Yamaha MT-01 T 2005 Service Manual
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Yamaha MT-01 T 2005 Service Manual

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2005
MT-01(T)
SERVICE MANUAL
5YU1-AE1

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Summary of Contents for Yamaha MT-01 T 2005

  • Page 1 2005 MT-01(T) SERVICE MANUAL 5YU1-AE1...
  • Page 2 EAS20040 MT-01(T) 2005 SERVICE MANUAL ©2004 by Yamaha Motor Co., Ltd. First edition, December 2004 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3 EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 4: How To Use This Manual

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

  • Page 6: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
  • Page 7 INFO...

  • Page 8: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER ............. 1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ................. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7 GASKETS, OIL SEALS AND O-RINGS ............

  • Page 10: Identification

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

  • Page 11: Features

    FEATURES EAS20170 FEATURES ET5YU1009 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 12: Fi System

    FEATURES ET5YU1010 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 392 kPa (3.92 kg/cm², 55.7 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 13: Instrument Functions

    FEATURES Tachometer ET5YU1011 INSTRUMENT FUNCTIONS Multifunction display EW5YU1005 WARNING Be sure to stop the vehicle before making any setting changes to the multifunction dis- play. 1. Tachometer 2. Tachometer red zone The electric tachometer allows the rider to mon- itor the engine speed and keep it within the ideal power range.
  • Page 14 FEATURES To set the clock: If the multifunction display indicates an error 1. Push the “SELECT” button and “RESET” but- code, note the code number, and then check the ton together for at least two seconds. vehicle. Refer to “FUEL INJECTION SYSTEM” 2.
  • Page 15 FEATURES 3. Tachometer needle The brightness can be adjusted for the following: • the tachometer panel (item number “1”) • the LCD (item number “2”) • the tachometer needle (item number “3”) Select the brightness control mode as follows. 1. Turn the key to “OFF”. 2.

  • Page 16: Important Information

    5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...

  • Page 17: Bearings And Oil Seals

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

  • Page 18: Checking The Connections

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

  • Page 19: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 20 SPECIAL TOOLS Tool name/Tool No. Illustration Reference pages Compression gauge 3-10 90890-03081 Engine compression tester YU-33223 Extension 3-10 90890-04082 Oil filter wrench 3-12 90890-01426 YU-38411 Steering nut wrench 3-26, 4-59 90890-01403 Spanner wrench YU-33975 Vacuum/pressure pump gauge set 4-5, 6-9 90890-06756 Fork spring compressor 4-50, 4-55...
  • Page 21 SPECIAL TOOLS Tool name/Tool No. Illustration Reference pages Rod puller 4-53, 4-55 90890-01437 Universal damping rod bleeding tool YM-A8703 YM-A8703 Rod puller attachment (M10) 4-53, 4-55 90890-01436 Universal damping rod bleeding tool YM-A8703 YM-A8703 Ring nut wrench 4-59 90890-01268 Spanner wrench YU-01268 Pivot shaft wrench 5-13...
  • Page 22 Universal clutch holder 5-55, 5-58 90890-04086 YM-91042 Sheave holder 5-55, 5-57, 5-68, 90890-01701 5-69, 5-77, 5-79 Primary clutch holder YS-01880-A Yamaha bond No. 1215 5-57, 5-69, 5-78 90890-85505 Rotor puller 5-68 90890-01080 Stator rotor puller YM-01080-A Pressure gauge 90890-03153 1-13...
  • Page 23 SPECIAL TOOLS Tool name/Tool No. Illustration Reference pages Fuel pressure adapter 90890-03176 YM-03176 Digital circuit tester 6-10 90890-03174 Ignition checker 7-100 90890-06754 Opama pet-4000 spark checker YM-34487 1-14...
  • Page 24 SPEC...

  • Page 25: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................ 2-10 ELECTRICAL SPECIFICATIONS ..............2-14 TIGHTENING TORQUES ................2-17 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-17 ENGINE TIGHTENING TORQUES............2-18 CHASSIS TIGHTENING TORQUES............2-23 LUBRICATION POINTS AND LUBRICANT TYPES ........2-28 ENGINE....................

  • Page 27: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 5YU1 (Europe) 5YU2 (AUS) Dimensions Overall length 2185 mm (86.0 in) Overall width 790 mm (31.1 in) Overall height 1160 mm (45.7 in) Seat height 825 mm (32.5 in) Wheelbase 1525 mm (60.0 in) Ground clearance 143 mm (5.63 in) Minimum turning radius...

  • Page 28: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Air cooled 4-stroke, OHV Displacement 1670.0 cm³ (101.90 cu.in) Cylinder arrangement V-type 2 cylinders Bore × stroke 97.0 × 113.0 mm (3.82 × 4.45 in) Compression ratio 8.40 :1 Standard compression pressure (at sea level) 1200 kPa/200 r/min (170.7 psi/200 r/min) (12.0 kgf/cm²/200 r/min) Minimum–maximum...
  • Page 29 ENGINE SPECIFICATIONS Spark plug (s) Manufacturer/model NGK/DPR7EA-9 Manufacturer/model DENSO/X22EPR-U9 Spark plug gap 0.8–0.9 mm (0.031–0.035 in) Cylinder head Volume 98.60–103.60 cm³ (6.02–6.32 cu.in) Warpage limit* 0.03 mm (0.0012 in) Camshaft Drive system Gear drive Camshaft to crankcase clearance 0.050–0.084 mm (0.0020–0.0033 in) Camshaft lobe dimensions Intake A 38.241–38.341 mm (1.5055–1.5095 in) (cylinder...
  • Page 30 ENGINE SPECIFICATIONS Valve, valve seat, valve guide Valve clearance (cold) Intake 0.00–0.04 mm (0.0000–0.0016 in) Exhaust 0.00–0.04 mm (0.0000–0.0016 in) Valve dimensions Valve head diameter A (intake) 33.90–34.10 mm (1.3346–1.3425 in) Valve head diameter A (exhaust) 27.90–28.10 mm (1.0984–1.1063 in) Valve face width B (intake) 1.300–2.300 mm (0.0512–0.0906 in) Valve face width B (exhaust)
  • Page 31 ENGINE SPECIFICATIONS Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout 0.010 mm (0.0004 in) Valve spring Inner spring Free length (intake) 38.26 mm (1.51 in) Limit 36.26 mm (1.43 in)
  • Page 32 ENGINE SPECIFICATIONS Installed compression spring force (exhaust) 139.00–161.00 N (31.25–36.19 lb) (14.17– 16.42 kgf) Spring tilt (intake) 2.5°/1.9 mm (2.5°/0.075 in) Spring tilt (exhaust) 2.5°/1.9 mm (2.5°/0.075 in) Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Valve lifter Valve lifter outside diameter (intake) 22.962–22.974 mm (0.9040–0.9045 in) Valve lifter outside diameter (exhaust) 22.962–22.974 mm (0.9040–0.9045 in)
  • Page 33 ENGINE SPECIFICATIONS Piston ring Top ring Ring type Barrel Dimensions (B × T) 1.20 × 3.80 mm (0.05 × 0.15 in) End gap (installed) 0.30–0.50 mm (0.01–0.02 in) Limit 0.70 mm (0.0276 in) Ring side clearance 0.030–0.080 mm (0.0012–0.0032 in) Limit 0.120 mm (0.0047 in) 2nd ring...
  • Page 34 ENGINE SPECIFICATIONS Crankshaft Width A 132.80–133.20 mm (5.23–5.24 in) Runout limit C 0.040 mm (0.0016 in) Big end side clearance D 0.320–0.474 mm (0.0126–0.0187 in) Big end radial clearance E 0.037–0.074 mm (0.0015–0.0029 in) Limit 0.09 mm (0.0035 in) ® Journal oil clearance (using plastigauge 0.030–0.062 mm (0.0012–0.0024 in) Limit...
  • Page 35 ENGINE SPECIFICATIONS Shifting mechanism Shift mechanism type Guide bar Shift fork guide bar bending limit 0.025 mm (0.0010 in) Shift fork thickness 6.26–6.39 mm (0.2465–0.2516 in) Air filter Air filter element Oil-coated paper element Fuel pump Pump type Electrical Model/manufacturer 5YU/DENSO Maximum consumption amperage 4.6 A...

  • Page 36: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle 25.00° Trail 103.0 mm (4.06 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 37 CHASSIS SPECIFICATIONS Front brake Type Dual disc brake Operation Right hand operation Front brake lever free play 7.0–19.0 mm (0.28–0.75 in) Front disc brake Disc outside diameter × thickness 320.0 × 4.5 mm (12.60 × 0.18 in) Brake disc thickness limit 4.0 mm (0.16 in) Brake disc deflection limit 0.10 mm (0.0039 in)
  • Page 38 CHASSIS SPECIFICATIONS Front suspension Type Telescopic fork Spring/shock absorber type Coil spring/oil damper Front fork travel 120.0 mm (4.72 in) Fork spring free length 251.0 mm (9.88 in) Limit 246.0 mm (9.69 in) Collar length 100.8 mm (3.97 in) Installed length 235.0 mm (9.25 in) Spring rate K1 9.30 N/mm (53.10 lb/in) (0.95 kgf/mm)
  • Page 39 CHASSIS SPECIFICATIONS Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 50.0 mm (1.97 in) Spring free length 159.5 mm (6.28 in) Limit 156.0 mm (6.14 in) Installed length 150.0 mm (5.91 in) Spring rate K1 186.30 N/mm (1063.77 lb/in) (19.00 kgf/mm) Spring stroke K1...

  • Page 40: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Electric Ignition timing (B.T.D.C.) 10.0°/900 r/min Engine control unit Model/manufacturer F8T83071/MITSUBISHI Ignition coil Model/manufacturer 2JN/MORIC Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω...
  • Page 41 ELECTRICAL SPECIFICATIONS Bulb voltage, wattage × quantity 12 V, 51.0 W × 1 Low beam headlight 12 V, 55.0 W × 1 High beam headlight 12 V, 5.0 W × 3 Auxiliary light Tail/brake light 12 V, 10.0 W × 2 Front turn signal light 12 V, 10.0 W ×...
  • Page 42 ELECTRICAL SPECIFICATIONS Starting circuit cut-off relay Model/manufacturer G8R-30Y-U3/OMRON 162–198 Ω Coil resistance Headlight relay Model/manufacturer ACM33211M05/MATSUSHITA 86.40–105.60 Ω Coil resistance Fuel pump relay Model/manufacturer G8R-30Y-U3/OMRON 162–198 Ω Coil resistance Thermo unit Model/manufacturer 5PX/DENSO 898.38–1098.02 Ω Resistance at 100 °C Fuses Main fuse 50.0 A Headlight fuse...

  • Page 43: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 44: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil tank: Oil pipe bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) Oil tank and oil tank bracket nut 13 Nm (1.3 m·kg, 9.4 ft·lb) Oil tank bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) Oil tank and down tube bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Rocker arm base bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Rocker arm base bolt 24 Nm (2.4 m·kg, 17 ft·lb) Locknut (rocker arm adjusting 20 Nm (2.0 m·kg, 14 ft·lb) screw) Valve lifter case bolt...
  • Page 46 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Stopper lever bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Generator and starter clutch: Oil pipe 2 bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Generator cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Stator coil assembly lead holder 10 Nm (1.0 m·kg, 7.2 ft·lb) screw...
  • Page 47 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Crankshaft: NOTE. Connecting rod bolt (1st) 15 Nm (1.5 m·kg, 11 ft·lb) NOTE. Connecting rod bolt (final) Specified angle 120°–150° Chain drive: Drive sprocket cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Drive chain guide bolt (drive 24 Nm (2.4 m·kg, 17 ft·lb) sprocket side)
  • Page 48 TIGHTENING TORQUES Oil tank tightening sequence: Cylinder head tightening sequence: A. Front cylinder B. Rear cylinder 2-22...

