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Yamaha XV19SW Service Manual

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Table of Contents

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Summary of Contents for Yamaha XV19SW

  • Page 1 The best Service Manuals have been CycleHippied! Over 30 Years of Powersports Industy Experience goes into the arrangement of the official Yamaha Factory Service Data. If you obtained this manual from a source other than CycleHippie, It may not have been properly CycleHippied!
  • Page 2 XV19SW(C) XV19W(C) XV19MW(C) XV19CTSW(C) XV19CTW(C) XV19CTMW(C) SERVICE MANUAL LIT-11616-20-40 1D7-28197-11...
  • Page 3 EAS20050 XV19SW(C)/XV19W(C)/XV19MW(C)/ XV19CTSW(C)/XV19CTW(C)/XV19CTMW(C) SERVICE MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. First edition, July 2006 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-11616-20-40...
  • Page 4 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 5: 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 6: 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 8: Table Of Contents

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

  • Page 10: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER............. 1-1 MODEL LABEL ..................1-1 FEATURES ..................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM ....................1-3 INSTRUMENT FUNCTIONS..............1-4 IMPORTANT INFORMATION ................. 1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-8 REPLACEMENT PARTS ................

  • Page 11: Identification

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

  • Page 12: Features

    FEATURES EAS20170 FEATURES ET1D71017 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 13: Fi System

    FEATURES ET1D71018 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 392 kPa (3.92 kg/cm², 55.7 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 14: Instrument Functions

    FEATURES ET1D71036 INSTRUMENT FUNCTIONS Multi-function meter unit EW1D71008 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function meter unit. 1. Speedometer 2. Fuel gauge 1. “SELECT” switch 3. Odometer/tripmeter/fuel reserve 2. “RESET” switch tripmeter/clock 4.
  • Page 15 FEATURES Tachometer • The fuel gauge does not indicate the correct fuel level for the first 5 km/h (3 mi/h) after refu- eling. Odometer, tripmeter, and clock modes 1. Tachometer 2. Tachometer red zone The electric tachometer allows the rider to mon- itor the engine speed and keep it within the ideal 1.
  • Page 16 FEATURES To set the clock: Select the brightness control mode as follows. 1. Push the “SELECT” switch to change the dis- 1. Turn the key to “OFF”. play to the clock mode. 2. Push and hold the “SELECT” switch. 2. Push the “SELECT” and “RESET” switches 3.
  • Page 17 FEATURES 1. Speedometer needle 2. Tachometer needle 3. Fuel gauge needle 4. Item number 5. Brightness level 7. Push the “SELECT” switch. The odometer/tripmeter/clock display will re- turn to the prior mode.

  • 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...

  • Page 19: Bearings And Oil Seals

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

  • 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 Timing light 3-10 90890-03141 Inductive clamp timing light YU-03141 Oil filter wrench 3-12 90890-01426 YU-38411 Belt tension gauge 3-24 90890-03170 Rear drive belt tension gauge YM-03170 Steering nut wrench 3-26, 4-71 90890-01403 Spanner wrench YU-33975 Damper rod holder...
  • Page 23 Piston pin puller set 5-46 90890-01304 Piston pin puller YU-01304 YU-01304 Universal clutch holder 5-60, 5-65 90890-04086 YM-91042 Sheave holder 5-60, 5-64, 90890-01701 5-74, 5-75 Primary clutch holder YS-01880-A Yamaha bond No. 1215 5-66, 5-76, 90890-85505 5-93 ® (Three Bond No.1215 1-13...
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rotor puller 5-74 90890-01080 Stator rotor puller YM-01080-A Vacuum/pressure pump gauge set 6-12 90890-06756 Pressure gauge 6-12 90890-03153 Fuel pressure adapter 6-12 90890-03176 YM-03176 Digital circuit tester 6-12 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Ignition checker 7-83...
  • Page 25 SPECIAL TOOLS 1-15...

  • Page 26: 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............2-22 LUBRICATION POINTS AND LUBRICANT TYPES ........2-27 ENGINE ....................2-27 CHASSIS ....................

  • Page 27: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model XV19SW 1D74 (USA) XV19SW 1D76 (CDN) XV19SWC 1D75 (California) XV19W 4D45 (USA) XV19W 4D47 (CDN) XV19WC 4D46 (California) XV19MW 4D54 (USA) XV19MW 4D56 (CDN) XV19MWC 4D55 (California) XV19CTSW 2C54 (USA) XV19CTSW 2C56 (CDN)

  • Page 28: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Air cooled 4-stroke, OHV Displacement 1854.0 cm³ Cylinder arrangement V-type 2-cylinder Bore × stroke 100.0 × 118.0 mm (3.94 × 4.65 in) Compression ratio 9.48 :1 Starting system Electric starter Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 17.0 L (4.49 US gal) (3.74 Imp.gal)
  • Page 29 ENGINE SPECIFICATIONS Inner-rotor-to-outer-rotor-tip clearance Less than 0.12 mm (0.0047 in) Limit 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing clearance 0.10–0.15 mm (0.0039–0.0059 in) Limit 0.22 mm (0.0087 in) Oil-pump-housing-to-inner-and-outer-rotor clearance 0.04–0.09 mm (0.0016–0.0035 in) Limit 0.160 mm (0.0063 in) Spark plug (s) Manufacturer/model NGK/DPR8EA-9 Manufacturer/model...
  • Page 30 ENGINE SPECIFICATIONS Rocker arm/rocker arm shaft Rocker arm inside diameter 18.000–18.018 mm (0.7087–0.7094 in) Limit 18.036 mm (0.7101 in) Rocker arm shaft outside diameter 17.976–17.991 mm (0.7077–0.7083 in) Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.042 mm (0.0004–0.0017 in) Limit 0.080 mm (0.0032 in) Valve, valve seat, valve guide Valve clearance (cold) Intake 0.00–0.04 mm (0.0000–0.0016 in)
  • Page 31 ENGINE SPECIFICATIONS Valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in) Limit 6.050 mm (0.2382 in) Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout 0.010 mm (0.0004 in) Valve spring...
  • Page 32 ENGINE SPECIFICATIONS Valve push rod runout 0.3 mm (0.012 in) Cylinder Bore 100.000–100.010 mm (3.9370–3.9374 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.050 mm (0.0020 in) Piston Piston-to-cylinder clearance 0.025–0.050 mm (0.0010–0.0020 in) Limit 0.15 mm (0.0059 in) Diameter D 99.960–99.975 mm (3.9354–3.9360 in) Height H...
  • Page 33 ENGINE SPECIFICATIONS Oil ring Dimensions (B × T) 2.50 × 3.40 mm (0.10 × 0.13 in) End gap (installed) 0.20–0.70 mm (0.0079–0.0276 in) Connecting rod ® Oil clearance (using plastigauge 0.050–0.074 mm (0.0020–0.0029 in) Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow Crankshaft Width A 105.80–106.20 mm (4.165–4.181 in)
  • Page 34 ENGINE SPECIFICATIONS Primary reduction system Spur gear Primary reduction ratio 72/51 (1.412) Secondary reduction system Belt drive Secondary reduction ratio 70/31 (2.258) Operation Left foot operation Gear ratio 38/16 (2.375) 33/21 (1.571) 29/25 (1.160) 26/28 (0.929) 24/30 (0.800) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in)
  • Page 35 ENGINE SPECIFICATIONS Idling condition Engine idling speed 850–950 r/min Intake vacuum 31.3–35.3 kPa (9.3–10.4 inHg) (235–265 mmHg) Oil temperature 80.0–90.0 °C (176.00–194.00 °F) Throttle cable free play 4.0–6.0 mm (0.16–0.24 in)

  • Page 36: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle 31.20 ° Trail 152.0 mm (5.98 in) Front wheel Wheel type Cast wheel 18M/C × MT4.00 Rim size Rim material Aluminum Wheel travel 130.0 mm (5.12 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 37 CHASSIS SPECIFICATIONS Front brake Type Dual disc brake Operation Right hand operation Front disc brake Disc outside diameter × thickness 298.0 × 5.0 mm (11.73 × 0.20 in) Brake disc thickness limit 4.5 mm (0.18 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 5.5 mm (0.22 in)
  • Page 38 CHASSIS SPECIFICATIONS Recommended oil Fork oil 10WT Quantity 571.0 cm³ (19.31 US oz) (20.10 Imp.oz) Level 124.0 mm (4.88 in) Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 50.0 mm (1.97 in) Spring free length 180.0 mm (7.09 in) Limit...

  • Page 39: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Electrical Ignition timing (B.T.D.C.) 10.0 °/900 r/min Engine control unit Model/manufacturer F008T83271/MITSUBISHI Ignition coil Model/manufacturer 2JN/MORIC Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω...
  • Page 40 Built-in, self-canceling device Turn signal blinking frequency 75.0–95.0 cycles/min 21(23) W × 2 + LED × 2 Wattage Fuel gauge Model/manufacturer 1D7/YAMAHA 9–11 Ω Sender unit resistance (full) 213–219 Ω Sender unit resistance (empty) Starting circuit cut-off relay Model/manufacturer G8R-30Y-V3/OMRON 162–198 Ω...
  • Page 41 ELECTRICAL SPECIFICATIONS Fuel pump relay Model/manufacturer G8R-30Y-V3/OMRON 162–198 Ω Coil resistance Thermo unit Model/manufacturer 5PX/DENSO 898.4–1098.0 Ω Resistance at 100°C Fuses Main fuse 50.0 A Headlight fuse 20.0 A Taillight fuse 10.0 A Signaling system fuse 10.0 A Ignition fuse 25.0 A Auxiliary DC connector fuse 3.0 A...

  • Page 42: 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 43: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head nut 60 Nm (6.0 m·kg, 43 ft·lb) Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kg, 11 ft·lb) pipe) Spark plug 18 Nm (1.8 m·kg, 13 ft·lb) Engine temperature sensor —...
  • Page 44 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil pipe 2 bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil pipe 4 bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil pump housing cover 1 screw 7 Nm (0.7 m·kg, 5.1 ft·lb) (crankcase) Oil pump housing cover 2 screw 7 Nm (0.7 m·kg, 5.1 ft·lb)
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Clutch cover damper plate screw 10 Nm (1.0 m·kg, 7.2 ft·lb) Camshaft cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Generator damper cover bolt 5 Nm (0.5 m·kg, 3.6 ft·lb) Engine oil filler plug 10 Nm (1.0 m·kg, 7.2 ft·lb) Camshaft sprocket cover plate 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 46 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Dipstick joint bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Drive pulley case bolt 70 Nm (7.0 m·kg, 50 ft·lb) Oil strainer bolt (oil tank) 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil pipe 5 bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Transfer gear case cover plate 5 Nm (0.5 m·kg, 3.6 ft·lb)
  • Page 47 TIGHTENING TORQUES Cylinder head tightening sequence: A. Front cylinder B. Rear cylinder 2-21...

  • Page 48: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (left upper 66 Nm (6.6 m·kg, 48 ft·lb) side) Engine mounting bolt (right upper 59 Nm (5.9 m·kg, 43 ft·lb) side) Engine mounting nut (rear upper 98 Nm (9.8 m·kg, 71 ft·lb) side) Engine mounting spacer bolt...
  • Page 49 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Relay arm nut (relay arm and 59 Nm (5.9 m·kg, 43 ft·lb) connecting arm) Rear shock absorber assembly 40 Nm (4.0 m·kg, 29 ft·lb) nut (rear side) Rear shock absorber assembly 59 Nm (5.9 m·kg, 43 ft·lb) nut (front side) Upper drive belt cover bolt...
  • Page 50 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Fuel tank bracket bolt (front side) 16 Nm (1.6 m·kg, 11 ft·lb) Fuel tank bracket nut (rear side) 10 Nm (1.0 m·kg, 7.2 ft·lb) Sub-fuel tank bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Rider seat bracket bolt 23 Nm (2.3 m·kg, 17 ft·lb) Fuel tank and fuel tank bracket...
  • Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear fender bracket and frame 40 Nm (4.0 m·kg, 29 ft·lb) bolt Rear fender bracket and rear 23 Nm (2.3 m·kg, 17 ft·lb) fender bolt Passenger seat bolt 16 Nm (1.6 m·kg, 11 ft·lb) Rider seat bracket assembly and 7 Nm (0.7 m·kg, 5.1 ft·lb) seat lock assembly bolt...
  • Page 52 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Drive pulley cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Rectifier/regulator cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Lead cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Rectifier/regulator bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Drive pulley cover plate bolt 5 Nm (0.5 m·kg, 3.6 ft·lb) Wire harness guide bolt...

