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XV1700P
XV1700PC
SERVICEMANUAL
LIT-11616-15-37
5PX-28197-10

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Table of Contents

   Summary of Contents for Yamaha XV1700P

  • Page 1 XV1700P XV1700PC SERVICEMANUAL LIT-11616-15-37 5PX-28197-10...
  • Page 2 EAS00001 XV1700P/XV1700PC SERVICE MANUAL ©2001 by Yamaha Motor Corporation, U.S.A. First edition, October 2001 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-11616-15-37...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 4 EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 5: General Information

    EAS00009 SYMBOLS The following symbols are not relevant to SPEC every vehicle. Symbols 1 to 8 indicate the INFO subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments CHAS 4 Chassis 5 Engine 6 Fuel injection system 7 Electrical system 8 Troubleshooting TRBL...
  • Page 6: Table Of Contents

    EAS00013 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE FUEL INJECTION SYSTEM – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 7 CONTENTS CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ..............1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES ......................1-2 OUTLINE ....................1-2 FI SYSTEM ....................1-3 COMPONENTS ..................1-5 FUEL INJECTION SYSTEM ..............1-17 FIRST IDLE CONTROL SYSTEM ............1-28 COMPONENTS ..................1-29 IMPORTANT INFORMATION................1-32 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-32 REPLACEMENT PARTS .................1-32 GASKETS, OIL SEALS AND O-RINGS ..........1-32 LOCK WASHERS/PLATES AND COTTER PINS ........1-33...
  • Page 8 TIGHTENING TORQUES ................2-21 ENGINE TIGHTENING TORQUES ............2-21 CHASSIS TIGHTENING TORQUES ............2-24 LUBRICATION POINTS AND LUBRICANT TYPES........2-27 ENGINE ....................2-27 CHASSIS ....................2-28 ENGINE OIL LUBRICATION CHART ............2-29 ENGINE OIL FLOW DIAGRAMS ..............2-30 TRANSFER GEAR OIL FLOW DIAGRAMS ..........2-34 CABLE ROUTING ..................2-36 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE CHART...
  • Page 9 ENGINE......................3-11 ADJUSTING THE VALVE CLEARANCE..........3-11 SYNCHRONIZING THE THROTTLE BODIES ........3-15 ADJUSTING THE ENGINE IDLING SPEED ...........3-17 ADJUSTING THE THROTTLE CABLE FREE PLAY.......3-18 CHECKING THE SPARK PLUGS ............3-20 CHECKING THE IGNITION TIMING ............3-22 MEASURING THE COMPRESSION PRESSURE ........3-23 CHECKING THE ENGINE OIL LEVEL ............3-26 CHANGING THE ENGINE OIL..............3-27 MEASURING THE ENGINE OIL PRESSURE ........3-31 CHECKING THE TRANSFER GEAR OIL LEVEL ........3-32...
  • Page 10 INSTRUMENT FUNCTIONS................3-70 ODOMETER AND TRIPMETER..............3-70 ADJUSTING THE METER LIGHT ............3-71 ADJUSTING THE CLOCK ...............3-71 CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS ............4-1 REMOVING THE FRONT WHEEL ............4-4 CHECKING THE FRONT WHEEL ............4-4 CHECKING THE BRAKE DISCS ..............4-6 INSTALLING THE FRONT WHEEL ............4-7 ADJUSTING THE FRONT WHEEL STATIC BALANCE......4-9 REAR WHEEL, BRAKE DISC, AND REAR WHEEL PULLEY.....4-11 REMOVING THE REAR WHEEL ............4-17...
  • Page 11 FRONT FORK....................4-55 REMOVING THE FRONT FORK LEGS ..........4-58 DISASSEMBLING THE FRONT FORK LEGS ........4-58 CHECKING THE FRONT FORK LEGS...........4-60 ASSEMBLING THE FRONT FORK LEGS ..........4-62 INSTALLING THE FRONT FORK LEGS..........4-67 HANDLEBAR....................4-69 REMOVING THE HANDLEBAR ..............4-71 CHECKING THE HANDLEBAR...............4-71 INSTALLING THE HANDLEBAR.............4-71 STEERING HEAD..................4-75 REMOVING THE LOWER BRACKET .............4-77 CHECKING THE STEERING HEAD ............4-77...
  • Page 12 CHAPTER 5 ENGINE ENGINE......................5-1 INSTALLING THE ENGINE ...............5-9 INSTALLING THE MUFFLER AND EXHAUST PIPES......5-10 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ......5-11 REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS..................5-16 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS..5-16 CHECKING THE ROCKER ARM BASES ..........5-18 CHECKING THE PUSH RODS ...............5-18 CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES..5-18 BLEEDING A VALVE LIFTER ..............5-19...
  • Page 13 CLUTCH......................5-56 CLUTCH COVER ..................5-56 CLUTCH ....................5-59 REMOVING THE CLUTCH ..............5-61 REMOVING THE PRIMARY DRIVE GEAR ..........5-62 CHECKING THE FRICTION PLATES .............5-62 CHECKING THE CLUTCH PLATES ............5-62 CHECKING THE CLUTCH PLATE SPRING ...........5-63 CHECKING THE CLUTCH HOUSING ............5-63 CHECKING THE CLUTCH BOSS ............5-63 CHECKING THE PRESSURE PLATE ............5-64 CHECKING THE PULL LEVER SHAFT AND PULL ROD.......5-64 CHECKING THE PRIMARY DRIVE ............5-64...
  • Page 14 CRANKCASE ....................5-93 DISASSEMBLING THE CRANKCASE ............5-96 CHECKING THE CRANKCASE ..............5-97 CHECKING THE BEARINGS AND OIL SEALS ........5-98 CHECKING THE OIL DELIVERY PIPE ...........5-98 CHECKING THE ENGINE OIL PUMP DRIVE.........5-98 ASSEMBLING THE CRANKCASE ............5-99 ENGINE OIL PUMP ..................5-102 CHECKING THE OIL PUMP ..............5-105 CHECKING THE RELIEF VALVE ............5-105 CHECKING THE OIL STRAINER............5-106 ASSEMBLING THE OIL PUMP .............5-106...
  • Page 15 AIR INDUCTION SYSTEM ................6-43 AIR INJECTION ..................6-43 AIR CUT-OFF VALVE ................6-43 AIR CUT-OFF VALVE ASSEMBLY AND AIR INDUCTION SYSTEM HOSES............6-44 REED VALVES..................6-45 CHECKING THE PRESSURE REGULATOR..........6-46 CHECKING THE AIR INDUCTION SYSTEM ..........6-46 CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS................7-1 ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS ....................7-3 CHECKING SWITCH CONTINUITY ..............7-8 CHECKING THE SWITCHES ................7-10...
  • Page 16: Troubleshooting

    LIGHTING SYSTEM ..................7-38 CIRCUIT DIAGRAM ................7-38 TROUBLESHOOTING................7-39 CHECKING THE LIGHTING SYSTEM ............7-40 SIGNALING SYSTEM..................7-44 CIRCUIT DIAGRAM ................7-44 TROUBLESHOOTING................7-46 CHECKING THE SIGNALING SYSTEM ..........7-47 FUEL INJECTION SYSTEM ................7-54 CIRCUIT DIAGRAM ................7-54 TROUBLESHOOTING................7-56 CHECKING THE FUEL PUMP ..............7-64 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR ..........7-64 CHAPTER 8 TROUBLESHOOTING STARTING FAILURES ..................8-1...
  • Page 17 OVERHEATING ....................8-4 ENGINE .....................8-4 FUEL SYSTEM ..................8-4 CHASSIS ....................8-4 ELECTRICAL SYSTEMS ................8-4 POOR BRAKING PERFORMANCE..............8-4 FAULTY FRONT FORK LEGS................8-4 LEAKING OIL ....................8-4 MALFUNCTION ..................8-4 UNSTABLE HANDLING..................8-5 FAULTY LIGHTING OR SIGNALING SYSTEM..........8-6 HEADLIGHT DOES NOT COME ON ............8-6 HEADLIGHT BULB BURNT OUT ..............8-6 TAIL/BRAKE LIGHT DOES NOT COME ON ..........8-6 TAIL/BRAKE LIGHT LED BURNT OUT ............8-6 TURN SIGNAL DOES NOT COME ON.............8-6...
  • Page 18: General Information

    MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
  • Page 19: Features

    FEATURES INFO FEATURES OUTLINE The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the com- bustion chamber is created by the volume of the intake air and the fuel that is metered by the jet that is used in the respective chamber.
  • Page 20: Fi System

    FEATURES INFO FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 2.55 kg/cm higher than the intake manifold pres- sure. Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
  • Page 21 FEATURES INFO Fuel control block The fuel control block consists of the following main components: Component Function Control block Total FI system control Throttle body Air volume control Pressure regulator Fuel pressure adjustment Sensor block Intake air pressure sensor Intake air pressure detection Atmospheric pressure sensor Atmospheric pressure detection Engine temperature sensor...
  • Page 22: Components