  • Page 49: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting: Engine mounting bolt (left upper 53 Nm (5.3 m·kg, 38 ft·lb) side) Engine mounting bolt (right upper L=80 mm 53 Nm (5.3 m·kg, 38 ft·lb) side) (3.15 in) Engine mounting bolt (right upper...
  • Page 50 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder-#2 right ignition coil 10 Nm (1.0 m·kg, 7.2 ft·lb) bracket bolt Cylinder-#2 left ignition coil 10 Nm (1.0 m·kg, 7.2 ft·lb) bracket bolt Engine bracket (right upper side) 7 Nm (0.7 m·kg, 5.1 ft·lb) and holder bolt Fuel tank bolt 7 Nm (0.7 m·kg, 5.1 ft·lb)
  • Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Shift arm bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Left rider footrest assembly bolt 30 Nm (3.0 m·kg, 22 ft·lb) Right rider footrest assembly bolt 30 Nm (3.0 m·kg, 22 ft·lb) Footrest cover bracket 7 Nm (0.7 m·kg, 5.1 ft·lb) Passenger footrest nut...
  • Page 52 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Grip end 29 Nm (2.9 m·kg, 21 ft·lb) Clutch master cylinder holder bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) Rearview mirror 14 Nm (1.4 m·kg, 10 ft·lb) Front fork and steering head: Upper bracket pinch bolt 26 Nm (2.6 m·kg, 19 ft·lb) Steering stem nut...
  • Page 53 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Drive chain guard bolt (swingarm 7 Nm (0.7 m·kg, 5.1 ft·lb) side) Drive chain guide bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Locknut (drive chain adjusting 16 Nm (1.6 m·kg, 11 ft·lb) bolt) NOTE: 1.

  • Page 54: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head nuts and washers Connecting rod small end and big end Crankshaft journals Piston surfaces Piston pins Connecting rod bolts Camshaft cam lobes and camshaft journals Valve push rods Valve push rod end balls...
  • Page 55 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal lip Yamaha bond Crankcase mating surface No.1215 Yamaha bond Stator coil lead grommet No.1215 Yamaha bond Crankshaft position sensor lead grommet No.1215...

  • Page 56: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Down tube bolt (front and rear) Steering bearings and upper bearing dust cover lip Lower bearing dust seal lip Steering ring nut thread (upper and lower) Main switch bracket spacer outer surfaces Front wheel oil seal lips (left and right) Rear wheel oil seal lips (left and right) Rear wheel drive hub oil seal lip...

  • Page 57: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-31...
  • Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pan 2. Engine oil drain bolt (crankcase) 3. Oil strainer (crankcase) 4. Oil pump 5. Oil pump rotor 1 6. Oil pump rotor 2 7. Check ball 8. Relief valve 9. Oil tank 10.

  • Page 59: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-33...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil delivery pipe 2. Push rod 3. Oil filter cartridge 4. Rocker arm shaft 5. Oil delivery pipe 2 2-34...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Rocker arm shaft 2. Crankshaft 3. Valve lifter 4. Push rod 2-36...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Oil strainer (crankcase) 3. Oil pipe 1 2-38...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 3. Oil pump 4. Oil strainer (crankcase) A. To oil filter cartridge 2-40...

  • Page 67: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-41...
  • Page 68 CABLE ROUTING 1. Air temperature sensor coupler 2. Sub-wire harness 3 coupler 3. Front turn signal light coupler 4. Headlight assembly coupler 5. Headlight coupler (low beam) 6. Wire harness 7. Clutch fluid reservoir hose 8. Left handlebar switch lead 9.
  • Page 69 CABLE ROUTING 2-43...
  • Page 70 CABLE ROUTING 1. Meter assembly lead Q. Route the cylinder-#1 left spark plug lead under the frame boss and to the outside of the wire 2. Clutch hose harness and clutch hose. 3. Left handlebar switch lead R. Route the clutch hose to the outside of the wire 4.
  • Page 71 CABLE ROUTING 2-45...
  • Page 72 CABLE ROUTING 1. Fuel pump lead K. Fasten the wire harness and sub-wire harness 2 with the plastic band at the section just before the 2. Cylinder-#1 right spark plug lead split in the wire harness. Face the end of the plastic 3.
  • Page 73 CABLE ROUTING 2-47...
  • Page 74 CABLE ROUTING 1. Sub-wire harness 2 H. Route the tail/brake light lead and rear turn signal light leads along the side of the rear brake fluid 2. Intake solenoid lead reservoir, making sure that “UPPER” on the 3. ISC (idle speed control) unit lead reservoir is visible.
  • Page 75 CABLE ROUTING 2-49...
  • Page 76 CABLE ROUTING AB.Route the starter motor lead and sub-wire harness 1 under the battery box, making sure that they are routed between the bolt holes in the battery box. AC.Route the seat lock cable under the wire harness to the left of the battery box. Be sure not to pinch the seat lock cable when installing the battery box.
  • Page 77 CABLE ROUTING 2-51...
  • Page 78 CABLE ROUTING 1. Fuel tank 2. Pressure regulator 3. Fuel return hose 4. Fuel hose 5. Fuel return pipe 6. Fuel return hose (fuel return pipe to fuel pump) 7. Fuel pump 8. Fuel pipe 9. Fuel hose (intake manifold assembly to pressure regulator) A.
  • Page 79 CABLE ROUTING 2-53...
  • Page 80 CABLE ROUTING 1. Fuel tank overflow hose 2. Fuel tank breather hose 3. Rollover valve hose 1 4. Rollover valve hose 2 5. Rollover valve 1 6. Rollover valve 2 7. Rollover valve hose 3 8. Rollover valve hose 4 9.
  • Page 81 CABLE ROUTING 2-55...
  • Page 82 CABLE ROUTING 1. Cylinder-#2 intake air pressure sensor 2. Cylinder-#2 ISC (idle speed control) unit outlet hose 3. ISC (idle speed control) unit 4. Intake solenoid vacuum hose (one-way valve to throttle body) 5. Cylinder-#1 ISC (idle speed control) unit outlet hose 6.

  • Page 84: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART....... 3-1 ENGINE ......................3-3 ADJUSTING THE VALVE CLEARANCE ..........3-3 SYNCHRONIZING THE THROTTLE BODIES.......... 3-5 ADJUSTING THE THROTTLE CABLE FREE PLAY ........ 3-7 CHECKING THE SPARK PLUGS ............. 3-8 CHECKING THE IGNITION TIMING............
  • Page 85 ELECTRICAL SYSTEM................. 3-33 CHECKING AND CHARGING THE BATTERY........3-33 CHECKING THE FUSES ................ 3-33 REPLACING THE HEADLIGHT BULBS ..........3-33 ADJUSTING THE HEADLIGHT BEAM ........... 3-34...

  • Page 86: Periodic Maintenance

    • The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. • From 50000 km, repeat the maintenance intervals starting from 10000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ×...
  • Page 87 PERIODIC MAINTENANCE × 1000 km) ANNU- ODOMETER READING ( ITEM CHECK OR MAINTENANCE JOB CHECK Shock absorber as- √ √ √ √ 19 * • Check operation and shock absorber for oil leakage. sembly Rear suspension re- lay arm and connect- √...

  • Page 88: Engine

    ENGINE • Air filter case EAS20470 ENGINE Refer to “GENERAL CHASSIS” on page 4-1. 2. Disconnect: EAS20530 • Spark plug caps ADJUSTING THE VALVE CLEARANCE 3. Remove: The following procedure applies to all of the • Spark plugs valves. 4. Remove: NOTE: •...
  • Page 89 ENGINE d. Measure the valve clearance with a thickness Valve clearance (cold) gauge. Intake 0.00–0.04 mm (0.0000–0.0016 in) Thickness gauge Exhaust 90890-03079 0.00–0.04 mm (0.0000–0.0016 in) Narrow gauge set YM-34483 M MMM M MMM M MMM M MMM M MMM Piston #1 TDC (rear cylinder) L LLL L LLL...

  • Page 90: Synchronizing The Throttle Bodies

    ENGINE M MMM M MMM M MMM M MMM M MMM d. Hold the adjusting screw to prevent it from a. Loosen the locknut “1” with the locknut moving and tighten the locknut to specifica- wrench “2”. tion with the locknut wrench “6”. NOTE: Locknut wrench Set the torque wrench at a right angle to the...
  • Page 91 ENGINE 2. Remove: M MMM M MMM M MMM M MMM M MMM a. Start the engine, warm it up for several min- • Seat utes, and then let it run at the specified en- Refer to “GENERAL CHASSIS” on page 4-1. gine idling speed.

  • Page 92: Adjusting The Throttle Cable Free Play

    ENGINE 9. Install: NOTE: • Air filter case ® Apply locking agent (LOCTITE ) to the threads Refer to “GENERAL CHASSIS” on page 4-1. of the adjusting nut “3”. • Fuel tank c. Loosen the locknut “4” on the accelerator ca- Refer to “FUEL TANK”...

  • Page 93: Checking The Spark Plugs

    ENGINE c. Tighten the locknut “1”. 5. Check: • Electrode “1” Damage/wear → Replace the spark plug. • Insulator “2” Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • Spark plug (with a spark plug cleaner or wire brush) 7.

  • Page 94: Measuring The Compression Pressure

    ENGINE 1. Stand the vehicle on a level surface. 2. Remove: • Air duct “1” • Timing mark accessing screw “2” NOTE: The ignition timing is not adjustable. L LLL L LLL L LLL L LLL L LLL 3. Connect: 5.
  • Page 95 ENGINE M MMM M MMM M MMM M MMM M MMM a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. EWA12940 WARNING To prevent sparking, ground all spark plug leads before cranking the engine.

  • Page 96: Checking The Engine Oil Level

    ENGINE EAS20730 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. NOTE: • Place the vehicle on a suitable stand. • Make sure the vehicle is upright. 2. Start the engine, warm it up for approximately 15 minutes until the oil temperature rises to 60 °C (140 °F), and then turn it off.
  • Page 97 ENGINE 6. Remove: • Engine oil drain bolt (crankcase) “1” d. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. 7. Drain: Oil filter cartridge • Engine oil 17 Nm (1.7 m·kg, 12 ft·lb) (completely from the oil tank and crankcase) 8.

  • Page 98: Adjusting The Clutch Lever

    ENGINE M MMM M MMM M MMM M MMM M MMM NOTE: a. Slightly loosen the oil gallery bolts “1”. Pour the engine oil in two stages. First, pour in 2.5 L of oil, then start the engine and rev it 3 to 5 times.

  • Page 99: Checking The Clutch Fluid Level

    ENGINE ECA13420 CAUTION: Clutch fluid may damage painted surfaces or plastic parts. Therefore, always clean up any spilt clutch fluid immediately. NOTE: In order to ensure a correct reading of the clutch fluid level, make sure the top of the reservoir is horizontal.

  • Page 100: Replacing The Air Filter Element

    ENGINE d. Place the other end of the hose into a con- tainer. e. Slowly squeeze the clutch lever several times. f. Fully squeeze the clutch lever without releas- ing it. g. Loosen the bleed screw. This will release the tension and cause the clutch lever to contact the handlebar grip.

  • Page 101: Checking The Throttle Body Joints

    ENGINE EAS21010 CHECKING THE THROTTLE BODY JOINTS 1. Remove: • Seat Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. 2. Check: •...

  • Page 102: Checking The Oil Tank Breather Hose

    ENGINE • Fuel tank • Muffler bolts “13” Refer to “FUEL TANK” on page 6-1. Front exhaust pipe and front • Seat exhaust pipe joint bolt Refer to “GENERAL CHASSIS” on page 4-1. 20 Nm (2.0 m·kg, 14 ft·lb) Front exhaust pipe and rear EAS21060 CHECKING THE OIL TANK BREATHER exhaust pipe bolt...

  • Page 103: Adjusting The Exup Cables

    ENGINE EXUP cable free play (at the EXUP valve pulley) a: 3 mm (0.12 in) or less b: 0 mm 4. Install: • Seat Refer to “GENERAL CHASSIS” on page 4-1. EAS21100 ADJUSTING THE EXUP CABLES 1. Remove: 4. Adjust: •...
  • Page 104 ENGINE d d c c e. Tighten both locknuts and then slide the rub- ber cover to its original position. f. Remove the pin. g. Turn the main switch to “ON”, check that the EXUP valve pulley contacts the stoppers (ful- ly-open and fully-closed positions), and then check that the notch in the EXUP valve pulley is aligned with the hole in the EXUP valve...

  • Page 105: Chassis

    CHASSIS EAS21140 CHASSIS Installed rear brake master cylinder length 145.3–145.7 mm (5.72–5.74 in) EAS21160 ADJUSTING THE FRONT DISC BRAKE 1. Adjust: • Brake lever position (distance “a” from the throttle grip to the brake lever) NOTE: • While pushing the brake lever forward, turn the adjusting knob “1”...