  • Page 53: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head nuts and washers Connecting rod small end and big end Crankshaft journals Piston surfaces Piston pins Connecting rod bolts Balancer idle gear inner surface and balancer idle gear shaft Left balancer driven gear inner surface Right balancer...
  • Page 54 Transmission gears (wheel and pinion) and collar Drive pulley nut and washer Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal Shift fork pawl Yamaha bond No.1215 (Three Bond Crankcase mating surface ® No.1215 Yamaha bond No.1215 (Three Bond...

  • Page 55: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing dust cover lip Lower bearing dust seal lip Front wheel oil seal lips (left and right) Rear wheel oil seal lips Rear wheel drive hub oil seal lip Rear wheel drive hub mating surface Tube guide (throttle grip) inner surface and throttle cables Brake lever pivoting point and metal-to-metal moving parts...
  • Page 56 LUBRICATION POINTS AND LUBRICANT TYPES 2-30...

  • Page 57: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-31...
  • Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer (transfer gear case) 2. Oil pump 3. Oil tank 4. Drive axle 5. Main axle 6. Oil strainer (crankcase) 7. Balancer 8. Front cylinder head cover 9. Rear cylinder head cover 10. Rear cylinder camshaft 11.

  • Page 59: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-33...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil tank 2. Dipstick 3. Oil pipe 2 4. Oil delivery pipe 1 5. Oil filter cartridge 6. Oil delivery pipe 2 7. Oil pipe 3 8. Oil pipe 4 9. Oil pipe 5 10.
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Valve lifter 2. Push rod 3. Rocker arm shaft 4. Oil pipe 1 5. Crankshaft 6. Oil pipe (“F” mark) 7. Oil pipe (“R” mark) 2-36...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pipe 1 2. Oil pump 3. Oil strainer (crankcase) 4. Joint pipe 2-38...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 3. Oil strainer (crankcase) 4. Oil pump A. To the oil filter cartridge 2-40...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-41...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pipe 5 2. Transfer gear oil pump 3. Oil strainer (transfer gear case) 4. Middle drive shaft 5. Oil strainer (oil tank) A. From the oil pump 2-42...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-43...
  • Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Transfer gear oil pump 2. Middle driven shaft 2-44...

  • Page 71: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-45...
  • Page 72 CABLE ROUTING 1. Clutch hose 2. Right handlebar switch lead 3. Main switch 4. Left handlebar switch lead 5. Front brake hose 6. Throttle cable (decelerator cable) 7. Throttle cable (accelerator cable) 8. Horn 1 lead 9. Horn 1 10. Rear brake light switch 11.
  • Page 73 CABLE ROUTING 2-47...
  • Page 74 CABLE ROUTING 1. Main switch lead 2. Right handlebar switch lead 3. Wire harness 4. Left handlebar switch lead 5. Air temperature sensor lead 6. Front left turn signal/position light lead 7. Headlight lead 8. Front right turn signal/position light lead 9.
  • Page 75 CABLE ROUTING 2-49...
  • Page 76 CABLE ROUTING 1. EXUP servo motor J. Fasten the wire harness and the cylinder-#2 left and right spark plug leads with a plastic locking tie, 2. Fuse box making sure to install the tie just past the end of the 3.
  • Page 77 CABLE ROUTING 2 3 4 15 16 2-51...
  • Page 78 CABLE ROUTING 1. Clutch hose K. Fasten the stator coil lead and rectifier/regulator lead with the plastic locking tie. Face the end of the 2. Throttle cable (decelerator cable) plastic locking tie outward, and then cut off the 3. Throttle cable (accelerator cable) excess end of the tie.
  • Page 79 CABLE ROUTING 2-53...
  • Page 80 CABLE ROUTING 1. Meter assembly coupler L. Fasten the air filter case damper with the plastic locking tie so that the rubber part of the damper 2. Cylinder-#2 intake air pressure sensor coupler contacts the frame. Be sure to pass the plastic 3.
  • Page 81 CABLE ROUTING 2-55...
  • Page 82 CABLE ROUTING 1. Fuel tank breather hose Q. Install the fuel hose (fuel tank to fuel hose joint) with its white paint mark facing downward. 2. Fuel sender (fuel tank) R. To the pressure regulator 3. Fuel tank S. Install the air vent hose (fuel hose joint to fuel tank) 4.
  • Page 83 CABLE ROUTING 2-57...
  • Page 84 CABLE ROUTING 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#1 intake air pressure sensor hose 3. Air filter case breather hose 1 4. Fuel hose (intake manifold assembly to pressure regulator) 5. Pressure regulator 6. Air filter case breather hose 2 7.
  • Page 85 CABLE ROUTING 9 10 2-59...
  • Page 86 CABLE ROUTING 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#2 intake air pressure sensor hose 3. Cylinder-#2 intake air pressure sensor 4. ISC (idle speed control) unit coupler 5. ISC (idle speed control) unit 6. Rollover valve 1 7. Rollover valve 2 8.
  • Page 87 CABLE ROUTING 2-61...

  • Page 88: 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 ......... 3-7 ADJUSTING THE THROTTLE CABLE FREE PLAY ........ 3-8 CHECKING THE SPARK PLUGS.............
  • Page 89 ELECTRICAL SYSTEM ................3-31 CHECKING AND CHARGING THE BATTERY........3-31 CHECKING THE FUSES ................ 3-31 REPLACING THE HEADLIGHT BULBS ..........3-31 ADJUSTING THE HEADLIGHT BEAMS..........3-32...

  • Page 91: Periodic Maintenance

    √ √ damage. tem (For • Replace if necessary. California only) * 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 8000 mi...
  • Page 92 Lights, signals • Check operation. √ √ √ √ √ √ 26 * and switches • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
  • Page 93 PERIODIC MAINTENANCE NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. EAU38440 NOTE: • Air filter • This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it.

  • Page 94: Engine

    ENGINE EAS20470 • Fuel tank ENGINE Refer to “FUEL TANK” on page 6-1. • Air filter case EAS20530 Refer to “GENERAL CHASSIS” on page 4-1. ADJUSTING THE VALVE CLEARANCE • Muffler The following procedure applies to all of the • Exhaust pipes valves.
  • Page 95 ENGINE 8. Remove: 11.Measure: • Fuel tank damper “1” • Valve clearance • Cylinder head breather hose “2” Out of specification → Adjust. 9. Disconnect: • Oil tank breather hose “3” Valve clearance (cold) Intake • Fuel outlet hose “4” 0.00–0.04 mm (0.0000–0.0016 in) Exhaust 0.00–0.04 mm (0.0000–0.0016 in)
  • Page 96 ENGINE Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 L LLL L LLL L LLL L LLL L LLL 12.Adjust: • Valve clearance M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut “1”. d. Measure the valve clearance with a thickness gauge.

  • Page 97: Synchronizing The Throttle Bodies

    ENGINE • Cylinder-#1 ignition coil cover Refer to “ENGINE REMOVAL” on page 5-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. 3. Remove: • Cylinder-#1 intake air pressure sensor brack- et “1” • Cylinder-#2 intake air pressure sensor brack- et “2”...

  • Page 98: Adjusting The Throttle Cable Free Play

    ENGINE NOTE: The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (10 mmHg). L LLL L LLL L LLL L LLL L LLL 8. Stop the engine and remove the measuring equipment. 9. Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CA- 6.

  • Page 99: Checking The Spark Plugs

    ENGINE M MMM M MMM M MMM M MMM M MMM 4. Check: a. Loosen the locknut “1”. • Spark plug type b. Turn the adjusting nut “2” in direction “a” or “b” Incorrect → Change. until the specified throttle cable free play is obtained.

  • Page 100: Checking The Ignition Timing

    ENGINE 10.Install: • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. • Rider seat bracket assembly • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS20700 CHECKING THE IGNITION TIMING 5.

  • Page 101: Checking The Engine Oil Level

    ENGINE NOTE: Type Align the mark “a” on the shift pedal shaft with YAMALUBE 4 (20W40) or the slot in the shift pedal. SAE20W40 Recommended engine oil grade API service SG type or higher, JASO standard MA ECA13380 CAUTION: • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage.
  • Page 102 ENGINE c. Tighten the new oil filter cartridge to specifi- 5. Remove: cation with an oil filter wrench. • Engine oil drain bolts (crankcase) “1” (along with the gaskets) Oil filter cartridge 17 Nm (1.7 m·kg, 12 ft·lb) L LLL L LLL L LLL L LLL...

  • Page 103: Checking The Transfer Gear Oil Level

    ENGINE EC1D71008 CAUTION: Oil gallery bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) When starting the engine make sure the dip- stick is securely fitted into the oil tank. L LLL L LLL L LLL L LLL L LLL 12.Fill: (when engine is disassembled) EAS20840 •...

  • Page 104: Changing The Transfer Gear Oil

    ENGINE Transfer gear oil check bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) EAS20850 CHANGING THE TRANSFER GEAR OIL 1. Remove: • Muffler • Exhaust pipes Refer to “ENGINE REMOVAL” on page 5-1. 2. Place a container under the transfer gear oil 8.

  • Page 105: Bleeding The Hydraulic Clutch System

    ENGINE • Refill with the same type of clutch fluid that is already in the system. Mixing clutch flu- ids may result in a harmful chemical reac- tion, leading to poor clutch performance. • When refilling, be careful that water does not enter the clutch fluid reservoir.

  • Page 106: Checking The Throttle Body Joints

    ENGINE EAS21010 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds. 1. Remove: • Rider seat • Rider seat bracket assembly Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK”...

  • Page 107: Checking The Cylinder Head Breather Hose

    ENGINE 3. Install: • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. • Rider seat bracket assembly • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS21060 CHECKING THE OIL TANK BREATHER 3.

  • Page 108: Checking The Canister (For California Only)

    ENGINE • Muffler “3” EAS21090 CHECKING THE CANISTER (for California • Muffler bracket “4” only) Cracks/damage → Replace. 1. Remove: • Gaskets “5” • Horn 1 Exhaust gas leaks → Replace. Refer to “THROTTLE BODIES” on page 6-6. 2. Check: 2.
  • Page 109 ENGINE c. Tighten both locknuts. L LLL L LLL L LLL L LLL L LLL d. Turn the main switch to “ON” and check that 3. Check: the projection “c” on the EXUP valve pulley • EXUP cable free play (at the EXUP valve pul- contacts the stoppers (fully open and fully ley) “a”...

  • Page 110: Chassis

    CHASSIS EAS21140 CHASSIS EAS21190 ADJUSTING THE REAR DISC BRAKE 1. Check: • Brake pedal position (distance “a” from the top of the rider footrest to the top of the brake pedal) Out of specification → Adjust. Brake pedal position c. Tighten the locknut. 110.0 mm (4.33 in) EW1D71005 WARNING...

  • Page 111: Checking The Front Brake Pads

    CHASSIS EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • Front brake pad Wear indicator grooves “1” almost disap- peared → Replace the brake pads as a set. Refer to “FRONT BRAKE”...

  • Page 112: Checking The Rear Brake Hoses

    CHASSIS EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by move- ment of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1.

  • Page 113: Adjusting The Shift Pedal

    CHASSIS NOTE: NOTE: • Be careful not to spill any brake fluid or allow Loosening the bleed screw will release the pres- the brake master cylinder reservoir or brake sure and cause the brake lever to contact the fluid reservoir to overflow. throttle grip or the brake pedal to fully extend.

