal with the special tools. S Before installing the water pump seal, apply Yamaha bond No.1215 or Quick Gasket 2 to the water pump housing 3 . 6-14...
  • Page 335 WATER PUMP Mechanical seal installer 90890-04078, YM-33221 4 Middle driven shaft bearing driver 90890-04058, YM-04058 5 Quick Gasket ACC-11001-05-01 Yamaha bond #1215 90890-85505 A Push down. 3. Install: S rubber damper S rubber damper holder NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface.
  • Page 336: Installing The Water Pump

    COOL WATER PUMP INSTALLING THE WATER PUMP 1. Install: S O-ring S copper washer S water pump assembly 10 Nm (1.0 mSkg, 7.2 ftSlb) NOTE: Align the projection a at the oil pump shaft and water pump shaft groove b . 2.
  • Page 337: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM Ignition coil Throttle position sensor Battery Air filter case Fuel injector Intake air temperature sensor Catalytic converter Fuel injection system relay Fuel delivery hose Crankshaft position sensor Engine trouble warning light Fuel tank Coolant temperature sensor Lean angle cut-off switch...
  • Page 338: Wiring Diagram

    FUEL INJECTION SYSTEM WIRING DIAGRAM Main switch Fuse (fuel injection) Fuse (main) Battery Starting circuit cut-off relay Sidestand switch Neutral switch Fuel pump Throttle position sensor Intake air pressure sensor Lean angle cut-off switch Crankshaft position sensor Intake air temperature sensor Coolant temperature sensor Cylinder #1-injector Cylinder #2-injector...
  • Page 339: Ecu's Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS00899 ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 340: Fail-Safe Action

    FUEL INJECTION SYSTEM EAS00902 ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
  • Page 341 FUEL INJECTION SYSTEM Communication error with the meter ECU internal malfunction No signals are received from Er-1 – Unable Unable (output signal error) the ECU. No signals are received from ECU internal malfunction Er-2 the ECU within the specified – Unable Unable (output signal error)
  • Page 342: Troubleshooting Chart

    FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. * Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light does not come The engine trouble warning light comes on.
  • Page 343: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without con- necting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Setting the diagnostic mode 1.
  • Page 344 FUEL INJECTION SYSTEM 7. Verify the operation of the sensor or actuator. S Sensor operation The data representing the operating condi- tions of the sensor appears on the trip LCD. S Actuator operation Set the engine stop switch to “ON” to operate the actuator.
  • Page 345 FUEL INJECTION SYSTEM Fault code table Fault Diagnostic Symptom Probable cause of malfunction code No. code S Open or short circuit in wiring harness. No normal signals are received from S Defective crankshaft position sensor. the crankshaft position sensor. S Malfunction in pickup rotor. —...
  • Page 346 FUEL INJECTION SYSTEM Fault Diagnostic Symptom Probable cause of malfunction code No. code S Malfunction in ECU. (The program and data are not Faulty ECU memory. When this malfunction is detected, the code properly written on or read from the internal memory.) —...
  • Page 347 FUEL INJECTION SYSTEM EAS00907 Diagnostic mode table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “DIAGNOSTIC MODE”. NOTE: S Check the intake air temperature and coolant temperature as close as possible to the intake air tem- perature sensor and the coolant temperature sensor respectively.
  • Page 348 FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) AI system solenoid After 1 second has elapsed from the time the engine stop Check the operating sound of switch has been turned from OFF to ON, it actuates the AI the AI system solenoid 5 times system solenoid five times every second and illuminates the with the engine stop...
  • Page 349: Troubleshooting Details