    FEATURES INFO COMPONENTS ECU (Electronic Control Unit) The ECU is mounted underneath the seat, above the battery box. The main functions of the ECU are ignition control, fuel control, self-diagnosis, and load control. • ECU’s internal construction and functions The main components and functions of the ECU can be broadly divided into the following four items: A.
  • Page 23 FEATURES INFO • Ignition control The ignition timing control uses the signals from the throttle position sensor (to detect the angle of the throttle), and the crankshaft position sensor (to detect the speed of the engine) and the speed sensor. This control establishes an ignition timing that suits the operating condition of the engine through compensations made to the basic ignition timing control map.
  • Page 24 FEATURES INFO • Self-diagnosis function The ECU is equipped with a self-diagnosis function to ensure that the engine control system is operating normally. The ECU mode functions include a diagnosis mode in addition to the normal mode. Normal mode • To check for any blown bulbs, this mode illuminates a warning light while the main switch is turned ON, and while the starter switch is being pressed.
  • Page 25 FEATURES INFO Fuel pump The fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps it to the injector. A filter that is provided in the fuel pump prevents any debris in the fuel tank from entering the fuel system downstream of the pump.
  • Page 26 FEATURES INFO Pressure regulator It regulates the fuel pressure that is applied to the injectors that supply fuel to the cylinders in order to maintain a constant pressure. The fuel that is delivered by the fuel pump fills the fuel chamber through the fuel inlet of the regulator and exerts pressure on the diaphragm in the direction for opening the valve.
  • Page 27 FEATURES INFO Fuel injector Upon receiving injection signals from the ECU, the fuel injector injects fuel. In the normal state, the core is pressed downward by the force of the spring, as illustrated. The needle that is integrated with the bottom of the core keeps the fuel passage closed. When the current flows to the coil in accordance with the signal from the ECU, the core is drawn upward, allowing the flange that is integrated with the needle to move to the spacer.
  • Page 28 FEATURES INFO Crankshaft position sensor The crankshaft position sensor uses the signals of the crankshaft position sensor that is mounted on the left side of the crankshaft. When the rotation of the pickup rotor that is attached to the crankshaft causes the projections on the rotor to pass by the crankshaft position sensor, an electromotive force is generated in the coil.
  • Page 29 FEATURES INFO Cylinder identification sensor The cylinder identification sensor is installed on the camshaft drive gear cover. When the cam of cyl- inder #1 rotates, the pickup rotor installed on the cam also rotates. When the pickup rotor passes by the sensor, trigger poles on the rotor generate a signal and send it to the ECU.
  • Page 30 FEATURES INFO Throttle position sensor The throttle position sensor measures the intake air volume by detecting the position of the throttle valve. It detects the mechanical angle of the throttle valve through the positional relationship between the moving contact that moves in unison with the throttle shaft and the resistor board. In actual operation, the ECU supplies 5 V power to both ends of the resistor board and the voltage that is output by the throttle position sensor is used to determine the angle of the throttle valve.
  • Page 31 FEATURES INFO Intake air pressure sensor and atmospheric pressure sensor • Intake air pressure sensor The intake air pressure sensor is used for measuring the intake air volume. The intake air volume of every intake stroke is proportionate to the intake air pressure. Therefore, the intake air volume can be measured by measuring the intake air pressure.
  • Page 32 FEATURES INFO Engine temperature sensor The signals from the engine temperature sensor are used primarily for making fuel volume compen- sations during starting and warm-up. The engine temperature sensor converts the temperature of the engine into electrical signals and sends them to the ECU. È...
  • Page 33 FEATURES INFO Lean angle cut-off switch The lean angle cut-off switch stops the supply of fuel to the engine in case the motorcycle overturns. When the motorcycle is in the normal state, the cut-off switch outputs a constant voltage of approxi- mately 1.0 V (low level).
  • Page 34: Fuel Injection System

    FEATURES INFO FUEL INJECTION SYSTEM Operation and control The fuel injection timing, injection duration, ignition timing, and the coil energizing duration are con- trolled by the ECU. To determine the basic injection timing, the ECU calculates the intake air volume through the signals from the intake air pressure sensor, throttle position sensor, cylinder identifica- tion sensor, and crankshaft position sensor.
  • Page 35 FEATURES INFO Fuel injection duration during linear control valve operation The linear control valve supplies air to the intake manifold when starting or during engine warm up. The intake air volume determines the basic injection duration. As the intake air increases through the linear control valve, the intake air volume corrects the basic injection duration.
  • Page 36 FEATURES INFO Determining the final injection duration The intake air volume determines the basic injection duration. However, at a given intake air vol- ume, the volume of fuel that is required varies by the engine operating conditions such as accelera- tion or deceleration, or by weather conditions.
  • Page 37 FEATURES INFO Reactive injection duration: A lag is created between the time the ECU outputs a fuel injection signal to the injector and the time the injector actually opens. Therefore, the ECU calculates this lag in advance before sending the actuation signal to the injector.
  • Page 38 FEATURES INFO Fuel control during normal driving In synchronous injection during normal driving, fuel is injected on a cylinder-by-cylinder basis when all of the conditions below are met: 1 Other than the stop mode 2 Cylinder identification completed 3 Other than overrun To determine the injection timing, the ECU calculates the injection timing through the use of the 3D control map provided in the ECU, which is based on the throttle position and the engine speed.
  • Page 39 FEATURES INFO • Fuel injection control during normal driving È É Ê Ë È #1 cylinder fuel injection timing É Basic injection duration Ê Various types of fuel injection duration compensations Ë Final injection duration (É + Ê) 1 - 22...
  • Page 40 FEATURES INFO Fuel injection compensation control • Starting injection control The engine temperature is used for determining the injection duration in order to ensure proper start ability. To suit the engine’s operating conditions, the starting injection duration is determined by applying a starting compensation coefficient to the basic injection duration, which forms the basis of the injection duration.
  • Page 41 FEATURES INFO • After-start enrichment After-start enrichment provides enrichment compensation during a prescribed duration following the starting (firing) of the engine. While the amount of fuel enrichment is determined by the after-start enrichment coefficient, the coefficient varies by the engine temperature. Although the engine tem- perature determines the initial starting enrichment coefficient, the coefficient subsequently changes in accordance with the damping factor.
  • Page 42 FEATURES INFO • Warm-up enrichment When the engine temperature is low, a warm-up coefficient is applied in accordance with the signals from the engine temperature sensor in order to effect fuel enrichment. Because the engine temper- ature determines the coefficient, the coefficient changes with the fluctuations in the engine tempera- ture.
  • Page 43 FEATURES INFO • Acceleration enrichment Acceleration enrichment is provided in accordance with the signals from the throttle position sensor. As the rider operates the accelerator to accelerate the motorcycle from a constant speed, the throt- tle position sensor actuates in unison with the accelerator. The ECU interprets that acceleration has taken place through the throttle position sensor signal and executes acceleration enrichment.
  • Page 44 FEATURES INFO • Deceleration control Deceleration control is effected in accordance with the signals from the throttle position sensor. As the rider operates the accelerator to decelerate the motorcycle that is in motion, the throttle position sensor actuates in unison with the accelerator. When the engine speed is greater than a prescribed value with the throttle fully closed (thus applying engine braking), the ECU executes a deceleration fuel cut-off.
  • Page 45: First Idle Control System

    FEATURES INFO FIRST IDLE CONTROL SYSTEM This system temporarily increases the fuel injection volume of the injectors when starting a cold engine and until the engine is warm. The system improves startability and stabilizes engine speed during engine warm up. Basic operation The ECU receives a signal from the engine temperature sensor and determines the temperature of the engine with the collected data.
  • Page 46: Components

    FEATURES INFO COMPONENTS Linear control valve The linear control valve sends air from the silencer box to the intake manifold to increase the intake air volume. The linear control valve consists of a stepper motor that operates the valve, a valve unit that is attached to the motor, and a main body that distributes the intake air.
  • Page 47 FEATURES INFO Instrument panel Function indication The indications of the self-diagnosis function can be checked and inspection operations can be per- formed through the use of the tachometer on the instrument panel. Based on the signals received from the sensors, the ECU inputs the signals into the tachometer. Then, the conditions of the sensors appear on the clock and trip/odometer display of the tachome- ter.
  • Page 48 FEATURES INFO 2. DIAG mode inspection and adjustment (multi-function meter) Mode Selection (Make sure to disconnect the coupler from the fuel pump.) DIAG mode Normal mode 1. While keeping both the SELECT and Turn “ON” the main switch. RESET buttons pressed, turn “ON” the * The self-diagnostic function starts a sys- main switch.
  • Page 49: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
  • Page 50: Lock Washers/plates And Cotter Pins

    IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu-...
  • Page 51: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...
  • Page 52: Special Tools

    SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 53 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Valve spring compressor set YM-04019 This tool is used to remove or install the valve assemblies. Bearing driver YM-04058 This tool is needed when installing the crankshaft journal bearing. Valve guide remover (ø6) YM-04064-A This tool is used to remove or install the valve guides.
  • Page 54 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Dynamic spark tester YM-34487 This tool is used to check the ignition system components. Valve adjuster YM-8035 This tool is used to adjust the valve clearance. Universal clutch holder YM-91042 This tool is used to hold the clutch boss when removing or installing the clutch boss nut.
  • Page 55 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Carburetor synchronizer YU-08030 This gauge is needed for throttle bodies synchronization. Compression gauge set 14/18 mm Compression gauge Compression gauge adapter 12 mm YU-33223 Compression gauge adapter These tools are used to measure YU-33223-3 engine compression.
  • Page 56 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Pivot shaft wrench YM-01485 This tool is needed to loosen or tighten the spacer bolt. 1 - 39...
  • Page 57: Spec