  • Page 114: Adjusting The Drive Belt Slack

    CHASSIS M MMM M MMM M MMM M MMM M MMM 1. Stand the vehicle on a level surface. a. Loosen both locknuts “1”. EWA13120 WARNING b. Turn the shift rod “2” in direction “a” or “b” until the specified installed shift rod length is ob- Securely support the vehicle so that there is tained.

  • Page 115: Checking And Adjusting The Steering Head

    CHASSIS NOTE: Using the alignment marks on each side of the swingarm, make sure that both belt pullers are in the same position for proper wheel alignment. d. Tighten the locknuts to specification. Locknut (drive belt adjusting bolt) 16 Nm (1.6 m·kg, 11 ft·lb) 3.

  • Page 116: Checking The Front Fork

    CHASSIS 3. Remove: Lower ring nut (final tightening • Upper bracket torque) Refer to “FRONT FORK” on page 4-60. 18 Nm (1.8 m·kg, 13 ft·lb) 4. Adjust: • Steering head d. Check the steering head for looseness or M MMM M MMM M MMM M MMM...

  • Page 117: Adjusting The Rear Shock Absorber Assembly

    CHASSIS 3. Hold the vehicle upright and apply the front Spring preload adjusting posi- brake. tions 4. Check: Installed spring length • Front fork operation Minimum Push down hard on the handlebar several 162.0 mm (6.38 in) times and check if the front fork rebounds Standard smoothly.
  • Page 118 CHASSIS EWA13190 WARNING It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, re- place the tire immediately. 2. Check: • Tire surfaces Damage/wear → Replace the tire. Wear limit (front) 1.0 mm (0.04 in) EWA13180 WARNING Wear limit (rear)

  • Page 119: Checking The Wheels

    WARNING cerning handling characteristics can be giv- en if a tire combination other than one Never attempt to make any repairs to the approved by Yamaha is used on this vehicle. wheel. NOTE: Front tire After a tire or wheel has been changed or re- Size placed, always balance the wheel.

  • Page 120: Lubricating The Levers

    CHASSIS NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device. EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. Recommended lubricant Lithium-soap-based grease EAS21710...

  • Page 121: Electrical System

    ELECTRICAL SYSTEM EAS21750 5. Replace: ELECTRICAL SYSTEM • Low beam headlight bulb M MMM M MMM M MMM M MMM M MMM EAS21760 a. Disconnect: CHECKING AND CHARGING THE BATTERY • Headlight coupler “1” Refer to “ELECTRICAL COMPONENTS” on b. Remove: page 7-67.
  • Page 122 ELECTRICAL SYSTEM 7. Install: • Headlight assembly 8. Connect: • Air temperature sensor coupler 9. Install: • Headlight cover Headlight cover bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) 10.Install: b. Disconnect: • Windshield (For XV19CTS(C)/ • Headlight coupler “1” XV19CT(C)/XV19CTM(C)) c.
  • Page 123 ELECTRICAL SYSTEM L LLL L LLL L LLL L LLL L LLL 3-33...
  • Page 124 CHASSIS GENERAL CHASSIS ..................4-1 REMOVING THE WINDSHIELD ............... 4-2 ASSEMBLING THE WINDSHIELD ............4-2 INSTALLING THE WINDSHIELD.............. 4-2 REMOVING THE BACKREST ..............4-5 ASSEMBLING THE BACKREST .............. 4-5 INSTALLING THE BACKREST..............4-5 CHECKING THE SIDEBAG BRACKET SPRING NUTS......4-8 FRONT WHEEL ....................
  • Page 125 REAR BRAKE....................4-43 INTRODUCTION..................4-49 CHECKING THE REAR BRAKE DISC ........... 4-49 REPLACING THE REAR BRAKE PADS ..........4-49 REMOVING THE REAR BRAKE CALIPER ..........4-50 DISASSEMBLING THE REAR BRAKE CALIPER ........4-50 CHECKING THE REAR BRAKE CALIPER..........4-51 ASSEMBLING THE REAR BRAKE CALIPER ........4-51 INSTALLING THE REAR BRAKE CALIPER...........

  • Page 127: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the windshield (For XV19CTS(C)/XV19CT(C)/XV19CTM(C)) 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 8 Nm (0.8 m kg, 5.8 ft •...

  • Page 128: Removing The Windshield

    GENERAL CHASSIS ET1D71039 REMOVING THE WINDSHIELD 1. Remove: • Windshield M MMM M MMM M MMM M MMM M MMM a. Insert the key “1” into the windshield lock, turn it clockwise and then remove the key. ET1D71040 INSTALLING THE WINDSHIELD 1.
  • Page 129 GENERAL CHASSIS c. Insert the key into the windshield lock, turn it counterclockwise until it stops to lock the fas- tener, and then remove the key. 1. Lock 2. Fastener L LLL L LLL L LLL L LLL L LLL...
  • Page 130 Sidebag (left and right) tions to clean the leather on the sidebags. Polish the dry leather with a soft cloth, and then treat with Yamaha Mink Oil or another high-quality leather protectant for increased water resistance. Backrest assembly...

  • Page 131: Removing The Backrest

    GENERAL CHASSIS ET1D71041 NOTE: REMOVING THE BACKREST Align the projection “a” on the lock “1” with the 1. Remove: slot “b” in the left backrest lower bracket “2”. • Backrest M MMM M MMM M MMM M MMM M MMM a.
  • Page 132 GENERAL CHASSIS b. Push the rear of the backrest down smoothly but forcefully to lock it in place and make sure that the lever hook “1” on each side is secure- ly fit over its holder “2”. EW1D71017 WARNING Both lever hooks must be securely fitted over their holder.
  • Page 133 GENERAL CHASSIS Removing the sidebag brackets (For XV19CTS(C)/XV19CT(C)/XV19CTM(C)) 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 48 Nm (4.8 m kg, 35 ft •...

  • Page 134: Checking The Sidebag Bracket Spring Nuts

    GENERAL CHASSIS ET1D71047 CHECKING THE SIDEBAG BRACKET SPRING NUTS 1. Check: • Sidebag bracket spring nut height “a” Out of specification → Adjust. Sidebag bracket spring nut height 12.0 mm (0.47 in) 2. Check: • Sidebag bracket spring nuts Damage → Replace.
  • Page 135 GENERAL CHASSIS Removing the seats and side covers 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 136 GENERAL CHASSIS Removing the headlight 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 Headlight cover Air temperature sensor coupler Disconnect. Air temperature sensor Headlight (low beam) coupler Disconnect.
  • Page 137 GENERAL CHASSIS Removing the battery Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Tool kit tray/Seat bracket 4-1. ECU band ECU (electronic control unit) Coupler tray Negative terminal cover Negative battery lead Disconnect. Positive battery lead Disconnect.
  • Page 138 GENERAL CHASSIS Removing the battery Order Job/Parts to remove Q’ty Remarks Headlight relay Turn signal relay Plastic locking tie Battery box For installation, reverse the removal proce- dure. 4-12...
  • Page 139 GENERAL CHASSIS Removing the air filter case 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 16 Nm (1.6 m kg, 11 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 140 GENERAL CHASSIS Removing the air filter case 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 16 Nm (1.6 m kg, 11 ft • • Order Job/Parts to remove Q’ty Remarks Air filter case bracket Air filter case joint clamp screw Loosen.

  • Page 141: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 10 Nm (1.0 m kg, 7.2 ft • • 40 Nm (4.0 m kg, 29 ft • • 40 Nm (4.0 m kg, 29 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 142 FRONT WHEEL Removing the front wheel and brake discs 10 Nm (1.0 m kg, 7.2 ft • • 40 Nm (4.0 m kg, 29 ft • • 40 Nm (4.0 m kg, 29 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 143 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. 4-17...

  • Page 144: Removing The Front Wheel

    FRONT WHEEL EAS21900 EAS21910 REMOVING THE FRONT WHEEL DISASSEMBLING THE FRONT WHEEL 1. Stand the vehicle on a level surface. 1. Remove: • Oil seals EWA13120 WARNING • Wheel bearings Securely support the vehicle so that there is M MMM M MMM M MMM M MMM...

  • Page 145: Assembling The Front Wheel

    FRONT WHEEL EAS21960 ASSEMBLING THE FRONT WHEEL 1. Install: • Wheel bearings • Oil seals M MMM M MMM M MMM M MMM M MMM a. Install the new wheel bearings and oil seals in the reverse order of disassembly. EC1D71011 CAUTION: Do not contact the wheel bearing inner race...

  • Page 146: Installing The Front Wheel (Front Brake Discs)

    FRONT WHEEL ° c. If the heavy spot does not stay in that posi- c. Turn the front wheel 90 so that the “X ” mark tion, install a heavier weight. is positioned as shown. d. Repeat steps (b) and (c) until the front wheel d.
  • Page 147 FRONT WHEEL Front brake caliper bolt 40 Nm (4.0 m·kg, 29 ft·lb) EWA13500 WARNING Make sure the brake hose is routed properly. 7. Install: • Front fender • Left front brake hose guide bracket • Right front brake hose guide bracket 2.
  • Page 148 FRONT WHEEL 4-22...

  • Page 149: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear fender 23 Nm (2.3 m kg, 17 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/Passenger seat/Tool kit tray 4-1.
  • Page 150 REAR WHEEL Removing the rear wheel 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 150 Nm (15.0 m kg, 110 ft • • 27 Nm (2.7 m kg, 19 ft •...
  • Page 151 REAR WHEEL Removing the rear wheel 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 150 Nm (15.0 m kg, 110 ft • • 27 Nm (2.7 m kg, 19 ft •...
  • Page 152 REAR WHEEL Removing the rear brake disc and rear wheel drive hub Order Job/Parts to remove Q’ty Remarks Rear brake disc cover Rear brake disc Rear wheel pulley Oil seal Circlip Rear wheel drive hub Circlip Bearing Collar Bearing Rear wheel drive hub damper Rear wheel For installation, reverse the removal proce- dure.
  • Page 153 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. 4-27...

  • Page 154: Removing The Rear Wheel (Disc)

    REAR WHEEL EAS28760 REMOVING THE REAR WHEEL (DISC) 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 155: Checking The Rear Wheel Drive Hub

    REAR WHEEL EAS22110 EAS22150 CHECKING THE REAR WHEEL DRIVE HUB ADJUSTING THE REAR WHEEL STATIC 1. Check: BALANCE • Rear wheel drive hub NOTE: Cracks/damage → Replace. • After replacing the tire, wheel or both, the rear • Rear wheel drive hub dampers wheel static balance should be adjusted.
  • Page 156 REAR WHEEL NOTE: Temporarily tighten the wheel axle nut. 5. Adjust: • Drive belt slack Refer to “ADJUSTING THE DRIVE BELT SLACK” on page 3-24. 6. Tighten: • Rear wheel axle nut Rear wheel axle nut 150 Nm (15.0 m·kg, 110 ft·lb) 7.

  • Page 157: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 10 Nm (1.0 m kg, 7.2 ft • • 40 Nm (4.0 m kg, 29 ft • • 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
  • Page 158 FRONT BRAKE Removing the front brake master cylinder 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 159 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-33...
  • Page 160 FRONT BRAKE Removing the front brake calipers 40 Nm (4.0 m kg, 29 ft • • 32 Nm (3.2 m kg, 23 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 161 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 Brake pad Brake pad shim Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro-...

  • Page 162: Introduction

    FRONT BRAKE EAS22220 e. Measure the deflection 1.5 mm (0.06 in) be- INTRODUCTION low the edge of the brake disc. EWA14100 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.

  • Page 163: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Brake pad shims steps until the brake disc deflection is within (onto the brake pads) specification. • Brake pads f. If the brake disc deflection cannot be brought •...

  • Page 164: Removing The Front Brake Calipers

    FRONT BRAKE • Front brake hose “4” NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. L LLL L LLL L LLL L LLL L LLL 3. Install: • Brake pad pin •...

