Yamaha YZFR6V Service Manual
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Yamaha YZFR6V Service Manual

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Table of Contents

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YZFR6V(C)
SERVICE MANUAL
LIT-11616-19-78
2C0-28197-10

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Summary of Contents for Yamaha YZFR6V

  • Page 1 YZFR6V(C) SERVICE MANUAL LIT-11616-19-78 2C0-28197-10...
  • Page 2 EAS20050 YZFR6V(C) SERVICE MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. First edition, December 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-19-78...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 4: How To Use This Manual

    EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...

  • Page 5: Symbols

    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 COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 7: General Information

    MODEL LABEL ..................1-1 FEATURES ..................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM ....................1-3 YCC-T (Yamaha Chip Controlled Throttle)..........1-4 INSTRUMENT FUNCTIONS..............1-7 IMPORTANT INFORMATION ............... 1-11 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-11 REPLACEMENT PARTS ................ 1-11 GASKETS, OIL SEALS AND O-RINGS ..........

  • Page 8: 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 frame under the passenger seat. This information will be needed to order spare parts.

  • Page 9: Features

    FEATURES EAS20170 FEATURES ET2C01025 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 10: Fi System

    FEATURES ET2C01019 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm², 46.1 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 11: Ycc-T (Yamaha Chip Controlled Throttle)

    Yamaha developed the YCC-T system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast- er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
  • Page 12 FEATURES YCC-T system outline 1. Throttle position sensor (for throttle cable 18. Atmospheric pressure sensor pulley) 2. Throttle servo motor 3. Throttle position sensor (for throttle valves) 4. ECU (engine control unit) 5. ETV main CPU (32 bit) 6. ETV sub CPU (16 bit) 7.
  • Page 13 FEATURES YCC-T control outline 1. Throttle position sensor (for throttle cable 18. Idle speed control pulley) 19. Calculated throttle valve opening angle 2. Throttle position sensor (for throttle valves) 3. Crankshaft position sensor 4. Speed sensor 5. Coolant temperature sensor 6.

  • Page 14: Instrument Functions

    FEATURES ET2C01020 • To switch the speedometer and odometer/trip- INSTRUMENT FUNCTIONS meter displays between kilometers and miles, press the “SELECT” button for at least one Multi-function meter unit second. EW2C01003 WARNING Be sure to stop the vehicle before making Tachometer any setting changes to the multi-function meter unit.
  • Page 15 FEATURES To set the clock: “SELECT” button, and then push it again for a 1. Push the “SELECT” button and “RESET” but- few seconds until the stopwatch digits stop ton together for at least two seconds. flashing. 2. When the hour digits start flashing, push the “RESET”...
  • Page 16 FEATURES EC2C01021 Display brightness and shift timing indicator CAUTION: light control mode Do not operate the engine if it is overheated. Air intake temperature display 1. Display brightness 2. Shift timing indicator light activation/deactivation 3. Shift timing indicator light 1. Air intake temperature display This mode cycles through five control functions, The air intake temperature display indicates the allowing you to make the following settings in the...
  • Page 17 FEATURES To adjust the brightness of the multi-function To set the shift timing indicator light deactivation meter displays and tachometer: function: 1. Turn the key to “OFF”. NOTE: 2. Push and hold the “SELECT” button. • The shift timing indicator light deactivation 3.

  • Page 18: Important Information

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

  • Page 19: Bearings And Oil Seals

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

  • Page 20: Checking The Connections

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

  • Page 21: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of 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 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-11 90890-01426 YU-38411 Oil pressure gauge set 3-13 90890-03120 Oil pressure adapter H 3-13 90890-03139 Steering nut wrench 3-27, 4-58 90890-01403 Spanner wrench YU-33975 Fork spring compressor 4-47, 4-52 90890-01441 YM-01441 Rod holder...
  • Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller 4-51, 4-52 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10) 4-51, 4-52 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Ring nut wrench 4-58 90890-01268 Spanner wrench YU-01268...
  • Page 24 Valve guide reamer (4.5 mm) YM-04118 Valve spring compressor 5-24 90890-04109 Sheave holder 5-28, 5-29, 90890-01701 5-31 Primary clutch holder YS-01880-A Flywheel puller 5-28 90890-01404 Flywheel puller YM-01404 Yamaha bond No. 1215 5-29, 5-31, 90890-85505 5-57 ® (Three Bond No.1215 1-17...
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-41, 5-45 90890-04086 YM-91042 Thickness gauge 5-41 0.15 0.10 0.05 90890-03180 0.20 0.03 0.50 Feeler gauge set 0.25 0.30 YU-26900-9 0.35 0.40 Piston pin puller set 5-60 90890-01304 Piston pin puller YU-01304 YU-01304 Radiator cap tester...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pressure gauge 7-12 90890-03153 Pressure gauge YU-03153 Fuel pressure adapter 7-12 90890-03176 YM-03176 Digital circuit tester 7-13 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Ignition checker 8-92 90890-06754 Opama pet-4000 spark checker YM-34487 1-19...

  • Page 27: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................ 2-10 ELECTRICAL SPECIFICATIONS..............2-13 TIGHTENING TORQUES................2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-16 ENGINE TIGHTENING TORQUES............2-17 CHASSIS TIGHTENING TORQUES............2-21 LUBRICATION POINTS AND LUBRICANT TYPES ........2-25 ENGINE ....................2-25 CHASSIS ....................

  • Page 28: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 2C05/2C08 (USA) 2C06 (California) Dimensions Overall length 2040 mm (80.3 in) Overall width 700 mm (27.6 in) Overall height 1100 mm (43.3 in) Seat height 850 mm (33.5 in) Wheelbase 1380 mm (54.3 in) Ground clearance 130 mm (5.12 in) Minimum turning radius...

  • Page 29: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid-cooled 4-stroke, DOHC Displacement 599 cm³ (36.55 cu.in) Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 67.0 × 42.5 mm (2.64 × 1.67 in) Compression ratio 12.8 :1 Standard compression pressure (at sea level) 1550 kPa/400 r/min (220.5 psi/400 r/min) (15.5 kgf/cm²/400 r/min) Minimum–maximum...
  • Page 30 ENGINE SPECIFICATIONS Coolant reservoir capacity (up to the maximum level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt) Radiator cap opening pressure 107.9–137.3 kPa (15.6–19.9 psi) (1.08–1.37 kgf/cm²) Thermostat Valve opening temperature 71 °C (159.8 °F) Valve full open temperature 85 °C (185 °F) Valve lift (full open) More than 8 mm (0.31 in)
  • Page 31 ENGINE SPECIFICATIONS Exhaust B 25.082–25.182 mm (0.9875–0.9914 in) Limit 25.032 mm (0.9855 in) Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Model/number of links 98XRH2015/118 Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.12–0.19 mm (0.0047–0.0075 in) Exhaust 0.16–0.23 mm (0.0063–0.0091 in) Valve dimensions...
  • Page 32 ENGINE SPECIFICATIONS Valve margin thickness D (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 0.8 mm (0.03 in) Valve margin thickness D (exhaust) 1.10–1.30 mm (0.0433–0.0512 in) Limit 1.0 mm (0.04 in) Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in) Limit 4.460 mm (0.1756 in) Valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in) Limit...
  • Page 33 ENGINE SPECIFICATIONS Spring tilt (intake) 2.5°/1.6 mm Spring tilt (exhaust) 2.5°/1.6 mm Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Cylinder Bore 67.000–67.010 mm (2.6378–2.6382 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.050 mm (0.0020 in) Piston Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in)
  • Page 34 ENGINE SPECIFICATIONS 2nd ring Ring type Taper Dimensions (B × T) 0.80 × 2.50 mm (0.03 × 0.10 in) End gap (installed) 0.70–0.80 mm (0.0276–0.0315 in) Limit 1.00 mm (0.0394 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Oil ring Dimensions (B ×...
  • Page 35 ENGINE SPECIFICATIONS Plate quantity 8 pcs Warpage limit 0.10 mm (0.0039 in) Clutch spring free length 55.00 mm (2.17 in) Minimum length 54.00 mm (2.13 in) Spring quantity 6 pcs Transmission Transmission type Constant mesh 6-speed Primary reduction system Spur gear Primary reduction ratio 85/41 (2.073) Secondary reduction system...
  • Page 36 ENGINE SPECIFICATIONS Fuel injection sensor 248–372 Ω at 20 °C (68 °F) Crankshaft position sensor resistance Cylinder identification sensor output voltage (ON) Less than 0.8 V Cylinder identification sensor output voltage (OFF) More than 4.8 V Intake air pressure sensor output voltage 3.15–4.15 V Atmospheric pressure sensor output voltage 3.15–4.15 V...

  • Page 37: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 24.00° Trail 97.0 mm (3.82 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 38 CHASSIS SPECIFICATIONS Brake disc thickness limit 4.0 mm (0.16 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter...
  • Page 39 CHASSIS SPECIFICATIONS Spring free length 163.5 mm (6.44 in) Installed length 152.5 mm (6.00 in) Spring rate K1 98.00 N/mm (559.58 lb/in) (9.99 kgf/mm) Spring stroke K1 0.0–60.0 mm (0.00–2.36 in) Optional spring available Enclosed gas/air pressure (STD) 1200 kPa (170.7 psi) (12.0 kgf/cm²) Swingarm Swingarm end free play limit (radial) 1.0 mm (0.04 in)

  • Page 40: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Throttle position sensor and electrical Ignition timing (B.T.D.C.) 10.0°/1300 r/min Engine control unit Model/manufacturer TBDF24/DENSO Ignition coil Model/manufacturer F6T558/MITSUBISHI Minimum ignition spark gap 6.0 mm (0.24 in) 1.19–1.61 Ω...
  • Page 41 ELECTRICAL SPECIFICATIONS High beam indicator light Fuel level warning light Coolant temperature warning light Engine trouble warning light Shift timing indicator light Electric starting system System type Constant mesh Starter motor Model/manufacturer SM14/MITSUBA Power output 0.60 kW 0.0012–0.0022 Ω at 20 °C (68 °F) Armature coil resistance Brush overall length 10.0 mm (0.39 in)
  • Page 42 ELECTRICAL SPECIFICATIONS Fuel pump relay Model/manufacturer G8R-30Y-V4/OMRON Fan motor relay Model/manufacturer ACM33211M05/MATSUSHITA Fuses Main fuse 50.0 A Headlight fuse 15.0 A Signaling system fuse 10.0 A Ignition fuse 15.0 A 15.0 A × 2 Radiator fan fuse Fuel injection system fuse 15.0 A Backup fuse 7.5 A...

  • 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 Camshaft cap bolt (intake and 10 Nm (1.0 m·kg, 7.2 ft·lb) exhaust) Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kg, 11 ft·lb) pipe assembly) Cylinder head nut (1st) 25 Nm (2.5 m·kg, 18 ft·lb) Cylinder head nut (final) 42 Nm (4.2 m·kg, 30 ft·lb)
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Upper air filter case to lower air 2 Nm (0.2 m·kg, 1.4 ft·lb) filter case bolt Upper air filter case joint bolt 4 Nm (0.4 m·kg, 2.9 ft·lb) Secondary injector fuel rail 5 Nm (0.5 m·kg, 3.6 ft·lb) Locknut (throttle cable) 5 Nm (0.5 m·kg, 3.6 ft·lb)
  • Page 46 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Drive sprocket cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Main gallery plug 8 Nm (0.8 m·kg, 5.8 ft·lb) Ventilation chamber cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil pipe 12 Nm (1.2 m·kg, 8.7 ft·lb) Crankshaft position sensor bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 47 TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence: 2-20...