  • Page 106: Checking The Brake Fluid Level

    CHASSIS EW5YU1001 WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce braking performance and could result in loss of control and possibly an accident.

  • Page 107: Checking The Rear Brake Pads

    CHASSIS 3. Hold the vehicle upright and apply the brake several times. 4. Check: • Brake hoses Brake fluid leakage → Replace the damaged hoses. Refer to “FRONT BRAKE” on page 4-18. EAS21290 CHECKING THE REAR BRAKE HOSE 1. Remove: •...

  • Page 108: Bleeding The Hydraulic Brake System

    CHASSIS M MMM M MMM M MMM M MMM M MMM M MMM M MMM M MMM M MMM M MMM a. Hold the main body “1” of the rear brake light a. Fill the brake fluid reservoir to the proper level switch so that it does not rotate and turn the with the recommended brake fluid.

  • Page 109: Adjusting The Shift Pedal

    CHASSIS M MMM M MMM M MMM M MMM M MMM NOTE: a. Loosen both locknuts “1”. Loosening the bleed screw will release the pres- b. Turn the shift rod “2” in direction “a” or “b” until sure and cause the brake lever to contact the the specified installed shift rod length is ob- throttle grip or the brake pedal to fully extend.

  • Page 110: Lubricating The Drive Chain

    CHASSIS NOTE: Rear wheel axle nut Measure the drive chain slack 85 mm (3.35 in) 150 Nm (15.0 m·kg, 110 ft·lb) “b” from the end of the drive chain guide. L LLL L LLL L LLL L LLL L LLL EAS21440 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting...

  • Page 111: Checking The Front Fork

    CHASSIS M MMM M MMM M MMM M MMM M MMM d. Check the steering head for looseness or a. Remove the lock washer “1”, the upper ring binding by turning the front fork all the way in nut “2”, and the rubber washer “3”. both directions.

  • Page 112: Adjusting The Front Fork Legs

    CHASSIS M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting bolt “1” in direction “a” or “b”. Direction “a” Spring preload is increased (suspension is harder). Direction “b” Spring preload is decreased (suspension is softer). 3.

  • Page 113: Adjusting The Rear Shock Absorber Assembly

    CHASSIS M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw “1” in direction “a” or Compression damping adjusting positions “b”. Minimum 16 click(s) out* Direction “a” (turn in) Standard Rebound damping is increased 7 click(s) out* (suspension is harder).
  • Page 114 CHASSIS M MMM M MMM M MMM M MMM M MMM Spring preload adjusting a. Turn the adjusting knob “1” in direction “a” or positions “b”. Installed spring length Minimum Direction “a” (turn in) 155.0 mm (6.10 in) Rebound damping is increased Standard (suspension is harder).

  • Page 115: Checking The Tires

    CHASSIS Compression damping adjusting Tire air pressure (measured on positions cold tires) Minimum Loading condition 12 click(s) out* 0–90 kg (0–198 lb) Standard Front 10 click(s) out* 250 kPa (36 psi) (2.50 kgf/cm²) Maximum (2.50 bar) 1 click(s) out* Rear 290 kPa (42 psi) (2.90 kgf/cm²) * With the adjusting screw fully turned in (2.90 bar)

  • Page 116: Checking The Wheels

    1. Check: en if a tire combination other than one • Wheel approved by Yamaha is used on this vehicle. Damage/out-of-round → Replace. EWA13260 WARNING Never attempt to make any repairs to the wheel.

  • Page 117: Checking And Lubricating The Cables

    CHASSIS EAS21740 NOTE: LUBRICATING THE REAR SUSPENSION After a tire or wheel has been changed or re- Lubricate the pivoting point and metal-to-metal placed, always balance the wheel. moving parts of the rear suspension. Recommended lubricant EAS21690 CHECKING AND LUBRICATING THE Lithium-soap-based grease CABLES The following procedure applies to all of the in-...

  • Page 118: Electrical System

    ELECTRICAL SYSTEM EAS21750 ECA13690 ELECTRICAL SYSTEM CAUTION: Avoid touching the glass part of the head- EAS21760 light bulb to keep it free from oil, otherwise CHECKING AND CHARGING THE BATTERY the transparency of the glass, the life of the Refer to “ELECTRICAL COMPONENTS” on bulb and the luminous flux will be adversely page 7-85.
  • Page 119 ELECTRICAL SYSTEM ECA13690 CAUTION: Direction “a” Headlight beam moves to the right. Avoid touching the glass part of the head- Direction “b” light bulb to keep it free from oil, otherwise Headlight beam moves to the left. the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
  • Page 120 CHAS...
  • Page 121 CHASSIS GENERAL CHASSIS..................4-1 CHECKING THE AIR FILTER CASE VALVE..........4-5 FRONT WHEEL....................4-6 REMOVING THE FRONT WHEEL............4-8 DISASSEMBLING THE FRONT WHEEL..........4-8 CHECKING THE FRONT WHEEL ............4-8 ASSEMBLING THE FRONT WHEEL............4-9 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-9 CHECKING THE FRONT BRAKE DISCS..........
  • Page 122 HANDLEBAR ....................4-42 REMOVING THE HANDLEBAR.............. 4-44 CHECKING THE HANDLEBAR .............. 4-44 INSTALLING THE HANDLEBAR ............4-44 FRONT FORK....................4-47 REMOVING THE FRONT FORK LEGS..........4-50 DISASSEMBLING THE FRONT FORK LEGS ........4-50 CHECKING THE FRONT FORK LEGS ..........4-51 ASSEMBLING THE FRONT FORK LEGS ..........
  • Page 123 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Seat...
  • Page 124 GENERAL CHASSIS Removing the side covers and headlight assembly 9 Nm (0.9 m kg, 6.5 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 125: General Chassis

    GENERAL CHASSIS Removing the tail/brake light assembly 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 3 4 5 Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat 4-1.
  • Page 126 GENERAL CHASSIS Removing the air filter case and oil catch tank 10 Nm (1.0 m kg, 7.2 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 6-1. Air filter case cover Air filter element Cylinder head breather hose (air filter case to oil...

  • Page 127: General Chassis

    GENERAL CHASSIS ET5YU1013 CHECKING THE AIR FILTER CASE VALVE 1. Check: • Air filter case valve operation M MMM M MMM M MMM M MMM M MMM a. Remove the air filter case (with the air filter case valve). b. Connect the vacuum/pressure pump gauge set “1”...

  • Page 128: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 35 Nm (3.5 m kg, 25 ft • • 35 Nm (3.5 m kg, 25 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 72 Nm (7.2 m kg, 52 ft •...
  • Page 129 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly procedure.

  • Page 130: Removing The Front Wheel

    FRONT WHEEL EAS21900 EAS21920 REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL 1. Stand the vehicle on a level surface. 1. Check: • Front wheel axle EWA13120 WARNING Roll the wheel axle on a flat surface. Bends → Replace. Securely support the vehicle so that there is no danger of it falling over.

  • Page 131: Assembling The Front Wheel

    FRONT WHEEL NOTE: Place the front wheel on a suitable balancing stand. M MMM M MMM M MMM M MMM M MMM a. Spin the front wheel. b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. •...

  • Page 132: Checking The Front Brake Discs

    FRONT WHEEL EAS22000 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) The following procedure applies to both of the front brake discs. 1. Install: • Front brake disc Front brake disc bolt 18 Nm (1.8 m·kg, 13 ft·lb) ® LOCTITE b. Turn the front wheel 90° so that the heavy spot is positioned as shown.
  • Page 133 FRONT WHEEL Front wheel axle 72 Nm (7.2 m·kg, 52 ft·lb) • Front wheel axle pinch bolt Front wheel axle pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) EC5YU1002 CAUTION: Before tightening the wheel axle, push down hard on the handlebar several times and check if the front fork rebounds smoothly.

  • Page 134: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel 27 Nm (2.7 m kg, 19 ft • • 22 Nm (2.2 m kg, 16 ft • • 150 Nm (15.0 m kg, 110 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 135 REAR WHEEL Removing the rear brake disc and rear wheel sprocket 100 Nm (10.0 m kg, 72 ft • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar (brake disc side) Collar (wheel sprocket side) Dust cover...
  • Page 136 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly procedure. 4-14...

  • Page 137: Removing The Rear Wheel

    REAR WHEEL EAS22040 EAS22090 REMOVING THE REAR WHEEL CHECKING THE REAR WHEEL 1. Stand the vehicle on a level surface. 1. Check: • Rear wheel axle EWA13120 WARNING • Rear wheel Securely support the vehicle so that there is • Wheel bearings no danger of it falling over.

  • Page 138: Assembling The Rear Wheel

    REAR WHEEL EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1.
  • Page 139 REAR WHEEL • Collar (brake disc side) “2” NOTE: The collar (brake disc side) has marks “a” to dis- tinguish it from the collar (wheel sprocket side). 5. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-24. Drive chain slack 40.0–50.0 mm (1.57–1.97 in) 6.

  • Page 140: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kg, 4.3 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
  • Page 141 FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 14 Nm (1.4 m kg, 10 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Drain.
  • Page 142 FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 14 Nm (1.4 m kg, 10 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Front brake master cylinder For installation, reverse the removal...
  • Page 143 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Bleed screw Brake master cylinder body For assembly, reverse the disassembly procedure. 4-21...
  • Page 144 FRONT BRAKE Removing the front brake calipers 6 Nm (0.6 m kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 145 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Front brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly procedure.

  • Page 146: Introduction

    FRONT BRAKE c. Remove the brake caliper. EAS22220 INTRODUCTION d. Hold the dial gauge at a right angle against EWA14100 the brake disc surface. WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.

  • Page 147: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Brake pads steps until the brake disc deflection is within • Brake pad spring specification. NOTE: f. If the brake disc deflection cannot be brought Always install new brake pads and a brake pad within specification, replace the brake disc.

  • Page 148: Removing The Front Brake Calipers

    FRONT BRAKE NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. L LLL L LLL L LLL L LLL L LLL 3. Install: • Brake pad pin • Brake pad clips •...

  • Page 149: Checking The Front Brake Calipers

    FRONT BRAKE EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS EWA13620 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.

  • Page 150: Removing The Front Brake Master Cylinder

    FRONT BRAKE 3. Install: • Front brake pads • Brake pad spring • Brake pad pin • Brake pad clips • Front brake caliper Front brake caliper bolt 35 Nm (3.5 m·kg, 25 ft·lb) Refer to “REPLACING THE FRONT BRAKE 7.

  • Page 151: Assembling The Front Brake Master Cylinder

    FRONT BRAKE 2. Check: • Front brake hose union bolt “2” • Brake master cylinder kit Front brake hose union bolt Damage/scratches/wear → Replace. 30 Nm (3.0 m·kg, 22 ft·lb) 3. Check: • Brake fluid reservoir EWA13530 Cracks/damage → Replace. WARNING •...
  • Page 152 FRONT BRAKE ECA13540 CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-23. 5. Check: • Brake fluid level Below the minimum level mark “a”...

  • Page 153: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 17 Nm (1.7 m kg, 12 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • 22 Nm (2.2 m kg, 16 ft •...
  • Page 154 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 155 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake hose joint Bush Brake master cylinder body For assembly, reverse the disassembly procedure. 4-33...
  • Page 156 REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 22 Nm (2.2 m kg, 16 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks Drain.
  • Page 157 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.3 ft • • 17 Nm (1.7 m kg, 12 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Brake pad shim...

  • Page 158: Introduction

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 5.5 mm (0.22 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...

  • Page 159: Removing The Rear Brake Caliper

    REAR BRAKE 4. Check: NOTE: • Brake fluid level Always install new brake pads, brake pad shims, Below the minimum level mark “a” → Add the and a brake pad spring as a set. recommended brake fluid to the proper level. M MMM M MMM M MMM...

  • Page 160: Checking The Rear Brake Caliper

    REAR BRAKE • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. EWA13610 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston seals. M MMM M MMM M MMM...

  • Page 161: Installing The Rear Brake Caliper

    REAR BRAKE EAS22670 INSTALLING THE REAR BRAKE CALIPER Recommended fluid 1. Install: DOT 4 • Rear brake caliper “1” (temporarily) EWA13090 WARNING • Copper washers • Use only the designated brake fluid. Other • Rear brake hose “2” brake fluids may cause the rubber seals to •...