  • Page 165: Checking The Front Brake Calipers

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

  • Page 166: Removing The Front Brake Master Cylinder

    FRONT BRAKE 2. Remove: Refer to “CHECKING THE BRAKE FLUID • Front brake caliper LEVEL” on page 3-20. 3. Install: • Brake pads • Brake pad spring • Brake pad pin • Brake pad clips • Front brake caliper • Brake hose guide Brake caliper bolt 40 Nm (4.0 m·kg, 29 ft·lb) Brake hose holder bolt...

  • Page 167: Assembling The Front Brake Master Cylinder

    FRONT BRAKE • Brake fluid delivery passages • First, tighten the rear bolt, then the front bolt. (brake master cylinder body) Obstruction → Blow out with compressed air. 2. Install: • Copper washers 2. Check: • Front brake hose “1” •...
  • Page 168 FRONT BRAKE EWA13540 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 169: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Rear brake caliper Rear brake pad Brake pad spring For installation, reverse the removal proce-...
  • Page 170 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 171 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 172 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Circlip Brake hose joint O-ring Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-46...
  • Page 173 REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-22. Rear brake hose union bolt Copper washer Rear brake hose...
  • Page 174 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure. 4-48...

  • Page 175: Introduction

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

  • Page 176: Removing The Rear Brake Caliper

    REAR BRAKE Refer to “BLEEDING THE HYDRAULIC NOTE: BRAKE SYSTEM” on page 3-22. Always install new brake pads and brake pad springs as a set. EAS22590 REMOVING THE REAR BRAKE CALIPER M MMM M MMM M MMM M MMM M MMM a.

  • Page 177: Checking The Rear Brake Caliper

    REAR BRAKE EAS22650 ASSEMBLING THE REAR BRAKE CALIPER EWA13620 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.

  • Page 178: Removing The Rear Brake Master Cylinder

    REAR BRAKE • Brake pad springs • Rear brake caliper bolts • Rear brake caliper Refer to “REPLACING THE REAR BRAKE PADS” on page 4-49. Rear brake caliper bolt 27 Nm (2.7 m·kg, 19 ft·lb) 4. Fill: • Brake fluid reservoir 7.

  • Page 179: Assembling The Rear Brake Master Cylinder

    REAR BRAKE 2. Check: • Brake master cylinder kit Damage/scratches/wear → Replace. 3. Check: • Brake fluid reservoir Cracks/damage → Replace. • Brake fluid reservoir diaphragm Cracks/damage → Replace. 4. Check: • Brake hoses Cracks/damage/wear → Replace. 2. Fill: • Brake fluid reservoir EAS22730 (with the specified amount of the recom- ASSEMBLING THE REAR BRAKE MASTER...
  • Page 180 REAR BRAKE 5. Check: • Brake pedal operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-22. 6. Adjust: • Brake pedal position Refer to “ADJUSTING THE REAR DISC BRAKE”...

  • Page 181: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 28 Nm (2.8 m kg, 20 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 50 Nm (5.0 m kg, 36 ft •...
  • Page 182 HANDLEBAR Removing the handlebar 28 Nm (2.8 m kg, 20 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 50 Nm (5.0 m kg, 36 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 183: Removing The Handlebar

    HANDLEBAR EAS22860 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” NOTE: 3. Pass the left and right handlebar switch leads Blow compressed air between the handlebar through the handlebar.
  • Page 184 HANDLEBAR EWA13700 • There should be 1–3 mm (0.04–0.12 in) of WARNING clearance “c” between the throttle grip and the Do not touch the handlebar grip until the rub- grip end. ber adhesive has fully dried. L LLL L LLL L LLL L LLL L LLL...
  • Page 185 HANDLEBAR Throttle cable free play 4.0–6.0 mm (0.16–0.24 in) 4-59...

  • Page 186: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 10 Nm (1.0 m kg, 7.2 ft • • 115 Nm (11.5 m kg, 85 ft • • 19 Nm (1.9 m kg, 13 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 187 FRONT FORK Removing the front fork legs 10 Nm (1.0 m kg, 7.2 ft • • 115 Nm (11.5 m kg, 85 ft • • 19 Nm (1.9 m kg, 13 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 188 FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer...
  • Page 189 FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks Spring Oil flow stopper Outer tube For assembly, reverse the disassembly pro- cedure.

  • Page 190: Removing The Front Fork Legs

    FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: 3.

  • Page 191: Checking The Front Fork Legs

    FRONT FORK ECA14200 CAUTION: • The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork.
  • Page 192 FRONT FORK • Washer (with the fork seal driver “2”) Fork seal driver 90890-01442 Adjustable fork seal driver (36–46 YM-01442 2. Lubricate: • Inner tube’s outer surface Recommended oil Fork oil 10WT 3. Install: • Inner tube (in the outer tube) 7.
  • Page 193 FRONT FORK Quantity 571.0 cm³ (19.31 US oz) (20.10 Imp.oz) Recommended oil Fork oil 10WT 11.Measure: • Front fork leg oil level “a” (from the top of the inner tube, with the outer tube fully compressed and without the fork 8.

  • Page 194: Installing The Front Fork Legs

    FRONT FORK NOTE: Align the groove “a” in the upper front fork cover “1” with the lower front fork cover nut “2”. EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 6. Tighten: 1.

  • Page 195: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 1st 52 Nm (5.2 m kg, 37 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 196 STEERING HEAD Removing the lower bracket 1st 52 Nm (5.2 m kg, 37 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 16 Nm (1.6 m kg, 11 ft •...

  • Page 197: Removing The Lower Bracket

    STEERING HEAD EAS23110 M MMM M MMM M MMM M MMM M MMM REMOVING THE LOWER BRACKET a. Remove the bearing races from the steering 1. Stand the vehicle on a level surface. head pipe with a long rod “1” and hammer. EWA13120 b.
  • Page 198 STEERING HEAD 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-25. 3. Install: • Front brake hose joint “1” •...

  • Page 199: Rear Shock Absorber Assembly And Swingarm

    REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM ET1D71001 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM Removing the rear shock absorber assembly and swingarm 48 Nm (4.8 m kg, 35 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 200 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM Removing the rear shock absorber assembly and swingarm 48 Nm (4.8 m kg, 35 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...
  • Page 201 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM Removing the rear shock absorber and swingarm 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Parts to remove Q’ty...

  • Page 202: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 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. Loosen: compressed nitrogen gas. Before handling •...

  • Page 203: Checking The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM EAS23360 CHECKING THE SWINGARM 1. Check: • Swingarm Bends/cracks/damage → Replace. 2. Check: • Pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. EWA13770 WARNING L LLL L LLL L LLL L LLL L LLL Do not attempt to straighten a bent pivot...
  • Page 204 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 2. Install: • Spacer “2” • Bearings “1”, “2”, “3” EC1D71010 CAUTION: (to the relay arm) When inserting the spacer into the connect- • Oil seals “4”, “5” ing arms and the rear shock absorber, be (to the relay arm) careful not to damage the bushings and O- Installed depth “a”...

  • Page 205: Installing The Swingarm

    REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 6. Tighten: 2. Swingarm • Connecting-arm-to-relay-arm nut A. Left side B. Right side Connecting-arm-to-relay-arm nut 3. Install: 59 Nm (5.9 m·kg, 43 ft·lb) • Pivot shaft • Rear-shock-absorber-assembly-to-relay-arm • Washer • Pivot shaft nut NOTE: Rear-shock-absorber-assembly- Temporarily tighten the pivot shaft nut.

  • Page 206: Belt Drive

    BELT DRIVE EAS23510 BELT DRIVE Removing the drive belt and drive pulley 10 Nm (1.0 m kg, 7.2 ft 53 Nm (5.3 m kg, 38 ft • • • • 63 Nm (6.3 m kg, 45 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 207 BELT DRIVE Removing the drive belt and drive pulley 10 Nm (1.0 m kg, 7.2 ft 53 Nm (5.3 m kg, 38 ft • • • • 63 Nm (6.3 m kg, 45 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 208: Checking The Drive Belt

    BELT DRIVE EAS23520 • The drive belt can not be bent smaller than REMOVING THE DRIVE BELT AND DRIVE 127 mm (5 in) “a”. PULLEY • The removed drive belt can not be twisted NOTE: inside out. Loosen the drive pulley nut before removing the rear wheel.
  • Page 209 BELT DRIVE 3. Install: • Swingarm • Rear shock absorber Refer to “REAR SHOCK ABSORBER AS- SEMBLY AND SWINGARM” on page 4-73. • Rear wheel Refer to “REAR WHEEL” on page 4-23. 4. Tighten: • Drive pulley nut Drive pulley nut 140 Nm (14.0 m·kg, 100 ft·lb) NOTE: •...
  • Page 210 ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE SHIFT PEDAL ASSEMBLY......... 5-5 CHECKING THE OIL COOLER ..............5-7 REMOVING THE ENGINE..............5-12 INSTALLING THE ENGINE ..............5-12 CAMSHAFTS ....................5-14 REMOVING THE CYLINDER HEAD COVERS ........5-21 REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS....................
  • Page 211 CLUTCH ......................5-50 REMOVING THE CLUTCH ..............5-60 REMOVING THE PRIMARY DRIVE GEAR ..........5-60 REMOVING THE LEFT BALANCER DRIVE GEAR ....... 5-60 CHECKING THE FRICTION PLATES ............ 5-61 CHECKING THE CLUTCH PLATES............5-61 CHECKING THE CLUTCH SPRING PLATE .......... 5-61 CHECKING THE CLUTCH HOUSING............
  • Page 212 CRANKCASE....................5-89 DISASSEMBLING THE CRANKCASE ........... 5-92 CHECKING THE CRANKCASE.............. 5-92 CHECKING THE BEARINGS AND OIL SEAL ........5-92 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE......5-92 CHECKING THE OIL STRAINERS............5-92 CHECKING THE ENGINE OIL PUMP DRIVEN GEAR ......5-93 INSTALLING THE BEARING RETAINERS ..........

  • Page 213: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the muffler and exhaust pipes 10 Nm (1.0 m kg, 7.2 ft • • 29 Nm (2.9 m kg, 21 ft • • 53 Nm (5.3 m kg, 38 ft • • 24 Nm (2.4 m kg, 17 ft •...
  • Page 214 ENGINE REMOVAL Removing the muffler and exhaust pipes 10 Nm (1.0 m kg, 7.2 ft • • 29 Nm (2.9 m kg, 21 ft • • 53 Nm (5.3 m kg, 38 ft • • 24 Nm (2.4 m kg, 17 ft •...
  • Page 215 ENGINE REMOVAL Removing the cylinder-#1 ignition coils and sidestand 7 Nm (0.7 m kg, 5.1 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 216 ENGINE REMOVAL Removing the cylinder-#1 ignition coils and sidestand 7 Nm (0.7 m kg, 5.1 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft •...

  • Page 217: Installing The Shift Pedal Assembly

    ENGINE REMOVAL ET1D71029 INSTALLING THE SHIFT PEDAL ASSEMBLY 1. Assemble: • Shift pedal (heel side) “1” • Shift pedal (toe side) “2” Shift pedal (heel side) bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) NOTE: Align the mark “a” on the pin on the toe side with the mark “b”...
  • Page 218 ENGINE REMOVAL Removing the oil cooler and oil filter bracket 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 • • 17 Nm (1.7 m kg, 12 ft •...