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5PX1 (USA) ---- 5PX2 (California) ---- 5PX3 (CDN) ---- Dimensions Overall length 2,385 mm (93.9 in) ---- Overall width 955 mm (37.6 in) ---- Overall height 1,120 mm (44.1 in) ---- Seat height 725 mm (28.5 in)
  • Page 58: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Air-cooled, 4-stroke, OHV ---- Displacement 1,670 cm (101.9 cu.in) ---- Cylinder arrangement V-type 2-cylinder ---- Bore × stroke 97 × 113 mm (3.82 × 4.45 in) ---- Compression ratio 8.36 : 1 ---- Engine idling speed...
  • Page 59 SPEC ENGINE SPECIFICATIONS Item Standard Limit Transfer gear oil Recommended oil SAE 80 API “GL-4” hypoid gear oil ---- Total amount 0.49 L (0.43 Imp qt, 0.52 US qt) ---- Periodic oil replacement 0.4 L (0.35 Imp qt, 0.42 US qt) ---- Oil filter Oil filter type...
  • Page 60 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Gear drive ---- Crankcase hole inside diameter 25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in) ---- Camshaft cover hole inside diameter 28.000 ~ 28.021 mm (1.1024 ~ 1.1032 in) ---- Camshaft journal diameter 24.937 ~ 24.950 mm (0.9818 ~ 0.9823 in) ---- (crankcase side)
  • Page 61 SPEC ENGINE SPECIFICATIONS Item Standard Limit Rocker arms, Rocker arm shafts Rocker arm inside diameter 18.000 ~ 18.018 mm (0.7087 ~ 0.7094 in) 18.036 mm (0.7101 in) Rocker arm shaft outside diameter 17.976 ~ 17.991 mm (0.7077 ~ 0.7083 in) 14.970 mm (0.5894 in) Rocker arm to rocker arm shaft clear- 0.009 ~ 0.042 mm (0.0004 ~ 0.0017 in)
  • Page 62 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve stem diameter Intake 5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in) 5.945 mm (0.2341 in) Exhaust 5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in) 5.920 mm (0.2331 in) Valve guide inside diameter Intake 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.05 mm (0.2382 in)
  • Page 63 SPEC ENGINE SPECIFICATIONS Item Standard Limit Compressed spring force (installed) Intake 63 ~ 73 N (6.3 ~ 7.3 kg, 13.9 ~ 16.1 lb) ---- Exhaust 63 ~ 73 N (6.3 ~ 7.3 kg, 13.9 ~ 16.1 lb) ---- Spring tilt Intake ---- 2.5°/2.4 mm...
  • Page 64 SPEC ENGINE SPECIFICATIONS Item Standard Limit Spring tilt Intake ---- 2.5°/2.4 mm (2.5°/0.094 in) Exhaust ---- 2.5°/2.4 mm (2.5°/0.094 in) Winding direction (top view) Intake Clockwise ---- Exhaust Clockwise ---- Valve lifters Valve lifter outside diameter 22.9680 ~ 22.9744 mm ---- (0.9043 ~ 0.9045 in) Valve lifter case inside diameter...
  • Page 65 SPEC ENGINE SPECIFICATIONS Item Standard Limit Pistons Piston-to-cylinder clearance 0.025 ~ 0.050 mm (0.001 ~ 0.002 in) 0.15 mm (0.006 in) Diameter D 96.960 ~ 96.975 mm (3.8173 ~ 3.8179 in) ---- Height H 5 mm (0.20 in) ---- Piston pin bore (in the piston) Diameter 22.004 ~ 22.015 mm (0.8663 ~ 0.8667 in) 22.045 mm (0.8679 in)
  • Page 66 SPEC ENGINE SPECIFICATIONS Item Standard Limit 2nd ring Ring type Taper ---- Dimensions (B × T) 1.2 × 3.8 mm (0.047 × 0.150 in) ---- End gap (installed) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.8 mm (0.031 in) Ring side clearance 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 0.12 mm...
  • Page 67 SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch Clutch type Wet, multiple disc ---- Clutch release method Outer pull, rack and pinion (pull rod type) ---- Clutch release method operation Cable operation ---- Operation Left-hand operation ---- Clutch cable free play (at the end of 10 ~ 15 mm (0.39 ~ 0.59 in) ---- the clutch lever)
  • Page 68 SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Transmission type Constant mesh, 5-speed ---- Primary reduction system Spur gear ---- Primary reduction ratio 72/47 (1.532) ---- Secondary reduction system Belt drive ---- 35/32 × 70/32 (2.393) Secondary reduction ratio ---- Operation Left-foot operation ---- Gear ratios...
  • Page 69: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Double cradle ---- Caster angle 29.5° ---- Trail 130 mm (5.12 in) ---- Front wheel Wheel type Cast wheel ---- 18 M/C × MT 3.50 Size ---- 18 × MT 3.50 Material Aluminum ----...
  • Page 70 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless ---- Size 200/50 ZR 17 M/C (75 W) ---- 200/50 ZR 17 (75 W) Model (manufacturer) D220ST (DUNLOP)/ ---- BT020R (BRIDGESTONE) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kgf/cm , 36 psi) ----...
  • Page 71 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear brake Brake type Single-disc brake ---- Operation Right-foot operation ---- Brake pedal free play (P) 0 mm (0 in) ---- Brake pedal position 80 mm (3.2 in) ---- (from the top of the rider footrest to the top of the brake pedal) Recommended fluid DOT 4...
  • Page 72 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension Suspension type Swingarm (link suspension) ---- Rear shock absorber assembly type Coil spring/gas-oil damper ---- Rear shock absorber assembly travel 50 mm (1.97 in) ---- Spring Free length 188 mm (7.4 in) 183 mm (7.2 in) Installed length...
  • Page 73: Electrical Specifications

    Resin ---- Resistance 10 kΩ ---- Charging system System type AC magneto ---- Model (manufacturer) F5PX/YAMAHA ---- Nominal output 14 V/31 A at 5,000 r/min ---- 0.12 ~ 0.20 Ω/W–W Stator coil resistance/color ---- Rectifier/regulator Regulator type Semiconductor, short circuit...
  • Page 74 ---- LED × 1 Tachometer light ---- Electric starting system System type Constant mesh ---- Starter motor Model (manufacturer) 5PX (YAMAHA) ---- Power output 0.9 kW ---- 0.0081 ~ 0.0099 Ω Armature coil resistance ---- Brushes Overall length 9.8 mm (0.39 in) 5 mm (0.2 in)
  • Page 75 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Headlight relay Model/manufacturer ACM33211 M04/MATSUSHITA ---- 86.4 ~ 105.6 Ω Coil resistance ---- Fuel injection system relay Model/manufacturer G8R-30Y-S/OMRON ---- 162 ~ 198 Ω Coil resistance ---- Throttle position sensor Resistance 4 ~ 6 kΩ/L-B ---- Output voltage (at idle) 0.605 ~ 0.755 V...
  • Page 76: Conversion Table

    CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.
  • Page 77: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size m·kg ft·lb Spark plug — Front cylinder head cover Bolt Rear cylinder head cover Bolt Front rocker arm base Bolt Front rocker arm base Bolt Rear rocker arm base Bolt...
  • Page 78 SPEC TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size m·kg ft·lb Intake manifold Bolt Throttle body joint Screw Pressure regulator Bolt Intake vacuum hose bracket Bolt Intake air pressure sensor bracket 2 Bolt A.I.S. bracket Bolt Resonator Screw Air cut-off valve assembly Bolt Air cut-off valve assembly...
  • Page 79 SPEC TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size m·kg ft·lb Cover Bolt Cover Bolt Oil tank left cover Bolt Oil tank left cover Bolt Oil strainer Bolt Transfer gear case Bolt Transfer gear case cover Transfer gear oil checking bolt Bolt Transfer gear oil pump cover Bolt...
  • Page 80 SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kg ft·lb Upper bracket and outer tube Lower bracket and outer tube Upper bracket and steering shaft 11.5 Handlebar holder (lower) and handlebar holder (upper) Ring nut (steering shaft) 2.9 See NOTE.
  • Page 81 SPEC TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kg ft·lb Rear fender bracket and frame Rear fender bracket and rear fender Fuel tank and fuel filter Fuel tank bracket and frame Fuel tank and frame Sub fuel tank and frame Seat bracket and frame Side cover and side cover bracket Side cover bracket and frame...
  • Page 82 SPEC TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kg ft·lb Damper rod assembly bolt — Reflector bracket (front) Footrest bracket and rear brake bracket Footrest bracket and shift rod bracket Rear brake bracket and brake pedal Shift shaft and shift pedal NOTE: 1.
  • Page 83: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Connecting rod bolts and nuts Connecting rod small end and big end Crankshaft pins Crankshaft journals Piston surfaces Piston pins Camshaft cam lobes and camshaft journals Valve push rods Valve push rod end balls...
  • Page 84: Chassis

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Steering bearing cover Steering head pipe lower oil seal Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Shift pedal Rear footrest pivot...
  • Page 85: Engine Oil Lubrication Chart

    SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART Pressure feed Rear cylinder intake valve Front cylinder intake valve Rear cylinder Crankshaft journal Piston Connecting rod Crank pin (left) Valve stem Rocker Push Valve Rear lifter camshaft Front cylinder Valve stem Rocker Push Valve...
  • Page 86: Engine Oil Flow Diagrams

    SPEC ENGINE OIL FLOW DIAGRAMS ENGINE OIL FLOW DIAGRAMS 1 Oil tank 2 Dipstick 3 Oil delivery pipe 4 Push rod 5 Oil filter cartridge 2 - 30...
  • Page 87 SPEC ENGINE OIL FLOW DIAGRAMS 1 Valve lifter 2 Push rod 3 Rocker arm shaft 4 Crankshaft 2 - 31...
  • Page 88 SPEC ENGINE OIL FLOW DIAGRAMS 1 Engine oil pump 2 Oil strainer 3 Engine oil drain bolt (engine) 2 - 32...
  • Page 89 SPEC ENGINE OIL FLOW DIAGRAMS 1 Main axle È To oil filter cartridge 2 Drive axle 3 Engine oil pump 4 Oil strainer È 2 - 33...
  • Page 90: Transfer Gear Oil Flow Diagrams

    SPEC TRANSFER GEAR OIL FLOW DIAGRAMS TRANSFER GEAR OIL FLOW DIAGRAMS 1 Middle driven shaft 2 Transfer gear oil pump 2 - 34...
  • Page 91 SPEC TRANSFER GEAR OIL FLOW DIAGRAMS 1 Transfer gear oil pump 2 Middle driven shaft 2 - 35...
  • Page 92: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING 1 Brake hose È Fasten Ê Fasten the rear brake light rectifier/regulator 2 Clutch cable lead, horn lead, and rear brake switch lead, horn lead, and sta- 3 Rectifier/regulator light switch lead with a plastic tor coil assembly lead with a 4 Rectifier/regulator lead locking tie to the frame.
  • Page 93 SPEC CABLE ROUTING 1 Clutch cable È Fasten the left handlebar switch lead with a plas- 2 Left handlebar switch lead tic holder. 3 Right handlebar switch lead É Fasten the right handlebar switch lead with a 4 Throttle cable 1 plastic holder.
  • Page 94 SPEC CABLE ROUTING 1 Throttle cables È Pass throttle cable 1 and throttle cable 2 through 2 Clutch cable the cable guide, and then fasten them with a 3 Atmospheric pressure sensor plastic holder. 4 Spark plug cap (ignition coil 1-L spark plug lead) É...
  • Page 95 SPEC CABLE ROUTING Ë Fasten the engine stop switch lead, crankshaft position sensor lead, and horn lead with a plastic locking tie. Ì Fasten the starter motor lead, and side stand switch lead with a plastic locking tie to the frame. Í...
  • Page 96 SPEC CABLE ROUTING 1 Ignition coil 1 È To the rectifier/regulator, horn 1 and rear brake 2 Atmospheric pressure sensor lead light switch. 3 Ignition coil 2 É 30 ~ 50 degrees 4 Ignition coil 2 lead Ê 40 ~ 60 degrees 5 Rear brake light switch coupler 6 Rectifier/regulator lead and horn lead 7 Linear control valve lead...
  • Page 97 SPEC CABLE ROUTING 1 Tail/brake light lead È Be sure to position the ECU leads and sensor 2 Fuel pump lead leads toward the left side of the frame, and then 3 Sidestand switch lead fasten the wire harness protector with a plastic 4 Starter motor lead locking tie.
  • Page 98 SPEC CABLE ROUTING Ë Fasten the decompression solenoid lead, speed sensor lead, cylinder identification sensor lead, sidestand switch lead, crankshaft position sensor lead, neutral switch lead, and fuel pump lead with a plastic band. Ì Position the gray mark on the starter motor lead at the center of the bolt. Fit the starter motor lead and sid- estand switch lead into the groove in the frame, and then fasten them with a plastic locking tie.
  • Page 99 SPEC CABLE ROUTING 1 Fuse box A Cut-off relay 2 ECU lead B Turn signal relay 3 Battery C Headlight relay 4 Starter motor lead 5 ECU ground lead È Clamp the fuel tank/air filter breather hose, and 6 Fuel tank/air filter breather hose fuel tank/air filter drain hose with a plastic clamp.
  • Page 100 SPEC CABLE ROUTING 1 Roll over valve A Fuel tank drain hose 2 Fuel tank breather hose B Fuel tank/air filter breather hose 3 Fuel hose joint 1 C Ignition coil 1 4 Fuel hose 5 Fuel inlet hose È Make sure that the white paint mark is facing for- 6 Fuel outlet hose ward.
  • Page 101 SPEC CABLE ROUTING 1 Oil temperature sensor 9 Intake air pressure sensor 2 H Ignition coil 1-R spark plug lead 2 Fuel hose 0 Throttle cables I Lean angle cut-off switch lead 3 Spark plug cap (ignition coil 1-R A Brake hose J Crankshaft position sensor lead B Spark plug cap (ignition coil 2-R K Sidestand switch lead...
  • Page 102 SPEC CABLE ROUTING È To the battery box. Í Fasten the main wire harness, intake air pres- É Fasten the main wire harness, and fuel hose sure sensor lead #2, ignition coil 1-R spark plug with a plastic locking tie to the frame. lead, and intake air temperature sensor coupler Ê...
  • Page 103 SPEC CABLE ROUTING Ð To the injector sub lead. × To the speed sensor. Ñ To the engine temperature sensor. Ø Fasten the crankshaft position sensor lead, side- Ò 10 30 mm (0.4 1.2 in) stand switch lead, lean angle cut-off switch lead, Ó...
  • Page 104 SPEC CABLE ROUTING 1 Ignition coil 2-R spark plug lead 8 ECU 2 Ignition coil 1-R spark plug lead 9 Fuel hose 3 Main wire harness 0 Ignition coil 1-L spark plug lead 4 Negative battery ground lead A Ignition coil 2-L spark plug lead 5 Fuse box 6 Main fuse coupler È...
  • Page 105 SPEC CABLE ROUTING 1 Canister (California only) 0 Pressure regulator 2 Canister purge hose (California only) A A.I.S. vacuum hose 3 Intake vacuum hose B Silencer air filter case drain hose 4 Liner control valve inlet hose 5 Liner control valve outlet hose 6 Throttle position sensor 7 Fuel hose 8 Throttle stop screw...
  • Page 106 SPEC CABLE ROUTING Canister (California only) 1 Canister charge hose È To the fuel tank. 2 Canister purge hose É To the silencer air filter case. 3 Starter motor lead Ê To the throttle bodies. 4 Canister 5 Fuel tank drain hose 6 Regulator lead 7 Horn lead 8 Rear brake light switch lead...
  • Page 107: Chk Adj