  • Page 162: Removing The Rear Brake Master Cylinder

    REAR BRAKE EAS22700 EAS22730 REMOVING THE REAR BRAKE MASTER ASSEMBLING THE REAR BRAKE MASTER CYLINDER CYLINDER EWA13520 NOTE: WARNING Before removing the rear brake master cylinder, • Before installation, all internal brake com- drain the brake fluid from the entire brake sys- ponents should be cleaned and lubricated tem.
  • Page 163 REAR BRAKE 7. Adjust: EWA13090 WARNING • Rear brake light operation timing • Use only the designated brake fluid. Other Refer to “ADJUSTING THE REAR BRAKE brake fluids may cause the rubber seals to LIGHT SWITCH” on page 3-22. deteriorate, causing leakage and poor brake performance.

  • Page 164: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 20 Nm (2.0 m kg, 14 ft 14 Nm (1.4 m kg, 10 ft • • • • 29 Nm (2.9 m kg, 21 ft 14 Nm (1.4 m kg, 10 ft • • •...
  • Page 165 HANDLEBAR Removing the handlebar 20 Nm (2.0 m kg, 14 ft 14 Nm (1.4 m kg, 10 ft • • • • 29 Nm (2.9 m kg, 21 ft 14 Nm (1.4 m kg, 10 ft • • • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 166: Removing The Handlebar

    HANDLEBAR EAS22860 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” NOTE: Blow compressed air between the handlebar 3.
  • Page 167 HANDLEBAR NOTE: Grip end • Align the mating surfaces of the clutch master 29 Nm (2.9 m·kg, 21 ft·lb) cylinder holder with the punch mark “a” on the handlebar. M MMM M MMM M MMM M MMM M MMM a. Apply a thin coat of rubber adhesive onto the •...
  • Page 168 HANDLEBAR 9. Install: • Front brake master cylinder assembly • Front brake master cylinder holder “1” Front brake master cylinder holder bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: • Align the end of the brake master cylinder hold- er with the punch mark “a” on the handlebar. •...

  • Page 169: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 26 Nm (2.6 m kg, 19 ft • • 20 Nm (2.0 m kg, 14 ft • • 28 Nm (2.8 m kg, 20 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 170 FRONT FORK Disassembling the front fork legs 20 Nm (2.0 m kg, 14 ft • • 25 Nm (2.5 m kg, 18 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs.
  • Page 171 FRONT FORK Disassembling the front fork legs 20 Nm (2.0 m kg, 14 ft • • 25 Nm (2.5 m kg, 18 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks Inner tube For assembly, reverse the disassembly procedure.

  • Page 172: Removing The Front Fork Legs

    FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the 2.

  • Page 173: Checking The Front Fork Legs

    FRONT FORK d. Remove the cap bolt. EAS23010 CHECKING THE FRONT FORK LEGS e. Remove the rod holder and fork spring com- The following procedure applies to both of the pressor. front fork legs. f. Remove the spacer and nut. 1.

  • Page 174: Assembling The Front Fork Legs

    FRONT FORK ECA14200 CAUTION: • The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork.
  • Page 175 FRONT FORK • Lubricate the outer surface of the inner tube NOTE: with fork oil. Adjust the oil seal clip so that it fits into the outer • Before installing the oil seal, cover the top of tube’s groove. the front fork leg with a plastic bag to protect the oil seal during installation.
  • Page 176 FRONT FORK 14.Measure: • Front fork leg oil level “a” (from the top of the inner tube, with the outer tube fully compressed and without the fork spring) Out of specification → Correct. Level 65.0 mm (2.56 in) 10.Fully compress the front fork leg. 11.Fill: •...
  • Page 177 FRONT FORK j. Install the nut “4” all the way onto the damper rod assembly. d. Install the upper spring seat and nut. e. Reinstall the rod puller attachment. f. Install the spacer. k. Install the damper adjusting rod. g. Press down on the spacer with the fork spring l.

  • Page 178: Installing The Front Fork Legs

    FRONT FORK EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure the outer tube is flush with the top of the handlebar holder.

  • Page 179: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 110 Nm (11.0 m kg, 80 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 2nd 23 Nm (2.3 m kg, 17 ft •...
  • Page 180 STEERING HEAD Removing the lower bracket 110 Nm (11.0 m kg, 80 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 2nd 23 Nm (2.3 m kg, 17 ft •...

  • Page 181: Removing The Lower Bracket

    STEERING HEAD 3. Replace: EAS23110 REMOVING THE LOWER BRACKET • Bearings 1. Stand the vehicle on a level surface. • Bearing races EWA13120 M MMM M MMM M MMM M MMM M MMM WARNING a. Remove the bearing races from the steering Securely support the vehicle so that there is head pipe with a long rod “1”...
  • Page 182 STEERING HEAD 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-25. 3. Install: • Front brake hose joint bracket “1” •...

  • Page 183: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 40 Nm (4.0 m kg, 29 ft • • 40 Nm (4.0 m kg, 29 ft • • 49 Nm (4.9 m kg, 35 ft •...

  • Page 184: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling •...

  • Page 185: Installing The Connecting Arm And Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY • Oil seals Damage/pitting → Replace. 3. Check: • Collars • Spacers Damage/scratches → Replace. EAS23270 INSTALLING THE CONNECTING ARM AND RELAY ARM 1. Lubricate: • Spacers • Bearings Recommended lubricant Lithium-soap-based grease 2. Install: • Bearing “1” (to the relay arm) •...

  • Page 186: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY Relay arm nut (relay arm and connecting arm) 49 Nm (4.9 m·kg, 35 ft·lb) EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: • Spacers • Bearings Recommended lubricant Lithium-soap-based grease 2. Install: • Relay arm (to the swingarm) NOTE: When installing the relay arm, lift up the swing-...

  • Page 187: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 25 Nm (2.5 m kg, 18 ft •...
  • Page 188 SWINGARM Removing the swingarm 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 25 Nm (2.5 m kg, 18 ft • • 17 10 25 Nm (2.5 m kg, 18 ft...

  • Page 189: Removing The Swingarm

    SWINGARM EAS23350 EAS23360 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: • Swingarm EWA13120 WARNING Bends/cracks/damage → Replace. Securely support the vehicle so that there is 2. Check: no danger of it falling over. •...
  • Page 190 SWINGARM • Bearing “3” • Oil seal “4” Installed depth of bearing “a” 6.3 mm (0.25 in) Installed depth of bearing “b” 5.7 mm (0.22 in) Installed depth of oil seal “c” 0.5–1.0 mm (0.02–0.04 in) Installed depth of oil seal “d” 0.5 mm (0.02 in) Installed depth of bearing “e”...

  • Page 191: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain 10 Nm (1.0 m kg, 7.2 ft 26 Nm (2.6 m kg, 19 ft • • • • 24 Nm (2.4 m kg, 17 ft • • 95 Nm (9.5 m kg, 68 ft •...

  • Page 192: Removing The Drive Chain

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

  • Page 193: Checking The Drive Sprocket

    CHAIN DRIVE b. Correct L LLL L LLL L LLL L LLL L LLL 1. Drive chain roller 4. Check: 2. Drive chain sprocket • O-rings “1” Damage → Replace the drive chain. EAS23470 • Drive chain rollers “2” CHECKING THE REAR WHEEL SPROCKET Damage/wear →...
  • Page 194 CHAIN DRIVE 3. Install: • Clutch release cylinder Refer to “INSTALLING THE CLUTCH RE- LEASE CYLINDER” on page 5-62. 4-72...
  • Page 196 ENGINE ENGINE REMOVAL ..................5-1 CHECKING THE OIL PIPES ..............5-2 CHECKING THE OIL STRAINER ............. 5-2 INSTALLING THE OIL TANK ..............5-2 REMOVING THE MUFFLER END COVERS ..........5-4 INSTALLING THE MUFFLER END COVERS........... 5-4 REMOVING THE ENGINE ..............5-13 INSTALLING THE ENGINE..............
  • Page 197 CLUTCH ......................5-46 REMOVING THE CLUTCH ..............5-55 REMOVING THE PRIMARY DRIVE GEAR ..........5-55 CHECKING THE FRICTION PLATES............. 5-55 CHECKING THE CLUTCH PLATES ............5-56 CHECKING THE CLUTCH SPRING PLATE........... 5-56 CHECKING THE CLUTCH HOUSING ............ 5-56 CHECKING THE CLUTCH BOSS............5-56 CHECKING THE PRESSURE PLATE ............
  • Page 198 OIL PUMP...................... 5-81 CHECKING THE OIL PUMP ..............5-84 CHECKING THE RELIEF VALVE ............5-84 CHECKING THE OIL STRAINER ............5-84 ASSEMBLING THE OIL PUMP............... 5-84 INSTALLING THE OIL PUMP ..............5-85 CRANKSHAFT ....................5-86 REMOVING THE CONNECTING RODS ..........5-87 CHECKING THE CRANKSHAFT AND CONNECTING RODS ....

  • Page 200: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the oil tank 13 Nm (1.3 m kg, 9.4 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 13 Nm (1.3 m kg, 9.4 ft •...

  • Page 201: Checking The Oil Pipes

    ENGINE REMOVAL ET5YU1027 CHECKING THE OIL PIPES 1. Check: • Oil pipes Damage → Replace. Obstruction → Wash and blow out with com- pressed air. ET5YU1028 CHECKING THE OIL STRAINER 1. Check: • Oil strainer (oil tank) Damage → Replace. Contaminants →...
  • Page 202 ENGINE REMOVAL Removing the exhaust pipe 7 Nm (0.7 m kg, 5.1 ft • • 24 Nm (2.4 m kg, 17 ft • • 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 203: Removing The Muffler End Covers

    ENGINE REMOVAL ET5YU1029 REMOVING THE MUFFLER END COVERS 1. Remove: • Muffler end covers “1” NOTE: Before removing a muffler end cover, turn it in the direction of the arrow shown in the illustra- tion. ET5YU1030 INSTALLING THE MUFFLER END COVERS 1.
  • Page 204 ENGINE REMOVAL Removing the EXUP servo motor and rear exhaust pipe joint 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 17 Nm (1.7 m kg, 12 ft •...
  • Page 205 ENGINE REMOVAL Removing the EXUP servo motor and rear exhaust pipe joint 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 17 Nm (1.7 m kg, 12 ft •...
  • Page 206 ENGINE REMOVAL Removing the EXUP servo motor and rear exhaust pipe joint 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 17 Nm (1.7 m kg, 12 ft •...
  • Page 207 ENGINE REMOVAL Removing the leads 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Stator coil assembly lead Horn lead Wire harness Decompression solenoid coupler Disconnect. Speed sensor coupler Disconnect. Starter motor connector Starter motor lead Crankshaft position sensor coupler Disconnect.
  • Page 208 ENGINE REMOVAL Removing the down tube 53 Nm (5.3 m kg, 38 ft 53 Nm (5.3 m kg, 38 ft • • • • 53 Nm (5.3 m kg, 38 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 209 ENGINE REMOVAL Removing the down tube 53 Nm (5.3 m kg, 38 ft 53 Nm (5.3 m kg, 38 ft • • • • 53 Nm (5.3 m kg, 38 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 210 ENGINE REMOVAL Removing the engine 7 Nm (0.7 m kg, 5.1 ft • • 74 Nm (7.4 m kg, 53 ft • • 53 Nm (5.3 m kg, 38 ft • • 11 13 74 Nm (7.4 m kg, 53 ft •...
  • Page 211 ENGINE REMOVAL Removing the engine 7 Nm (0.7 m kg, 5.1 ft • • 74 Nm (7.4 m kg, 53 ft • • 53 Nm (5.3 m kg, 38 ft • • 11 13 74 Nm (7.4 m kg, 53 ft •...

  • Page 212: Removing The Engine

    ENGINE REMOVAL 3. Position the engine “6” under the vehicle for ET5YU1031 REMOVING THE ENGINE installation. NOTE: 4. Install: Pass a suitable rod through the hole in the swin- • Engine “6” garm pivot shaft and secure the rod to support •...
  • Page 213 ENGINE REMOVAL NOTE: Engine mounting nut (front lower Do not fully tighten the bolts and nuts. side) 94 Nm (9.4 m·kg, 68 ft·lb) 7. Tighten: Engine bracket nut (front upper • Down tube nut (front side) “14” side) • Engine mounting nut (rear lower side) “15” 53 Nm (5.3 m·kg, 38 ft·lb) •...
  • Page 214 ENGINE REMOVAL 5-15...