  • Page 48: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front right 45 Nm (4.5 m·kg, 32 ft·lb) side) Engine mounting bolt (front left 45 Nm (4.5 m·kg, 32 ft·lb) side) Engine mounting nut (rear upper 68 Nm (6.8 m·kg, 49 ft·lb) side) Engine mounting nut (rear lower...
  • Page 49 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Lower bracket pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) NOTE Horn and front brake hose joint 10 Nm (1.0 m·kg, 7.2 ft·lb) bolt Front brake hose guide bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Lower bracket and front brake 10 Nm (1.0 m·kg, 7.2 ft·lb) hose joint bracket bolt...
  • Page 50 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Fuel tank bracket and fuel tank 7 Nm (0.7 m·kg, 5.1 ft·lb) bolt Canister and canister bracket 7 Nm (0.7 m·kg, 5.1 ft·lb) Canister bracket and ventilation 10 Nm (1.0 m·kg, 7.2 ft·lb) chamber cover Radiator bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 51 TIGHTENING TORQUES 4. In the order pinch bolt “4” → pinch bolt “3” → pinch bolt “4”, tighten each bolt to 21 Nm (2.1 m·kg, 15 ft·lb) without performing temporary tightening. NOTE: Lower ring nut 1. First, tighten the lower ring nut to approximately 52 Nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then loosen the lower ring nut completely.

  • Page 52: Lubrication Points And Lubricant Types

    Primary driven gear inner surface Clutch pull rod Transmission gears (wheel and pinion) and collars Main axle and drive axle Shift forks and shift fork guide bars Shift shaft Yamaha bond No.1215 Cylinder head cover mating surface (Three Bond ® No.1215...
  • Page 53 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond No.1215 Crankshaft position sensor lead grommet (Three Bond ® No.1215 Yamaha bond No.1215 Stator coil lead grommet (Three Bond ® No.1215 2-26...

  • Page 54: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing cover lip Lower bearing dust seal lip Tube guide (throttle grip) inner surface and throttle cables Brake lever pivoting point and metal-to-metal moving parts Clutch cable end Clutch lever pivoting point and metal-to-metal moving parts Relay arm, connecting arm and rear shock absorber spacer Swingarm pivot shaft...

  • Page 55: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-29...
  • Page 56 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil filter 5. Oil cooler 6. Main gallery 7. Oil nozzle 8. Timing chain tensioner 9. Intake camshaft 10. Exhaust camshaft 11. Oil pipe 12. Main axle 13.

  • Page 57: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-31...
  • Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Ventilation chamber cover 2. Relief valve 3. Ventilation chamber oil drain pipe 4. Oil cooler 2-32...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Oil check bolt 5. Oil strainer 6. Ventilation chamber oil drain pipe 7. Oil pipe 8. Oil pump 2-34...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil filter 3. Oil pipe 4. Oil pump 5. Oil strainer 2-36...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil pump 3. Oil pipe 4. Ventilation chamber oil drain pipe 5. Relief valve 2-38...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Oil nozzle 2-40...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-41...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pipe 2. Main axle 3. Drive axle 2-42...

  • Page 69: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-43...
  • Page 70 COOLING SYSTEM DIAGRAMS 1. Radiator inlet hose 2. Radiator inlet pipe 3. Thermostat outlet hose 4. Radiator 2-44...
  • Page 71 COOLING SYSTEM DIAGRAMS 2-45...
  • Page 72 COOLING SYSTEM DIAGRAMS 1. Water pump breather hose 2. Coolant reservoir hose 3. Coolant reservoir 4. Radiator 5. Radiator outlet hose 6. Oil cooler outlet hose 7. Radiator outlet pipe 8. Water jacket joint inlet hose 9. Water pump outlet pipe 10.

  • Page 73: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-47...
  • Page 74 CABLE ROUTING 1. Front brake light switch lead 2. Front brake fluid reservoir hose 3. Right handlebar switch lead 4. Clutch cable 5. Main switch lead 6. Left handlebar switch lead 7. Clutch switch lead 8. Horn lead 9. Front brake hose 10.
  • Page 75 CABLE ROUTING 60˚ 2-49...
  • Page 76 CABLE ROUTING 1. EXUP servo motor lead K. Fasten the EXUP cables and O sensor lead with a plastic locking tie. Face the end of the plastic 2. Crankshaft position sensor lead locking tie rearward, and then cut off the excess 3.
  • Page 77 CABLE ROUTING 2-51...
  • Page 78 CABLE ROUTING 1. Main switch lead 2. Left handlebar switch lead 3. Left radiator fan motor lead 4. Wire harness 5. Radiator inlet pipe 6. Fuel tank breather hose (except for California) 7. Sidestand switch lead 8. AC magneto lead 9.
  • Page 79 CABLE ROUTING 28 29 45˚ 135˚ 2-53...
  • Page 80 CABLE ROUTING 1. Front right turn signal/position light lead M. To the ECU 2. Right radiator fan motor lead N. Install both the engine ground lead terminal and the negative battery lead terminal to the crankcase 3. Throttle position sensor (for throttle valves) lead with the bolt.
  • Page 81 CABLE ROUTING 2-55...
  • Page 82 CABLE ROUTING 1. Throttle cable (decelerator cable) 2. Throttle cable (accelerator cable) 3. Front brake hose A. Pass the throttle cables between the front fork and the front brake hose. B. When installing the guide on the lower bracket, be sure to pass the front brake hose through it.
  • Page 83 CABLE ROUTING 2-57...
  • Page 84 CABLE ROUTING 1. Canister purge hose (throttle body-#4 to 3-way joint) (for California only) 2. Canister purge hose (3-way joint to canister) (for California only) 3. Fuel tank breather hose (fuel tank to rollover valve) (for California only) 4. Fuel tank breather hose (fuel tank to hose joint) (except for California) 5.
  • Page 85 CABLE ROUTING 2-59...
  • Page 86 CABLE ROUTING 1. Negative battery lead 2. Main fuse leads 3. Lean angle sensor lead 4. ECU (engine control unit) 5. Tail/brake light lead 6. Turn signal light lead (right and left side) 7. License plate light lead 8. Seat lock cable 9.

  • Page 87: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE................3-1 INTRODUCTION..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART....... 3-1 ENGINE ......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODIES ......... 3-6 ADJUSTING THE THROTTLE CABLE FREE PLAY ........ 3-8 CHECKING THE SPARK PLUGS.............
  • Page 88 LUBRICATING THE PEDALS..............3-34 LUBRICATING THE SIDESTAND ............3-34 LUBRICATING THE REAR SUSPENSION ..........3-34 ELECTRICAL SYSTEM ................3-35 CHECKING AND CHARGING THE BATTERY........3-35 CHECKING THE FUSES ................ 3-35 REPLACING THE HEADLIGHT BULBS ..........3-35 ADJUSTING THE HEADLIGHT BEAMS..........3-35...

  • Page 89: Periodic Maintenance

    √ √ age. • Replace any damaged parts. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU32183 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS...
  • Page 90 Front and rear √ √ √ √ √ √ 23 * • Check operation. brake switches • Apply Yamaha chain and ca- √ √ √ √ √ √ 24 * Control cables ble lube or engine oil SAE 10W-30 thoroughly.
  • Page 91 26 * and switches • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.

  • Page 92: Engine

    ENGINE EAS20470 ENGINE Valve clearance (cold) Intake 0.12–0.19 mm (0.0047–0.0075 in) EAS20490 ADJUSTING THE VALVE CLEARANCE Exhaust The following procedure applies to all of the 0.16–0.23 mm (0.0063–0.0091 in) valves. M MMM M MMM M MMM M MMM M MMM NOTE: a.
  • Page 93 ENGINE • Measure the valve clearance in the following NOTE: sequence. • Refer to “CAMSHAFTS” on page 5-7. • When removing the timing chain and cam- Valve clearance measuring sequence shafts, fasten the timing chain with a wire to re- Cylinder #1 →...

  • Page 94: Synchronizing The Throttle Bodies

    ENGINE c. Check the thickness of the current valve pad. NOTE: NOTE: • Lubricate the valve lifter with engine oil. The thickness “a” of each valve pad is marked in • The valve lifter must turn smoothly when rotat- hundredths of millimeters on the side that touch- ed by hand.
  • Page 95 ENGINE 1. Stand the vehicle on a level surface. b. Turn the bypass air screw “1” with a white paint mark out a little, and then turn it in fully. NOTE: Place the vehicle on a suitable stand. 2. Remove: •...

  • Page 96: Adjusting The Throttle Cable Free Play

    ENGINE b. Turn all of the bypass air screws in fully. 1. Check: c. Using the throttle body with the lowest vacu- • Throttle cable free play “a” Out of specification → Adjust. um pressure as the standard, turn out the by- pass air screws of the other throttle bodies to Throttle cable free play adjust them.

  • Page 97: Measuring The Compression Pressure

    ENGINE 1. Remove: • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 7-1. • Air filter case Refer to “AIR FILTER CASE” on page 7-5. • Canister (for California only) Refer to “THROTTLE BODIES”...

  • Page 98: Checking The Engine Oil Level

    ENGINE • Radiator NOTE: Refer to “RADIATOR” on page 6-1. The difference in compression pressure be- 4. Remove: tween cylinders should not exceed 100 kPa (1 • Ignition coils kg/cm², 14 psi). • Spark plugs c. If the compression pressure is above the ECA13340 CAUTION: maximum specification, check the cylinder...

  • Page 99: Changing The Engine Oil

    ENGINE 4. Check: EAS20780 CHANGING THE ENGINE OIL • Engine oil level 1. Start the engine, warm it up for several min- The engine oil level should be between the utes, and then turn it off. minimum level mark “a” and maximum level 2.

  • Page 100: Measuring The Engine Oil Pressure

    ENGINE L LLL L LLL L LLL L LLL L LLL 8. Check: • Engine oil drain bolt gasket Damage → Replace. 9. Install: • Engine oil drain bolt (along with the gasket) Engine oil drain bolt 43 Nm (4.3 m·kg, 31 ft·lb) d.

  • Page 101: Adjusting The Clutch Lever Free Play

    ENGINE 2. Start the engine, warm it up for several min- Oil pressure (hot) utes, and then turn it off. 80.0 kPa/1300 r/min (11.6 ECA13410 psi/1300 r/min) (0.80 CAUTION: kgf/cm²/1300 r/min) When the engine is cold, the engine oil will Oil temperature have a higher viscosity, causing the engine 82–92 °C (180–198 °F)

  • Page 102: Replacing The Air Filter Element

    ENGINE M MMM M MMM M MMM M MMM M MMM EAS20960 REPLACING THE AIR FILTER ELEMENT Handlebar side 1. Remove: a. Turn the adjusting bolt “1” in direction “a” or • Rider seat “b” until the specified clutch lever free play is Refer to “GENERAL CHASSIS”...

  • Page 103: Checking The Throttle Body Joints

    ENGINE EAS21010 • Breather hose “3” (except for California) CHECKING THE THROTTLE BODY JOINTS Cracks/damage → Replace. The following procedure applies to all of the Loose connection → Connect properly. throttle body joints and intake manifolds. ECA14940 1. Remove: CAUTION: •...