    Evaporative Emission control • Check control system for damage. √ √ system (For • Replace if necessary. California only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. 3 - 1...
  • Page 108: General Maintenance And Lubrication Chart

    SAE 80 API “GL-4” • Replace every Change. Check. Change. (See page 3-32.) hypoid gear oil 16,000 mi (25,000 km) or 24 months. Yamaha chain and Control cables • Apply chain lube thor- √ √ √ √ √ √ cable lube or (See page 3-58.)
  • Page 109 (See page 3-47.) • Adjust if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.
  • Page 110: Seat And Side Covers

    SEAT AND SIDE COVERS EAS00038 SEAT AND SIDE COVERS 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 111: Headlight And Meter Assemblies

    HEADLIGHT AND METER ASSEMBLIES HEADLIGHT AND METER ASSEMBLIES 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 112: Battery

    BATTERY BATTERY Order Job/Part Q’ty Remarks Removing the battery Remove the parts in the order listed. Seat Refer to “SEAT AND SIDE COVERS”. Battery cover Negative battery lead Positive battery lead Battery Belt For installation, reverse the removal procedure. 3 - 6...
  • Page 113: Fuel Tank

    FUEL TANK FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Seat Refer to “SEAT AND SIDE COVERS”. Air induction system cover Air duct Fuel hose joint 1...
  • Page 114: Air Filter Case

    AIR FILTER CASE EAS00043 AIR FILTER CASE 3 Nm (0.3 m kg, 2.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Fuel tank Refer to “FUEL TANK”.
  • Page 115: Silencer Air Filter Case

    SILENCER AIR FILTER CASE EAS00043 SILENCER AIR FILTER CASE 10 Nm (1.0 m kg, 7.2 ft • • 15 Nm (1.5 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the silencer air filter case Remove the parts in the order listed.
  • Page 116 SILENCER AIR FILTER CASE 10 Nm (1.0 m kg, 7.2 ft • • 15 Nm (1.5 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Intake air pressure sensor 1 coupler Disconnect.
  • Page 117: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00047 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • The valve clearance automatically adjusted by the hydraulic valve lifter. How- ever, there are times that the valve clearance is needed to be adjusted manually.
  • Page 118 ADJUSTING THE VALVE CLEARANCE 4. Remove: • engine left side cover 1 5. Remove: • timing mark accessing screw 1 • crankshaft end cover 2 6. Remove: • decompression solenoid cover 1 • camshaft sprocket cover 2 7. Measure: • valve clearance Out of specification →...
  • Page 119 ADJUSTING THE VALVE CLEARANCE M MMM M MMM M MMM M MMM M MMM Piston #1 TDC (rear cylinder) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the crankshaft position sensor rotor with the pointer b on the clutch/crankshaft position sensor rotor cover.
  • Page 120 ADJUSTING THE VALVE CLEARANCE 8. Adjust: • valve clearance M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut 1. b. Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip. c.
  • Page 121: Synchronizing The Throttle Bodies

    SYNCHRONIZING THE THROTTLE BODIES EAS00051 SYNCHRONIZING THE THROTTLE BODIES NOTE: Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand.
  • Page 122 SYNCHRONIZING THE THROTTLE BODIES 7. Adjust: • throttle body synchronization M MMM M MMM M MMM M MMM M MMM a. With throttle body #1 as standard, adjust throttle body #2 using the air screw 1. NOTE: Rev the engine two or three times, each time for less than a second, and check the synchro- nization again.
  • Page 123: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED EAS00053 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the throttle bodies synchronization should be adjusted properly, the air filter element should be clean, and the engine should have ade- quate compression.
  • Page 124: Adjusting The Throttle Cable Free Play

    ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: • throttle cable free play a Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) 4 ~ 6 mm (0.16 ~ 0.24 in)
  • Page 125 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: ® Apply locking agend (LOCKTITE ) to the threads of the locknut 2. e. Loosen the locknut 4 on the accelerator cable. f. Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained.
  • Page 126: Checking The Spark Plugs

    CHECKING THE SPARK PLUGS EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: • seat Refer to “SEAT AND SIDE COVERS”. • fuel tank Refer to “FUEL TANK”. • air filter case Refer to “AIR FILTER CASE”.
  • Page 127 CHECKING THE SPARK PLUGS 5. Check: • electrode 1 Damage/wear → Replace the spark plug. • insulator 2 Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7.
  • Page 128: Checking The Ignition Timing

    CHECKING THE IGNITION TIMING EAS00061 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition sys- tem. Make sure all connections are tight and free of corrosion. 1. Remove: • engine left side cover 1 2.
  • Page 129: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 5. Install: • timing mark accessing screw 6. Install: • engine left side cover EAS00065 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance.
  • Page 130 MEASURING THE COMPRESSION PRESSURE 7. Remove: • spark plug CAUTION: Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 8. Install: •...
  • Page 131 MEASURING THE COMPRESSION PRESSURE c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. d. Carbon deposits → Eliminate. e. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure again.
  • Page 132: Checking The Engine Oil Level

    CHECKING THE ENGINE OIL LEVEL EAS00071 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 133: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 6. Install: • dipstick 7. Start the engine, warm it up for several min- utes, and then turn it off. 8. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
  • Page 134 CHANGING THE ENGINE OIL 5. If the oil filter cartridge is also to be replaced, perform the following procedure. M MMM M MMM M MMM M MMM M MMM a. Remove the oil filter cartridge 1 with an oil filter wrench 2. Oil filter wrench YU-38411 b.
  • Page 135 CHANGING THE ENGINE OIL 8. Fill: • oil tank (with the specified amount of the recom- mended engine oil) Quantity Total amount 5.0 L (4.40 Imp qt, 5.29 US qt) Without oil filter cartridge replacement 3.7 L (3.26 Imp qt, 3.91 US qt) With oil filter cartridge replacement 4.1 L (3.61 Imp qt, 4.33 US qt)
  • Page 136 CHANGING THE ENGINE OIL 10.Install: • dipstick 11.Start the engine, warm it up for several min- utes, and then turn it off. 12.Check: • engine (for engine oil leaks) 13.Check: • engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”.
  • Page 137: Measuring The Engine Oil Pressure

    MEASURING THE ENGINE OIL PRESSURE EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: • engine oil level Below the minimum level mark → Add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 138: Checking The Transfer Gear Oil Level

    MEASURING THE ENGINE OIL PRESSURE/ CHECKING THE TRANSFER GEAR OIL LEVEL 5. Measure: • engine oil pressure (at the following conditions) Engine oil pressure 40 ~ 80 kPa (0.4 ~ 0.8 kg/cm 5.688 ~ 11.376 psi) Engine speed Approx. 900 r/min Engine oil temperature 70 ~ 90 °C (158 ~ 194 °F) Engine oil pressure...
  • Page 139: Changing The Transfer Gear Oil

    CHECKING THE TRANSFER GEAR OIL LEVEL/ CHANGING THE TRANSFER GEAR OIL 4. Check: • transfer gear oil level The transfer gear oil level should be up to the brim 2 of the hole. Below the brim → Add the recommended transfer gear oil to the proper level.
  • Page 140 CHECKING THE TRANSFER GEAR OIL LEVEL 6. Install: • transfer gear oil drain bolt 18 Nm (1.8 m • kg, 13 ft • lb) 7. Fill: • transfer gear case (with the specified amount of the recom- mended transfer gear oil) Quantity Total amount 0.49 L (0.43 Imp qt, 0.52 US qt)
  • Page 141: Adjusting The Clutch Cable Free Play

    ADJUSTING THE CLUTCH CABLE FREE PLAY EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: • clutch cable free play a Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10 ~ 15 mm (0.39 ~ 0.59 in) 2.
  • Page 142: Cleaning The Air Filter Elements

    CLEANING THE AIR FILTER ELEMENTS EAS00088 CLEANING THE AIR FILTER ELEMENTS The following procedure applies to both air fil- ter elements. 1. Remove: • seat Refer to “SEAT AND SIDE COVERS”. • fuel tank Refer to “FUEL TANK”. • air filter case Refer to “AIR FILTER CASE”.
  • Page 143: Checking The Throttle Body Joints