  • Page 215: Camshafts

    CAMSHAFTS EAS23750 CAMSHAFTS Removing the camshaft sprocket cover 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 216 CAMSHAFTS Removing cylinder head covers 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Tappet cover bolt Tappet cover O-ring Cylinder head cover bolt...
  • Page 217 CAMSHAFTS Removing the push rods and rocker arms 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • • 24 Nm (2.4 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Rear rocker arm base assembly Front rocker arm base assembly...
  • Page 218 CAMSHAFTS Removing the valve lifters 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “CYLINDERS AND PISTONS” on Front cylinder page 5-41. Push rod cover O-ring Seal Rear valve lifter case...
  • Page 219 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 52 Nm (5.2 m kg, 37 ft •...

  • Page 220: Removing The Rocker Arms, Push Rods And Valve Lifters

    CAMSHAFTS EAS23790 REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Align: • TDC mark “a” on the crankshaft position sen- sor rotor (with the pointer “b” on the clutch cover) M MMM M MMM M MMM M MMM M MMM a.

  • Page 221: Checking The Camshafts

    CAMSHAFTS EAS23860 CHECKING THE CAMSHAFTS 1. Check: • Cam Blue discoloration/pitting/scratches → Re- place the camshaft. 2. Measure: • Cam dimensions “a” and “b” Out of specification → Replace the camshaft. Camshaft lobe dimensions 3. Remove: Intake A 38.241–38.341 mm (1.5055– •...
  • Page 222 CAMSHAFTS Crankcase hole inside diameter 25.000–25.021 mm (0.9843– 0.9851 in) 3. Measure: • Camshaft journal diameter (crankcase side) “a” Out of specification → Replace the camshaft. 6. Measure: Camshaft journal diameter • Camshaft cover hole inside diameter “a” (crankcase side) Out of specification →...

  • Page 223: Checking The Rocker Arms And Rocker Arm Shafts

    CAMSHAFTS NOTE: Rocker arm shaft outside Calculate the clearance by subtracting the cam- diameter shaft journal diameter (camshaft cover side) 17.976–17.991 mm (0.7077– from the camshaft cover hole inside diameter. 0.7083 in) Camshaft to camshaft cover clearance 0.020–0.054 mm (0.0008–0.0021 9.

  • Page 224: Checking The Valve Lifters And Valve Lifter Cases

    CAMSHAFTS 4. Measure: EAS23920 • Valve lifter case inside diameter “a” CHECKING THE VALVE LIFTERS AND Out of specification → Replace. VALVE LIFTER CASES 1. Check: Valve lifter hole inside diameter • Valve lifter (intake) Blue discoloration/excessive wear/pitting/ 23.000–23.021 mm (0.9055– scratches →...

  • Page 225: Checking The Decompression System

    CAMSHAFTS • O-ring Damage/wear → Replace the oil seal and O- ring as a set. EAS23980 CHECKING THE DECOMPRESSION SYSTEM 1. Check: • Decompression system NOTE: • Check the decompression system while the decompression push rod is installed in the 2.

  • Page 226: Bleeding A Valve Lifter

    CAMSHAFTS • Align the punch mark “a” on the camshaft drive gear “1” with the punch mark “b” on the cam- shaft driven gear “2”. • Insert a cross-headed screwdriver into one of the holes in the outer camshaft driven gear and rotate the gear until the teeth of both driven gears are aligned.
  • Page 227 CAMSHAFTS ECA14630 CAUTION: • Do not pump the valve lifter excessively. • Kerosene is highly flammable. 1. Kerosene 2. Valve lifter b. Install the valve lifter into the engine. ECA14650 CAUTION: Be sure to install the valve lifter in its appro- priate position.

  • Page 228: Installing The Valve Lifters

    CAMSHAFTS EAS24070 INSTALLING THE ROCKER ARMS AND PUSH RODS The following procedure applies to both cylin- ders. 1. Install: • Rocker arms “1” • Rocker arm shafts “2” (onto rocker arm base) NOTE: The thread hole “a” of the rocker arm shaft must face to the outside.

  • Page 229: Installing The Cylinder Head Covers

    CAMSHAFTS NOTE: ® Apply locking agent (LOCTITE ) to the threads of the bolt “3”. Cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Bolts “3”, “4”: l = 40 mm (1.57 in) Bolts “5”: l = 50 mm (1.97 in) Bolt with washer “6”: l = 50 mm (1.97 in) Bolts “7”: l = 60 mm (2.36 in) A.

  • Page 230: Cylinder Heads

    CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads 45 Nm (4.5 m kg, 32 ft • • 39 Nm (3.9 m kg, 28 ft • • 21 Nm (2.1 m kg, 15 ft • • 18 Nm (1.8 m kg, 13 ft •...

  • Page 231: Removing The Cylinder Heads

    CYLINDER HEADS EAS24140 REMOVING THE CYLINDER HEADS 1. Remove: • Cylinder head nuts NOTE: • Loosen the nuts in the proper sequence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. 2.

  • Page 232: Installing The Cylinder Heads

    CYLINDER HEADS EAS24250 INSTALLING THE CYLINDER HEADS 1. Tighten: • Cylinder head nuts (M12) “1”–“4” Cylinder head nut (M12) 45 Nm (4.5 m·kg, 32 ft·lb) • Cylinder head nuts (M10) “5”, “6” Cylinder head nut (M10) 39 Nm (3.9 m·kg, 28 ft·lb) NOTE: •...
  • Page 233 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both cylinders. Cylinder heads Refer to “CYLINDER HEADS” on page 5-31. Valve cotter Upper spring seat Outer valve spring Inner valve spring Intake valve...

  • Page 234: Valves And Valve Springs

    VALVES AND VALVE SPRINGS 3. Remove: EAS24280 REMOVING THE VALVES • Upper spring seat “1” The following procedure applies to all of the • Outer valve spring “2” valves and related components. • Inner valve spring “3” NOTE: • Valve “4” Before removing the internal parts of the cylinder •...
  • Page 235 VALVES AND VALVE SPRINGS c. After installing the valve guide, bore the valve guide with the valve guide reamer “3” to ob- tain the proper valve-stem-to-valve-guide clearance. NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover (ø6) 90890-04064 2.

  • Page 236: Checking The Valve Seats

    VALVES AND VALVE SPRINGS Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 2.0 mm (0.08 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Limit 2.0 mm (0.08 in) 6. Measure: • Valve stem runout Out of specification → Replace the valve. NOTE: •...

  • Page 237: Checking The Valve Springs

    VALVES AND VALVE SPRINGS M MMM M MMM M MMM M MMM M MMM a. Apply a coarse lapping compound “a” to the valve face. ECA13790 CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide.

  • Page 238: Installing The Valves

    VALVES AND VALVE SPRINGS Inner spring Installed compression spring force (intake) 63.00–73.00 N (14.16–16.41 lb) (6.42–7.44 kgf) Installed compression spring force (exhaust) 63.00–73.00 N (14.16–16.41 lb) (6.42–7.44 kgf) Installed length (intake) 29.00 mm (1.14 in) Installed length (exhaust) EAS24340 INSTALLING THE VALVES 29.00 mm (1.14 in) The following procedure applies to all of the Outer spring...
  • Page 239 VALVES AND VALVE SPRINGS • Upper spring seat “7” 5. To secure the valve cotters onto the valve (into the cylinder head) stem, lightly tap the valve tip with a soft-face hammer. NOTE: ECA13800 Install the valve springs with the larger pitch “a” CAUTION: facing up.
  • Page 240 CYLINDERS AND PISTONS EAS24360 CYLINDERS AND PISTONS Removing the cylinders and pistons Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEADS” on page 5-31. Front cylinder Rear cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Top ring 2nd ring...

  • Page 241: Cylinders And Pistons

    CYLINDERS AND PISTONS • Oil ring EAS24380 REMOVING THE PISTONS NOTE: The following procedure applies to all of the pis- When removing a piston ring, open the end gap tons. with your fingers and lift the other side of the ring 1.

  • Page 242: Checking The Piston Rings

    CYLINDERS AND PISTONS EAS24430 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 243: Checking The Piston Pins

    CYLINDERS AND PISTONS 3. Measure: 3. Measure: • Piston ring end gap • Piston pin bore diameter “b” Out of specification → Replace the piston Out of specification → Replace the piston. ring. Piston pin bore inside diameter NOTE: 22.004–22.015 mm (0.8663– The oil ring expander spacer’s end gap cannot 0.8667 in) be measured.
  • Page 244 CYLINDERS AND PISTONS 90 ˚ 90 ˚ 45 ˚ 2. Install: a. Top ring • Piston “1” b. Upper oil ring rail • Piston pin “2” c. Oil ring expander • Piston pin clips “3” d. Lower oil ring rail e.
  • Page 245 CLUTCH EAS25060 CLUTCH Removing the clutch cover 10 Nm (1.0 m kg, 7.2 ft • • (10) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-11.
  • Page 246 CLUTCH Removing the crankshaft position sensor 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Crankshaft position sensor lead holder Crankshaft position sensor For installation, reverse the removal procedure. 5-47...
  • Page 247 CLUTCH Removing the clutch 23 22 125 Nm (12.5 m kg, 90 ft • • 12 11 10 9 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Clutch spring plate retainer...
  • Page 248 CLUTCH Removing the clutch 23 22 125 Nm (12.5 m kg, 90 ft • • 12 11 10 9 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Washer...
  • Page 249 CLUTCH Removing the clutch master cylinder 14 Nm (1.4 m kg, 10 ft • • 30 Nm (3.0 m kg, 22 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM”...
  • Page 250 CLUTCH Removing the clutch master cylinder 14 Nm (1.4 m kg, 10 ft • • 30 Nm (3.0 m kg, 22 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Parts to remove Q’ty Remarks Clutch master cylinder holder Clutch master cylinder For installation, reverse the removal procedure.
  • Page 251 CLUTCH Disassembling the clutch master cylinder Order Job/Parts to remove Q’ty Remarks Clutch master cylinder push rod Clutch master cylinder kit Dust seal Circlip Clutch fluid reservoir hose joint O-ring Clutch master cylinder body For assembly, reverse the disassembly procedure. 5-52...
  • Page 252 CLUTCH Removing the clutch release cylinder 26 Nm (2.6 m kg, 19 ft 10 Nm (1.0 m kg, 7.2 ft • • • • Order Job/Parts to remove Q’ty Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-14. Clutch pipe union bolt cap Clutch pipe union bolt Copper washer...
  • Page 253 CLUTCH Disassembling the clutch release cylinder 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Boots Clutch release cylinder piston Clutch release cylinder spring Clutch release cylinder piston seal Bleed screw For assembly, reverse the disassembly procedure.

  • Page 254: Clutch

    CLUTCH EAS25080 REMOVING THE CLUTCH Sheave holder 1. Loosen: 90890-01701 • Clutch boss nut “1” Primary clutch holder YS-01880-A NOTE: While holding the clutch boss “2” with the univer- sal clutch holder “3”, loosen the clutch boss nut. Universal clutch holder 90890-04086 YM-91042 2.

  • Page 255: Checking The Clutch Plates

    CLUTCH EAS25150 CHECKING THE CLUTCH HOUSING 1. Check: • Clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause er- ratic clutch operation. EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates.

  • Page 256: Checking The Clutch Push Rods

    CLUTCH EAS25190 CHECKING THE CLUTCH PUSH RODS Yamaha bond No. 1215 1. Check: 90890-85505 • O-ring • Short clutch push rod • Long clutch push rod • Ball Cracks/damage/wear → Replace the defec- tive part(s). 2. Measure: • Long clutch push rod bending limit Out of specification →...

  • Page 257: Installing The Clutch

    CLUTCH 3. Install: • Clutch boss “1” • Conical spring washer “2” • Clutch boss nut “3” Clutch boss nut 125 Nm (12.5 m·kg, 90 ft·lb) NOTE: • Lubricate the clutch boss nut threads and con- ical spring washer mating surfaces with engine oil.

  • Page 258: Disassembling The Clutch Master Cylinder

    CLUTCH EAS25280 DISASSEMBLING THE CLUTCH MASTER CYLINDER ECA13840 CAUTION: • Clutch components rarely require disas- sembly. • Therefore, always follow these preventive measures: • Never disassemble clutch components un- less absolutely necessary. 6. Install: • If any connection on the hydraulic clutch •...