  • Page 219: Checking The Oil Cooler

    ENGINE REMOVAL ET1D71028 CHECKING THE OIL COOLER 1. Check: • Oil cooler fins Obstruction → Clean. Apply compressed air to the rear of the oil cooler. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver.
  • Page 220 ENGINE REMOVAL Disconnecting the leads 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft 7 Nm (0.7 m kg, 5.1 ft • • • •...
  • Page 221 ENGINE REMOVAL Disconnecting the leads 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft 7 Nm (0.7 m kg, 5.1 ft • • • •...
  • Page 222 ENGINE REMOVAL Removing the engine 105 Nm (10.5 m kg, 75 ft 59 Nm (5.9 m kg, 43 ft 53 Nm (5.3 m kg, 38 ft • • • • • • 18 Nm (1.8 m kg, 13 ft 66 Nm (6.6 m kg, 48 ft •...
  • Page 223 ENGINE REMOVAL Removing the engine 105 Nm (10.5 m kg, 75 ft 59 Nm (5.9 m kg, 43 ft 53 Nm (5.3 m kg, 38 ft • • • • • • 18 Nm (1.8 m kg, 13 ft 66 Nm (6.6 m kg, 48 ft •...

  • Page 224: Removing The Engine

    ENGINE REMOVAL ET1D71019 3. Tighten: REMOVING THE ENGINE • Spacer bolt “1” 1. Loosen: • Spacer bolt Spacer bolt 18 Nm (1.8 m·kg, 13 ft·lb) NOTE: Loosen the spacer bolt with the pivot shaft NOTE: wrench “1”. • Tighten the spacer bolt “1” to specification with a pivot shaft wrench.
  • Page 225 ENGINE REMOVAL 9. Tighten: Engine mounting nut (rear lower • Engine bracket nut (front upper side) “3” side) • Engine cross-member bracket bolts “5” 98 Nm (9.8 m·kg, 71 ft·lb) • Engine mounting nut (front upper side) “7” Engine mounting nut (front lower side) Engine bracket nut (front upper 105 Nm (10.5 m·kg, 75 ft·lb)

  • Page 226: Camshafts

    CAMSHAFTS EAS23750 CAMSHAFTS Removing the camshaft sprocket cover 10 Nm (1.0 m kg, 7.2 ft • • 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 227 CAMSHAFTS Removing the cylinder head covers 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Cylinder head breather hose Oil tank breather hose Disconnect. Wire harness guide Fuel tank damper Fuel outlet hose Disconnect.
  • Page 228 CAMSHAFTS Removing the push rods and rocker arms 10 Nm (1.0 m kg, 7.2 ft 24 Nm (2.4 m kg, 17 ft • • • • 24 Nm (2.4 m kg, 17 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 229 CAMSHAFTS Removing the valve lifters 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “CYLINDERS AND PISTONS” on Front cylinder page 5-45. Push rod cover O-ring O-ring Seal...
  • Page 230 CAMSHAFTS Removing the camshafts and right balancer 40 Nm (4.0 m kg, 29 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 40 Nm (4.0 m kg, 29 ft 60 Nm (6.0 m kg, 43 ft •...
  • Page 231 CAMSHAFTS Removing the camshafts and right balancer 40 Nm (4.0 m kg, 29 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 40 Nm (4.0 m kg, 29 ft 60 Nm (6.0 m kg, 43 ft •...
  • Page 232 CAMSHAFTS Disassembling the camshafts Order Job/Parts to remove Q’ty Remarks Circlip Washer Decompression cam spring Decompression cam Decompression pin Front cylinder camshaft Rear cylinder camshaft For assembly, reverse the disassembly pro- cedure. 5-20...

  • Page 233: Removing The Cylinder Head Covers

    CAMSHAFTS ET1D71030 REMOVING THE CYLINDER HEAD COVERS 1. Remove: • Front cylinder • Rear cylinder “1” NOTE: Due to the small clearance between the frame and the rear cylinder head cover, the three bolts “2” cannot be removed when the cover is in place.
  • Page 234 CAMSHAFTS NOTE: • Place a folded copper washer “3” between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them. • Place a folded copper washer “4” between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them.

  • Page 235: Checking The Camshafts

    CAMSHAFTS EAS23860 CHECKING THE CAMSHAFTS 1. Check: • Cam Blue discoloration/pitting/scratches → Re- place the camshaft. 2. Measure: • Cam dimensions A “a” and B “b” Out of specification → Replace the camshaft. Camshaft lobe dimensions 3. Measure: Intake A •...

  • Page 236: Checking The Rocker Arms And Rocker Arm Shafts

    CAMSHAFTS NOTE: Calculate the clearance by subtracting the cam- shaft journal diameter (crankcase side) from the crankcase hole inside diameter. Camshaft to crankcase clearance 0.020–0.064 mm (0.0008–0.0025 8. Calculate: 5. Measure: • Camshaft to camshaft cover clearance Out of specification → Replace the defective •...

  • Page 237: Checking The Rocker Arm Bases

    CAMSHAFTS • Push rod end Bends/damage → Replace. 2. Measure: • Push rod runout Out of specification → Replace. Valve push rod runout 0.3 mm (0.012 in) 4. Measure: • Rocker arm shaft outside diameter “a” Out of specification → Replace. Rocker arm shaft outside diame- 17.976–17.991 mm (0.7077–...

  • Page 238: Checking The Push Rod Cover

    CAMSHAFTS Valve lifter outside diameter (in- Valve-lifter-to-valve-lifter-hole take) clearance 22.962–22.974 mm (0.9040– 0.026–0.059 mm (0.0010–0.0023 0.9045 in) Valve lifter outside diameter (ex- haust) EAS23930 22.962–22.974 mm (0.9040– CHECKING THE PUSH ROD COVER 0.9045 in) 1. Check: • Push rod cover Cranks/damage →...

  • Page 239: Checking The Oil Delivery Pipe

    CAMSHAFTS EAS24030 INSTALLING THE CAMSHAFTS Decompression cam spring 1. Install: Free length • Camshafts 20.0 mm (0.79 in) Limit NOTE: 19.0 mm (0.75 in) Lubricate molybdenum disulfide oil onto the camshaft journals and lobes. 2. Install: • Camshaft cover 1 “1” •...
  • Page 240 CAMSHAFTS NOTE: Camshaft drive gear bolt • Align the projection “a” on the washer “3” with 60 Nm (6.0 m·kg, 43 ft·lb) the punch mark “b” on the front cylinder cam- Right balancer driven gear bolt shaft gear. 40 Nm (4.0 m·kg, 29 ft·lb) •...

  • Page 241: Bleeding A Valve Lifter

    CAMSHAFTS NOTE: • Place a folded copper washer “2” between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them. • Do not damage the teeth of the camshaft drive and camshaft driven gears. •...

  • Page 242: Installing The Valve Lifters

    CAMSHAFTS ECA14650 h. Rotate the crankshaft until the mark (on the CAUTION: camshaft driven gear) for the valve lifter to be Be sure to install the valve lifter in its appro- bled aligns with the camshaft drive gear as priate position. shown.

  • Page 243: Installing The Rocker Arms And Push Rods

    CAMSHAFTS M MMM M MMM M MMM M MMM M MMM a. Put the rocker arm base on the cylinder head. b. Install the push rods. NOTE: • Be sure to correctly install the push rods be- tween the rocker arms and valve lifters as shown.

  • Page 244: Installing The Cylinder Head Covers

    CAMSHAFTS Bolts “2”: l = 45 mm (1.77 in) Bolts “3”: l = 70 mm (2.76 in) L LLL L LLL L LLL L LLL L LLL EAS24080 INSTALLING THE CYLINDER HEAD COVERS 1. Install: • Rear cylinder head cover “1” •...

  • Page 245: Cylinder Heads

    CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads 59 Nm (5.9 m kg, 43 ft • • 66 Nm (6.6 m kg, 48 ft • • 53 Nm (5.3 m kg, 38 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 246 CYLINDER HEADS Removing the cylinder heads 59 Nm (5.9 m kg, 43 ft • • 66 Nm (6.6 m kg, 48 ft • • 53 Nm (5.3 m kg, 38 ft • • 20 Nm (2.0 m kg, 14 ft •...

  • Page 247: Removing The Cylinder Heads

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

  • Page 248: Installing The Cylinder Heads

    CYLINDER HEADS EAS24250 INSTALLING THE CYLINDER HEADS 1. Install: • Cylinder head gasket “1” • Dowel pins “2” NOTE: The “1D7” mark on the cylinder head gasket must face up and towards the left side of the cyl- inder. A. Front cylinder B.
  • Page 249 CYLINDER HEADS Engine mounting bolt (right up- per side) 59 Nm (5.9 m·kg, 43 ft·lb) Engine mounting bolt (left upper side) 66 Nm (6.6 m·kg, 48 ft·lb) ® LOCTITE Engine bracket bolt (right upper side) 53 Nm (5.3 m·kg, 38 ft·lb) Engine bracket bolt (left upper side) 53 Nm (5.3 m·kg, 38 ft·lb)
  • Page 250 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both cyl- inders. Cylinder heads Refer to “CYLINDER HEADS” on page 5-33. Valve cotter Upper spring seat Valve spring Intake valve...

  • Page 251: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 252 VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover ance (intake) “1”. 0.010–0.037 mm (0.0004–0.0015 Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 mm (0.0010–0.0020 Limit 0.100 mm (0.0039 in) c.

  • Page 253: Checking The Valve Seats

    VALVES AND VALVE SPRINGS • Valve stem end 1. Eliminate: Mushroom shape or diameter larger than the • Carbon deposits body of the valve stem → Replace the valve. (from the valve face and valve seat) 5. Measure: 2. Check: •...

  • Page 254: Checking The Valve Springs

    VALVES AND VALVE SPRINGS 4. Lap: • Valve face • Valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. M MMM M MMM M MMM M MMM M MMM a.

  • Page 255: Installing The Valves

    VALVES AND VALVE SPRINGS Free length (intake) Spring tilt (intake) 46.71 mm (1.84 in) 2.5 °/2.0 mm Limit Spring tilt (exhaust) 44.71 mm (1.76 in) 2.5 °/2.0 mm Free length (exhaust) 46.71 mm (1.84 in) Limit 44.71 mm (1.76 in) EAS24340 INSTALLING THE VALVES The following procedure applies to all of the...
  • Page 256 VALVES AND VALVE SPRINGS • Lower spring seat “2” • Valve stem seal “3” • Valve “4” • Valve spring “5” • Upper spring seat “6” (into the cylinder head) NOTE: • Make sure each valve is installed in its original place.
  • Page 257 CYLINDERS AND PISTONS EAS24360 CYLINDERS AND PISTONS Removing the cylinders and pistons Order Job/Parts to remove Q’ty Remarks Cylinder heads Refer to “CYLINDER HEADS” on page 5-33. Front cylinder Rear cylinder Cylinder gasket Dowel pin Circlip Piston pin Piston Top ring 2nd ring Oil ring For installation, reverse the removal proce-...

  • Page 258: Cylinders And Pistons

    CYLINDERS AND PISTONS EAS24380 NOTE: REMOVING THE PISTON When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring • Piston pin clips “1” over the piston crown. • Piston pin “2” •...

  • Page 259: Checking The Piston Rings

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

  • Page 260: Checking The Piston Pins

    CYLINDERS AND PISTONS 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Piston ring 3.
  • Page 261 CYLINDERS AND PISTONS • Oil ring expander “5” 3. Lubricate: • Piston NOTE: • Piston rings Be sure to install the piston rings so that the • Cylinder manufacturer’s marks or numbers face up. (with the recommended lubricant) Recommended lubricant Engine oil 4.