    FUEL INJECTION SYSTEM EAS00908 TROUBLESHOOTING DETAILS This section describes the countermeasures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order. After the check and service of the malfunctioned part has been completed, reset the meter display ac- cording to the “Reinstatement method”.
  • Page 350 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor - open or short circuit detected. Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by Inspect the coupler for any pins that...
  • Page 351 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor - hose system malfunction (clogged or detached hose). Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Intake air pressure sensor hose de-...
  • Page 352 FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Used diagnostic code No. 01 (throttle position sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Installed condition of throttle position Check the installed area for looseness or pinching. Reinstated by sensor.
  • Page 353 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit detected from the intake air temperature sensor. Used diagnostic code No. 05 (intake air temperature sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Installed condition of sensor Check the installed area for looseness or Reinstated by...
  • Page 354 FUEL INJECTION SYSTEM Fault code No. Symptom The motorcycle has overturned. Used diagnostic code No. 08 (lean angle cut-off switch) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by The motorcycle has overturned. Raise the motorcycle upright. turning the Installed condition of the lean angle cut- Check the installed area for looseness or...
  • Page 355 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the ignition coil (#1, #4). Used diagnostic code No. 30 (ignition coil #1, #4) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of connector If there is a malfunction, repair it and connect it...
  • Page 356 FUEL INJECTION SYSTEM Fault code No. Symptom 1 No normal signals are received from the speed sensor. 2 Open or short circuit is detected in the neutral switch. Used diagnostic code No. 07 (speed sensor) ! A1 X A4 No. 21 (neutral switch) ! B1 X B4 Order Inspection operation item and probable Operation item and countermeasure Reinstatement...
  • Page 357 FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09 (fuel system voltage) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Connected condition of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that securely.
  • Page 358 FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading or writing on EEP-ROM (CO adjustment value). Used diagnostic No. 60 (EEP-ROM improper cylinder indication) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Malfunction in ECU Execute diagnostic code 60 Reinstated by...
  • Page 359 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Used diagnostic code No. – – Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Connected condition of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that securely.
  • Page 360 FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Used diagnostic code No. – – Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Connected condition of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that securely.
  • Page 361: Throttle Bodies

    THROTTLE BODIES EAS00909 THROTTLE BODIES Order Job/Part Q’ty Remarks Removing the throttle bodies Remove the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Front cowling inner panel (left and right) Refer to “COWLINGS” in chapter 3. Fuel tank Refer to “FUEL TANK”...
  • Page 362 THROTTLE BODIES Order Job/Part Q’ty Remarks Plunger control unit hose Disconnect For installation, reverse the removal procedure. 7-26...
  • Page 363: Injectors

    THROTTLE BODIES EAS00910 INJECTORS Order Job/Part Q’ty Remarks Removing the injectors Remove the parts in the order listed. Throttle position sensor coupler Disconnect Intake air pressure sensor coupler Disconnect Cylinder #1-injector coupler Cylinder #2-injector coupler Cylinder #3-injector coupler Cylinder #4-injector coupler Sub wire harness Negative pressure hose Intake air pressure sensor...
  • Page 364: Checking The Injectors

    THROTTLE BODIES EAS00911 CAUTION: The throttle bodies should not be disas- sembled. EAS00912 CHECKING THE INJECTORS 1. Check: S injectors Damage ! Replace. EAS00913 CHECKING THE THROTTLE BODIES 1. Check: S throttle bodies Cracks/damage ! Replace the throttle bo- dies as a set. 2.
  • Page 365: Checking The Fuel Pump And Pressure Regulator Operation

    THROTTLE BODIES CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: S fuel pump operation Refer to “FUEL TANK” in chapter 3. a. Remove the seat fuel tank. Refer to “SEAT AND FUEL TANK” in chapter b. Connect the pressure gauge 1 and adapter 2 onto the fuel injection pipe.
  • Page 366: Checking And Adjusting The Throttle Position Sensor

    THROTTLE BODIES EAS00916 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. 1. Check: S throttle position sensor a. Disconnect the throttle position sensor cou- pler. b.
  • Page 367 THROTTLE BODIES f. While slowly opening the throttle, check that the throttle position sensor resistance is with- in the specified range. The resistance does not change or it changes abruptly ! Replace the throttle position sensor. The slot is worn or broken ! Replace the throttle position sensor.
  • Page 368: Air Induction System

    AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.
  • Page 369: Air Induction System Diagrams

    AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut-off valve A To cylinder #1 and #2 2 Reed valve B To cylinder #3 and #4 3 To air filter case 7-33...
  • Page 370: Checking The Air Induction System

    AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: S hoses Loose connection ! Connect properly. Cracks/damage ! Replace. S pipes Cracks/damage ! Replace. 2. Check: S reed valve 1 S reed valve stopper S reed valve seat Cracks/damage ! Replace the reed valve.
  • Page 371 AIR INDUCTION SYSTEM 5. Check S AI system solenoid a. Remove the AI system solenoid coupler from the wire harness. b. Connect the pocket tester (Ω 1) to the AI system solenoid terminal as shown. Tester positive probe ! brown/red 1 Tester negative probe ! red/white 2 c.
  • Page 372: Elec

    ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS Main switch Oil level switch Front brake light switch Radiator fan motor Starter relay Horn Battery Ignition coil Fuse box Rear brake light switch Neutral switch Sidestand switch...
  • Page 373 ELEC ELECTRICAL COMPONENTS Coolant temperature sensor Radiator fan motor relay Intake air temperature sensor Turn signal relay Intake air pressure sensor Rectifier/ regulator Fuel pump Throttle position sensor Lean angle cut-off switch Starting circuit cut-off relay Dimmer relay...
  • Page 374: Checking Switch Continuity

    ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY 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. CAUTION: Never insert the tester probes into the cou- pler terminal slots.
  • Page 375: Checking The Switches

    ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.
  • Page 376: Checking The Bulbs And Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear ! Repair or replace the bulb, bulb socket or both.
  • Page 377: Checking The Condition Of The Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS CAUTION: S Be sure to hold the socket firmly when re- moving the bulb. Never pull the lead, other- wise it may be pulled out of the terminal in the coupler. S Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adverse-...
  • Page 378: Checking The Leds

    ELEC CHECKING THE BULBS AND BULB SOCKETS Pocket tester 90890-03112, YU-3112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. a. Install a good bulb into the bulb socket. b.
  • Page 379: Ignition System

    ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM Main switch Fuse (main) Ignition coil #1 and #4 Battery ignition coil #2 and #3 Starting circuit cut-off relay Spark plug Sidestand switch Engine stop switch Neutral switch Fuse (ignition) Lean angle cut-off switch Clutch switch Crankshaft position sensor...
  • Page 380: Troubleshooting

    ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING AND CHARGING spark or intermittent spark). THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1.
  • Page 381 ELEC IGNITION SYSTEM EAS00743 4. Ignition spark gap The following procedure applies to all of the spark plugs. S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker and spark plug cap as shown. S Set the main switch to “ON”. S Measure the ignition spark gap Spark plug cap resistance S Crank the engine by pushing the starter...
  • Page 382 ELEC IGNITION SYSTEM Negative tester probe ! Crankshaft position sensor resis- spark plug lead tance Positive tester probe ! 248 X 372 Ω at 20_C (68_F) spark lug lead (between gray and black) S Is the crankshaft position sensor OK? Replace the crank- shaft position sen- sor.
  • Page 383 ELEC IGNITION SYSTEM EAS00752 Positive tester probe ! 11. Sidestand switch sky blue S Check the sidestand switch for continuity. Negative tester probe ! Refer to “CHECKING THE SWITCHES”. black/red S Is the sidestand switch OK? Positive tester probe ! continuity blue/green Negative tester probe !
  • Page 384 ELEC IGNITION SYSTEM EAS00754 15. Wiring S Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the ignition system’s wiring properly con- nected and without defects? Replace the ECU. Properly connect or repair the ignition system’s wiring. 8-13...
  • Page 385: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Sidestand switch Fuse (main) Neutral switch Starter relay Engine stop switch Starter motor Start switch Battery Fuse (ignition) Starting circuit cut-off relay Clutch switch 8-14...
  • Page 386: Starting Circuit Cut-Off System Operation

    ELEC ELECTRIC STARTING SYSTEM EAS00756 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: S The transmission is in neutral (the neutral switch is closed).
  • Page 387: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses Minimum open-circuit voltage 2.
  • Page 388 ELEC ELECTRIC STARTING SYSTEM EAS00759 4. Starting circuit cut-off relay S Disconnect the starting circuit cut-off relay coupler from the wire harness. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown.
  • Page 389 ELEC ELECTRIC STARTING SYSTEM EAS00752 EAS00766 9. Sidestand switch 12. Wiring S Check the sidestand switch for continuity. S Check the entire starting system’s wiring. Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”. S Is the sidestand switch OK? S Is the starting system’s wiring properly con- nected and without defects? Replace the side-...
  • Page 390: Starter Motor