  • Page 104: Checking The Exhaust System

    ENGINE EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipe assembly and gaskets. 1. Remove: • Side cowlings • Bottom cowlings Refer to “GENERAL CHASSIS” on page 4-1. 2. Check: • Exhaust pipe assembly “1” •...
  • Page 105 ENGINE 2. Check: 4. Adjust: • EXUP system operation • EXUP cable free play M MMM M MMM M MMM M MMM M MMM M MMM M MMM M MMM M MMM M MMM a. Activate the diagnostic mode and select the a.

  • Page 106: Checking The Coolant Level

    ENGINE f. Repeat steps (2) and (3). 3. Start the engine, warm it up for several min- utes, and then turn it off. L LLL L LLL L LLL L LLL L LLL 4. Check: 5. Install: • Coolant level •...

  • Page 107: Changing The Coolant

    ENGINE be blown out, which could cause serious in- jury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter- clockwise toward the detent to allow any re- sidual pressure to escape.
  • Page 108 ENGINE 8. Install: • If coolant comes into contact with painted • Coolant reservoir surfaces, immediately wash them with wa- 9. Connect: ter. • Water pump inlet hose • Do not mix different types of antifreeze. 10.Install: 12.Install: • Coolant drain bolt (water pump) •...

  • Page 109: Chassis

    CHASSIS EAS21140 ECA13490 CHASSIS CAUTION: After adjusting the brake lever position, EAS21150 make sure there is no brake drag. ADJUSTING THE FRONT DISC BRAKE 1. Adjust: L LLL L LLL L LLL L LLL L LLL • Brake lever position EAS21190 (distance “a”...

  • Page 110: Checking The Brake Fluid Level

    CHASSIS EC2C01009 EWA13090 CAUTION: WARNING After adjusting the installed rear master cyl- • Use only the designated brake fluid. Other inder length, make sure there is no brake brake fluids may cause the rubber seals to drag. deteriorate, causing leakage and poor brake performance.

  • Page 111: Checking The Front Brake Hoses

    CHASSIS 1. Operate the brake. 2. Check: 2. Check: • Brake hose holders “2” Loose connection → Connect. • Rear brake pad Wear limit “a” reached → Replace the brake pads as a set. Refer to “REAR BRAKE” on page 4-29. Limit 1.0 mm (0.04 in) 3.

  • Page 112: Bleeding The Hydraulic Brake System

    CHASSIS L LLL L LLL L LLL L LLL L LLL EAS21360 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA13100 WARNING Bleed the hydraulic brake system whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. A.

  • Page 113: Adjusting The Shift Pedal

    CHASSIS Bleed screw (front brake master Direction “a” cylinder) Installed shift rod length increases. 6 Nm (0.6 m·kg, 4.3 ft·lb) Direction “b” Bleed screw (front brake caliper) Installed shift rod length decreases. 5 Nm (0.5 m·kg, 3.6 ft·lb) Bleed screw (rear brake caliper) 5 Nm (0.5 m·kg, 3.6 ft·lb) k.

  • Page 114: Lubricating The Drive Chain

    CHASSIS Drive chain slack Drive chain adjusting bolt 35.0–45.0 mm (1.38–1.77 in) 2 Nm (0.2 m·kg, 1.4 ft·lb) f. Tighten the locknuts to specification. NOTE: Measure the drive chain slack halfway between Drive chain adjusting locknut the drive axle and the rear wheel axle. 16 Nm (1.6 m·kg, 11 ft·lb) L LLL L LLL...
  • Page 115 CHASSIS 4. Adjust: d. Check the steering head for looseness or • Steering head binding by turning the front fork all the way in M MMM M MMM M MMM M MMM M MMM both directions. If any binding is felt, remove a.

  • Page 116: Checking The Front Fork

    CHASSIS d. Hold the spring gauge at a 90° angle from the handlebar, pull the spring gauge, and then record the measurement when the handlebar starts to run. Steering head tension 200–500 g 3. Hold the vehicle upright and apply the front brake.
  • Page 117 CHASSIS Direction “a” Direction “a” (turn in) Spring preload is increased (suspen- Rebound damping is increased (sus- sion is harder). pension is harder). Direction “b” Direction “b” (turn out) Spring preload is decreased (suspen- Rebound damping is decreased (sus- sion is softer). pension is softer).

  • Page 118: Adjusting The Rear Shock Absorber Assembly

    CHASSIS Compression damping adjusting Compression damping adjusting positions (fast compression damp- positions (slow compression ing) damping) Minimum Minimum Distance “c” = 8 mm (0.31 in) 16 click(s) out* Standard Standard Distance “c” = 10 mm (0.39 in) 10 click(s) out* Maximum Maximum Distance “c”...
  • Page 119 CHASSIS Spring preload adjusting positions Minimum Standard Maximum L LLL L LLL L LLL L LLL L LLL Compression damping ECA13590 CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: • Compression damping (fast compression L LLL L LLL L LLL L LLL...

  • Page 120: Checking The Tires

    CHASSIS 2. Adjust: EWA13180 WARNING • Compression damping (slow compression • The tire pressure should only be checked damping) and regulated when the tire temperature M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw “1” in direction “a” or equals the ambient air temperature.

  • Page 121: Checking The Wheels

    CHASSIS and of the same design. No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. Front tire Size 120/70 ZR17M/C (58W) Manufacturer/model DUNLOP/D209F PT 1.

  • Page 122: Checking And Lubricating The Cables

    CHASSIS EWA13260 EAS21720 LUBRICATING THE SIDESTAND WARNING Lubricate the pivoting point and metal-to-metal Never attempt to make any repairs to the moving parts of the sidestand. wheel. Recommended lubricant NOTE: Lithium-soap-based grease After a tire or wheel has been changed or re- placed, always balance the wheel.

  • Page 123: Electrical System

    ELECTRICAL SYSTEM EAS21750 EWA13320 ELECTRICAL SYSTEM WARNING Since the headlight bulb gets extremely hot, EAS21760 keep flammable products and your hands CHECKING AND CHARGING THE BATTERY away from the bulb until it has cooled down. Refer to “ELECTRICAL COMPONENTS” on 5.
  • Page 124 ELECTRICAL SYSTEM A. Left headlight B. Right headlight L LLL L LLL L LLL L LLL L LLL 2. Adjust: • Headlight beam (horizontally) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw “1” in direction “a” or “b”.
  • Page 125 CHASSIS GENERAL CHASSIS ..................4-1 FRONT WHEEL ....................4-4 REMOVING THE FRONT WHEEL ............4-7 DISASSEMBLING THE FRONT WHEEL..........4-7 CHECKING THE FRONT WHEEL ............4-7 ASSEMBLING THE FRONT WHEEL............4-8 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-8 CHECKING THE FRONT BRAKE DISCS..........4-9 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ....
  • Page 126 REAR BRAKE....................4-29 INTRODUCTION..................4-34 CHECKING THE REAR BRAKE DISC ........... 4-34 REPLACING THE REAR BRAKE PADS ..........4-34 REMOVING THE REAR BRAKE CALIPER ..........4-35 DISASSEMBLING THE REAR BRAKE CALIPER ........4-35 CHECKING THE REAR BRAKE CALIPER..........4-36 ASSEMBLING THE REAR BRAKE CALIPER ........4-36 INSTALLING THE REAR BRAKE CALIPER...........
  • Page 127 CHAIN DRIVE ....................4-70 REMOVING THE DRIVE CHAIN ............4-71 CHECKING THE DRIVE CHAIN ............. 4-71 CHECKING THE DRIVE SPROCKET ............ 4-72 CHECKING THE REAR WHEEL SPROCKET........4-72 CHECKING THE REAR WHEEL DRIVE HUB........4-72 INSTALLING THE DRIVE CHAIN ............4-72...
  • Page 128 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 • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Rider seat...

  • Page 129: 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 • • 28 Nm (2.8 m kg, 20 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 130 GENERAL CHASSIS Removing the side cowlings and front cowling assembly 7 Nm (0.7 m kg, 5.1 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Parts to remove Q’ty Remarks Side panel Upper side cowling Lower side cowling Front turn signal/position light coupler Disconnect.
  • Page 131 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. Left reflector assembly Right reflector assembly Left front brake hose holder Right front brake hose holder Left front brake caliper Right front brake caliper...
  • Page 132 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Front brake disc For installation, reverse the removal proce- dure.
  • Page 133 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure.

  • Page 134: Front Wheel

    FRONT WHEEL EAS21900 EAS21920 REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL 1. Stand the vehicle on a level surface. 1. Check: • 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 135: 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. EAS21960 ASSEMBLING THE FRONT WHEEL 1.

  • Page 136: Checking The Front Brake Discs

    FRONT WHEEL 1. Install: • Front brake disc Front brake disc bolt 18 Nm (1.8 m·kg, 13 ft·lb) ® LOCTITE NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. b. Turn the front wheel 90° so that the heavy spot is positioned as shown.
  • Page 137 FRONT WHEEL EWA13500 Front wheel axle WARNING 91 Nm (9.1 m·kg, 66 ft·lb) Make sure the brake hose is routed properly. Front wheel axle pinch bolt 21 Nm (2.1 m·kg, 15 ft·lb) EC2C01015 CAUTION: Before tightening the wheel axle, push down hard on the handlebar several times and check if the front fork rebounds smoothly.

  • Page 138: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. Rear brake caliper Drive chain adjusting locknut Loosen. Drive chain adjusting bolt Loosen.
  • Page 139 REAR WHEEL Removing the rear brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar Dust cover Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Dust cover Collar For installation, reverse the removal proce- dure.
  • Page 140 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly pro- cedure. 4-13...

  • Page 141: 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 142: 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 143 REAR WHEEL 4. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-25. Drive chain slack 35.0–45.0 mm (1.38–1.77 in) 5. Install: • Rear brake caliper Rear brake caliper bolt (M12) 27 Nm (2.7 m·kg, 19 ft·lb) Rear brake caliper bolt (M8) 22 Nm (2.2 m·kg, 16 ft·lb) ®...

  • Page 144: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Reflector assembly Brake hose holder Front brake caliper Brake pad clip Brake pad pin Brake pad spring Front brake pad For installation, reverse the removal proce-...
  • Page 145 FRONT BRAKE Removing the front brake master cylinder 13 Nm (1.3 m kg, 9.4 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 146 FRONT BRAKE Disassembling the front brake master cylinder 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Bleed screw Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-19...
  • Page 147 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-24. Reflector assembly Brake hose holder Front brake hose union bolt Copper washer Front brake hose...
  • Page 148 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 pro- cedure.

  • Page 149: Introduction

    FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake e.

  • Page 150: Replacing The Front Brake Pads

    FRONT BRAKE NOTE: Brake disc bolt Always install new brake pads, and a brake pad 18 Nm (1.8 m·kg, 13 ft·lb) spring as a set. ® LOCTITE M MMM M MMM M MMM M MMM M MMM a. Connect a clear plastic hose “1” tightly to the d.

  • Page 151: Removing The Front Brake Calipers

    FRONT BRAKE Refer to “CHECKING THE BRAKE FLUID EW2C01005 WARNING LEVEL” on page 3-22. Do not loosen the bolts “3”. 5. Check: • Brake lever operation M MMM M MMM M MMM M MMM M MMM Soft or spongy feeling → Bleed the brake sys- a.