  • Page 262: Clutch

    CLUTCH EAS25060 CLUTCH Removing the clutch cover 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (11) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Drain.
  • Page 263 CLUTCH Removing the clutch cover 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (11) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Dowel pin For installation, reverse the removal proce- dure.
  • Page 264 CLUTCH Removing the crankshaft position sensor 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Clutch cover damper plate Clutch cover damper Crankshaft position sensor lead holder Crankshaft position sensor For installation, reverse the removal proce- dure.
  • Page 265 CLUTCH Removing the clutch 26 25 105 Nm (10.5 m kg, 75 ft • • 15 14 13 12 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Clutch spring plate retainer...
  • Page 266 CLUTCH Removing the clutch 26 25 105 Nm (10.5 m kg, 75 ft • • 15 14 13 12 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Thrust washer 1...
  • Page 267 CLUTCH Removing the left balancer 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks Left balancer idle gear shaft holder Dowel pin O-ring Left balancer idle gear...
  • Page 268 CLUTCH Removing the clutch master cylinder 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-15. Left rearview mirror Clutch master cylinder reservoir cap Clutch master cylinder reservoir diaphragm...
  • Page 269 CLUTCH Disassembling the clutch master cylinder Order Job/Parts to remove Q’ty Remarks Clutch master cylinder push rod Dust boot Circlip Washer Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. 5-57...
  • Page 270 CLUTCH Removing the clutch release cylinder 19 Nm (1.9 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 26 Nm (2.6 m kg, 19 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 271 CLUTCH Disassembling the clutch release cylinder 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Boots Clutch release cylinder piston Clutch release cylinder spring Clutch release cylinder piston seal Bleed screw Clutch release cylinder body For assembly, reverse the disassembly pro- cedure.

  • Page 272: Removing The Clutch

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

  • Page 273: Checking The Friction Plates

    CLUTCH A. Friction plate 1, 3 B. Friction plate 2 EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- EAS25110 CHECKING THE CLUTCH PLATES tion plates. The following procedure applies to all of the 1. Check: clutch plates.

  • Page 274: Checking The Clutch Housing

    CLUTCH 2. Check: • Bearing Damage/wear → Replace. • Clutch spring plate seat Damage → Replace. EAS25190 CHECKING THE CLUTCH PUSH RODS EAS25150 CHECKING THE CLUTCH HOUSING 1. Check: 1. Check: • O-ring • Clutch housing dogs • Short clutch push rod Damage/pitting/wear →...

  • Page 275: Installing The Left Balancer Drive Gear

    CLUTCH • Left balancer driven gear NOTE: • Left balancer idle gear Calculate the clearance by subtracting the left Burrs/chips/roughness/wear → Replace the balancer driven gear housing outside diameter defective part(s). from the left balancer driven gear inside diame- 2. Measure: ter.

  • Page 276: Installing The Primary Drive Gear

    CLUTCH L LLL L LLL L LLL L LLL L LLL 4. Install: • Generator rotor Refer to “INSTALLING THE GENERATOR” on page 5-75. 5. Install: • Left balancer drive gear “1” • Left balancer idle gear “2” • Left balancer driven gear “3” NOTE: •...

  • Page 277: Installing The Clutch

    CLUTCH • Washer • Conical spring washer “2” • Clutch boss nut “3” Clutch boss nut 105 Nm (10.5 m·kg, 75 ft·lb) NOTE: • Lubricate the clutch boss nut threads and con- ical spring washer mating surfaces with engine oil. •...

  • Page 278: Disassembling The Clutch Master Cylinder

    • Sealant (onto the crankshaft position sensor lead NOTE: grommet) To collect any remaining clutch fluid, place a container under the master cylinder and the end Yamaha bond No. 1215 of the clutch hose. 90890-85505 ® (Three Bond No.1215 ET1D71037 CHECKING THE CLUTCH MASTER 8.

  • Page 279: Assembling The Clutch Master Cylinder

    CLUTCH • Clutch master cylinder reservoir diaphragm EW1D71002 WARNING Damage/wear → Replace. Proper clutch hose routing is essential to in- 4. Check: sure safe vehicle operation. Refer to “CABLE • Clutch hose Cracks/damage/wear → Replace. ROUTING” on page 2-45. NOTE: EAS25300 ASSEMBLING THE CLUTCH MASTER •...

  • Page 280: Removing The Clutch Release Cylinder

    CLUTCH EAS25330 NOTE: CHECKING THE CLUTCH RELEASE In order to ensure a correct reading of the clutch CYLINDER fluid level, make sure the top of the reservoir is Recommended clutch component replace- horizontal. ment schedule 4. Bleed: Piston seal Every two years •...

  • Page 281: Installing The Clutch Release Cylinder

    CLUTCH EAS25350 • When refilling, be careful that water does INSTALLING THE CLUTCH RELEASE not enter the clutch fluid reservoir. Water CYLINDER will significantly lower the boiling point of 1. Install: the clutch fluid and could cause vapor lock. • Copper washers ECA13420 •...
  • Page 282 SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-50. Washer Circlip Shift shaft...

  • Page 283: 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 284: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 285 GENERATOR AND STARTER CLUTCH Removing the generator rotor 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 80 Nm (8.0 m kg, 58 ft • • Order Job/Parts to remove Q’ty Remarks Torque limiter Starter clutch idle gear shaft...

  • Page 286: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS24490 NOTE: REMOVING THE GENERATOR While holding the generator rotor “1” with the 1. Remove: sheave holder “2”, loosen the starter clutch • Generator rotor bolt “1” bolts. • Washer NOTE: Sheave holder While holding the generator rotor “2” with the 90890-01701 sheave holder “3”, loosen the generator rotor Primary clutch holder...

  • Page 287: Checking The Torque Limiter

    GENERATOR AND STARTER CLUTCH • Generator rotor “1” • Washer • Generator rotor bolt “2” NOTE: • Clean the tapered portion of the generator shaft and the generator rotor hub. • When installing the rotor, make sure the woo- druff key is properly seated in the key way of the generator shaft.
  • Page 288 GENERATOR AND STARTER CLUTCH Yamaha bond No. 1215 90890-85505 ® (Three Bond No.1215 5-76...

  • Page 289: 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 Starter motor lead Disconnect. Starter motor For installation, reverse the removal proce- dure. 5-77...
  • Page 290 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor front cover Bearing Oil seal Circlip Starter motor rear cover Brush Brush holder (along with the brushes) Brush seat (along with the brushes) Bearing Gasket Armature assembly Starter motor yoke For assembly, reverse the disassembly pro- cedure.

  • Page 291: 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 “a” Armature coil Out of specification → Replace the starter Commutator resistance “1”...

  • Page 292: Assembling The Starter Motor

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

  • Page 293: Transfer Gear Case

    TRANSFER GEAR CASE EAS25460 TRANSFER GEAR CASE Removing the middle driven shaft 18 Nm (1.8 m kg, 13 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 294 TRANSFER GEAR CASE Removing the middle driven shaft 18 Nm (1.8 m kg, 13 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 295 TRANSFER GEAR CASE Disassembling the transfer gear oil pump ( 6 ) 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Transfer gear oil pump cover Transfer gear oil pump outer rotor Transfer gear oil pump inner rotor Washer Transfer gear oil pump shaft Transfer gear oil pump housing...
  • Page 296 TRANSFER GEAR CASE Removing the transfer gear case 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 • • 50 Nm (5.0 m kg, 36 ft •...
  • Page 297 TRANSFER GEAR CASE Disassembling the oil tank 28 Nm (2.8 m kg, 20 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (15) 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 298: Removing The Middle Driven Shaft

    TRANSFER GEAR CASE EAS25470 2. Check: REMOVING THE MIDDLE DRIVEN SHAFT • Primary chain NOTE: Damage/stiffness → Replace the primary Loosen the middle drive gear nut before remove chain, middle drive gear and middle driven the drive pulley. shaft as a set. 1.

  • Page 299: Checking The Oil Pipes

    TRANSFER GEAR CASE • Transfer gear oil pump outer rotor “6” Inner-rotor-to-outer-rotor-tip • Transfer gear oil pump cover “7” clearance NOTE: Less than 0.12 mm (0.0047 in) When installing the inner rotor, align the pin in Limit the oil pump shaft with the groove in the inner ro- 0.20 mm (0.0079 in) tor.
  • Page 300 TRANSFER GEAR CASE • Install the middle drive gear “2” with its cham- fered side facing “b” the transfer gear case. • Install the middle driven shaft, middle drive gear and primary chain at the same time. • Align the splines on the middle drive gear with the splines on the drive axle.

  • Page 301: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 302 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft •...
  • Page 303 CRANKCASE Removing the oil seals and bearings 20 Nm (2.0 m kg, 14 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 Oil pump Refer to “OIL PUMP”...

  • Page 304: Disassembling The Crankcase

    CRANKCASE EAS25570 DISASSEMBLING THE CRANKCASE 1. Remove: • Crankcase bolts NOTE: • Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. •...

  • Page 305: Checking The Engine Oil Pump Driven Gear

    • Tighten each bolt 1/4 of a turn at a time, in stag- (onto the crankcase mating surfaces) es and in a crisscross pattern. • Tighten the bolts in numerical order (refer to Yamaha bond No. 1215 the numbers in the illustration). 90890-85505 • M8 × 90 mm bolts: “1”, “2”...
  • Page 306 CRANKCASE 14 19 20 16 15 A. Right crankcase B. Left crankcase 5. Apply: • Engine oil (onto the crankshaft pin bearings and oil de- livery holes) 6. Check: • Crankshaft and transmission operation Rough movement → Repair. 5-94...

  • Page 307: Oil Pump

    OIL PUMP EAS24910 OIL PUMP Removing the oil pump 24 Nm (2.4 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-89. Oil pump assembly For installation, reverse the removal proce- dure.
  • Page 308 OIL PUMP Disassembling the oil pump 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 Oil pump housing cover 1 Oil scavenging pump outer rotor 1 Oil scavenging pump inner rotor 1 Oil pump housing 1 Oil strainer...
  • Page 309 OIL PUMP Disassembling the oil pump 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 Oil pump shaft Oil seal Circlip Oil seal Ball Ball guide Oil pump housing 2 For assembly, reverse the disassembly pro- cedure.

  • Page 310: Checking The Oil Pump

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

  • Page 311: Checking The Oil Strainer

    OIL PUMP 2. Measure: • Oil pump shaft • Ball spring force (with the recommended lubricant) • Relief valve spring force Recommended lubricant Out of specification → Replace the defective Engine oil part(s). 2. Install: Ball spring • Oil pump housing 2 “1” Installed compression spring •...

  • Page 312: Installing The Oil Pump

    OIL PUMP 14 21 3. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-98. EAS25020 INSTALLING THE OIL PUMP 1. Install: • Oil pump assembly “1” Oil pump assembly bolt 24 Nm (2.4 m·kg, 17 ft·lb) ECA13890 CAUTION: After tightening the bolts, make sure the oil...

  • Page 313: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-89. Crankshaft Generator shaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal proce- dure.

  • Page 314: Removing The Connecting Rods

    CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS 1. Remove: • Connecting rod caps “1” • Connecting rods • Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place. 3. Measure: •...
  • Page 315 CRANKSHAFT d. Assemble the connecting rod halves. h. Tighten the connecting rod bolts further to reach the specified angle 125–135°. NOTE: • Do not move the connecting rod or crankshaft Connecting rod bolt (final) until the clearance measurement has been Specified angle 125–135°...
  • Page 316 CRANKSHAFT For example, if the connecting rod “P ” and the crankshaft web “P” numbers are “5” and “2” respectively, then the bearing size for “P ” “P ” (connecting rod) - “P” (crankshaft) 5 - 2 = 3 (brown) Bearing color code 1.Blue 2.Black 3.Brown 4.Green L LLL...

  • Page 317: Installing The Connecting Rods

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

  • Page 318: Installing The Crankshaft Assembly

    CRANKSHAFT a. Tighten the connecting rod bolts with a torque • Crankshaft assembly “2” wrench. ECA13970 CAUTION: Connecting rod bolt (1st) To avoid scratching the crankshaft and to 15 Nm (1.5 m·kg, 11 ft·lb) ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease b.

  • Page 319: Transmission

    TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-89. Shift fork guide bar Shift drum assembly Shift fork 1 Shift fork 2 Drive axle assembly Main axle assembly Spacer For installation, reverse the removal proce-...
  • Page 320 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 5th pinion gear Collar Toothed washer Circlip 3rd pinion gear Circlip Toothed washer 4th pinion gear Collar Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure.
  • Page 321 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip Washer 1st wheel gear Collar 4th wheel gear Circlip Toothed washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 5th wheel gear Circlip Toothed washer 2nd wheel gear Collar 5-109...
  • Page 322 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Drive axle For assembly, reverse the disassembly pro- cedure. 5-110...