    CHECKING THE THROTTLE BODY JOINTS/ CHECKING THE FUEL HOSES EAS00094 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joint. 1. Remove: • seat Refer to “SEAT AND SIDE COVERS”. • fuel tank Refer to “FUEL TANK”. •...
  • Page 144: Checking The Cylinder Head Breather Hose And Oil Tank Breather Hose

    CHECKING THE FUEL HOSES/ CHECKING THE CYLINDER HEAD BREATHER HOSE AND OIL TANK BREATHER HOSE 2. Check: • fuel hose 1 Cracks/damage → Replace. Loose connection → Connect properly. 3. Install: • air induction system cover Refer to “FUEL TANK”. EAS00098 CHECKING THE CYLINDER HEAD BREATHER HOSE AND OIL TANK...
  • Page 145: Checking The Exhaust System

    CHECKING THE EXHAUST SYSTEM EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Check: • exhaust pipe 1 • muffler 2 Cracks/damage → Replace. • gasket 3 Exhaust gas leaks → Replace. 2.
  • Page 146: Chassis

    ADJUSTING THE FRONT BRAKE EAS00108 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: • brake lever free play a Out of specification → Adjust. Brake lever free play (at the end of the brake lever) 2 ~ 5 mm (0.08 ~ 0.20 in) 2.
  • Page 147: Adjusting The Rear Brake

    ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Check: • brake pedal position (distance a from the top of the rider foot- rest to the top of the brake pedal) Out of specification → Adjust. Brake pedal position (from the top of the rider footrest to the top of the brake pedal) 80 mm (3.2 in)
  • Page 148: Checking The Brake Fluid Level

    ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL CAUTION: After adjusting the brake pedal position, make sure there is no brake drag. L LLL L LLL L LLL L LLL L LLL 3. Adjust: • rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”.
  • Page 149: Checking The Front Brake Pads

    CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE PADS CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal.
  • Page 150: Adjusting The Rear Brake Light Switch

    ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT AND REAR BRAKE HOSES EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by movement of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.
  • Page 151: Bleeding The Hydraulic Brake System

    CHECKING THE FRONT AND REAR BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM 4. Check: È • brake hose Brake fluid leakage → Replace the dam- aged hose. Refer to “FRONT AND REAR BRAKES” in chapter 4. È Front É Rear É...
  • Page 152 BLEEDING THE HYDRAULIC BRAKE SYSTEM 1. Bleed: È • hydraulic brake system M MMM M MMM M MMM M MMM M MMM a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir).
  • Page 153: Adjusting The Shift Pedal

    ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE BELT SLACK EAS00137 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the installed shift rod length a. 1. Measure: • installed shift rod length a Incorrect → Adjust. Installed shift rod length 368 ~ 372 mm (14.49 ~ 14.65 in) 2.
  • Page 154 ADJUSTING THE DRIVE BELT SLACK 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on the sidestand and or on a suitable stand so that the rear wheel is elevated.
  • Page 155 ADJUSTING THE DRIVE BELT SLACK 4. Adjust: • drive belt slack M MMM M MMM M MMM M MMM M MMM NOTE: Place the motorcycle on the suitable stand so that the rear wheel is elevated. a. Loosen the brake caliper bracket bolt 1. b.
  • Page 156: Checking And Adjusting The Steering Head

    CHECKING AND ADJUSTING THE STEERING HEAD EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 157 CHECKING AND ADJUSTING THE STEERING HEAD 6. Adjust: • steering head M MMM M MMM M MMM M MMM M MMM a. Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3. b. Loosen the lower ring nut 4 and then tighten it to specification with a spanner wrench 5.
  • Page 158: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK 7. Install: • upper bracket • washer • steering stem nut 115 Nm (11.5 m • kg, 85 ft • lb) 8. Tighten: • upper bracket pinch bolt 26 Nm (2.6 m • kg, 19 ft • lb) 9.
  • Page 159: Adjusting The Front Fork Legs

    ADJUSTING THE FRONT FORK LEGS EAS00152 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. •...
  • Page 160: Adjusting The Rear Shock Absorber Assembly

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EAS00156 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or mini- mum adjustment positions. 1.
  • Page 161: Checking The Tires

    CHECKING THE TIRES EAS00166 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification → Regulate. WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
  • Page 162 Tube or tubeless Tubeless wheel tire • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.
  • Page 163 CHECKING THE TIRES Front tire Manufacturer Model Size 120/70 ZR 18 M/C (59 W) BRIDGESTONE BT020FG 120/70 ZR 18 (59 W) 120/70 ZR 18 M/C (59 W) DUNLOP D220FST 120/70 ZR 18 (59 W) Rear tire Manufacturer Model Size 200/50 ZR 17 M/C (75 W) BRIDGESTONE BT020R...
  • Page 164: Checking The Wheels

    CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: • wheel Damage/out-of-round → Replace. WARNING Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel.
  • Page 165: Lubricating The Levers And Pedals

    LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Lithium-soap-based grease EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand.
  • Page 166: Electrical System

    CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 167 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 168 CHECKING AND CHARGING THE BATTERY 5. Charge: Charging Ambient temperature 20 °C (68 °F) • battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit voltage. CAUTION: • Never remove the MF battery sealing caps.
  • Page 169 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger NOTE: Leave the battery unused for Measure the open-circuit more than 30 minutes before measuring its open-circuit voltage. voltage prior to charging. Charger Ammeter NOTE: Set the charging voltage to Connect a charger and 16 ~ 17 V.
  • Page 170 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.
  • Page 171: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery Refer to “BATTERY”. 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: •...
  • Page 172 CHECKING THE FUSES 1. Remove: • seat Refer to “SEAT AND SIDE COVERS”. 2. Check: • fuse M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω...
  • Page 173 CHECKING THE FUSES 3. Replace: • blown fuse M MMM M MMM M MMM M MMM M MMM a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage rating. c. Set on the switches to verify if the electrical circuit is operational.
  • Page 174: Replacing The Headlight Bulb

    REPLACING THE HEADLIGHT BULB EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: • screws 1 • headlight lens unit 2 2. Disconnect: • headlight coupler 1 3. Remove: • headlight bulb holder cover 2 4. Detach: • headlight bulb holder 1 5.
  • Page 175: Adjusting The Headlight Beam

    REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 7. Attach: • headlight bulb holder 8. Install: • headlight bulb holder cover 9. Connect: • headlight coupler 10.Install: • headlight lens unit • screws EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: •...
  • Page 176: Odometer And Tripmeter

    INSTRUMENT FUNCTIONS INSTRUMENT FUNCTIONS ODOMETER AND TRIPMETER 1 Tachometer 2 Clock 3 Odometer/trip meter/fuel reserve trip meter 4 “RESET” button 5 “SELECT” button Pushing the “SELECT” button switches the dis- play between the odometer mode “ODO” and the tripmeter modes “TRIP 1” and “TRIP 2” in the following order: “ODO”...
  • Page 177: Adjusting The Meter Light

    INSTRUMENT FUNCTIONS ADJUSTING THE METER LIGHT 1. Adjust: • meter light M MMM M MMM M MMM M MMM M MMM a. Turn the key to “OFF”. b. Push and hold the “SELECT” button. c. Turn the key to “ON”, and then after five seconds, release the “SELECT”...
  • Page 178: Chas

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 8 Nm (0.8 m kg, 5.8 ft • • 40 Nm (4.0 m kg, 29 ft • • 16 Nm (1.6 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft •...
  • Page 179 CHAS FRONT WHEEL AND BRAKE DISCS 8 Nm (0.8 m kg, 5.8 ft • • 40 Nm (4.0 m kg, 29 ft • • 16 Nm (1.6 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft •...
  • Page 180 CHAS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly procedure. 4 - 3...
  • Page 181: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 182 CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: • radial wheel runout 1 • lateral wheel runout 2 Over the specified limits → Replace. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) 4.
  • Page 183: Checking The Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc.
  • Page 184: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS 4. Adjust: • brake disc deflection M MMM M MMM M MMM M MMM M MMM a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern.
  • Page 185 CHAS FRONT WHEEL AND BRAKE DISCS 2. Lubricate: • wheel axle • oil seal lips Recommended lubricant Lithium-soap-based grease 3. Install: • collars • front wheel • front wheel axle 4. Tighten: • front wheel axle 1 72 Nm (7.2 m • kg, 52 ft • lb) •...
  • Page 186: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the front wheel static balance should adjusted. • Adjust the front wheel static balance with the brake discs installed. 1.
  • Page 187 CHAS FRONT WHEEL AND BRAKE DISCS 3. Adjust: • front wheel static balance M MMM M MMM M MMM M MMM M MMM a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”. NOTE: Start with the lightest weight. b.
  • Page 188: Rear Wheel, Brake Disc, And Rear Wheel Pulley

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00550 REAR WHEEL, BRAKE DISC, AND REAR WHEEL PULLEY 40 Nm (4.0 m kg, 29 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 189 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY 27 Nm (2.7 m kg, 19 ft • • 30 Nm (3.0 m kg, 22 ft • • 150 Nm (15.0 m kg, 110 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 190 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY 27 Nm (2.7 m kg, 19 ft • • 30 Nm (3.0 m kg, 22 ft • • 150 Nm (15.0 m kg, 110 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 191 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00556 Order Job/Part Q’ty Remarks Removing the brake disc and rear Remove the parts in the order listed. wheel pulley Brake disc cover Brake disc Rear wheel pulley Refer to “INSTALLING THE REAR WHEEL”.
  • Page 192 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY Order Job/Part Q’ty Remarks Collar Bearing Collar Bearing Rear wheel drive hub damper Rear wheel For installation, reverse the removal procedure. 4 - 15...
  • Page 193 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Oil seal Bearing Refer to “ASSEMBLING THE REAR WHEEL”. Spacer Bearing Rear wheel For assembly, reverse the disassembly procedure.
  • Page 194: Removing The Rear Wheel

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 195: Checking The Rear Wheel Drive Hub

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: • rear wheel drive hub 1 Cracks/damage → Replace. • rear wheel drive hub dampers 2 Damage/wear → Replace. EAS00568 CHECKING AND REPLACING THE REAR WHEEL PULLEY 1.
  • Page 196: Installing The Rear Wheel

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: • oil seal lips Recommended lubricant Lithium-soap-based grease 2. Install: • rear wheel drive hub dampers 1 3. Install: • rear wheel drive hub assembly 1 4.
  • Page 197 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY 6. Install: • brake caliper bracket 1 • washer • brake caliper bracket bolt 2 NOTE: Temporarily tighten the brake caliper bracket bolt. 7. Install: • collars • rear wheel • adjusting plates •...
  • Page 198 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY 12.Install: • upper drive belt cover plate 1 7 Nm (0.7 m • kg, 5.1 ft • lb) • upper drive belt cover 2 7 Nm (0.7 m • kg, 5.1 ft • lb) 13.Install: •...
  • Page 199: Adjusting The Rear Wheel Static Balance