    ELEC STARTER MOTOR EAS00767 STARTER MOTOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 5 Nm (0.5 mSkg, 3.6 ftSlb) Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Front cowling inner panel (left and right) Refer to “COWLINGS”...
  • Page 391 ELEC STARTER MOTOR EAS00768 7.8 Nm (0.78 mSkg, 5.6 ftSlb) 3.4 Nm (0.34 mSkg, 2.5 ftSlb) Order Job/Part Q’ty Remarks Disassembling the starter motor Disassembly the parts in the order listed. O-ring Front cover Lock washer Oil seal Bearing Washer set Rear cover Washer set O-ring...
  • Page 392: Checking The Starter Motor

    ELEC STARTER MOTOR EAS00770 CHECKING THE STARTER MOTOR 1. Check: S commutator Dirt ! Clean with 600 grit sandpaper. 2. Measure: S commutator diameter a Out of specification ! Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3.
  • Page 393: Assembling The Starter Motor

    ELEC STARTER MOTOR 5. Measure: S brush length a . Out of specification ! Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: S brush spring force Out of specification ! Replace the brush springs as a set.
  • Page 394 ELEC STARTER MOTOR 3. Install: S starter motor yoke 1 S O-ring 2 S front cover 3 Srear cover 4 S bolts 5 3.4 Nm (0.34 mSkg, 2.5 ftSlb) NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers.
  • Page 395: Charging System

    ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Fuse (main) Battery 8-24...
  • Page 396: Troubleshooting

    ELEC CHARGING SYSTEM EAS00774 Minimum open-circuit voltage TROUBLESHOOTING 12.8 V or more at 20_C (68_F) The battery is not being charged. S Is the battery OK? Check: 1. main fuse 2. battery S Clean the battery 3. charging voltage 4. stator coil lead terminals.
  • Page 397 ELEC CHARGING SYSTEM EAS00776 4. Stator coil lead 5. Stator coil resistance S Disconnect stator coil lead coupler. S Remove the generator cover. S Connect the pocket tester (Ω S Connect the pocket tester (Ω 1) to the sta- 1) to the sta- tor coil lead coupler as shown.
  • Page 398: Lighting System

    ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 8-27...
  • Page 399 ELEC LIGHTING SYSTEM Main switch Fuse (main) Battery High beam indicator light Fuse (headlight) Fuse (ignition) Fuse (tail) License plate light Tail / brake light Dimmer switch Dimmer relay Headlight (high beam) Headlight (low beam) Front turn signal/position light (right) Front turn signal/position light (left) 8-28...
  • Page 400: Troubleshooting

    ELEC LIGHTING SYSTEM EAS00781 Minimum open-circuit voltage TROUBLESHOOTING 12.8 V or more at 20_C (68_F) Any of the following fail to light: headlight, S Is the battery OK? high beam indicator light, taillight, licence light or meter light. Check: S Clean the battery 1.
  • Page 401 ELEC LIGHTING SYSTEM 5. Dimmer relay S Disconnect the dimmer relay from the cou- pler. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the dimmer relay as shown. Positive battery lead ! red/yellow Negative battery lead ! yellow/black Positive tester probe ! red/yellow Negative tester probe ! green S Does the dimmer relay have continuity be-...
  • Page 402: Checking The Lighting System

    ELEC LIGHTING SYSTEM EAS00788 Headlight CHECKING THE LIGHTING SYSTEM Positive tester probe ! black 1. The headlight and the high beam indicator Negative tester probe ! black/yellow light fail to come on. Headlight coupler (wire harness side) 1. Headlight bulb and socket High beam S Check the headlight bulb and socket for con- tinuity.
  • Page 403 ELEC LIGHTING SYSTEM EAS00792 2. The license plate light fails to come on. 1. License plate light bulb and socket S Check the license plate light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. S Are the license plate light bulb and socket Replace the license plate light bulb, sock- et or both.
  • Page 404 ELEC LIGHTING SYSTEM EAS00790 EAS00791 3. The tail/brake light fails to come on. 4. The turn signal/position light fails to come on. 1. Tail/brake light bulb and socket 1. Turn signal/position light and socket S Check the tail/brake light bulb and socket for S Check the turn signal/position light bulb and continuity.
  • Page 405: Signaling System

    ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 8-34...
  • Page 406 ELEC SIGNALING SYSTEM Main switch Fuse (backup) Fuse (main) Battery Starting circuit cut-off relay Neutral switch Fuel pump Oil level waning light Neutral indicator light Multi-function meter Turn signal indicator light Oil level switch Front brake light switch Fuse (signal) Fuse (ignition) Fuse (tail) Turn signal relay...
  • Page 407: Troubleshooting