  • Page 259: Checking The Clutch Master Cylinder

    CLUTCH EAS25290 EAS25310 CHECKING THE CLUTCH MASTER INSTALLING THE CLUTCH MASTER CYLINDER CYLINDER 1. Install: Recommended clutch component replace- • Clutch master cylinder “1” ment schedule • Clutch master cylinder holder “2” Piston seals Every two years Clutch master cylinder holder Clutch hose Every four years bolt...

  • Page 260: Removing The Clutch Release Cylinder

    CLUTCH 3. Fill: 6. Check: • Clutch fluid reservoir • Clutch lever operation Soft or spongy feeling → Bleed the clutch (with the specified amount of the recom- mended clutch fluid) system. Refer to “BLEEDING THE HYDRAULIC Recommended clutch fluid CLUTCH SYSTEM”...

  • Page 261: Assembling The Clutch Release Cylinder

    CLUTCH 1. Check: • Clutch release cylinder body Cracks/damage → Replace the clutch re- lease cylinder. 2. Check: • Clutch release cylinder • Clutch release cylinder piston Rust/scratches/wear → Replace the clutch release cylinder and clutch release cylinder piston as a set. 2.
  • Page 262 CLUTCH 5. Check: • Clutch lever operation Soft or spongy feeling → Bleed the clutch system. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-14. 5-63...

  • Page 263: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-46. Shift shaft Circlip Shift shaft spring...

  • Page 264: Checking The Shift Shaft

    SHIFT SHAFT • Hook the end of the shift shaft spring onto the EAS25420 CHECKING THE SHIFT SHAFT shift shaft spring stopper “3”. 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1.

  • Page 265: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil assembly 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...
  • Page 266 GENERATOR AND STARTER CLUTCH Removing the generator rotor 80 Nm (8.0 m kg, 58 ft • • Order Job/Parts to remove Q’ty Remarks Starter clutch idle gear shaft #2 Starter clutch idle gear shaft #1 Starter clutch idle gear #2 Starter clutch idle gear #1 Generator rotor Woodruff key...

  • Page 267: Removing The Generator

    GENERATOR AND STARTER CLUTCH 2. Check: EAS24490 REMOVING THE GENERATOR • Starter clutch gear’s contacting surfaces 1. Remove: Damage/pitting/wear → Replace the starter • Generator rotor bolt “1” clutch gear. • Washer 3. Check: NOTE: • Starter clutch operation While holding the generator rotor “2” with the M MMM M MMM M MMM...
  • Page 268 Tighten the generator rotor bolt “1” while holding the generator rotor “2” with a sheave holder “3”. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 5-69...

  • Page 269: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Oil tank Refer to “ENGINE REMOVAL” on page 5-1. Starter motor lead Disconnect. Starter motor assembly For installation, reverse the removal procedure. 5-70...
  • Page 270 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Circlip Starter motor gear Starter motor rear cover Bearing Oil seal Circlip Starter motor front cover Brush Brush holder (along with the brushes) Brush seat (along with the brushes) Bearing Gasket Armature assembly...

  • Page 271: Checking The Starter Motor

    ELECTRIC STARTER M MMM M MMM M MMM M MMM M MMM EAS24790 CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances 1. Check: with the pocket tester. • Commutator Dirt → Clean with 600 grit sandpaper. Pocket tester 2.

  • Page 272: Assembling The Starter Motor

    ELECTRIC STARTER 3. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” NOTE: Align the match mark “a” on the starter motor yoke with the match mark “b” on the starter mo- tor rear cover.

  • Page 273: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Camshafts Refer to “CAMSHAFTS” on page 5-16. Refer to “CYLINDERS AND PISTONS” on Pistons page 5-41. Shift shaft Refer to “SHIFT SHAFT” on page 5-64. Refer to “GENERATOR AND STARTER Generator rotor CLUTCH”...
  • Page 274 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Right crankcase For installation, reverse the removal procedure. 5-75...
  • Page 275 CRANKCASE Removing the oil baffle plate and bearings Order Job/Parts to remove Q’ty Remarks Oil pump Refer to “OIL PUMP” on page 5-81. Crankshaft Refer to “CRANKSHAFT” on page 5-86. Transmission Refer to “TRANSMISSION” on page 5-92. Oil baffle plate Bearing retainer Bearing retainer Oil seal...

  • Page 276: Disassembling The Crankcase

    CRANKCASE • M6 × 75 mm bolts: “14”, “15” EAS25570 DISASSEMBLING THE CRANKCASE • M6 × 60 mm bolts: “4”–“7” NOTE: • M6 × 40 mm bolts: “8”, “10”–“12”, “16”–“20” Loosen the generator shaft bolt before removing the generator rotor. 1.

  • Page 277: Checking The Crankcase

    • Sealant 3. Check: (onto the crankcase mating surfaces) • Crankcase Cracks/damage → Replace. Yamaha bond No. 1215 • Oil delivery passages 90890-85505 Obstruction → Blow out with compressed air. NOTE: ET5YU1022 CHECKING THE BEARINGS AND OIL SEAL Do not allow any sealant to come into contact 1.
  • Page 278 CRANKCASE • Tap lightly on the left crankcase with a soft- face hammer. 4. Install: • Crankcase bolts (M8) • Crankcase bolts (M6) Crankcase bolt (M8) 24 Nm (2.4 m·kg, 17 ft·lb) Crankcase bolt (M6) 10 Nm (1.0 m·kg, 7.2 ft·lb) A.
  • Page 279 CRANKCASE 5-80...

  • Page 280: Oil Pump

    OIL PUMP EAS24910 OIL PUMP Removing the oil pump Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-74. Oil strainer (crankcase) Oil pump assembly For installation, reverse the removal procedure. 5-81...
  • Page 281 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Spring retainer Spring Relief valve Oil pump housing cover 1 Spring Collar Ball Oil pump outer rotor 1 Oil pump inner rotor 1 Oil pump housing cover 2 Oil pump shaft Oil pump inner rotor 2 Oil pump outer rotor 2...
  • Page 282 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil seal Oil pump housing For assembly, reverse the disassembly procedure. 5-83...

  • Page 283: Checking The Oil Pump

    OIL PUMP 3. Check: EAS24960 CHECKING THE OIL PUMP • Oil pump operation 1. Check: Rough movement → Repeat steps (1) and • Oil pump housing (2) or replace the defective part(s). • Oil pump housing cover Cracks/damage/wear → Replace the defec- tive part(s).

  • Page 284: Installing The Oil Pump

    OIL PUMP • Oil pump shaft “6” 3. Check: • Pins “7” • Oil pump operation • Oil pump housing cover 2 “8” Refer to “CHECKING THE OIL PUMP” on page 5-84. Oil pump housing cover 2 screw 2 Nm (0.2 m·kg, 1.4 ft·lb) EAS25020 INSTALLING THE OIL PUMP 1.

  • Page 285: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-74. Crankshaft Generator shaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal procedure.

  • Page 286: Removing The Connecting Rods

    CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS The following procedure applies to all of the con- necting rods. 1. Remove: • Connecting rod caps “1” • Connecting rod • Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
  • Page 287 CRANKSHAFT ® c. Put a piece of Plastigauge “1” on the crank- g. Put a mark “1” on the connecting rod bolts “2” shaft pin. and the connecting rod cap “3”. h. Tighten the connecting rod bolts further to d. Assemble the connecting rod halves. reach the specified angle 120°–150°.
  • Page 288 CRANKSHAFT For example, if the connecting rod “P ” and the crankshaft web “P” numbers are “5” and “2” respectively, then the bearing size for “P ” “P ” (connecting rod) - “P” (crankshaft) 5 - 2 = 3 (brown) Bearing color code 1.Blue 2.Black 3.Brown 4.Green L LLL...

  • Page 289: Installing The Connecting Rods

    CRANKSHAFT • Be sure to reinstall each big end bearing in its original place. • Make sure the projections “c” on the connect- ing rods face towards the left side of the crank- shaft. • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned.

  • Page 290: Installing The Crankshaft Assembly

    CRANKSHAFT a. Tighten the connecting rod bolts to the spec- ECA13970 CAUTION: ified torque. To avoid scratching the crankshaft and to Connecting rod bolt (1st) ease the installation procedure, lubricate the 15 Nm (1.5 m·kg, 11 ft·lb) oil seal lips with lithium-soap-based grease and each bearing with engine oil.

  • Page 291: Transmission

    TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-74. Shift fork guide bar Shift drum assembly Shift fork-L Shift fork-R Shift fork-C Drive axle assembly Main axle assembly Spacer For installation, reverse the removal...
  • Page 292 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Circlip Washer 5th pinion gear Collar Washer 2nd/3rd pinion gear Circlip Washer 4th pinion gear Collar Main axle/1st pinion gear For assembly, reverse the disassembly procedure. 5-93...
  • Page 293 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks 5th wheel gear Circlip Washer 2nd wheel gear Collar Circlip Washer 1st wheel gear Collar Washer 4th wheel gear Circlip Washer 3rd wheel gear Collar Drive axle For assembly, reverse the disassembly procedure.

  • Page 294: Checking The Shift Forks

    TRANSMISSION EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • Shift fork cam follower “1” • Shift fork pawl “2” Bends/damage/scoring/wear → Replace the shift fork. EAS26300 CHECKING THE TRANSMISSION 1. Measure: •...

  • Page 295: Assembling The Main Axle And Drive Axle

    TRANSMISSION • Transmission gear dogs EAS26320 INSTALLING THE SHIFT FORKS AND SHIFT Cracks/damage/rounded edges → Replace DRUM ASSEMBLY the defective gear(s). 1. Install: 4. Check: • Shift fork-R “1” • Transmission gear engagement • Shift fork-C “2” (each pinion gear to its respective wheel •...
  • Page 296 FUEL...

  • Page 297: Fuel System

    FUEL SYSTEM FUEL TANK..................... 6-1 REMOVING THE FUEL TANK ..............6-2 REMOVING THE FUEL PUMP ..............6-2 CHECKING THE FUEL PUMP BODY............6-2 CHECKING THE FUEL PUMP OPERATION..........6-2 INSTALLING THE FUEL PUMP..............6-2 INSTALLING THE FUEL TANK..............6-2 THROTTLE BODIES ..................6-4 CHECKING THE INJECTORS ..............

  • Page 299: Fuel Tank

    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank and fuel pump 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat 4-1.

  • Page 300: Fuel Tank

    FUEL TANK EAS26630 EAS26670 REMOVING THE FUEL TANK CHECKING THE FUEL PUMP BODY 1. Extract the fuel in the fuel tank through the 1. Check: fuel tank cap with a pump. • Fuel pump body Obstruction → Clean. 2. Disconnect: Cracks/damage →...
  • Page 301 FUEL TANK EC5YU1017 CAUTION: When installing the fuel hose and the fuel re- turn hose, make sure that they are securely connected, and that the fuel hose connector cover on the fuel hose is in the correct posi- tion, otherwise the fuel hose will not be prop- erly installed.

  • Page 302: Throttle Bodies

    THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the pressure regulator and rollover valves 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Parts to remove Q’ty Remarks...
  • Page 303 THROTTLE BODIES Removing the pressure regulator and rollover valves 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Parts to remove Q’ty Remarks Rollover valve 2...
  • Page 304 THROTTLE BODIES Removing the throttle bodies 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat/Air filter case 4-1.
  • Page 305 THROTTLE BODIES Removing the intake manifolds 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Fuel hose Fuel hose (intake manifold assembly to pressure regulator) Cylinder-#2 ISC (idle speed control) unit outlet hose Cylinder-#1 ISC (idle speed control) unit outlet hose Intake manifold assembly Cylinder-#2 injector coupler...
  • Page 306 THROTTLE BODIES Removing the injectors 30 Nm (3.0 m kg, 22 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks Fuel pipe Injector joint 1 Injector joint 2 Injector...

  • Page 307: Checking The Injectors

    THROTTLE BODIES EAS26980 EAS27010 CHECKING THE INJECTORS CHECKING THE PRESSURE REGULATOR 1. Check: OPERATION • Injectors 1. Check: Damage → Replace. • Pressure regulator operation M MMM M MMM M MMM M MMM M MMM a. Remove the pressure regulator cover. EAS26990 CHECKING THE THROTTLE BODIES Refer to “THROTTLE BODIES”...