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed.
  • Page 200: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 40 Nm (4.0 m kg, 29 ft • • 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed.
  • Page 201: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Brake caliper retaining bolt Brake caliper Brake pad...
  • Page 202: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 203 CHAS FRONT AND REAR BRAKES 2. Remove: • brake pad clips 1 • brake pad pin 2 • brake pad spring 3 3. Remove: • brake pads 1 (along with the brake pad shims) • brake pad shims 4. Measure: •...
  • Page 204: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES d. Install new brake pads and a new brake pad spring. NOTE: The arrow a on the brake pad spring must point in the direction of disc rotation. L LLL L LLL L LLL L LLL L LLL 6.
  • Page 205 CHAS FRONT AND REAR BRAKES 2. Remove: • brake pads 1 (along with the brake pad shims) • brake pad springs 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.03 in) 4.
  • Page 206 CHAS FRONT AND REAR BRAKES 5. Install: • brake caliper retaining bolt 1 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
  • Page 207 CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain. Rear view mirror (right) Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm...
  • Page 208: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Front brake light switch connector Disconnect. Refer to “REMOVING THE Union bolt FRONT BRAKE MASTER Brake hose Disconnect. CYLINDER” and “ASSEM- BLING AND INSTALLING Copper washer THE FRONT BRAKE MAS- Brake master cylinder holder TER CYLINDER”.
  • Page 209 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. master cylinder Dust boot Refer to “ASSEMBLING AND INSTALL- Circlip ING THE FRONT BRAKE MASTER CYL- Brake master cylinder kit INDER”.
  • Page 210: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the brake fluid reservoir Remove the parts in the order listed. Brake fluid Drain. Brake fluid reservoir cover Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm...
  • Page 211 CHAS FRONT AND REAR BRAKES 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft • • 30 Nm (3.0 m kg, 22 ft • •...
  • Page 212 CHAS FRONT AND REAR BRAKES 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft • • 30 Nm (3.0 m kg, 22 ft • •...
  • Page 213 CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake Remove the parts in the order listed. master cylinder Dust boot Circlip Brake master cylinder kit Circlip Brake hose joint O-ring Brake master cylinder For assembly, reverse the disassembly procedure.
  • Page 214: Removing The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00588 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the...
  • Page 215: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES 2. Check: È É • brake master cylinder kit Damage/scratches/wear → Replace. È Front É Rear 3. Check: • rear brake fluid reservoir 1 Cracks/damage → Replace. • rear brake fluid reservoir diaphragm 2 Cracks/damage → Replace. 4.
  • Page 216 CHAS FRONT AND REAR BRAKES 1. Install: • brake master cylinder • brake master cylinder holder 1 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: • Install the brake master cylinder holder with the “UP” mark facing up. •...
  • Page 217 CHAS FRONT AND REAR BRAKES 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 218: Assembling And Installing The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00608 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • copper washers 1 • brake hoses 2 • union bolt 3 30 Nm (3.0 m • kg, 22 ft • lb) WARNING Proper brake hose routing is essential to insure safe motorcycle operation.
  • Page 219 CHAS FRONT AND REAR BRAKES 3. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.
  • Page 220: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 40 Nm (4.0 m kg, 29 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.
  • Page 221 CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. calipers The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring...
  • Page 222: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 m kg, 22 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Union bolt Refer to “DISASSEM- BLING THE REAR BRAKE...
  • Page 223 CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Disassembling the rear brake Remove the parts in the order listed. caliper Brake caliper piston Refer to “DISASSEMBLING THE REAR BRAKE CALIPER”. Brake caliper piston seal Bleed screw For assembly, reverse the disassembly...
  • Page 224: Disassembling The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 •...
  • Page 225: Disassembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00627 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.
  • Page 226: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Every years and whenever the Brake fluid brake is disassem- bled 1.
  • Page 227: Assembling And Installing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00638 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. •...
  • Page 228 CHAS FRONT AND REAR BRAKES 3. Install: • brake pads • brake pad spring • brake caliper bolt 40 Nm (4.0 m • kg, 29 ft • lb) • brake hose holder 8 Nm (0.8 m • kg, 5.8 ft • lb) 4.
  • Page 229: Assembling And Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: • brake lever operation Soft or spongy feeling →...
  • Page 230 CHAS FRONT AND REAR BRAKES 1. Install: • brake caliper 1 (temporarily) • copper washers 2 • brake hose 3 • union bolt 4 30 Nm (3.0 m • kg, 22 ft • lb) WARNING Proper brake hose routing is essential to insure safe motorcycle operation.
  • Page 231 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 232: Front Fork

    CHAS FRONT FORK EAS00647 FRONT FORK 26 Nm (2.6 m kg, 19 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 233: Disassembling The Front Fork Legs

    CHAS FRONT FORK EAS00648 Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Refer to “DISASSEMBLING THE FRONT FORK LEGS”...
  • Page 234 CHAS FRONT FORK Order Job/Part Q’ty Remarks Oil seal clip Oil seal Washer Refer to “DISASSEMBLING THE FRONT Damper rod assembly bolt FORK LEGS” and “ASSEMBLING THE FRONT FORK LEGS”. Copper washer Damper rod assembly Inner tube For assembly, reverse the disassembly procedure.
  • Page 235 CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 236 CHAS FRONT FORK NOTE: Use the side of the rod holder that is marked “B”. c. Loosen the nut. d. Remove the cap bolt. e. Remove the rod holder and fork spring com- pressor. WARNING The fork spring is compressed. f.
  • Page 237: Checking The Front Fork Legs

    CHAS FRONT FORK 4. Remove: • damper rod assembly bolt • copper washer NOTE: While holding the damper rod with the damper rod holder 1, loosen the damper rod assem- bly bolt. Damper rod holder YM-01423 EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
  • Page 238 CHAS FRONT FORK 3. Check: • damper rod 1 Damage/wear → Replace. Obstruction → Blow out all of the oil pas- sages with compressed air. CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particu- larly sensitive to foreign material.
  • Page 239: Assembling The Front Fork Legs

    CHAS FRONT FORK EAS00660 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Make sure the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor han- dling and a loss of stability.
  • Page 240 CHAS FRONT FORK 3. Install: • dust seal 1 • oil seal clip 2 • oil seal 3 • washer 4 CAUTION: Make sure the numbered side of the oil seal faces down. NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease.
  • Page 241 Quantity (each front fork leg) 476 cm (16.8 Imp qt, 16.1 US qt) Recommended oil Yamaha suspension oil “01” CAUTION: • Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.
  • Page 242 CHAS FRONT FORK 12.Slowly stroke the outer tube 1 up and down to distribute the fork oil once more (1 stroke = about 150 mm (8.12 in)). NOTE: Be careful not to stroke the outer tube over 150 mm (8.12 in) as this will cause air to enter. If the outer tube is stroke more than 150 mm (8.12 in), repeat steps (11) and (12).
  • Page 243 CHAS FRONT FORK 15.Install: • nut 1 • fork spring 2 • spring seat 3 • spacer 4 • cap bolt 5 M MMM M MMM M MMM M MMM M MMM a. Remove the rod puller. b. Install the nut 1. c.
  • Page 244: Installing The Front Fork Legs

    CHAS FRONT FORK k. Remove the rod holder and fork spring com- pressor. CAUTION: The fork spring is compressed. Always use a new cap bolt O-ring. L LLL L LLL L LLL L LLL L LLL 16.Install: • cap bolt (onto the outer tube) NOTE: Temporary tighten the cap bolt.
  • Page 245 CHAS FRONT FORK 3. Adjust: • spring preload Refer to “ADJUSTING THE FRONT FORK LEGS” in chapter 3. 4 - 68...
  • Page 246: Handlebar

    CHAS HANDLEBAR EAS00664 HANDLEBAR Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Rear view mirror (left and right) Plastic clamp Front brake light switch connector Disconnect. Brake master cylinder holder Brake master cylinder Refer to “INSTALLING THE Right handlebar switch HANDLEBAR”.
  • Page 247 CHAS HANDLEBAR Order Job/Part Q’ty Remarks Left handlebar switch Handlebar grip Refer to “REMOV- ING THE HANDLE- BAR”. Refer to “INSTALL- Clutch cable Disconnect. ING THE HANDLE- Clutch lever holder BAR”. Upper handlebar holder Handlebar Lower handlebar holder For installation, reverse the removal procedure.
  • Page 248: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
  • Page 249 CHAS HANDLEBAR 3. Install: • handlebar 1 • upper handlebar holders 2 28 Nm (2.8 m • kg, 20 ft • lb) CAUTION: • First, tighten the bolts on the front side of the handlebar holder, and then on the rear side.
  • Page 250 CHAS HANDLEBAR 7. Install: • left handlebar switch NOTE: Align the end a of the left handlebar switch with the punch mark b on the handlebar. 8. Connect: • clutch switch coupler 9. Install: • handlebar grip M MMM M MMM M MMM M MMM M MMM...
  • Page 251 CHAS HANDLEBAR 13.Install: • brake master cylinder • brake master cylinder holder 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: • Install the brake master cylinder holder with the “UP” mark facing up. • Align the end of the brake master cylinder holder with the punch mark a in the handle- bar.
  • Page 252: Steering Head

    CHAS STEERING HEAD EAS00676 STEERING HEAD 23 Nm (2.3 m kg, 17 ft 1st 52 Nm (5.2 m kg, 37 ft • • • • 2nd 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 253 CHAS STEERING HEAD 23 Nm (2.3 m kg, 17 ft 1st 52 Nm (5.2 m kg, 37 ft • • • • 2nd 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...
  • Page 254: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • ring nut 1 (with the spanner wrench 2) Spanner wrench YU-33975 WARNING...
  • Page 255: Installing The Steering Head