    ELEC SIGNALING SYSTEM EAS00794 TROUBLESHOOTING S Any of the following fail to light: turn sig- nal light, brake light or an indicator light. S Clean the battery S The horn fails to sound. terminals. S Recharge or re- Check: place the battery. 1.
  • Page 408 ELEC SIGNALING SYSTEM EAS00797 2. Voltage 2. The tail/brake light fails to come on. S Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket horn connector at the horn terminal as S Check the tail/brake light bulb and socket for shown.
  • Page 409 ELEC SIGNALING SYSTEM S Turn the main switch to “ON”. S Measure the voltage (DC 12 V) on brown/ green at the turn signal relay coupler (wire wiring circuit This circuit is OK. harness side). from the main switch S Is the voltage within specification? to the tail/brake light coupler is faulty and must be repaired.
  • Page 410 ELEC SIGNALING SYSTEM Left turn signal/position light Positive tester probe ! ground Negative tester probe ! chocolate Replace the meter Right turn signal/position light assembly. Positive tester probe ! ground Negative tester probe ! dark green 2. Neutral switch S Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”.
  • Page 411 ELEC SIGNALING SYSTEM EAS00802 S Are the tester readings correct? 5. The oil level warning light fails to come on. 1. Oil level warning light (LEDs) S Check the oil level warning light for continu- ity. Replace the starting When the main switch is turn to “ON”, the oil circuit cut-off relay.
  • Page 412 ELEC SIGNALING SYSTEM EAS00803 3. Voltage 6. The fuel level warning light fails to come on. S Connect the pocket tester (DC 20 V) to the 1. Fuel sender meter assembly coupler (wire harness side) S Drain the fuel from the fuel tank and remove as shown.
  • Page 413 ELEC SIGNALING SYSTEM 2. Voltage S Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Positive tester probe ! green/white Negative tester probe ! black/white S Turn the main switch to “ON”. S Measure the voltage (DC 12 V) of green/white and black/white...
  • Page 414: Cooling System

    ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM Main switch Fuse (main) Battery Coolant temperature sensor Fuse (radiator fan motor) Radiator fan motor relay Radiator fan motor Fuse (ignition) 8-43...
  • Page 415: Troubleshooting

    ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. S The radiator fan motor fails to turn. S The coolant temperature indicator light Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. fails to light when the engine is warm. Minimum open-circuit voltage Check: 12.8 V or more at 20_C (68_F)
  • Page 416 ELEC COOLING SYSTEM EAS00809 5. Radiator fan motor relay 4. Radiator fan motor S Disconnect the radiator fan motor coupler S Disconnect the radiator fan motor relay from the wire harness. form the wire harness. S Connect the battery (DC 12 V) as shown. S Connect the pocket tester (Ω...
  • Page 417 ELEC COOLING SYSTEM EAS00812 6. Coolant temperature sensor S Remove the coolant temperature sensor. S Connect the pocket tester (Ω 1k) to the coolant temperature sensor as shown. S Immerse the coolant temperature sensor in a container filled with coolant NOTE: Make sure the coolant temperature sensor terminals do not get wet.
  • Page 418: Fuel Pump System

    ELEC FUEL PUMP SYSTEM EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM Main switch Fuse (fuel injection) Fuse (main) Battery Starting circuit cut-off relay Fuel pump Engine stop switch Fuse (ignition) 8-47...
  • Page 419 ELEC FUEL PUMP SYSTEM EAS00815 FUEL PUMP SYSTEM Battery The ECU includes the control unit for the Fuse (main) fuel pump. Main switch Fuse (ignition) Engine stop switch Fuse (fuel injection) Starting circuit cut-off relay (fuel injection system relay) Fuel pump 8-48...
  • Page 420: Troubleshooting

    ELEC FUEL PUMP SYSTEM EAS00816 EAS00739 TROUBLESHOOTING 2. Battery If the fuel pump fails to operate. S Check the condition of the battery Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition and fuel injection fuses Minimum open-circuit voltage 2.
  • Page 421 ELEC FUEL PUMP SYSTEM EAS00759 EAS00817 5 Starting circuit cut-off relay (fuel injection 6. Fuel pump resistance system relay) S Disconnect the fuel pump coupler from the S Disconnect the starting circuit cut-off relay wire harness. S Connect the pocket tester (Ω coupler from the wire harness.
  • Page 422: Checking The Fuel Pump