  • Page 308: Adjusting The Throttle Position Sensor

    THROTTLE BODIES h. Use the vacuum/pressure pump gauge set to adjust the fuel pressure in relation to the vac- uum pressure as described below. NOTE: The vacuum pressure should not exceed 100 kPa (760 mm Hg). • Increase the vacuum pressure → Fuel pressure is decreased •...

  • Page 309: Isc (Idle Speed Control) Unit

    ISC (IDLE SPEED CONTROL) UNIT ET5YU1012 ISC (IDLE SPEED CONTROL) UNIT Removing the ISC (idle speed control) unit and intake solenoid 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft 9 Nm (0.9 m kg, 6.5 ft •...
  • Page 310 ISC (IDLE SPEED CONTROL) UNIT Removing the ISC (idle speed control) unit and intake solenoid 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft 9 Nm (0.9 m kg, 6.5 ft • • •...

  • Page 311: Checking The Isc (Idle Speed Control) System

    ISC (IDLE SPEED CONTROL) UNIT ET5YU1015 CHECKING THE ISC (IDLE SPEED CONTROL) SYSTEM 1. Check: • Hoses Loose connections → Connect properly. Cracks/damage → Replace. 2. Check: • Surge tank Cracks/damage → Replace. 3. Check: • One-way valve Cracks/damage/faulty → Replace. NOTE: Check that air flows smoothly only in the direc- tion of the arrow shown in the illustration.
  • Page 313 – ELEC...

  • Page 314: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................7-1 CIRCUIT DIAGRAM .................. 7-1 TROUBLESHOOTING ................7-3 ELECTRIC STARTING SYSTEM ..............7-5 CIRCUIT DIAGRAM .................. 7-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......7-7 TROUBLESHOOTING ................7-9 CHARGING SYSTEM..................7-11 CIRCUIT DIAGRAM ................7-11 TROUBLESHOOTING ................7-13 LIGHTING SYSTEM ..................
  • Page 315 ELECTRICAL COMPONENTS..............7-85 CHECKING THE SWITCHES ..............7-89 CHECKING THE BULBS AND BULB SOCKETS ........7-92 CHECKING THE FUSES ................ 7-93 CHECKING AND CHARGING THE BATTERY........7-94 CHECKING THE RELAYS ..............7-96 CHECKING THE TURN SIGNAL/HAZARD RELAY........ 7-97 CHECKING THE RELAY UNIT (DIODE) ..........7-98 CHECKING THE SPARK PLUG CAPS...........

  • Page 316: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 317 IGNITION SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 19.Sidestand switch 20.Crankshaft position sensor 24.Lean angle cut-off switch 29.ECU (electronic control unit) 32.Spark plug 33.Cylinder-#2 right ignition coil 34.Cylinder-#2 left ignition coil 35.Cylinder-#1 left ignition coil 36.Cylinder-#1 right ignition coil 56.Clutch switch...

  • Page 318: Troubleshooting

    IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case 4. Battery box 5. Engine NG → 1. Check the fuses. (Main, ignition, and ECU) Replace the fuse(s).
  • Page 319 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch/immobilizer unit. SWITCHES” on page 7-89. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES”...

  • Page 320: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 321 ELECTRIC STARTING SYSTEM 3. Main switch 4. Battery 6. Starter relay 7. Starter motor 8. Main fuse 10.ECU fuse 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 19.Sidestand switch 29.ECU (electronic control unit) 38.Decompression solenoid 56.Clutch switch 70.Auto decompression fuse 73.Engine stop switch 74.Start switch 81.Ignition fuse...

  • Page 322: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is turned “ON” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 323 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.

  • Page 324: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case 4. Oil tank NG → 1. Check the fuses. (Main, ignition, auto decompression, and ECU) Replace the fuse(s).
  • Page 325 ELECTRIC STARTING SYSTEM NG → 8. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 7-89. OK ↓ NG → 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. SWITCHES”...

  • Page 326: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-11...
  • Page 327 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Battery 8. Main fuse 7-12...

  • Page 328: Troubleshooting

    CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUSES” on page 7-93. OK ↓ NG →...
  • Page 329 CHARGING SYSTEM 7-14...

  • Page 330: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-15...
  • Page 331 LIGHTING SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 29.ECU (electronic control unit) 47.High beam indicator light 50.Meter light 54.Headlight relay 57.Pass switch 58.Dimmer switch 67.Auxiliary light 68.Headlight (high beam) 69.Headlight (low beam) 75.Tail/brake light 76.License plate light 80.Headlight fuse 82.Signaling system fuse 83.Parking lighting fuse...

  • Page 332: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light, taillight, license plate light, auxiliary light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2.
  • Page 333 LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting Refer to “CIRCUIT DIAGRAM” on system wiring. page 7-15. OK ↓ This circuit is OK. 7-18...

  • Page 334: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-19...
  • Page 335 SIGNALING SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 12.Backup fuse (odometer, clock and immobilizer system) 13.Relay unit 16.Neutral switch 18.Fuel sender 25.Speed sensor 29.ECU (electronic control unit) 42.Fuel level warning light 43.Neutral indicator light 44.Multi-function meter 45.Engine trouble warning light 48.Left turn signal indicator light 49.Right turn signal indicator light...

  • Page 336: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or indicator light. • The horn fails to sound. • The speedometer fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1.
  • Page 337 SIGNALING SYSTEM NG → 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 7-19. OK ↓ This circuit is OK. The tail/brake light fails to come on. NG → 1.
  • Page 338 SIGNALING SYSTEM NG → 5. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 7-19. OK ↓ This circuit is OK. The neutral indicator light fails to come on. NG →...
  • Page 339 SIGNALING SYSTEM 7-24...

  • Page 340: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 7-25...
  • Page 341 FUEL INJECTION SYSTEM 3. Main switch 4. Battery 5. Fuel injection system fuse 8. Main fuse 10.ECU fuse 15.Fuel pump relay 16.Neutral switch 17.Fuel pump 19.Sidestand switch 20.Crankshaft position sensor 21.Throttle position sensor 22.Cylinder-#1 intake air pressure sensor 23.Cylinder-#2 intake air pressure sensor 24.Lean angle cut-off switch 25.Speed sensor 26.Muffler cooling fan temperature sensor...

  • Page 342: Ecu Self-Diagnostic Function

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

  • Page 343: Self-Diagnostic Function Table

    FUEL INJECTION SYSTEM a. Main switch “OFF” d. Engine trouble warning light on for 1.4 seconds b. Main switch “ON” c. Engine trouble warning light off EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE 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 344 FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive No normal signal is received from sensor Able Able the O sensor. Cylinder-#2 intake air Cylinder-#2 intake air pressure pressure sensor sensor: open or short circuit Able Able...
  • Page 345 FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive No normal signals are received Speed sensor from the speed sensor. Able Able Open or short circuit is detected in Neutral switch the neutral switch.

  • Page 346: Troubleshooting Method

    FUEL INJECTION SYSTEM 4. Turn the main switch to “OFF” and back to EAS27400 TROUBLESHOOTING METHOD “ON”, then check that no fault code number is displayed. The engine operation is not normal and the NOTE: engine trouble warning light comes on. If fault codes are displayed, repeat steps (1) to 1.
  • Page 347 FUEL INJECTION SYSTEM NOTE: • All displays on the meter disappear except the clock and odometer/trip meter/fuel reserve trip meter displays. • “dIAG” appears on the odometer/trip meter/fuel reserve trip meter LCD. 4. Press the “SELECT” button to select the diagnostic mode “dIAG”. 5.
  • Page 348 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Cylinder-#1 intake air pressure sensor: hose • Cylinder-#1 intake air pressure sensor hose system malfunction is detached, clogged, kinked, or pinched. (clogged or detached • Malfunction in ECU. hose).
  • Page 349 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire sub lead. • Open or short circuit in wire harness. Malfunction detected in the • Malfunction in cylinder-#1 left or right primary wire of the ignition coil.
  • Page 350 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open circuit in wire harness. • Defective speed sensor. No normal signals are • Malfunction in vehicle speed sensor received from the speed detected. sensor. • Defective neutral switch. Open circuit is detected in •...
  • Page 351 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Non-registered data has • Improper connection in wire harness. Er-4 been received from the • Malfunction in meter. — meter. • Malfunction in ECU. Sensor operation table Diag- nostic Item...
  • Page 352 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Engine temperature Displays the engine Compare the actually temperature. measured engine temperature with the meter display value. Muffler cooling fan Displays the muffler cooling Compare the actually temperature fan temperature. measured muffler cooling fan temperature with the meter display value.
  • Page 353 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Stopping the flashing of the To stop the flashing of the engine trouble warning light engine trouble warning (erasing the muffler cooling light, set the engine stop fan temperature sensor switch to “...

  • Page 354: Troubleshooting Details

    FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the fuel pump relay for five times every second. Illuminates the engine trouble warning light. Check the operating sound Fuel pump relay (The engine trouble warning of the fuel pump relay five light is OFF when the relay is times.
  • Page 355 FUEL INJECTION SYSTEM Code number displayed on the meter when the engine failed to work normally. Refer to “Self-Diagnos- tic Function table”. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC MODE”...
  • Page 356 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#1 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code No. Cylinder-#1 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 357 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#1 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code No. Cylinder-#1 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Cylinder-#1 intake air pressure sensor •...
  • Page 358 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or Turning the sensor.
  • Page 359 FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor circuit: open or short circuit detected. Diagnostic code No. EXUP servo motor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 360 FUEL INJECTION SYSTEM Fault code No. Symptom A break or disconnection of the blue/yellow lead of the ECU is detected. Diagnostic code No. Sidestand switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Execute the diagnostic mode. If the •...
  • Page 361 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of O sensor. Check for looseness or pinching. Starting the engine and Connections •...
  • Page 362 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#2 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code No. Cylinder-#2 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 363 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#2 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code No. Cylinder-#2 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Cylinder-#2 intake air pressure sensor •...
  • Page 364 FUEL INJECTION SYSTEM Fault code No. Symptom Engine temperature sensor: open or short circuit detect- Diagnostic code No. Engine temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of engine temperature Check for looseness or pinching. Turning the sensor.
  • Page 365 FUEL INJECTION SYSTEM Fault code No. Symptom Decompression solenoid (thermistor): open or short cir- cuit detected. Diagnostic code No. Decompression solenoid Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of decompression Check for looseness or pinching. Turning the solenoid.
  • Page 366 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code No. 30, 32 Cylinder-#1 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 367 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#2 left ignition coil. Diagnostic code No. Cylinder-#2 left ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the connector and Starting the •...
  • Page 368 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code No. 30, 32 Cylinder-#1 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 369 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#2 right ignition coil. Diagnostic code No. Cylinder-#2 right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the connector and Starting the •...
  • Page 370 FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling. Diagnostic code No. ISC valve Order Item/components and probable Check or maintenance job Reinstatement cause method ECU fuse is blown. • Check the ECU fuse. ISC valve Refer to “CHECKING THE returns to its...
  • Page 371 FUEL INJECTION SYSTEM Fault code No. Symptom Decompression solenoid: open or short circuit detected. Diagnostic code No. Decompression solenoid Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of decompression Check for looseness or pinching. Turning the solenoid.
  • Page 372 FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle cut-off switch: open or short circuit detected. Diagnostic code No. Lean angle cut-off switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 373 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. Speed sensor Neutral switch Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 374 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. Speed sensor Neutral switch Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 375 FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. Fuel system voltage Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 376 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the •...
  • Page 377 FUEL INJECTION SYSTEM Fault code No. Symptom Muffler cooling fan temperature sensor: open or short cir- cuit detected. Diagnostic code No. Muffler cooling fan temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of muffler cooling Check for looseness or pinching.
  • Page 378 FUEL INJECTION SYSTEM Fault code No. Symptom Engine trouble warning light is flashing. (Abnormally high temperature is detected by muffler cooling fan tempera- ture sensor.) Diagnostic code No. Muffler cooling fan temperature sensor Muffler cooling fan motor relay Stopping the flashing of the engine trouble warning light (erasing the muffler cooling fan temperature sensor fault code) Order Item/components and probable...
  • Page 379 FUEL INJECTION SYSTEM Fault code No. Er-2 Symptom No signals are received from the ECU within the specified duration. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 380 FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 381 FUEL INJECTION SYSTEM 7-66...