  • Page 152: Assembling The Front Brake Calipers

    FRONT BRAKE • Brake caliper cylinders “2” Front brake hose union bolt Scratches/wear → Replace the brake caliper 30 Nm (3.0 m·kg, 22 ft·lb) assembly. • Brake caliper body “3” EWA13530 Cracks/damage → Replace the brake caliper WARNING assembly. Proper brake hose routing is essential to in- •...

  • Page 153: Removing The Front Brake Master Cylinder

    FRONT BRAKE • Refill with the same type of brake fluid that NOTE: is already in the system. Mixing brake fluids To collect any remaining brake fluid, place a may result in a harmful chemical reaction, container under the master cylinder and the end leading to poor brake performance.

  • Page 154: Installing The Front Brake Master Cylinder

    FRONT BRAKE EAS22540 INSTALLING THE FRONT BRAKE MASTER 15.8˚ CYLINDER 1. Install: • Front brake master cylinder “1” • Front brake master cylinder holder “2” Front brake master cylinder hold- er bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) 3. Fill: NOTE: •...
  • Page 155 FRONT BRAKE 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-24. 4-28...
  • Page 156 REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad insulator Rear brake pad Brake pad spring For installation, reverse the removal proce- dure.
  • Page 157 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kg, 5.1 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.
  • Page 158 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake hose joint Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-31...
  • Page 159 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-24. Rear brake hose union bolt Copper washer Rear brake hose Rear brake caliper Brake pad spring For installation, reverse the removal proce- dure.
  • Page 160 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Brake pad shim Brake pad insulator Rear brake pad Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.

  • Page 161: Rear Brake

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...

  • Page 162: Removing The Rear Brake Caliper

    REAR BRAKE • Brake pad spring 4. Check: • Brake fluid level NOTE: Below the minimum level mark “a” → Add the Always install new brake pads, brake pad insu- recommended brake fluid to the proper level. lators, brake pad shims, and a brake pad spring Refer to “CHECKING THE BRAKE FLUID as a set.

  • Page 163: 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 164: 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 165: 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 166 REAR BRAKE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

  • Page 167: Handlebars

    HANDLEBARS EAS22850 HANDLEBARS Removing the handlebars 13 Nm (1.3 m kg, 9.4 ft 115 Nm (11.5 m kg, 85 ft • • • • 13 Nm (1.3 m kg, 9.4 ft 26 Nm (2.6 m kg, 19 ft • • •...
  • Page 168 HANDLEBARS Removing the handlebars 13 Nm (1.3 m kg, 9.4 ft 115 Nm (11.5 m kg, 85 ft • • • • 13 Nm (1.3 m kg, 9.4 ft 26 Nm (2.6 m kg, 19 ft • • • • 11 Nm (1.1 m kg, 8.0 ft •...

  • Page 169: Removing The Handlebars

    HANDLEBARS EAS22870 • Align the mating surfaces of the brake master REMOVING THE HANDLEBARS cylinder holder with the punch mark “b” on the 1. Stand the vehicle on a level surface. handlebar. EWA13120 • First, tighten the upper bolt, then the lower bolt. WARNING Securely support the vehicle so that there is no danger of it falling over.
  • Page 170 HANDLEBARS M MMM M MMM M MMM M MMM M MMM NOTE: a. Apply a thin coat of rubber adhesive onto the There should be 1–3 mm (0.04–0.12 in) of clear- end of the left handlebar. ance “a” between the throttle grip and the right b.

  • Page 171: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 13 Nm (1.3 m kg, 9.4 ft • • 32 Nm (3.2 m kg, 23 ft • • 26 Nm (2.6 m kg, 19 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 172 FRONT FORK Disassembling the front fork legs 25 Nm (2.5 m kg, 18 ft • • 20 Nm (2.0 m kg, 14 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 173 FRONT FORK Disassembling the front fork legs 25 Nm (2.5 m kg, 18 ft • • 20 Nm (2.0 m kg, 14 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks Inner tube For assembly, reverse the disassembly pro- cedure.

  • Page 174: Removing The Front Fork Legs

    FRONT FORK EAS22970 1. Position the collar “1” as shown in the illustra- REMOVING THE FRONT FORK LEGS tion by turning the spring preload adjusting The following procedure applies to both of the bolt “2” counterclockwise until it stops. front fork legs. 1.

  • Page 175: Checking The Front Fork Legs

    FRONT FORK NOTE: Loosen the nut using a proper tool that has a thickness of 3 mm (0.12 in) or less. 5. Remove: • Oil seal clip “1” (with a flat-head screwdriver) d. Remove the cap bolt. e. Remove the rod holder and fork spring com- pressor.

  • Page 176: Assembling The Front Fork Legs

    FRONT FORK 3. Check: ECA14210 CAUTION: • Damper rod Damage/wear → Replace. Allow the damper rod assembly to slide Obstruction → Blow out all of the oil passag- slowly down the inner tube “2” until it pro- trudes from the bottom of the inner tube. Be es with compressed air.
  • Page 177 FRONT FORK EC2C01012 CAUTION: Make sure the numbered side of the oil seal faces bottom side. NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil. •...
  • Page 178 FRONT FORK Rod puller 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M10) 90890-01436 Universal damping rod bleeding tool set YM-A8703 13.Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.
  • Page 179 FRONT FORK NOTE: Use the side of the rod holder that is marked “B”. M MMM M MMM M MMM M MMM M MMM a. Remove the rod puller attachment. b. Install the spring seat. c. Install the fork spring. i.

  • Page 180: Installing The Front Fork Legs

    FRONT FORK n. Remove the rod holder and fork spring com- 3. Tighten: pressor. • Cap bolt “1” L LLL L LLL L LLL L LLL L LLL Cap bolt 16.Install: 20 Nm (2.0 m·kg, 14 ft·lb) • Cap bolt (to the outer tube) •...
  • Page 181 FRONT FORK • Fasten the front brake hose to the right front fork leg with the plastic locking tie. 6. Adjust: • Spring preload • Rebound damping • Compression damping Refer to “ADJUSTING THE FRONT FORK LEGS” on page 3-28. 4-54...

  • Page 182: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 183 STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 184 STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 185: Removing The Lower Bracket

    STEERING HEAD EAS23110 3. Replace: 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 race from the steering Securely support the vehicle so that there is head pipe “1”...
  • Page 186 STEERING HEAD 2. Install: NOTE: • Lower ring nut “1” Make sure that the tab “a” on the front brake • Rubber washer “2” hose joint bracket contacts the side “b” of the • Upper ring nut “3” front brake hose joint. •...

  • Page 187: 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 • • 44 Nm (4.4 m kg, 32 ft • • 40 Nm (4.0 m kg, 29 ft •...
  • Page 188 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 40 Nm (4.0 m kg, 29 ft • • 44 Nm (4.4 m kg, 32 ft • • 40 Nm (4.0 m kg, 29 ft • • 16 Nm (1.6 m kg, 11 ft •...

  • Page 189: 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 190: Checking The Connecting Arm And Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY • Spring Damage/wear → Replace the rear shock ab- sorber assembly. • Bushing Damage/wear → Replace. • Spacer Damage/scratches → Replace. • Bolts Bends/damage/wear → Replace. EAS23260 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: •...
  • Page 191 REAR SHOCK ABSORBER ASSEMBLY 4. Tighten: • Spacer bolt Spacer bolt 16 Nm (1.6 m·kg, 11 ft·lb) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 40 Nm (4.0 m·kg, 29 ft·lb) • Rear shock absorber assembly upper nut Rear shock absorber assembly upper nut 44 Nm (4.4 m·kg, 32 ft·lb)

  • Page 192: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm 7 Nm (0.7 m kg, 5.1 ft • • 95 Nm (9.5 m kg, 68 ft • • 16 Nm (1.6 m kg, 11 ft • • 70 Nm (7.0 m kg, 50 ft •...
  • Page 193 SWINGARM Removing the swingarm 7 Nm (0.7 m kg, 5.1 ft • • 95 Nm (9.5 m kg, 68 ft • • 16 Nm (1.6 m kg, 11 ft • • 70 Nm (7.0 m kg, 50 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 194: Removing The Swingarm

    SWINGARM EAS23350 4. Remove: REMOVING THE SWINGARM • Swingarm pivot shaft ring nut “1” 1. Stand the vehicle on a level surface. NOTE: EWA13120 WARNING Loosen the swingarm pivot shaft ring nut with the ring nut wrench “2”. Securely support the vehicle so that there is no danger of it falling over.

  • Page 195: Installing The Swingarm

    SWINGARM EWA13770 WARNING Do not attempt to straighten a bent pivot shaft. 3. Wash: • Pivot shaft • Dust covers • Spacers • Washers • Bearings Recommended cleaning solvent 5. Swingarm Kerosene 6. Swingarm pivot shaft 7. Bolt 4. Check: A.
  • Page 196 SWINGARM Swingarm pivot shaft ring nut 95 Nm (9.5 m·kg, 68 ft·lb) NOTE: • Lubricate the swingarm pivot ring nut threads and mating surfaces with lithium-soap-based grease. • Tighten the swingarm pivot shaft ring nut with the ring nut wrench “2”. Ring nut wrench 90890-01507 YM-01507...
  • Page 197 CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain 10 Nm (1.0 m kg, 7.2 ft • • 85 Nm (8.5 m kg, 61 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks...
  • Page 198 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 199 CHAIN DRIVE EAS23460 CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth “a” wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprock- ets as a set. b. Correct 1.
  • Page 200 CHAIN DRIVE 4-73...

  • Page 201: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-6 CAMSHAFTS ....................5-7 REMOVING THE CAMSHAFTS ............... 5-9 CHECKING THE CAMSHAFTS ..............5-9 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES................ 5-11 CHECKING THE TIMING CHAIN TENSIONER ........5-11 INSTALLING THE CAMSHAFTS ............
  • Page 202 CLUTCH ......................5-37 REMOVING THE CLUTCH ..............5-41 CHECKING THE FRICTION PLATES ............ 5-41 CHECKING THE CLUTCH PLATES............5-41 CHECKING THE CLUTCH SPRINGS ............ 5-42 CHECKING THE CLUTCH HOUSING............ 5-43 CHECKING THE CLUTCH BOSS............5-43 CHECKING THE PRESSURE PLATE ............ 5-43 CHECKING THE PRIMARY DRIVE GEAR..........
  • Page 203 TRANSMISSION ................... 5-71 REMOVING THE TRANSMISSION ............5-76 CHECKING THE SHIFT FORKS ............5-76 CHECKING THE SHIFT DRUM ASSEMBLY.......... 5-76 CHECKING THE TRANSMISSION............5-77 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE......5-77 INSTALLING THE TRANSMISSION............5-78...

  • Page 204: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe assembly 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 45 Nm (4.5 m kg, 32 ft •...
  • Page 205 ENGINE REMOVAL Removing the exhaust pipe assembly 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 45 Nm (4.5 m kg, 32 ft •...
  • Page 206 ENGINE REMOVAL Disconnecting the leads and hoses 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 207 ENGINE REMOVAL Disconnecting the leads and hoses 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 208 ENGINE REMOVAL Removing the engine 45 Nm (4.5 m kg, 32 ft • • 68 Nm (6.8 m kg, 49 ft • • 10 11 45 Nm (4.5 m kg, 32 ft • • 68 Nm (6.8 m kg, 49 ft •...