  • Page 323: Checking The Shift Forks

    TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks. • Shift drum groove Damage/scratches/wear → Replace the shift 1. Check: • Shift fork cam follower “1” drum assembly.

  • Page 324: Assembling The Main Axle And Drive Axle

    TRANSMISSION • Install the circlip so that both ends “b” rest on the sides of a spline “c” with both axles aligned. 3. Check: • Transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). • Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s).
  • Page 325 TRANSMISSION • Shift fork guide bars “4” NOTE: The embossed marks “1D7” on the shift forks should face towards the left side of the engine. 2. Check: • Transmission Rough movement → Repair. NOTE: • Apply engine oil to each gear and bearing thor- oughly.

  • Page 326: Fuel System

    FUEL SYSTEM FUEL TANK ....................6-1 REMOVING THE FUEL TANK..............6-3 REMOVING THE FUEL PUMP ..............6-3 CHECKING THE FUEL PUMP BODY ............6-4 CHECKING THE FUEL PUMP OPERATION ........... 6-4 INSTALLING THE FUEL PUMP..............6-4 INSTALLING THE FUEL TANK ..............6-4 THROTTLE BODIES..................

  • Page 327: Fuel Tank

    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 328 FUEL TANK Removing the fuel pump and sub-fuel tank 5 Nm (0.5 m kg, 3.6 ft • • 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/Rider seat bracket 4-1.

  • Page 329: Removing The Fuel Tank

    FUEL TANK EAS26630 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel tank EC1D71021 CAUTION: Although the fuel has been removed from the fuel tank, be careful when removing the fuel hoses, since there may be fuel remain- d.

  • Page 330: Checking The Fuel Pump Body

    FUEL TANK EC1D71022 • Install the fuel pump as shown in the illustra- CAUTION: tion. • Be sure to disconnect the fuel outlet hose • Align the projection “a” on the fuel pump with by hand. Do not forcefully disconnect the the slot in the fuel pump bracket.
  • Page 331 FUEL TANK M MMM M MMM M MMM M MMM M MMM a. Install the fuel tank. b. Remove the fuel hose joint caps. c. Connect the fuel hose (fuel hose joint to fuel pump) and air vent hose (fuel pump to fuel hose joint).
  • Page 332 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the rollover valves 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 For California only Horn 1 connector Disconnect. Horn 1 For California only Fuel tank breather hose...
  • Page 333 THROTTLE BODIES Removing the pressure regulator 7 Nm (0.7 m kg, 5.1 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Pressure regulator cover Fuel hose (intake manifold assembly to pres- sure regulator) Air filter case breather hose 1...
  • Page 334 THROTTLE BODIES Removing the throttle bodies 3 Nm (0.3 m kg, 2.2 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/Rider seat bracket 4-1.
  • Page 335 THROTTLE BODIES Removing the intake manifolds 10 Nm (1.0 m kg, 7.2 ft • • ( 2 ) ( 2 ) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Engine temperature sensor coupler Disconnect.

  • Page 336: Throttle Bodies

    THROTTLE BODIES Disassembling the intake manifolds 30 Nm (3.0 m kg, 22 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks Cylinder-#1 injector coupler Disconnect.

  • Page 337: Removing The Fuel Hose

    THROTTLE BODIES ET1D71026 b. Blow out all of the passages with compressed REMOVING THE FUEL HOSE air. 1. Disconnect: L LLL L LLL L LLL L LLL L LLL • Fuel hose (intake manifold assembly to pres- sure regulator) ET1D71007 CHECKING THE ROLLOVER VALVES EC1D71014 1.

  • Page 338: Installing The Fuel Pipe

    THROTTLE BODIES EAS27030 ADJUSTING THE THROTTLE POSITION Vacuum/pressure pump gauge SENSOR 1. Check: 90890-06756 Pressure gauge • Throttle position sensor 90890-03153 Refer to “CHECKING THE THROTTLE PO- Fuel pressure adapter SITION SENSOR” on page 7-89. 90890-03176 2. Adjust: YM-03176 • Throttle position sensor angle M MMM M MMM M MMM...

  • Page 339: Installing The Fuel Hose

    THROTTLE BODIES NOTE: Install the fuel pipe “1” so that it contacts the pro- jections “a” on the injector joints. ET1D71027 INSTALLING THE FUEL HOSE 1. Connect: • Fuel hose (intake manifold assembly to pres- sure regulator) EC1D71015 CAUTION: When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position, otherwise the fuel hose...

  • Page 340: Isc (Idle Speed Control) Unit

    ISC (IDLE SPEED CONTROL) UNIT ET1D71009 ISC (IDLE SPEED CONTROL) UNIT Removing the ISC (idle speed control) unit 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 •...

  • Page 341: Checking The Isc (Idle Speed Control) System

    ISC (IDLE SPEED CONTROL) UNIT ET1D71010 CHECKING THE ISC (IDLE SPEED CONTROL) SYSTEM 1. Check: • Hoses Loose connections → Connect properly. Cracks/damage → Replace. 6-15...

  • Page 342: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................7-1 CIRCUIT DIAGRAM .................. 7-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION....... 7-3 TROUBLESHOOTING ................7-4 ELECTRIC STARTING SYSTEM..............7-7 CIRCUIT DIAGRAM .................. 7-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......7-9 TROUBLESHOOTING ................7-11 CHARGING SYSTEM ................... 7-13 CIRCUIT DIAGRAM ................
  • Page 343 ELECTRICAL COMPONENTS ..............7-67 CHECKING THE SWITCHES ..............7-71 CHECKING THE BULBS AND BULB SOCKETS ........7-74 CHECKING THE FUSES ................ 7-75 CHECKING AND CHARGING THE BATTERY........7-76 CHECKING THE RELAYS ..............7-79 CHECKING THE TURN SIGNAL RELAY ..........7-80 CHECKING THE DIODES ..............

  • Page 345: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 346 IGNITION SYSTEM 3. Main switch 4. Main fuse 6. Battery 11.Relay unit 14.Neutral switch 16.Sidestand switch 19.Crankshaft position sensor 23.Lean angle sensor 27.ECU (electronic control unit) 28.Cylinder-#1 left ignition coil 29.Cylinder-#1 right ignition coil 30.Cylinder-#2 left ignition coil 31.Cylinder-#2 right ignition coil 32.Spark plug 68.Engine stop switch 77.Ignition fuse...

  • Page 347: Engine Stopping Due To Sidestand Operation

    IGNITION SYSTEM ET1D71043 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 348: Troubleshooting

    IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Rider seat bracket assembly 4. Fuel tank 5. Air filter case 6.
  • Page 349 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 7-71. OK ↓ NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch.
  • Page 350 IGNITION SYSTEM...

  • Page 351: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 352 ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 6. Battery 8. Starter relay 9. Starter motor 10.Diode 1 11.Relay unit 12.Starting circuit cut-off relay 14.Neutral switch 15.Diode 2 16.Sidestand switch 27.ECU (electronic control unit) 54.Clutch switch 68.Engine stop switch 69.Start switch 77.Ignition fuse 81.ECU fuse...

  • Page 353: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is turned “ON” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 354 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 355: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Headlight assembly NG → 1. Check the fuses. (Main, ignition and ECU) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 356 ELECTRIC STARTING SYSTEM NG → 9. Check the starter relay. Refer to “CHECKING THE RE- Replace the starter relay. LAYS” on page 7-79. OK ↓ NG → 10.Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 7-71. OK ↓...

  • Page 357: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-13...
  • Page 358 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 6. Battery 7-14...

  • Page 359: Troubleshooting

    CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Rectifier/regulator cover 3. Lead cover NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
  • Page 360 CHARGING SYSTEM 7-16...

  • Page 361: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-17...
  • Page 362 LIGHTING SYSTEM 3. Main switch 4. Main fuse 6. Battery 27.ECU (electronic control unit) 44.Meter light 47.High beam indicator light 52.Headlight relay 55.Dimmer switch 59.Front right turn signal/position light 60.Front left turn signal/position light 64.Headlight (high beam) 65.Headlight (low beam) 70.Accessory light switch 71.Accessory light (OPTION) 72.Tail/brake light...

  • Page 363: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light, taillight, license light, position light, meter light or accessory light (OPTION). NOTE: • Before troubleshooting, remove the following part(s): 1.
  • Page 364 LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 7-17. OK ↓ The lighting system circuit is OK. 7-20...

  • Page 365: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-21...
  • Page 366 SIGNALING SYSTEM 3. Main switch 4. Main fuse 5. Backup fuse (odometer and clock) 6. Battery 11.Relay unit 14.Neutral switch 18.Fuel sender (fuel pump) 24.Speed sensor 27.ECU (electronic control unit) 39.Neutral indicator light 40.Multi-function meter 43.Fuel level warning light 45.Left turn signal indicator light 46.Right turn signal indicator light 48.Fuel sender (fuel tank) 49.Horn 1...

  • Page 367: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel level gauge fails to operate. • The speedometer fails to operate. NOTE: •...
  • Page 368 SIGNALING SYSTEM NG → 2. Check the horns. Refer to “CHECKING THE Replace the horn(s). HORNS” on page 7-86. OK ↓ NG → 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring.
  • Page 369 SIGNALING SYSTEM NG → 4. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 7-21. OK ↓ This circuit is OK. The neutral indicator light fails to come on. NG →...
  • Page 370 SIGNALING SYSTEM NG → 2. Check the fuel sender (fuel pump). Refer to “CHECKING THE FUEL Replace the fuel pump assembly. SENDER (FUEL PUMP)” on page 7-88. OK ↓ NG → 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM”...

  • Page 371: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 7-27...
  • Page 372 FUEL INJECTION SYSTEM 3. Main switch 4. Main fuse 6. Battery 7. Fuel injection system fuse 11.Relay unit 12.Starting circuit cut-off relay 13.Fuel pump relay 14.Neutral switch 15.Diode 2 16.Sidestand switch 17.Fuel pump 19.Crankshaft position sensor 20.Throttle position sensor 21.Cylinder-#1 intake air pressure sensor 22.Cylinder-#2 intake air pressure sensor 23.Lean angle sensor 24.Speed sensor...

  • Page 373: 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 374: Self-Diagnostic Function Table

    FUEL INJECTION SYSTEM 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 375 FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Able Able (depending (depending Cylinder-#1 left or Malfunction detected in the prima- on the on the right ignition coil ry wire of the cylinder-#1 left or number of number of (faulty ignition)

  • Page 376: Troubleshooting Method

    FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Engine has been left idling. (The ECU automatically stops the en- Engine idling stop Able Able gine after 20 minutes if it is left idling.) Communication error with the meter Able / un-...

  • Page 377: Diagnostic Mode

    FUEL INJECTION SYSTEM 5. Erase the malfunction history in the diagnos- The engine operation is not normal but the tic mode. Refer to “Sensor operation table engine trouble warning light does not come (Diagnostic code No. 62)”. 1. Check the operation of following sensors and NOTE: actuators in the Diagnostic mode.
  • Page 378 FUEL INJECTION SYSTEM “d01 d70” “d70 d01” 7. Verify the operation of the sensor or actuator. • Sensor operation The data representing the operating conditions of the sensor appears on the odometer/trip meter/fu- el reserve trip meter/clock LCD. • Actuator operation Set the engine stop switch to “...
  • Page 379 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. A break or disconnection of • Open circuit in wire harness (ECU coupler). the blue/black lead of the • Malfunction in ECU. ECU is detected. • Open or short circuit in wire harness. Air temperature sensor: •...
  • Page 380 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire sub lead. • Open or short circuit in wire harness. Malfunction detected in the • Malfunction in cylinder-#2 left or right igni- primary wire of the cylin- tion coil.
  • Page 381 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. No signals are received • Improper connection in wire harness. Er-2 from the ECU within the • Malfunction in meter. — specified duration. • Malfunction in ECU. •...
  • Page 382 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Fuel system voltage Approximately 12.0 Set the engine stop switch (battery voltage) to “ ”, and then compare with the actually measured battery voltage. (If the bat- tery voltage is lower, per- form recharging.) Engine temperature Displays the engine tempera-...
  • Page 383 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Control number 0–255 — Actuator operation table Diag- nostic Item Actuation Checking method code Actuates the cylinder-#1 left or right ignition coil five times Check the spark five times. Cylinder-#1 left or right ig- at one-second intervals.