  • Page 382: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 7-67...
  • Page 383 FUEL PUMP SYSTEM 3. Main switch 4. Battery 5. Fuel injection system fuse 8. Main fuse 10.ECU fuse 15.Fuel pump relay 17.Fuel pump 29.ECU (electronic control unit) 73.Engine stop switch 81.Ignition fuse 7-68...

  • Page 384: Troubleshooting

    FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case NG → 1. Check the fuses. (Main, ignition, fuel injection system, and ECU) Replace the fuse(s).
  • Page 385 FUEL PUMP SYSTEM 7-70...

  • Page 386: Muffler Cooling System

    MUFFLER COOLING SYSTEM ET5YU1002 MUFFLER COOLING SYSTEM ET5YU1003 CIRCUIT DIAGRAM 7-71...
  • Page 387 MUFFLER COOLING SYSTEM 4. Battery 8. Main fuse 9. Muffler cover fan fuse 10.ECU fuse 26.Muffler cooling fan temperature sensor 29.ECU (electronic control unit) 78.Muffler cooling fan motor 79.Muffler cooling fan motor relay 7-72...

  • Page 388: Troubleshooting

    MUFFLER COOLING SYSTEM ET5YU1004 TROUBLESHOOTING The muffler cooling fan motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat NG → 1. Check the fuses. (Main, muffler cover fan, and ECU) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 7-93.
  • Page 389 MUFFLER COOLING SYSTEM 7-74...

  • Page 390: Immobilizer System

    IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 7-75...
  • Page 391 IMMOBILIZER SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 11.Immobilizer unit 12.Backup fuse (odometer, clock and immobilizer system) 29.ECU (electronic control unit) 44.Multi-function meter 46.Immobilizer system indicator light 81.Ignition fuse 7-76...

  • Page 392: General Information

    IMMOBILIZER SYSTEM EAS27670 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that can be re-registered with new codes •...
  • Page 393 IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration re- Accesso- bilizer unit Standard quirement ry lock* Main Immobiliz- and key switch er unit √ Standard key is lost New standard key All keys have been Code re-registering √ √...
  • Page 394 IMMOBILIZER SYSTEM Standby mode a. Main switch “ON” d. LED off b. Main switch “OFF” e. Standby mode on c. LED on f. Standby mode off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
  • Page 395 IMMOBILIZER SYSTEM Standard key registration a. Main switch “ON” g. First standard key b. Main switch “OFF” h. Second standard key c. LED on i. Registration mode d. LED off A. Registration of the second standard key is e. Less than 5.0 s complete.

  • Page 396: Troubleshooting

    IMMOBILIZER SYSTEM EAS27700 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NG → 1. Check the fuses. (Main, ignition, backup, and ECU) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 7-93.
  • Page 397 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Codes between the 1. Signal received from 1. Place the UNIT key and immobilizer other transponder immobilizer unit unit do not match. (failed to recognize at least 50 mm code after ten away from the consecutive transponder of...
  • Page 398 IMMOBILIZER SYSTEM Example: fault code 52 a. Light on b. Light off 7-83...
  • Page 399 IMMOBILIZER SYSTEM 7-84...

  • Page 400: Electrical Components

    ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 7-85...
  • Page 401 ELECTRICAL COMPONENTS 1. Air temperature sensor 2. Cylinder-#2 left ignition coil 3. Cylinder-#2 right ignition coil 4. ISC (idle speed control) unit 5. Intake solenoid 6. Cylinder-#1 right ignition coil 7. Cylinder-#1 left ignition coil 8. Muffler cooling fan temperature sensor 9.
  • Page 402 ELECTRICAL COMPONENTS 7-87...
  • Page 403 ELECTRICAL COMPONENTS 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#2 intake air pressure sensor 3. Immobilizer unit 4. Throttle position sensor 5. Main fuse 6. Fuse box 7. Muffler cooling fan motor relay 8. ECU (electronic control unit) 9. Headlight relay 10.Relay unit 11.Turn signal/hazard relay 12.Fuel injection system fuse...

  • Page 404: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES R/W L/W (BLUE) R/W R/B Br/R R Br/L Br/R L/W B/Y L/W B/Y Br/L Br/W (BROWN) (BLUE) Dg Br/W Ch (BLACK) Dg Br/W Ch R/Y Y Y L/B G P B/Y 7-89...
  • Page 405 ELECTRICAL COMPONENTS 1. Front brake light switch 2. Engine stop switch 3. Start switch 4. Main switch 5. Neutral switch 6. Sidestand switch 7. Rear brake light switch 8. Hazard switch 9. Turn signal switch 10.Horn switch 11.Clutch switch 12.Pass switch 13.Dimmer switch 7-90...
  • Page 406 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 407: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS 1. Remove: EAS27990 CHECKING THE BULBS AND BULB • Bulb SOCKETS EW5YU1009 NOTE: WARNING Do not check any of the lights that use LEDs. Since headlight bulbs get extremely hot, keep flammable products and your hands Check each bulb and bulb socket for damage or away from them until they have cooled wear, proper connections, and also for continuity down.

  • Page 408: Checking The Fuses

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Checking the condition of the bulb sockets b.

  • Page 409: Checking And Charging The Battery

    ELECTRICAL COMPONENTS cal system, cause the lighting and ignition electrolyte level will drop considerably. systems to malfunction and could possibly Therefore, take special care when charging cause a fire. the battery. L LLL L LLL L LLL L LLL L LLL NOTE: 4.
  • Page 410 ELECTRICAL COMPONENTS b. Check the charge of the battery, as shown in M MMM M MMM M MMM M MMM M MMM Charging method using a variable-current the charts and the following example. (voltage) charger Example a. Measure the open-circuit voltage prior to Open-circuit voltage = 12.0 V charging.

  • Page 411: Checking The Relays

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM 8. Check: Charging method using a constant volt- • Battery terminals age charger Dirt → Clean with a wire brush. a. Measure the open-circuit voltage prior to Loose connection → Connect properly. charging.

  • Page 412: Checking The Turn Signal/Hazard Relay

    ELECTRICAL COMPONENTS Relay unit (starting circuit cut-off relay) 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3” and “4”) Sb/W R/L L/R Muffler cooling fan motor relay L/G L/Y Sb B/Y L/W 1. Positive battery terminal 2.

  • Page 413: Checking The Relay Unit (Diode)

    ELECTRICAL COMPONENTS EAS28050 CHECKING THE RELAY UNIT (DIODE) 1. Check: • Relay unit (diode) Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Turn the main switch to “ON”. NOTE: c. Measure the turn signal/hazard relay input The pocket tester and the analog pocket tester voltage.

  • Page 414: Checking The Spark Plug Caps

    ELECTRICAL COMPONENTS EAS28100 CHECKING THE IGNITION COILS The following procedure applies to all of the igni- tion coils. 1. Check: • Primary coil resistance Out of specification → Replace. Sb/W R/L L/R Primary coil resistance L/G L/Y Sb B/Y 2.16–2.64 Ω M MMM M MMM M MMM...

  • Page 415: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS c. Turn the main switch to “ON” and engine stop • Positive tester probe → switch to “ ”. black/red “1” • Negative tester probe → d. Measure the ignition spark gap “a”. spark plug lead “2” e. Crank the engine by pushing the start switch “...

  • Page 416: Checking The Stator Coil

    ELECTRICAL COMPONENTS 2. Check: M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 1) to the stator • Lean angle cut-off switch output voltage coil coupler as shown. Out of specification → Replace. Pocket tester Lean angle cut-off switch output 90890-03112...

  • Page 417: Checking The Horn

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Set the engine tachometer to the cylinder-#1 left spark plug lead or right spark plug lead. b. Connect the pocket tester (DC 20 V) to the rectifier/regulator coupler as shown. Pocket tester 90890-03112 Analog pocket tester...

  • Page 418: Checking The Fuel Sender

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 1k) to the en- Fuel sender resistance 1.35–1.65 kΩ at 25 °C (77 °F) gine temperature sensor terminal as shown. Pocket tester M MMM M MMM M MMM...

  • Page 419: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS b. Turn the main switch to “ON”. b. Measure the throttle position sensor maxi- c. Elevate the rear wheel and slowly rotate it. mum resistance. d. Measure the voltage of white/yellow and L LLL L LLL L LLL L LLL L LLL black/blue.

  • Page 420: Checking The Exup Servo Motor

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM For counterclockwise rotation “a” a. Insert a plug “1” into the fuel return hose end. • Positive battery lead → b. Fill the fuel tank. black/green “1” c. Put the end of the fuel hose “2” into an open •...

  • Page 421: Checking The Intake Air Pressure Sensors

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Disconnect the decompression solenoid cou- plers from the wire harness. b. Connect the pocket tester (Ω × 10) to the de- compression solenoid coupler as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C...

  • Page 422: Checking The Air Temperature Sensor

    ELECTRICAL COMPONENTS ET5YU1007 ET5YU1008 CHECKING THE AIR TEMPERATURE CHECKING THE INTAKE SOLENOID SENSOR 1. Check: 1. Remove: • Intake solenoid resistance Out of specification → Replace. • Air temperature sensor EW5YU1002 WARNING Intake solenoid resistance 42–48 Ω at 20 °C (68 °F) •...

  • Page 423: Checking The Muffler Cooling Fan Temperature Sensor

    ELECTRICAL COMPONENTS c. Check the muffler cooling fan motor move- b. Immerse the muffler cooling fan temperature ment. sensor “3” in a container filled with water “4”. L LLL L LLL L LLL L LLL L LLL NOTE: Make sure that the muffler cooling fan tempera- ET5YU1006 CHECKING THE MUFFLER COOLING FAN ture sensor terminals do not get wet.
  • Page 424 TRBL SHTG...

  • Page 425: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................8-1 GENERAL INFORMATION ............... 8-1 STARTING FAILURES................8-1 INCORRECT ENGINE IDLING SPEED ............ 8-1 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ......8-2 FAULTY GEAR SHIFTING................ 8-2 SHIFT PEDAL DOES NOT MOVE ............8-2 JUMPS OUT OF GEAR................8-2 FAULTY CLUTCH ..................8-2 OVERHEATING ..................

  • Page 427: Troubleshooting

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

  • Page 428: Poor Medium And High-Speed Performance

    TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •...

  • Page 429: Overheating

    TROUBLESHOOTING Malfunction EAS28590 OVERHEATING • Bent or damaged inner tube • Bent or damaged outer tube Engine • Damaged fork spring 1. Cylinder head(s) and piston(s) • Worn or damaged outer tube bushing • Heavy carbon buildup • Bent or damaged damper rod 2.
  • Page 430 TROUBLESHOOTING • Incorrect connection • Faulty main switch • Improperly grounded circuit • Faulty horn switch • Poor contacts (main or light switch) • Faulty battery • Burnt-out headlight bulb • Blown, damaged or incorrect fuse • Faulty wire harness Headlight bulb burnt out •...

  • Page 431: Wiring Diagram

    EAS28740 57. Pass switch WIRING DIAGRAM 58. Dimmer switch MT-01(T) 2005 59. Hazard switch 1. AC magneto 60. Turn signal switch 2. Rectifier/regulator 61. Horn switch 3. Main switch 62. Front left turn signal light 4. Battery 63. Front right turn signal light 5.
  • Page 432 Blue/Black Blue/Green Blue/Red Blue/White Blue/Yellow Pink/Blue Pink/White Pink/Yellow Red/Black Red/Green Red/Blue Red/White Red/Yellow Sb/W Sky blue/White White/Black White/Green White/Red White/Yellow Yellow/Black Yellow/Green Yellow/Blue...
  • Page 434 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 435 MT-01(T) 2005 WIRING DIAGRAM Sb/W Sb/W L/W1 L/W1 WIRE HARNESS SUB-WIRE-HARNESS1 Br/W Br/Y Gy/G R/L R/W B/Br B/Br Br/L R/G B2 Br/B R/W Lg R/W Lg Y/L Gy/R Gy/W Br/B Gy/B (BLUE) Br/B Br/B (BLACK) (BLACK) (DARK GREEN) (BLUE) Gy/B Gy/B WIRE HARNESS SUB-WIRE-HARNESS2...

This manual is also suitable for:

2005 mt-012005 mt-01t

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