  • Page 209: Installing The Engine

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Engine “1” • Engine mounting bolt (rear lower side) “2” • Engine mounting bolt (rear upper side) “3” • Engine mounting collars (inside) “4” 10 9 • Engine mounting collars (outside) “5” •...

  • Page 210: Camshafts

    CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 8 Nm (0.8 m kg, 5.8 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Parts to remove Q’ty Remarks Radiator Refer to “RADIATOR”...
  • Page 211 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kg, 7.2 ft • • (10) 12 Nm (1.2 m kg, 8.7 ft • • (10) 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 212: Removing The Camshafts

    CAMSHAFTS EAS23810 ECA13720 REMOVING THE CAMSHAFTS CAUTION: 1. Remove: To prevent damage to the cylinder head, • Pickup rotor cover camshafts or camshaft caps, loosen the Refer to “PICKUP ROTOR” on page 5-30. camshaft cap bolts in stages and in a criss- 2.
  • Page 213 CAMSHAFTS Camshaft lobe dimensions Intake A 33.725–33.875 mm (1.3278– 1.3337 in) Limit 33.675 mm (1.3258 in) Intake B 25.225–25.325 mm (0.9931– 0.9970 in) Limit 4. Measure: 25.175 mm (0.9911 in) • Camshaft-journal-to-camshaft-cap clearance Exhaust A Out of specification → Measure the camshaft 32.925–33.075 mm (1.2963–...

  • Page 214: Checking The Timing Chain, Camshaft Sprockets, And Timing Chain Guides

    CAMSHAFTS L LLL L LLL L LLL L LLL L LLL a. 1/4 tooth b. Correct 5. Measure: 1. Timing chain roller • Camshaft journal diameter “a” Out of specification → Replace the camshaft. 2. Camshaft sprocket Within specification → Replace the cylinder 3.

  • Page 215: Installing The Camshafts

    CAMSHAFTS NOTE: Prior to installing the timing chain tensioner rod, drain the engine oil from the timing chain ten- sioner housing. M MMM M MMM M MMM M MMM M MMM a. Install the timing chain tensioner springs, tim- ing chain tensioner spring seat, and timing chain tensioner rod “1”.
  • Page 216 CAMSHAFTS 2. Install: • Timing chain “1” • Exhaust camshaft “2” • Intake camshaft “3” (with the camshaft sprockets temporarily tightened) NOTE: • Make sure the match marks “a” on the cam- shaft sprockets are aligned with the cylinder head edge “b”. 4.
  • Page 217 CAMSHAFTS 6. Rotate the crankshaft a few times to release the timing chain tensioner rod. 9. Measure: • Valve clearance Out of specification → Adjust. NOTE: Refer to “ADJUSTING THE VALVE CLEAR- If the engine is not disassembled, set the engine ANCE”...

  • Page 218: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 1st 25 Nm (2.5 m kg, 18 ft 1st 30 Nm (3.0 m kg, 22 ft • • • • 2nd 42 Nm (4.2 m kg, 30 ft 2nd 60 Nm (6.0 m kg, 43 ft •...

  • Page 219: Removing The Cylinder Head

    CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD Warpage limit 1. Remove: 0.05 mm (0.0020 in) • Cylinder head bolts • Cylinder head nuts NOTE: • Loosen the nuts, cap nuts, and bolts in de- creasing numerical order (refer to the numbers in the illustration).
  • Page 220 CYLINDER HEAD Cylinder head cap nut (1st) 30 Nm (3.0 m·kg, 22 ft·lb) Cylinder head cap nut (final) 60 Nm (6.0 m·kg, 43 ft·lb) • Cylinder head bolts “11”, “12” Cylinder head bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) NOTE: Tighten the cylinder head nuts, cap nuts, and bolts in the proper tightening sequence as shown and torque them in two stages.
  • Page 221 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-15. Valve lifter Valve pad Valve cotter Upper spring seat Intake valve spring Exhaust valve spring Intake valve Exhaust valve...

  • Page 222: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 NOTE: REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment NOTE: “2”.
  • Page 223 VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”...

  • Page 224: Checking The Valve Seats

    VALVES AND VALVE SPRINGS • If the valve is removed or replaced, always re- Valve guide remover (ø4.5) place the valve stem seal. 90890-04116 Valve guide remover (4.5 mm) Valve stem runout YM-04116 0.040 mm (0.0016 in) Valve guide installer (ø4.5) 90890-04117 Valve guide installer (4.5 mm) YM-04117...

  • Page 225: Checking The Valve Springs

    VALVES AND VALVE SPRINGS NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hands. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion.

  • Page 226: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 1. Measure: 3. Measure: • Valve spring free length “a” • Valve spring tilt “a” Out of specification → Replace the valve Out of specification → Replace the valve spring. spring. Free length (intake) Spring tilt (intake) 37.47 mm (1.48 in) 2.5°/1.6 mm Limit...
  • Page 227 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 YM-04019 Valve spring compressor 90890-04109 Valve spring compressor attach- ment 90890-04108 Valve spring compressor adapt- er 22 mm 3. Install: YM-04108 • Lower spring seat “1” • Valve stem seal “2” • Valve “3” •...
  • Page 228 VALVES AND VALVE SPRINGS • Each valve lifter and valve pad must be rein- stalled in its original position. 5-25...

  • Page 229: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the generator and starter clutch 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 230 GENERATOR AND STARTER CLUTCH Removing the generator and starter clutch 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft •...

  • Page 231: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS24490 EAS24570 REMOVING THE GENERATOR CHECKING THE STARTER CLUTCH 1. Remove: 1. Check: • Generator rotor bolt “1” • Starter clutch rollers Damage/wear → Replace. • Washer 2. Check: NOTE: • Starter clutch idle gear While holding the generator rotor “2” with the •...

  • Page 232: Installing The Generator

    GENERATOR AND STARTER CLUTCH Yamaha bond No. 1215 90890-85505 ® (Three Bond No.1215 EAS24500 INSTALLING THE GENERATOR 1. Install: • Generator rotor • Washer • Generator rotor bolt NOTE: • Clean the tapered portion of the crankshaft and the generator rotor hub.

  • Page 233: Pickup Rotor

    PICKUP ROTOR EAS24520 PICKUP ROTOR Removing the pickup rotor 35 Nm (3.5 m kg, 25 ft • • 15 Nm (1.5 m kg, 11 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 234: Removing The Pickup Rotor

    When installing the pickup rotor, align the 3. Apply: groove “a” in the crankshaft with the projection • Sealant “b” on the pickup rotor. (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 90890-85505 ® (Three Bond No.1215 5-31...
  • Page 235 PICKUP ROTOR 5-32...

  • Page 236: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat 4-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Canister (for California only) Refer to “THROTTLE BODIES”...
  • Page 237 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Lock washer Oil seal Bearing Washer set Starter motor yoke Armature assembly Gasket Washer set Brush holder (along with the brushes) Starter motor rear cover For assembly, reverse the disassembly pro- cedure.

  • Page 238: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 600 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “1” Armature coil Out of specification → Replace the starter Commutator resistance “1”...

  • Page 239: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing • Oil seal Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Starter motor yoke “1” NOTE: Align the tab “a” on the brush holder with the slot “b”...

  • Page 240: Clutch

    CLUTCH EAS25060 CLUTCH Removing the clutch cover 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 241 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever shaft Oil seal Bearing Bearing For installation, reverse the removal proce- dure. 5-38...
  • Page 242 CLUTCH Removing the clutch 115 Nm (11.5 m kg, 85 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 25 Nm (2.5 m kg, 18 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty...
  • Page 243 CLUTCH Removing the clutch 115 Nm (11.5 m kg, 85 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 25 Nm (2.5 m kg, 18 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty...

  • Page 244: Removing The Clutch

    CLUTCH EAS25070 EAS25100 REMOVING THE CLUTCH CHECKING THE FRICTION PLATES 1. Remove: The following procedure applies to all of the fric- • Friction plates tion plates. • Clutch plates 1. Check: • Friction plate NOTE: Damage/wear → Replace the friction plates Be sure to mark the friction plates and clutch as a set.

  • Page 245: Checking The Clutch Springs

    CLUTCH NOTE: Clutch plate “2” The clutch plate thickness specification listed Part No. Thickness above is for the plates with the standard thick- ness only. If a clutch plate with one of the other 3J2-16324-00 2.0 mm (0.079 in) STD two plate thicknesses is installed, use 1.50–1.70 168-16324-00 2.3 mm (0.091 in)

  • Page 246: Checking The Clutch Housing

    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. EAS25200 CHECKING THE PRIMARY DRIVE GEAR 1.

  • Page 247: Checking The Oil Pump Drive Sprocket And Oil Pump Drive Chain

    CLUTCH NOTE: Fit the projections “a” on the clutch boss into the grooves “b” in the clutch boss plate. 2. Check: • Bearing Damage/wear → Replace. 3. Install: ET2C01011 CHECKING THE OIL PUMP DRIVE • Springs “1” SPROCKET AND OIL PUMP DRIVE CHAIN NOTE: 1.
  • Page 248 CLUTCH • Stake the clutch boss nut at a cutout “a” in the main axle. Universal clutch holder 90890-04086 YM-91042 8. Install: • Seat plate • Clutch springs • Clutch spring bolts Clutch spring bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) 5.
  • Page 249 CLUTCH 10.Install: • Pull lever spring “1” • Pull lever “2” • Washer • Circlip NOTE: • Make sure that the mark “a” on the pull lever is facing up. • When installing the pull lever, push it and check that its punch mark “b” aligns with the mark “c”...

  • Page 250: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kg, 16 ft • • Order Job/Parts to remove Q’ty Remarks Shift arm Refer to “ENGINE REMOVAL” on page 5-1. Clutch housing Refer to “CLUTCH” on page 5-37. Circlip Washer Shift shaft...
  • Page 251 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kg, 16 ft • • Order Job/Parts to remove Q’ty Remarks Bearing For installation, reverse the removal proce- dure. 5-48...

  • Page 252: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.

  • Page 253: Oil Pump

    OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • (10) 12 Nm (1.2 m kg, 8.7 ft • • 43 Nm (4.3 m kg, 31 ft 10 Nm (1.0 m...
  • Page 254 OIL PUMP Removing the oil pan and oil pump 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • (10) 12 Nm (1.2 m kg, 8.7 ft • • 43 Nm (4.3 m kg, 31 ft 10 Nm (1.0 m kg, 7.2 ft...
  • Page 255 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump housing Oil pump driven sprocket For assembly, reverse the disassembly pro- cedure. 5-52...

  • Page 256: Removing The Oil Pan

    OIL PUMP EAS24930 REMOVING THE OIL PAN Inner-rotor-to-outer-rotor-tip 1. Remove: clearance • Oil level switch lead holder Less than 0.12 mm (0.0047 in) Limit • Bottom cowling brackets 0.20 mm (0.0079 in) • Oil pan Outer-rotor-to-oil-pump-housing • Oil pan gasket clearance NOTE: 0.090–0.150 mm (0.0035–0.0059...

  • Page 257: Checking The Oil Pipes

    OIL PUMP EAS24980 EAS25050 CHECKING THE OIL PIPES INSTALLING THE OIL PAN The following procedure applies to all of the oil 1. Install: delivery pipes. • Oil pan gasket 1. Check: • Oil pan • Ventilation chamber oil drain pipe •...