    CHAS STEERING HEAD 3. Replace: • bearings • bearing races M MMM M MMM M MMM M MMM M MMM a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer.
  • Page 256 CHAS STEERING HEAD 3. Install: • upper bracket • steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: • front fork legs Refer to “FRONT FORK”. NOTE: Temporarily tighten the lower bracket pinch bolts. 5. Tighten: • steering stem nut 115 Nm (11.5 m •...
  • Page 257: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 258 CHAS REAR SHOCK ABSORBER AND SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 259 CHAS REAR SHOCK ABSORBER AND SWINGARM 59 Nm (5.9 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed.
  • Page 260 CHAS REAR SHOCK ABSORBER AND SWINGARM 59 Nm (5.9 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Part Q’ty Remarks Swingarm Dust cover Spacer Bearing For installation, reverse the removal...
  • Page 261: Handling The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00686 HANDLING THE REAR SHOCK ABSORBER WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held responsible for property damage or per- sonal injury that may result from improper handling of the rear shock absorber.
  • Page 262: Removing The Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00703 REMOVING THE REAR SHOCK ABSORBER AND SWINGARM 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 263: Checking The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00696 CHECKING THE REAR SHOCK ABSORBER 1. Check: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. •...
  • Page 264: Installing The Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM 3. Wash: • pivot shaft • dust covers • spacer • bearings Recommended cleaning solvent Kerosine 4. Check: • dust covers • spacer • oil seals Damage/wear → Replace. • bearings Damage/pitting → Replace. EAS00711 INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM...
  • Page 265 CHAS REAR SHOCK ABSORBER AND SWINGARM 3. Install: • bolt (shock absorber-connecting arm- frame) 1 NOTE: When installing the bolt (shock absorber-con- necting arm-frame), hold the swingarm so that it does not drop down. 4. Adjust: • drive belt slack Refer to “ADJUSTING THE DRIVE BELT SLACK”...
  • Page 266: Drive Belt And Drive Sprocket

    CHAS DRIVE BELT AND DRIVE SPROCKET DRIVE BELT AND DRIVE SPROCKET Order Job/Part Q’ty Remarks Removing the drive belt and drive Remove the parts in the order listed. sprocket Rear wheel Refer to “REAR WHEEL, BRAKE DISC, AND REAR WHEEL PULLEY”. Rear shock absorber and swingarm Refer to “REAR SHOCK ABSORBER assembly...
  • Page 267: Checking The Drive Belt

    CHAS DRIVE BELT AND DRIVE SPROCKET REMOVING THE DRIVE BELT AND DRIVE SPROCKET NOTE: Loosen the drive sprocket nut before remove the rear wheel. 1. Straighten the lock washer tab. 2. Loosen: • drive sprocket nut 1 NOTE: When loosening the drive sprocket nut, press down on the brake pedal so the drive sprocket does not move.
  • Page 268: Installing The Drive Belt And Drive Sprocket

    CHAS DRIVE BELT AND DRIVE SPROCKET 3. Check: • drive sprocket • rear wheel pulley Bent teeth → Replace the drive belt and pulleys as a set. INSTALLING THE DRIVE BELT AND DRIVE SPROCKET 1. Install: • drive sprocket 1 •...
  • Page 269: Eng

    ENGINE EAS00188 ENGINE ENGINE 24 Nm (2.4 m kg, 17 ft • • 20 Nm (2.0 m kg, 14 ft • • 20 Nm (2.0 m kg, 14 ft • • 53 Nm (5.3 m kg, 38 ft • • 12 Nm (1.2 m kg, 8.7 ft •...
  • Page 270 ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the oil filter bracket and Remove the parts in the order listed.
  • Page 271 ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Engine oil/oil filter cartridge Drain.
  • Page 272 ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Rectifier/regulator coupler Disconnect.
  • Page 273 ENGINE 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Spark plug caps Cylinder head breather hose Oil tank breather hose Clutch cable Plastic clamp...
  • Page 274 ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the ignition coil and Remove the parts in the order listed. linear control valve Hose bracket Wire harness bracket Ignition coil connector Disconnect.
  • Page 275 ENGINE 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft • • 98 Nm (9.8 m kg, 71 ft • • 53 Nm (5.3 m kg, 38 ft • • 88 Nm (8.8 m kg, 64 ft •...
  • Page 276 ENGINE 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft • • 98 Nm (9.8 m kg, 71 ft • • 53 Nm (5.3 m kg, 38 ft • • 88 Nm (8.8 m kg, 64 ft •...
  • Page 277: Installing The Engine

    ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: • spacer bolt 1 • lower front mounting bolt 2 • lower rear mounting bolt 3 2. Tighten: • spacer bolt 1 18 Nm (1.8 m • kg, 13 ft • lb) NOTE: •...
  • Page 278: Installing The Muffler And Exhaust Pipes

    ENGINE 6. Connect: • oil tank breather hose 1 • cylinder head breather hose 2 • spark plug caps 3 NOTE: Refer to “CABLE ROUTING” in chapter 2. INSTALLING THE MUFFLER AND EXHAUST PIPES 1. Install: • gaskets • exhaust pipes NOTE: Finger tighten the exhaust pipe nuts and bolts.
  • Page 279: Rocker Arms, Push Rods And Valve Lifters

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • •...
  • Page 280 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 281 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing cylinder head covers Remove the parts in the order listed. Ignition coil/rectifier/regulator/ Refer to “ENGINE”. liner control valve Cylinder head breather hose Oil tank breather hose Bolt = 60 mm (2.36 in)
  • Page 282 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • • 24 Nm (2.4 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the push rods and rocker Remove the parts in the order listed.
  • Page 283 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the valve lifters Remove the parts in the order listed. Push rod cover O-ring Seal...
  • Page 284: Removing The Rocker Arms, Push Rods And Valve Lifters

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Align: • TDC mark a on the crankshaft position sensor rotor (with the pointer b on the clutch/crankshaft position sensor rotor cover) M MMM M MMM M MMM M MMM...
  • Page 285 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 2. Check: • rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrica- tion system. 3. Measure: • rocker arm inside diameter a Out of specification → Replace. Rocker arm inside diameter 18.000 ~ 18.018 mm (0.7087 ~ 0.7094 in) 4.
  • Page 286: Checking The Rocker Arm Bases

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS CHECKING THE ROCKER ARM BASES 1. Check: • rocker arm base Cracks/damage → Replace. CHECKING THE PUSH RODS 1. Check: • push rod • push rod end Bends/damage → Replace. 2. Measure: • push rod runout Out of specification →...
  • Page 287: Bleeding A Valve Lifter

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 3. Measure: • valve lifter outside diameter a Out of specification → Replace. Valve lifter outside diameter 22.9680 ~ 22.9744 mm (0.9043 ~ 0.9045 in) 4. Measure: • valve lifter case inside diameter a Out of specification →...
  • Page 288 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Bleed: • valve lifter M MMM M MMM M MMM M MMM M MMM a. Fill a container with kerosene and place the valve lifter into the container as shown. Pump the plunger side of the valve lifter with a press a number of times to let in kero- sene.
  • Page 289: Checking The Push Rod Cover

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS h. Rotate the crankshaft unit the mark (on the camshaft driven gear) for the valve lifter to be bled aligns with the camshaft drive gear as shown. Example: For bleeding the cylinder #2 intake valve lifter, align mark 2 as shown.
  • Page 290: Installing The Rocker Arms And Push Rods

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS INSTALLING THE ROCKER ARMS AND PUSH RODS The following procedure applies to both cylin- ders. 1. Install: • rocker arms 1 • rocker arm shafts 2 (onto rocker arm base) NOTE: The thread hole a of the rocker arm shaft must face to the outside.
  • Page 291: Installing The Cylinder Head Covers

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS c. Install the rocker arm base bolts. NOTE: Tighten the rocker arm base bolts in stages and in a crisscross pattern. Rocker arm base bolt 1 10 Nm (1.0 m • kg, 7.2 ft • lb) Rocker arm base bolt 2 24 Nm (2.4 m •...
  • Page 292 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 2. Install: • canister (for California only) NOTE: Refer to “CABLE ROUTING” in chapter 2. 3. Install: • spark plugs 4. Connect: • spark plug caps NOTE: Refer to “CABLE ROUTING” in chapter 2. È...
  • Page 293: Camshafts

    CAMSHAFTS EAS00196 CAMSHAFTS 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 52 Nm (5.2 m kg, 37 ft • • Order Job/Part Q’ty Remarks...
  • Page 294 CAMSHAFTS 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 52 Nm (5.2 m kg, 37 ft • • Order Job/Part Q’ty Remarks Camshaft driven gear Straight key...
  • Page 295 CAMSHAFTS REMOVING THE CAMSHAFTS 1. Loosen: • front cylinder camshaft end cover bolts 1 • camshaft drive gear bolt 2 NOTE: • Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them. •...
  • Page 296: Checking The Camshafts

    CAMSHAFTS EAS00204 CHECKING THE CAMSHAFTS 1. Check: • cam Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • cam dimensions a and b Out of specification → Replace the cam- shaft. Camshaft lobe dimension limit Intake camshaft a 38.231 ~ 38.331 mm (1.5052 ~ 1.5091 in) b 32.013 ~ 32.113 mm (1.2604 ~ 1.2643 in)
  • Page 297 CAMSHAFTS 5. Measure: • crankcase hole inside diameter c Out of specification → Replace the crank- case. Crankcase hole inside diameter 25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in) 6. Measure: • camshaft cover hole inside diameter d Out of specification → Replace the cam- shaft cover.
  • Page 298: Checking The Decompression System

    CAMSHAFTS 9. Check: • camshaft drive gears • camshaft driven gears Chips/pitting/roughness/wear → Replace the defective part(s). CHECKING THE DECOMPRESSION SYSTEM 1. Check: • decompression system NOTE: • Check the decompression system while the decompression push rod is installed in the camshaft.
  • Page 299: Installing The Camshafts

    CAMSHAFTS INSTALLING THE CAMSHAFTS 1. Install: • camshafts (to the camshaft cover) • front cylinder camshaft end cover NOTE: • Lubricate molybdenum disulfide oil onto the camshaft journals and lobes. • Align the punch mark a on the rear cylinder camshaft with the punch mark b on the front cylinder camshaft.
  • Page 300 CAMSHAFTS 4. Install: • front cylinder camshaft end cover 1 NOTE: • Align the projection a on the front cylinder camshaft end cover with the hole b on the front cylinder camshaft. • Finger tighten the place bolts. 5. Install: •...
  • Page 301 CAMSHAFTS 6. Tighten: • camshaft driven gear nut 1 52 Nm (5.2 m • kg, 37 ft • lb) NOTE: • Place a folded copper washer 2 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them. •...
  • Page 302: Cylinder Heads

    CYLINDER HEADS EAS00221 CYLINDER HEADS 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 39 Nm (3.9 m kg, 28 ft • • 60 Nm (6.0 m kg, 43 ft • •...
  • Page 303 CYLINDER HEADS 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 39 Nm (3.9 m kg, 28 ft • • 60 Nm (6.0 m kg, 43 ft • • 21 Nm (2.1 m kg, 15 ft •...
  • Page 304: Removing The Cylinder Heads