    ELEC FUEL PUMP SYSTEM EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: S Stop the engine before refueling. S Do not smoke, and keep away from open flames, sparks, or any other source of fire.
  • Page 423: Self-Diagnosis

    ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS The FZ6-SS/FZ6-SSC features a self-diagnosing system for the following circuit(-s): S Fuel pump thermistor S Oil level switch If any of these circuits are defective, their respective condition codes will be displayed on the warning light when the main switch is turned “ON” (irrespective of whether the engine is running or not).
  • Page 424 ELEC SELF-DIAGNOSIS TROUBLESHOOTING 1. Wire harness The warning light starts to indicate the S Check the wire harness for continuity. self-diagnosis sequence. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? Check: 1. fuel pump thermistor 2. oil level switch NOTE: S Before troubleshooting, remove the following Repair or replace the...
  • Page 425 ELEC SELF-DIAGNOSIS 2. Oil level switch 2. Oil level switch CIRCUIT DIAGRAM S Check the oil level switch for continuity. Refer to “The oil level warning light fails to come on”. S Is the oil level switch OK? Replace the multi- Replace the oil level function meter.
  • Page 426: Troubleshooting

    TRBL STARTING FAILURES SHTG EAS00844 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
  • Page 427: Trbl Shtg

    STARTING FAILURE/INCORRECT ENGINE IDLING SPEED/ TRBL POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE SHTG Switches and wiring Starting system S Faulty main switch S Faulty starter motor S Faulty engine stop switch S Faulty starter relay S Broken or shorted wiring S Faulty starting circuit cut-off relay S Faulty neutral switch S Faulty starter clutch S Faulty start switch...
  • Page 428: Faulty Gear Shifting

    TRBL FAULTY GEAR SHIFTING/FAULTY CLUTCH SHTG EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT JUMPS OUT OF GEAR Refer to “CLUTCH DRAGS”. Shift shaft S Incorrect shift pedal position SHIFT PEDAL DOES NOT MOVE S Improperly returned stopper lever Shift shaft S Improperly adjusted shift rod Shift forks S Bent shift shaft.
  • Page 429: Overheating

    OVERHEATING/OVERCOOLING/ TRBL POOR BRAKING PERFORMANCE SHTG EAS00855 OVERHEATING ENGINE FUEL SYSTEM Clogged coolant passages Throttle body(-ies) S Cylinder head(s) and piston(s) S Damaged or loose carburetor joint S Heavy carbon buildup Air filter S Clogged air filter element Engine oil S Incorrect oil level CHASSIS S Incorrect oil viscosity...
  • Page 430: Faulty Front Fork Legs

    TRBL FAULTY FRONT FORK LEGS/UNSTABLE HANDLING SHTG EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL S Bent, damaged or rusty inner tube S Cracked or damaged outer tube S Improperly installed oil seal S Damaged oil seal lip S Incorrect oil level (high) S Loose damper rod assembly bolt S Damaged damper rod assembly bolt copper washer S Cracked or damaged cap bolt O-ring...
  • Page 431: Faulty Lighting Or Signaling System

    TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON TURN SIGNAL DOES NOT COME ON S Wrong headlight bulb S Faulty turn signal switch S Too many electrical accessories S Faulty turn signal relay S Hard charging S Burnt-out turn signal bulb S Incorrect connection...
  • Page 432 FZ6-SS/FZ6-SSC WIRING DIAGRAM Br/W G/W Br/W Y R/B R/L R/W L/R Y Y/L R/G P/W B/L G/B L G/W W Ch Dg Lg B/W WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS HEADLIGHT SUB WIRE HARNESS 2...
  • Page 433 FZ6-SS/FZ6-SSC WIRING DIAGRAM...
  • Page 434 FZ6-SS/FZ6-SSC WIRING DIAGRAM Main switch Hazard switch A.C. magneto Turn signal switch Rectifier/ regulator Horn switch Fuse (backup) Horn Fuse (fuel injection) Dimmer relay Fuse (main) Headlight (high beam) Starter relay Headlight (low beam) Starter motor Rear turn signal light (right)

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