  • Page 258: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 20 Nm (2.0 m kg, 14 ft • • 12 Nm (1.2 m kg, 8.7 ft •...
  • Page 259 CRANKCASE Separating the crankcase 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 20 Nm (2.0 m kg, 14 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft •...

  • Page 260: Disassembling The Crankcase

    • M6 × 55 mm bolts: “15”, “22”–“27” 2. Apply: • M6 × 45 mm bolts: “17”–“19” • Sealant 24 23 22 (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 ® (Three Bond No.1215 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.
  • Page 261 CRANKCASE ECA13980 NOTE: CAUTION: Tighten the bolts in the tightening sequence cast Before tightening the crankcase bolts, make on the crankcase. sure the transmission gears shift correctly when the shift drum assembly is turned by hand. 8. Tighten: • Crankcase bolts “11”–“28” 6.
  • Page 262 CONNECTING RODS AND PISTONS EAS24370 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 1st 15 Nm (1.5 m kg, 11 ft • • 2nd Specified angle 175˚-185˚ Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-55. Connecting rod cap Big end lower bearing Piston pin clip...

  • Page 263: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS26030 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the con- necting rods and pistons. 1. Remove: • Connecting rod cap “1” NOTE: Identify the position of each connecting rod so that it can be reinstalled in its original place.

  • Page 264: Checking The Piston Rings

    CONNECTING RODS AND PISTONS d. If out of specification, replace the piston and NOTE: piston rings as a set. Measure cylinder bore “C” by taking side-to-side e. Calculate the piston-to-cylinder clearance and front-to-back measurements of the cylinder. with the following formula. Then, find the average of the measurements.

  • Page 265: Checking The Piston Pins

    CONNECTING RODS AND PISTONS NOTE: Piston pin outside diameter Level the piston ring into the cylinder with the 14.991–15.000 mm (0.5902– piston crown. 0.5906 in) Limit 14.971 mm (0.5894 in) a. 5 mm (0.20 in) 3. Measure: 3. Measure: • Piston ring end gap Out of specification →...

  • Page 266: Checking The Connecting Rods

    CONNECTING RODS AND PISTONS ET2C01013 CHECKING THE CONNECTING RODS 1. Measure: • Crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace the big end bearings. Oil clearance (using plasti- ® gauge 0.037–0.061 mm (0.0015–0.0024 d. Assemble the connecting rod halves. NOTE: M MMM M MMM M MMM M MMM...

  • Page 267: Installing The Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS For example, if the connecting rod P and the crankshaft web P numbers are 5 and 1 re- spectively, then the bearing size for P (connecting rod) - P (crankshaft) 5 - 1 = 4 (green) Bearing color code 1.Blue 2.Black 3.Brown 4.Green L LLL...
  • Page 268 CONNECTING RODS AND PISTONS Recommended lubricant Molybdenum disulfide oil 6. Lubricate: • Crankshaft pins • Big end bearings • Connecting rod inner surface (with the recommended lubricant) Recommended lubricant Engine oil 7. Install: • Big end bearings • Connecting rod and piston assembly •...
  • Page 269 CONNECTING RODS AND PISTONS M MMM M MMM M MMM M MMM M MMM NOTE: EW2C01007 On a hexagonal nut, note that the angle from WARNING one corner to another is 60°. Replace the connecting rod bolts and nuts with new ones. L LLL L LLL L LLL...

  • Page 270: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-55. Refer to “CONNECTING RODS AND PIS- Connecting rod caps TONS” on page 5-59. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Oil nozzle For installation, reverse the removal proce- dure.

  • Page 271: Removing The Crankshaft Journal Bearings

    CRANKSHAFT EAS26040 3. Measure: REMOVING THE CRANKSHAFT JOURNAL • Crankshaft-journal-to-crankshaft-journal- BEARINGS bearing clearance 1. Remove: Out of specification → Replace the crank- • Crankshaft journal lower bearings shaft journal bearings. (from the lower crankcase) • Crankshaft journal upper bearings Journal oil clearance (using plas- (from the upper crankcase) ®...
  • Page 272 CRANKSHAFT NOTE: • The numbers “A” stamped into the crankshaft web and the numbers “B” stamped into the lower crankcase are used to determine the re- placement crankshaft journal bearing sizes. • J –J refer to the bearings shown in the crank- shaft illustration.

  • Page 273: Installing The Crankshaft

    CRANKSHAFT EAS26200 INSTALLING THE CRANKSHAFT 1. Install: • Crankshaft journal upper bearings (into the upper crankcase) • Crankshaft journal lower bearings (into the lower crankcase) NOTE: • Align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcases.
  • Page 274 TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 Nm (1.2 m kg, 8.7 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...
  • Page 275 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 Nm (1.2 m kg, 8.7 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 Bearing...
  • Page 276 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd/4th pinion gear Circlip Washer 5th pinion gear Collar Bearing housing Bearing Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure.
  • Page 277 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer 5-74...
  • Page 278 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks 2nd wheel gear Collar Bearing Drive axle For assembly, reverse the disassembly pro- cedure. 5-75...

  • Page 279: Transmission

    TRANSMISSION ET2C01014 REMOVING THE TRANSMISSION 1. Remove: • Main axle assembly “1” M MMM M MMM M MMM M MMM M MMM a. Remove the main axle assembly bearing housing bolts “2” 2. Check: • Shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends →...

  • Page 280: Checking The Transmission

    TRANSMISSION • Shift drum bearing “2” • Transmission gear dogs Damage/pitting → Replace the shift drum as- Cracks/damage/rounded edges → Replace sembly. the defective gear(s). 4. Check: EAS26300 • Transmission gear engagement CHECKING THE TRANSMISSION (each pinion gear to its respective wheel 1.

  • Page 281: Installing The Transmission

    TRANSMISSION 2. Install: • Main axle assembly “1” NOTE: Stake the main axle assembly bearing housing bolts “2” at a cutout “a” in the main axle assem- bly bearing housing “3”. 2. Install: • Toothed lock washer retainer “1” • Toothed lock washer “2” NOTE: •...
  • Page 282 TRANSMISSION • Shift fork guide bar • Springs • Shift drum retainers “3” • Bearing • Oil seal • Circlip “4” • Drive axle assembly “5” Shift drum retainer bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) ® LOCTITE NOTE: • Install shift fork-R into the groove “a” in the 5th wheel gear and shift fork-L into the groove “b”...

  • Page 283: Cooling System

    COOLING SYSTEM RADIATOR...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 OIL COOLER ....................6-4 CHECKING THE OIL COOLER ..............6-6 INSTALLING THE OIL COOLER .............. 6-6 THERMOSTAT....................6-7 CHECKING THE THERMOSTAT ............. 6-8 INSTALLING THE THERMOSTAT ............6-8 WATER PUMP ....................

  • Page 284: Radiator

    RADIATOR EAS26380 RADIATOR Removing the radiator 13 Nm (1.3 m kg, 9.4 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 5 Nm (0.5 m kg, 3.6 ft •...
  • Page 285 RADIATOR Removing the radiator 13 Nm (1.3 m kg, 9.4 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 286: Checking The Radiator

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head b. Apply the specified pressure for ten seconds screwdriver.

  • Page 287: Oil Cooler

    OIL COOLER EAS26410 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kg, 7.2 ft 63 Nm (6.3 m kg, 45 ft • • • • Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-11.
  • Page 288 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kg, 7.2 ft 63 Nm (6.3 m kg, 45 ft • • • • Order Job/Parts to remove Q’ty Remarks O-ring For installation, reverse the removal proce- dure.

  • Page 289: Checking The Oil Cooler

    OIL COOLER EAS26420 • Crankcase CHECKING THE OIL COOLER (with the specified amount of the recom- 1. Check: mended engine oil) • Oil cooler Refer to “CHANGING THE ENGINE OIL” on Cracks/damage → Replace. page 3-11. 2. Check: 4. Check: •...

  • Page 290: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Air filter case Refer to “AIR FILTER CASE” on page 7-5. Canister (for California only) Refer to “THROTTLE BODIES” on page 7-8. Drain.

  • Page 291: Checking The Thermostat

    THERMOSTAT EAS26450 2. Check: CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage → Replace. • Thermostat Does not open at 71–85 °C (159.8–185.0 °F) EAS26480 → Replace. INSTALLING THE THERMOSTAT 1. Install: • Thermostat NOTE: Install the thermostat with its breather hole “a” facing up.

  • Page 292: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks It is not necessary to remove the water...

  • Page 293: Checking The Water Pump

    WATER PUMP EAS26540 CHECKING THE WATER PUMP 1. Check: • Water pump assembly Cracks/damage → Replace. 2. Check: • Water pump inlet hose • Water pump outlet hose • Water pump breather hose Cracks/damage/wear → Replace. EAS26590 INSTALLING THE WATER PUMP 1.

  • Page 294: Fuel System

    FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY ............7-3 CHECKING THE FUEL PUMP OPERATION ........... 7-3 INSTALLING THE FUEL PUMP..............7-3 INSTALLING THE FUEL TANK ..............7-4 AIR FILTER CASE ..................

  • Page 295: Fuel Tank

    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank and fuel pump 9 Nm (0.9 m kg, 6.5 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 (6) 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 296 FUEL TANK Removing the fuel tank and fuel pump 9 Nm (0.9 m kg, 6.5 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 (6) 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 297: Fuel Tank

    FUEL TANK EAS26630 EAS26640 REMOVING THE FUEL TANK REMOVING THE FUEL PUMP 1. Extract the fuel in the fuel tank through the 1. Remove: fuel tank cap with a pump. • Fuel pump 2. Remove: ECA14720 CAUTION: • Fuel hose (fuel tank to primary injector rail) •...

  • Page 298: Installing The Fuel Tank

    FUEL TANK NOTE: • Install the fuel hose securely onto the fuel pump until a distinct “click” is heard. • To install the fuel hose onto the fuel pump, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown.

  • Page 299: Air Filter Case

    AIR FILTER CASE ET2C01003 AIR FILTER CASE Removing the air filter case and secondary injectors 1.5 Nm (0.15 m kg, 1.08 ft 5 Nm (0.5 m kg, 3.6 ft 2 Nm (0.2 m kg, 1.4 ft • • • • •...
  • Page 300 AIR FILTER CASE Removing the air filter case and secondary injectors 1.5 Nm (0.15 m kg, 1.08 ft 5 Nm (0.5 m kg, 3.6 ft 2 Nm (0.2 m kg, 1.4 ft • • • • • • 4 Nm (0.4 m kg, 2.9 ft •...

  • Page 301: Removing The Fuel Hose (Primary Injector Fuel Rail To Secondary Injector Fuel Rail)

    AIR FILTER CASE ET2C01005 EC2C01017 REMOVING THE FUEL HOSE (PRIMARY CAUTION: INJECTOR FUEL RAIL TO SECONDARY When installing the fuel hose, make sure that INJECTOR FUEL RAIL) it is securely connected, and that the fuel 1. Remove: hose connector cover on the fuel hose is in •...
  • Page 302 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the rollover valve and canister (for California only) 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 Fuel tank Refer to “FUEL TANK”...