  • Page 384: Troubleshooting Details

    FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the headlight relay for five cycles of five sec- onds. (ON 2 seconds, OFF 3 Check the operating sound Headlight relay seconds) of the headlight relay five Illuminates the engine trou- times.
  • Page 385 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 386 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#1 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code No. Cylinder-#1 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 387 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#1 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code No. Cylinder-#1 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Cylinder-#1 intake air pressure sensor •...
  • Page 388 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or pinch- Turning the sensor.
  • Page 389 FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor circuit: open or short circuit detected. Diagnostic code No. EXUP servo motor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 390 FUEL INJECTION SYSTEM Fault code No. Symptom A break or disconnection of the blue/black lead of the ECU is detected. Diagnostic code No. Sidestand switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Execute the diagnostic mode. If the transmis- •...
  • Page 391 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of O sensor. Check for looseness or pinching. Starting the en- gine and oper- Connections •...
  • Page 392 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#2 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code No. Cylinder-#2 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 393 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#2 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code No. Cylinder-#2 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Cylinder-#2 intake air pressure sensor •...
  • Page 394 FUEL INJECTION SYSTEM Fault code No. Symptom Engine temperature sensor: open or short circuit detect- Diagnostic code No. Engine temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of engine temperature Check for looseness or pinching. Turning the sensor.
  • Page 395 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code No. 30, 32 Cylinder-#1 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 396 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#2 left or right ignition coil. Diagnostic code No. 31, 33 Cylinder-#2 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 397 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code No. 30, 32 Cylinder-#1 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 398 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#2 left or right ignition coil. Diagnostic code No. 31, 33 Cylinder-#2 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 399 FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling. Diagnostic code No. ISC valve Order Item/components and probable Check or maintenance job Reinstatement cause method ECU fuse is blown. • Check the ECU fuse. ISC valve re- Refer to “CHECKING THE turns to its orig-...
  • Page 400 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 coupler for any pins Turning the •...
  • Page 401 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 402 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 403 FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. Fuel system voltage Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 404 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •...
  • Page 405 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 406 FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...

  • Page 407: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 7-63...
  • Page 408 FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 6. Battery 7. Fuel injection system fuse 11.Relay unit 13.Fuel pump relay 15.Diode 2 17.Fuel pump 27.ECU (electronic control unit) 68.Engine stop switch 77.Ignition fuse 81.ECU fuse 7-64...

  • Page 409: 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. Tool kit tray 3. Rider seat bracket assembly 4. Left side cover 5. Headlight assembly NG → 1.
  • Page 410 FUEL PUMP SYSTEM NG → 8. Check the entire fuel pump system wiring. Properly connect or repair the fuel pump Refer to “CIRCUIT DIAGRAM” on system wiring. page 7-63. OK ↓ Replace the ECU. 7-66...

  • Page 411: Electrical Components

    ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 7-67...
  • Page 412 ELECTRICAL COMPONENTS 1. Cylinder-#2 right ignition coil 2. Cylinder-#2 left ignition coil 3. Fuel sender 4. Engine temperature sensor 5. Cylinder-#1 left ignition coil 6. Cylinder-#1 right ignition coil 7. ECU (electronic control unit) 8. EXUP servo motor 9. Speed sensor 10.
  • Page 413 ELECTRICAL COMPONENTS 7-69...
  • Page 414 ELECTRICAL COMPONENTS 1. Air temperature sensor 2. Main switch 3. Cylinder-#2 intake air pressure sensor 4. Throttle position sensor 5. Cylinder-#1 intake air pressure sensor 6. Fuse box 7. Starter relay 8. Fuel injection system fuse 9. Battery 10. Diode 2 11.

  • Page 415: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES R Br L/Y L/B (GRAY) Ch Br/W Dg B Y/R (BLUE) R/W B/R R/W B/R G/Y G/B G/L L/B (GRAY) L/W W/B (GRAY) G/Y G/B (BLACK) PUSH Br/W L/B G/L (GRAY) Y G/L G L/Y B/Y (BLACK) (BLACK)
  • Page 416 ELECTRICAL COMPONENTS 1. Main switch 2. Engine stop switch 3. Start switch 4. Accessory light switch 5. Front brake light switch 6. Neutral switch 7. Sidestand switch 8. Rear brake light switch 9. Clutch switch 10. Horn switch 11. Dimmer switch 12.
  • Page 417 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 418: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EAS27990 1. Remove: CHECKING THE BULBS AND BULB • Bulb SOCKETS EW1D71009 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 419: Checking The Fuses

    ELECTRICAL COMPONENTS NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. If the pocket tester indicates “∞”, replace the fuse. L LLL L LLL L LLL L LLL L LLL Checking the condition of the bulb sockets 3.

  • Page 420: 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 421 ELECTRICAL COMPONENTS 5. Remove: A. Open-circuit voltage (V) • Battery B. Charging condition of the battery (%) 6. Check: C. Ambient temperature 20 °C (68 °F) • Battery charge M MMM M MMM M MMM M MMM M MMM L LLL L LLL L LLL L LLL...
  • Page 422 ELECTRICAL COMPONENTS • If the battery becomes hot to the touch at • Standard charging current is reached any time during the charging process, dis- Battery is good. connect the battery charger and let the bat- • Standard charging current is not reached tery cool before reconnecting it.

  • Page 423: Checking The Relays

    ELECTRICAL COMPONENTS 12.8 V or more --- Charging is complete. Pocket tester 12.7 V or less --- Recharging is required. 90890-03112 Under 12.0 V --- Replace the battery. Analog pocket tester YU-03112-C L LLL L LLL L LLL L LLL L LLL 8.

  • Page 424: Checking The Turn Signal Relay

    ELECTRICAL COMPONENTS Relay unit (fuel pump relay) M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (DC 20 V) to the turn signal relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C •...

  • Page 425: Checking The Diodes

    ELECTRICAL COMPONENTS Continuity Positive tester probe → sky blue “1” Negative tester probe → black/yellow “2” No continuity Positive tester probe → black/yellow “2” Negative tester probe → sky blue “1” Continuity b. Turn the main switch to “ON”. Positive tester probe → sky blue c.

  • Page 426: Checking The Ignition Spark Gap

    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 Diode 1 1. Check: NOTE: •...

  • Page 427: Checking The Spark Plug Caps

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Disconnect the spark plug cap from the spark plug. b. Connect the ignition checker “1” as shown. Ignition checker 90890-06754 Opama pet-4000 spark checker YM-34487 c. Measure the spark plug cap resistance. L LLL L LLL L LLL...

  • Page 428: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS • Positive tester probe → Secondary coil resistance gray “1” 8.64–12.96 kΩ • Negative tester probe → black “2” M MMM M MMM M MMM M MMM M MMM a. Disconnect the spark plug cap from the igni- tion coil.

  • Page 429: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS EAS28150 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the rectifier/regulator) 2. Check: • Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.112–0.168 Ω c. Turn the lean angle sensor to 65°. d.

  • Page 430: Checking The Horns

    ELECTRICAL COMPONENTS • Positive tester probe → Charging voltage horn terminal “1” 14 V at 5000 r/min • Negative tester probe → horn terminal “2” M MMM M MMM M MMM M MMM M MMM a. Set the engine tachometer to the cylinder-#1 left spark plug lead or right spark plug lead.

  • Page 431: Checking The Engine Temperature Sensor

    ELECTRICAL COMPONENTS b. Immerse the engine temperature sensor “1” in a container filled with water “2”. NOTE: Make sure that the engine temperature sensor terminals do not get wet. c. Place a thermometer “3” in the water. d. Slowly heat the water, then let it cool down to the specified temperature.

  • Page 432: Checking The Fuel Sender (Fuel Pump)

    ELECTRICAL COMPONENTS • Positive tester probe → green “1” • Negative tester probe → black “2” b. Move the fuel sender float to maximum “3”/minimum “4” level position. b. Measure the fuel sender resistance. L LLL L LLL L LLL L LLL L LLL ET1D71044...

  • Page 433: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe → white “1” • Negative tester probe → black “2” b. Measure the throttle position sensor maxi- mum resistance. L LLL L LLL L LLL L LLL L LLL 3.

  • Page 434: Checking The Exup Servo Motor

    ELECTRICAL COMPONENTS ECA14390 • Positive battery lead → CAUTION: red/blue “2” To prevent damaging the EXUP servo motor, • Negative battery lead → perform this test within a few seconds of black “3” connecting the battery. L LLL L LLL L LLL L LLL L LLL...
  • Page 435 ELECTRICAL COMPONENTS EW1D71004 WARNING • Handle the air temperature sensor with special care. • Never subject the air temperature sensor to strong shocks. If the air temperature sen- sor is dropped, replace it. 2. Check: • Air temperature sensor resistance Out of specification →...

  • Page 436: Troubleshooting

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

  • Page 437: Troubleshooting

    TROUBLESHOOTING EAS28450 • Sucked-in air TROUBLESHOOTING Electrical system EAS28460 1. Battery GENERAL INFORMATION • Discharged battery NOTE: • Faulty battery The following guide for troubleshooting does not 2. Fuse(s) cover all the possible causes of trouble. It should • Blown, damaged or incorrect fuse be helpful, however, as a guide to basic trouble- •...

  • Page 438: Poor Medium And High-Speed Performance

    TROUBLESHOOTING • Improper throttle cable free play Transmission • Flooded throttle body • Seized transmission gear • Foreign object between transmission gears Electrical system • Improperly assembled transmission 1. Battery • Discharged battery EAS28550 JUMPS OUT OF GEAR • Faulty battery 2.

  • Page 439: Overheating

    TROUBLESHOOTING 2. Engine oil • Damaged oil seal lip • Incorrect oil level • Incorrect oil level (high) • Incorrect oil viscosity (high) • Loose damper rod assembly bolt • Deteriorated oil • Damaged damper rod assembly bolt copper washer EAS28590 •...

  • Page 440: Faulty Lighting Or Signaling System

    TROUBLESHOOTING EAS28710 • Faulty turn signal relay FAULTY LIGHTING OR SIGNALING SYSTEM • Burnt-out turn signal bulb Headlight does not come on Horn does not sound • Wrong headlight bulb • Improperly adjusted horn • Too many electrical accessories • Damaged or faulty horn •...
  • Page 441 XV19SW(C)/XV19W(C)/XV19MW(C)/XV19CTSW(C)/XV19CTW(C)/XV19CTMW(C) 2007 WIRING DIAGRAM WIRE HARNESS SUB WIRE HARNESS1 (BLUE) (BLUE) WIRE HARNESS SUB WIRE HARNESS2 (BLACK) (BLACK) WIRE HARNESS SUB WIRE HARNESS3 (BLACK) (GRAY) (BLACK) (BLACK) (BLACK) WIRE HARNESS SUB WIRE HARNESS4 (GRAY) (GRAY) (BLACK) (BLACK) (BLACK) (BLACK) (GRAY)

  • Page 442: Wiring Diagram

    EAS28740 52. Headlight relay EAS28750 WIRING DIAGRAM COLOR CODE 53. Left handlebar switch Black 54. Clutch switch XV19SW(C)/XV19W(C)/ Brown 55. Dimmer switch XV19MW(C)/XV19CTSW(C)/ Chocolate 56. Turn signal switch XV19CTW(C)/XV19CTMW(C) Dark green 57. Horn switch 2007 Green 58. Select switch 1. AC magneto Gray 59.
  • Page 444 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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