  • Page 303: Throttle Bodies

    THROTTLE BODIES Removing the throttle body assembly 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Canister (for California only) Refer to “THROTTLE BODIES”...
  • Page 304 THROTTLE BODIES Removing the throttle body assembly 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Heat protector Throttle body joint For installation, reverse the removal proce- dure. 7-10...
  • Page 305 THROTTLE BODIES Removing the primary injectors 3.5 Nm (0.35 m kg, 2.53 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 3.5 Nm (0.35 m kg, 2.53 ft • • 3.5 Nm (0.35 m kg, 2.53 ft •...

  • Page 306: Checking The Primary Injectors

    THROTTLE BODIES EAS26980 b. Disconnect the fuel hose (fuel tank to primary CHECKING THE PRIMARY INJECTORS injector fuel rail) “1” from the primary injector 1. Check: fuel rail. • Injectors EW2C01008 Damage → Replace. WARNING Cover fuel hose connections with a cloth EAS26990 when disconnecting them.

  • Page 307: Adjusting The Throttle Position Sensor (For Throttle Valves)

    THROTTLE BODIES ET2C01007 g. After adjusting the throttle position sensor an- ADJUSTING THE THROTTLE POSITION gle, tighten the throttle position sensor SENSOR (FOR THROTTLE VALVES) screws “3”. 1. Check: • Throttle position sensor (for throttle valves) Refer to “CHECKING THE THROTTLE PO- SITION SENSOR (FOR THROTTLE VALVES)”...

  • Page 308: Installing The Throttle Body Joints

    THROTTLE BODIES L LLL L LLL L LLL L LLL L LLL ET2C01009 INSTALLING THE THROTTLE BODY JOINTS 1. Install: • Throttle body joints “1” Throttle body joint bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: Be sure to install the throttle body joints with the “L”...

  • Page 309: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-15...
  • Page 310 AIR INDUCTION SYSTEM 1. Lower air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to cylinder head cover) 5. Reed valve assembly 6.
  • Page 311 AIR INDUCTION SYSTEM Removing the air cut-off valve Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-5. Canister (for California only) Refer to “THROTTLE BODIES” on page 7-8. Air induction system cover Air induction system solenoid coupler Disconnect.
  • Page 312 AIR INDUCTION SYSTEM Removing the reed valves 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 Reed valve cover Reed valve assembly Reed valve plate For installation, reverse the removal proce- dure.

  • Page 313: Checking The Air Induction System

    AIR INDUCTION SYSTEM EAS27060 2. Check: CHECKING THE AIR INDUCTION SYSTEM • Reed valve • Reed valve stopper Air injection • Reed valve seat The air induction system burns unburned ex- Cracks/damage → Replace the reed valve haust gases by injecting fresh air (secondary air) assembly.

  • Page 314: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM .................. 8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION....... 8-3 TROUBLESHOOTING ................8-4 ELECTRIC STARTING SYSTEM..............8-7 CIRCUIT DIAGRAM .................. 8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-9 TROUBLESHOOTING ................8-11 CHARGING SYSTEM ................... 8-13 CIRCUIT DIAGRAM ................
  • Page 315 ELECTRICAL COMPONENTS ..............8-77 CHECKING THE SWITCHES ..............8-81 CHECKING THE BULBS AND BULB SOCKETS ........8-84 CHECKING THE FUSES ................ 8-85 CHECKING AND CHARGING THE BATTERY........8-86 CHECKING THE RELAYS ..............8-89 CHECKING THE TURN SIGNAL RELAY ..........8-90 CHECKING THE RELAY UNIT (DIODE) ..........

  • Page 316: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 317 IGNITION SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 13.Relay unit 16.Neutral switch 17.Sidestand switch 22.ECU (engine control unit) 23.Spark plug 24.Cylinder-#1 ignition coil 25.Cylinder-#2 ignition coil 26.Cylinder-#3 ignition coil 27.Cylinder-#4 ignition coil 40.Crankshaft position sensor 47.Lean angle sensor 64.Engine stop switch...

  • Page 318: Engine Stopping Due To Sidestand Operation

    IGNITION SYSTEM ET2C01023 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.

  • Page 319: 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. Rider seat 2. Fuel tank 3. Air filter case 4. Canister (for California only) 5. Side cowlings 6.
  • Page 320 IGNITION SYSTEM NG → 8. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-81. OK ↓ NG → 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. SWITCHES”...

  • Page 321: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM R/B G/B Br/Y Br/Y L/B B/L Sb/W Br/B Br/B Sb/W (BLACK) (BLACK) NEUTRAL SWITCH SUB SUB- WIRE-HARNESS3 WIRE HARNESS WIRE HARNESS WIRE HARNESS SUB-WIRE-HARNESS2 -WIRE-HARNESS W W W (BLACK) W W W R/W L/W Br/L Br/L...
  • Page 322 ELECTRIC STARTING SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 8. Starter relay 10.Starter motor 11.Engine ground 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 17.Sidestand switch 64.Engine stop switch 65.Start switch 70.Clutch switch...

  • Page 323: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 324 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 325: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Air filter case 4. Canister (for California only) 5. Side cowlings 6. Thermostat NG → 1.
  • Page 326 ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-81. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES”...

  • Page 327: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM W W W (BLACK) W W W R/W L/W Br/L Br/L L/W3 L/Y L/B2 (RED) (RED) L/B2 Br/L Br/L L/W2 G/Y L/W2 R/W R/B B Br (BLUE) (BLUE) Br/L Br/L 8-13...
  • Page 328 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 6. Main fuse 7. Battery 11.Engine ground 8-14...

  • Page 329: Troubleshooting

    CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Bottom cowlings NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...

  • Page 330: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-17...
  • Page 331 LIGHTING SYSTEM 3. Main switch 6. Main fuse 7. Battery 11.Engine ground 22.ECU (engine control unit) 57.High beam indicator light 60.Meter light 68.Dimmer switch 75.Front right turn signal/position light 76.Front left turn signal/position light 77.Headlight (low beam) 78.Headlight (high beam) 79.Auxiliary light 80.License plate light 82.Tail/brake light...

  • 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. Rider seat 2.
  • Page 333 LIGHTING SYSTEM NG → 8. Check the entire lighting system’s wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring. page 8-17. OK ↓ This circuit is OK. 8-20...

  • Page 334: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21...
  • Page 335 SIGNALING SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 13.Relay unit 16.Neutral switch 19.Fuel sender 22.ECU (engine control unit) 40.Crankshaft position sensor 42.Coolant temperature sensor 45.Cylinder identification sensor 46.Speed sensor 49.Fuel level warning light 50.Oil level warning light 51.Neutral indicator light 52.Tachometer...

  • 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. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3.
  • Page 337 SIGNALING SYSTEM NG → 3. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-21. OK ↓ This circuit is OK. The brake light fails to come on. NG → 1.
  • Page 338 SIGNALING SYSTEM NG → 4. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-21. OK ↓ This circuit is OK. The neutral indicator light fails to come on. NG →...
  • Page 339 SIGNALING SYSTEM NG → 2. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-21. OK ↓ This circuit is OK. The coolant temperature warning light fails to come on. NG →...
  • Page 340 SIGNALING SYSTEM NG → 2. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-21. OK ↓ This circuit is OK. 8-27...

  • Page 341: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-29...
  • Page 342 COOLING SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 22.ECU (engine control unit) 42.Coolant temperature sensor 87.Radiator fan motor relay 88.Right radiator fan motor fuse 89.Left radiator fan motor fuse 90.Right radiator fan motor 91.Left radiator fan motor 8-30...

  • Page 343: Troubleshooting

    COOLING SYSTEM EAS27320 TROUBLESHOOTING NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings NG → 1. Check the fuses. (Main, ignition and radiator fan mo- tor) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...

  • Page 344: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-33...
  • Page 345 FUEL INJECTION SYSTEM 3. Main switch 4. Ignition fuse 5. Backup fuse (odometer and clock) 6. Main fuse 7. Battery 9. Fuel injection system fuse 11.Engine ground 12.ETV fuse 13.Relay unit 15.Fuel pump relay 16.Neutral switch 17.Sidestand switch 18.Fuel pump 20.Throttle position sensor (for throttle cable pulley) 21.Throttle position sensor (for throttle valves)

  • Page 346: 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 347: 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 348 FUEL INJECTION SYSTEM Able/un- Fault Able/un- Item Symptom able to code No. able to start drive EXUP servo motor EXUP servo motor is stuck. Able Able (stuck) Sidestand switch Open circuit is detected in the in- (open circuit in the put line from the sidestand switch Unable Unable...
  • Page 349 FUEL INJECTION SYSTEM Able/un- Fault Able/un- Item Symptom able to code No. able to start drive Able Able (depending (depending Primary injector Primary injector: on the on the (open circuit) open circuit detected. number of number of faulty cylin- faulty cylin- ders) ders) Able...

  • Page 350: Troubleshooting Method

    FUEL INJECTION SYSTEM Able/un- Fault Able/un- Item Symptom able to code No. able to start drive ECU internal malfunc- No signals are received from the Er-2 tion Unable Unable ECU within the specified duration. (output signal error) ECU internal malfunc- Data from the ECU cannot be re- Er-3 tion...

  • Page 351: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS27420 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.
  • Page 352 FUEL INJECTION SYSTEM Fault code table Fault Diagnostic code Symptom Probable cause of malfunction code No. No normal signals are re- • Open or short circuit in sub-wire-harness 1. ceived from the cylinder • Open or short circuit in wire harness. identification sensor when •...
  • Page 353 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. Air temperature sensor: • Defective air temperature sensor. open or short circuit detect- • Malfunction in ECU. • Improperly installed air temperature sensor. •...
  • Page 354 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Power supply to the injec- • Open or short circuit in wire harness. tors and the fuel pump is • Malfunction in ECU. not normal. An error is detected while •...
  • Page 355 FUEL INJECTION SYSTEM Sensor operation table Diag- nostic Item Meter display Checking method code Throttle position sensor (for throttle valves) signal 1 • Fully closed position 12–21 Check with throttle valves fully closed. • Fully opened position 97–106 Check with throttle valves fully opened.
  • Page 356 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Throttle position sensor (for throttle cable pulley) signal • Fully closed position 12–22 Check with throttle grip fully closed. • Fully opened position 97–107 Check with throttle grip fully opened.
  • Page 357 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction history code erasure • No history — • History exists • Displays the total number of To erase the history, set the malfunctions, including the engine stop switch from current malfunction, that “...
  • Page 358 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the cylinder-#4 igni- tion coil five times at one- Check the spark five times. Cylinder-#4 ignition coil second intervals. • Connect an ignition Illuminates the engine trou- checker. ble warning light. Actuates the primary injector #1 five times at one-second Check the operating sound...

  • Page 359: Troubleshooting Details

    FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the air induction system solenoid five times at Check the operating sound Air induction system sole- one-second intervals. of the air induction system noid Illuminates the engine trou- solenoid five times. ble warning light.
  • Page 360 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the cylinder identifi- cation sensor when the engine is started or while the ve- hicle is being driven. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause...
  • Page 361 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the tion sensor.
  • Page 362 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: open or short circuit detected. Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Reinstated au- •...
  • Page 363 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor (for throttle valves): open or short circuit detected. Diagnostic code No. Throttle position sensor (for throttle valves) signal 1 Throttle position sensor (for throttle valves) signal 2 Order Item/components and probable Check or maintenance job Reinstatement cause...
  • Page 364 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 couplers for any pins Reinstated au- •...
  • Page 365 FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit is detected in the input lead from the side- stand switch to the ECU. Diagnostic code No. Sidestand switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connections •...
  • Page 366 FUEL INJECTION SYSTEM Fault code No. Symptom Coolant temperature sensor: open or short circuit detect- Diagnostic code No. Coolant temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Reinstated au- •...
  • Page 367 FUEL INJECTION SYSTEM Fault code No. Symptom Atmospheric pressure sensor: open or short circuit de- tected. Diagnostic code No. Atmospheric pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Reinstated au- •...
  • Page 368 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. Execute the di- agnostic mode Connections •...
  • Page 369 FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit detected in the primary lead of the cylinder- #1 ignition coil. Diagnostic code No. Cylinder-#1 ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Cranking the •...
  • Page 370 FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit detected in the primary lead of the cylinder- #3 ignition coil. Diagnostic code No. Cylinder-#3 ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Cranking the •...
  • Page 371 FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit detected in the primary lead of the cylinder- #4 ignition coil. Diagnostic code No. Cylinder-#4 ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Cranking the •...
  • Page 372 FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit detected in a primary injector. Diagnostic code No. Primary injector #1 Primary injector #2 Primary injector #3 Primary injector #4 Order Item/components and probable Check or maintenance job Reinstatement cause method Connections •...
  • Page 373 FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit detected in a secondary injector. Diagnostic code No. Secondary injector #1 Secondary injector #2 Secondary injector #3 Secondary injector #4 Order Item/components and probable Check or maintenance job Reinstatement cause method Connections •...
  • Page 374 FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Reinstated au- •...
  • Page 375 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 376 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 377 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the injectors and fuel pump is not nor- mal. Diagnostic code No. Fuel system voltage (battery voltage) Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Turning the •...
  • Page 378 FUEL INJECTION SYSTEM Fault code No. Symptom An error is detected while reading or writing on EEPROM (CO adjustment value). Diagnostic code No. EEPROM fault cylinder No. Order Item/components and probable Check or maintenance job Reinstatement cause method Malfunction in ECU. •...
  • Page 379 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor (for throttle cable pulley): open or short circuit detected. Throttle position sensor (for throttle cable pulley): coupler connection is loose. Diagnostic code No. Throttle position sensor (for throttle cable pulley) signal 1 Throttle position sensor (for throttle cable pulley) signal 2 Order Item/components and probable Check or maintenance job...
  • Page 380 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle servo motor: open or short circuit detected. Defective throttle servo motor. Malfunction in ECU (servo motor driving system). Diagnostic code No. Throttle position sensor (for throttle valves) signal 1 Throttle position sensor (for throttle valves) signal 2 Order Item/components and probable Check or maintenance job Reinstatement...
  • Page 381 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 couplers for any pins Turning the •...
  • Page 382 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 couplers for any pins Turning the •...

  • Page 383: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-73...
  • Page 384 FUEL PUMP SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 9. Fuel injection system fuse 11.Engine ground 13.Relay unit 15.Fuel pump relay 18.Fuel pump 22.ECU (engine control unit) 64.Engine stop switch 8-74...

  • Page 385: Troubleshooting

    FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).

  • Page 386: Electrical Components

    ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-77...
  • Page 387 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Battery 5. Fuse box (backup, ETV) 6. Main fuse 7. Fuel injection system fuse 8. Starter relay 9. Neutral switch 10. EXUP servo motor 11. Rear brake light switch 12.
  • Page 388 ELECTRICAL COMPONENTS 8-79...
  • Page 389 ELECTRICAL COMPONENTS 1. Air temperature sensor 2. Atmospheric pressure sensor 3. Coolant temperature sensor 4. Fuel pump 5. ECU (engine control unit) 6. Lean angle sensor 7. Relay unit 8. Turn signal relay 9. Crankshaft position sensor 10. Intake air pressure sensor 11.

  • Page 390: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES L/Y2 R Br/L L/Y L/B Br/L (RED) R/Y R/B Y R/Y L/W B (BLUE) Br/W Br B Br/W (BLUE) (BROWN) 8-81...
  • Page 391 ELECTRICAL COMPONENTS 1. Clutch switch 2. Main switch 3. Dimmer switch 4. Horn switch 5. Turn signal switch 6. Sidestand switch 7. Front brake light switch 8. Engine stop switch 9. Start switch 10. Neutral switch 11. Rear brake light switch 8-82...
  • Page 392 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 393: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EAS27990 1. Remove: CHECKING THE BULBS AND BULB • Bulb SOCKETS EW2C01001 WARNING NOTE: 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 394: 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 395: 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 396 ELECTRICAL COMPONENTS b. Check the charge of the battery, as shown in • Do not use a high-rate battery charger the charts and the following example. since it forces a high-amperage current into the battery quickly and can cause bat- Example tery overheating and battery plate damage.
  • Page 397 ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM NOTE: Charging method using a variable-current Voltage should be measured 30 minutes after (voltage) charger the engine is stopped. a. Measure the open-circuit voltage prior to charging. b. Connect a charger and ammeter to the bat- tery and start charging.

  • Page 398: Checking The Relays

    ELECTRICAL COMPONENTS Relay unit (starting circuit cut-off relay) Recommended lubricant Dielectric grease 10.Install: • Fuel tank bracket • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket 1. Positive battery terminal tester.

  • Page 399: Checking The Turn Signal Relay

    ELECTRICAL COMPONENTS ET2C01021 3. Positive tester probe CHECKING THE TURN SIGNAL RELAY 4. Negative tester probe 1. Check: • Turn signal relay input voltage Result Out of specification → The wiring circuit from Continuity the main switch to the turn signal relay cou- (between “3”...

  • Page 400: Checking The Relay Unit (Diode)

    ELECTRICAL COMPONENTS • Positive tester probe → Continuity brown/white “1” Positive tester probe → sky blue • Negative tester probe → “1” ground Negative tester probe → black/yellow “2” No continuity Positive tester probe → black/yellow “2” Negative tester probe → sky blue “1”...

  • Page 401: Checking The Ignition Coils

    ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. Pocket tester d. Check the relay unit (diode) for no continuity. 90890-03112 L LLL L LLL L LLL L LLL L LLL Analog pocket tester YU-03112-C EAS28100 CHECKING THE IGNITION COILS The following procedure applies to all of the igni- •...

  • Page 402: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS d. Crank the engine by pushing the start switch Lean angle sensor output voltage “ ” and gradually increase the spark gap un- Less than 65°: 0.4–1.4 V til a misfire occurs. More than 65°: 3.7–4.4 V L LLL L LLL L LLL L LLL...

  • Page 403: Checking The Stator Coil

    ELECTRICAL COMPONENTS • This check is likely to produce sparks, therefore, make sure no flammable gas or fluid is in the vicinity. W W W b. Measure the stator coil resistance. L LLL L LLL L LLL L LLL L LLL EAS28170 CHECKING THE RECTIFIER/REGULATOR b.

  • Page 404: Checking The Horn

    ELECTRICAL COMPONENTS EAS28180 EAS28190 CHECKING THE HORN CHECKING THE OIL LEVEL SWITCH 1. Check: 1. Drain: • Horn resistance • Engine oil Out of specification → Replace. 2. Remove: • Oil level switch Coil resistance (from the oil pan) 1.15–1.25 Ω at 20 °C (68 °F) 3.

  • Page 405: Checking The Speed Sensor

    ELECTRICAL COMPONENTS • Fuel sender coupler Pocket tester (from the wire harness) 90890-03112 2. Remove: Analog pocket tester • Fuel tank YU-03112-C 3. Remove: • Fuel pump • Positive tester probe → (from the fuel tank) white/yellow “1” 4. Check: •...

  • Page 406: Checking The Coolant Temperature Sensor

    ELECTRICAL COMPONENTS EAS28260 NOTE: CHECKING THE COOLANT TEMPERATURE Make sure the coolant temperature sensor ter- SENSOR minals do not get wet. 1. Remove: • Coolant temperature sensor c. Place a thermometer “3” in the coolant. Refer to “THERMOSTAT” on page 6-7. d.

  • Page 407: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS NOTE: NOTE: When installing the throttle position sensor (for When installing the throttle position sensor (for throttle valves), adjust its angle properly. Refer throttle cable pulley), adjust its angle properly. to “ADJUSTING THE THROTTLE POSITION Refer to “ADJUSTING THE THROTTLE POSI- SENSOR (FOR THROTTLE VALVES)”...

  • Page 408: Checking The Air Induction System Solenoid

    ELECTRICAL COMPONENTS Br/R R/W c. Measure the air induction system solenoid re- sistance. L LLL L LLL L LLL L LLL L LLL EAS28380 CHECKING THE ATMOSPHERIC PRESSURE SENSOR 1. Check: • Atmospheric pressure sensor output voltage Out of specification → Replace. Atmospheric pressure sensor output voltage d.

  • Page 409: Checking The Cylinder Identification Sensor

    ELECTRICAL COMPONENTS EAS28390 CHECKING THE CYLINDER Intake air pressure sensor output IDENTIFICATION SENSOR voltage 1. Remove: 3.15–4.15 V • Timing plate cover M MMM M MMM M MMM M MMM M MMM 2. Check: a. Connect the pocket tester (DC 20 V) to the in- •...
  • Page 410 ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 100) to the air temperature sensor terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Immerse the air temperature sensor “1” in a container filled with water “2”.

  • Page 411: Troubleshooting

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

  • Page 412: Troubleshooting

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

  • Page 413: 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 414: Overcooling

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

  • Page 415: Faulty Lighting Or Signaling System

    TROUBLESHOOTING Rear shock absorber assembly Turn signal does not come on • Faulty rear shock absorber spring • Faulty turn signal switch • Leaking oil or gas • Faulty turn signal relay • Burnt-out turn signal bulb Tire(s) • Incorrect connection •...
  • Page 416 YZFR6V(C) 2006 WIRING DIAGRAM R/B G/B Gy/R Gy/R Br/Y Br/Y Br/W R/G Y/L G/W B/W Br/W L/B B/L Gy/G Br/R W/B Br/R Gy/G Sb/W Sb/W Sb/W Br/B Br/B Sb/W Y/B1 L/W2 L/W2 B/R Y/B1 (BLACK) (BLACK) NEUTRAL SWITCH SUB HEADLIGHT SUB-...
  • Page 417 YZFR6V(C) 2006 WIRING DIAGRAM (BLACK) (BLACK) NEUTRAL SWITCH SUB HEADLIGHT SUB- WIRE HARNESS SUB-WIRE-HARNESS3 WIRE HARNESS WIRE HARNESS SUB-WIRE-HARNESS2 WIRE HARNESS SUB-WIRE-HARNESS1 WIRE HARNESS WIRE-HARNESS WIRE HARNESS -WIRE-HARNESS HEADLIGHT SUB-WIRE-HARNESS (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (RED) (RED) (BLACK) (BLACK) (GRAY)

  • Page 418: Wiring Diagram

    EAS28740 55. Engine trouble warning light Br/B Brown/Black WIRING DIAGRAM 56. Coolant temperature warning Br/G Brown/Green light YZFR6V(C) 2006 Br/L Brown/Blue 57. High beam indicator light Br/R Brown/Red 1. AC magneto Br/W Brown/White 58. Left turn signal indicator light 2. Rectifier/regulator...
  • Page 419 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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