    CYLINDER HEADS REMOVING THE CYLINDER HEADS 1. Remove: • cylinder head NOTE: • Loosen the nuts in the proper sequence. • Follow the numerical order shown in the illus- tration. Loosen each bolt 1/4 of a turn at a time until all of the nuts are loose. EAS00228 CHECKING THE CYLINDER HEADS The following procedure applies to each cylin-...
  • Page 305: Checking The Oil Delivery Pipe

    CYLINDER HEADS CHECKING THE OIL DELIVERY PIPE 1. Check: • oil delivery pipe 1 Damage → Replace. Obstruction → Wash and blow out with compressed air. EAS00232 INSTALLING THE CYLINDER HEAD 1. Install: • cylinder head gasket 1 • dowel pins 2 2.
  • Page 306 CYLINDER HEADS 6. Install: • washer • engine temperature sensor 1 20 Nm (2.0 m • kg, 14 ft • lb) 5 - 38...
  • Page 307: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs The following procedure applies to both cylinders. Cylinder head Refer to “CYLINDER HEADS”. Valve cotter Upper spring seat Outer valve spring Inner valve spring...
  • Page 308: Removing The Valves

    VALVES AND VALVE SPRINGS EAS00238 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 309: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 3. Remove: • upper spring seat 1 • outer valve spring 2 • inner valve spring 3 • valve 4 • valve stem seal 5 • lower spring seat 6 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
  • Page 310 VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. M MMM M MMM M MMM M MMM M MMM a.
  • Page 311: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 5. Measure: • valve margin thickness a Out of specification → Replace the valve. Valve margin thickness 0.7 ~ 1.3 mm (0.0276 ~ 0.0512 in) 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: •...
  • Page 312 VALVES AND VALVE SPRINGS 3. Measure: • valve seat width a Out of specification → Replace the cylinder head. Valve seat width Intake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) Exhaust 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) M MMM M MMM M MMM...
  • Page 313 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 314: Checking The Valve Springs

    VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • valve spring free length a Out of specification → Replace the valve spring. Valve spring free length Intake valve spring 38.26 mm (1.51 in) <Limit>: 36.26 mm (1.43 in) Exhaust valve spring...
  • Page 315 VALVES AND VALVE SPRINGS EAS00246 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • valve stem end (with an oil stone) 2. Lubricate: • valve stem 1 • oil seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil...
  • Page 316 VALVES AND VALVE SPRINGS 4. Install: • valve cotters 1 NOTE: Install the valve cotters by compressing the valve springs with the valve spring compressor set 1. Valve spring compressor set YM-04019 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.
  • Page 317: Cylinders And Pistons

    CYLINDERS AND PISTONS EAS00252 CYLINDERS AND PISTONS Order Job/Part Q’ty Remarks Removing the cylinders and pistons Remove the parts in the order listed. Cylinder heads Refer to “CYLINDER HEADS”. Front cylinder Rear cylinder Cylinder gasket Dowel pin Refer to “INSTALL- Piston pin clip ING THE PIS- Refer to “REMOV-...
  • Page 318: Removing The Cylinders And Pistons

    CYLINDERS AND PISTONS EAS00254 REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 CAUTION: Do not use a hammer to drive the piston pin out.
  • Page 319: Checking The Cylinders And Pistons

    CYLINDERS AND PISTONS EAS00258 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Check: • piston wall • cylinder wall Vertical scratches → Replace the cylinder, and the piston and piston rings as a set. 2.
  • Page 320: Checking The Piston Rings

    CYLINDERS AND PISTONS Piston size “P” 96.960 ~ 96.975 mm Standard (3.8173 ~ 3.8179 in) d. If out of specification, replace the piston and piston rings as a set. e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C”...
  • Page 321: Checking The Piston Pins

    CYLINDERS AND PISTONS 2. Install: • piston ring (into the cylinder) NOTE: Level the piston ring into the cylinder with the piston crown. a 10 mm (0.39 in) 3. Measure: • piston ring end gap Out of specification → Replace the piston ring.
  • Page 322: Installing The Pistons And Cylinders

    CYLINDERS AND PISTONS 3. Measure: • piston pin bore diameter (in the piston) b Out of specification → Replace the piston pin. Piston pin bore diameter (in the piston) 22.004 ~ 22.015 mm (0.8663 ~ 0.8667 in) <Limit>: 22.045 mm (0.8679 in) 4.
  • Page 323 CYLINDERS AND PISTONS 2. Install: • piston 1 • piston pin 2 • piston pin clips 3 NOTE: • Apply engine oil onto the piston pin. • Make sure the “arrow” mark a on the piston faces towards the front of the motorcycle. •...
  • Page 324: Clutch

    CLUTCH EAS00273 CLUTCH CLUTCH COVER 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Left side cover Refer to “SEAT AND SIDE COVERS”...
  • Page 325: Clutch

    CLUTCH 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Shift arm Clutch cable holder Refer to “REMOV- Refer to “INSTALL- Clutch cover ING THE CLUTCH”. ING THE CLUTCH”. Clutch cover gasket Dowel pin For installation, reverse the removal...
  • Page 326 CLUTCH 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the pull lever shaft and Remove the parts in the order listed. crankshaft position sensor Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Crankshaft position sensor lead holder Refer to “INSTALLING THE CRANK-...
  • Page 327 CLUTCH EAS00274 CLUTCH 18 19 80 Nm (8.0 m kg, 58 ft • • 9 12 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed.
  • Page 328 CLUTCH 18 19 80 Nm (8.0 m kg, 58 ft • • 9 12 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Part Q’ty Remarks Clutch damper spring Refer to “REMOV- Clutch damper spring seat ING THE CLUTCH”.
  • Page 329: Removing The Clutch

    CLUTCH EAS00277 REMOVING THE CLUTCH 1. Remove: • clutch cable holder 1 • clutch cover 2 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.
  • Page 330: Removing The Primary Drive Gear

    CLUTCH EAS00279 REMOVING THE PRIMARY DRIVE GEAR 1. Remove: • crankshaft position sensor rotor bolt 1 NOTE: While holding the generator rotor 2 with the sheave holder 3, loosen the crankshaft posi- tion sensor rotor bolt. Primary sheave holder YS-01880-A EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the...
  • Page 331: Checking The Clutch Plate Spring

    CLUTCH 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge Out of specification → Replace the clutch plates as a set. Clutch plate warpage limit 0.2 mm (0.008 in) EAS00283 CHECKING THE CLUTCH PLATE SPRING 1. Check: •...
  • Page 332: Checking The Pressure Plate

    CLUTCH EAS00286 CHECKING THE PRESSURE PLATE 1. Check: • pressure plate 1 Cracks/damage → Replace. • bearing 2 Damage/wear → Replace. EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: • pull lever shaft pinion gear teeth a •...
  • Page 333: Installing The Primary Drive Gear

    CLUTCH 2. Install: • crankshaft position sensor 7 Nm (0.7 m • kg, 5.1 ft • lb) • crankshaft position sensor lead holder 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: ® Apply locking agent (LOCTITE ) to the threads of the crankshaft position sensor bolts and crankshaft position sensor lead holder bolts.
  • Page 334: Installing The Clutch

    CLUTCH EAS00293 INSTALLING THE CLUTCH 1. Install: • dowel pin 1 • oil pump drive gear 2 • plate 3 • circlip 4 2. Install: • clutch housing 1 • thrust washer 2 NOTE: • Lubricate the clutch housing bearings with engine oil.
  • Page 335 CLUTCH 4. Install: • clutch boss 1 • lock washer • clutch boss nut 2 80 Nm (8.0 m • kg, 58 ft • lb) NOTE: While holding the clutch boss with the univer- sal clutch holder 3, tighten the clutch boss nut.
  • Page 336 CLUTCH 8. Install: • pressure plate 1 NOTE: Align the punch mark a in the pressure plate with the punch mark b in the clutch boss. 9. Install: • clutch spring plate seat 1 • clutch spring plate 2 • clutch spring plate retainer 3 8 Nm (0.8 m •...
  • Page 337 CLUTCH 13.Install: • shift arm 1 12 Nm (1.2 m • kg, 8.7 ft • lb) NOTE: Align the mark a in the shift shaft with the slot in the shift arm. 14.Install: • pull lever spring • pull lever 12 Nm (1.2 m •...
  • Page 338: Shift Shaft And Stopper Lever

    SHIFT SHAFT AND STOPPER LEVER EAS00327 SHIFT SHAFT AND STOPPER LEVER 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the shift shaft and Remove the parts in the order listed. stopper lever Engine oil Drain.
  • Page 339: Checking The Shift Shaft

    SHIFT SHAFT AND STOPPER LEVER EAS00328 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 • shift lever spring 2 Damage/wear → Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.
  • Page 340 SHIFT SHAFT AND STOPPER LEVER 3. Install: • shift shaft spring • circlips • shift shaft 1 NOTE: Install the end of the shift shaft spring onto the shift shaft spring stopper 2. 5 - 72...
  • Page 341: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS00341 GENERATOR AND STARTER CLUTCH STATOR COIL ASSEMBLY 7 Nm (0.7 m kg, 5.1 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 342 GENERATOR AND STARTER CLUTCH 7 Nm (0.7 m kg, 5.1 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 • • 48 Nm (4.8 m kg, 35 ft •...
  • Page 343 GENERATOR AND STARTER CLUTCH EAS00343 GENERATOR AND STARTER CLUTCH Order Job/Part Q’ty Remarks Removing the generator rotor Remove the parts in the order listed. Starter clutch idle gear shaft #2 Starter clutch idle gear shaft #1 Starter clutch idle gear #2 Starter clutch idle gear #1 Generator rotor Woodruff key...
  • Page 344: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS00347 REMOVING THE GENERATOR 1. Remove: • generator cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.
  • Page 345: Installing The Generator

    GENERATOR AND STARTER CLUTCH 2. Check: • starter clutch operation M MMM M MMM M MMM M MMM M MMM a. Install the starter clutch gear 1 onto the starter clutch and hold the starter clutch. b. When turning the starter clutch gear clock- wise È, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be...
  • Page 346 GENERATOR AND STARTER CLUTCH 3. Apply: • sealant (onto the stator coil assembly lead grom- met) ® Quick Gasket ACC-11001-05-01 4. Install: • stator coil assembly 1 7 Nm (0.7 m • kg, 5.2 ft • lb) • stator coil assembly lead holder 10 Nm (1.0 m •...
  • Page 347: Transfer Gear Case

    TRANSFER GEAR CASE TRANSFER GEAR CASE 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 348 TRANSFER GEAR CASE 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 349 TRANSFER GEAR CASE Order Job/Part Q’ty Remarks Disassembling the transfer gear Remove the parts in the order listed. case oil pump Oil pump cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing For assembly, reverse the disassembly procedure.
  • Page 350: Fuel Pump

    TRANSFER GEAR CASE FUEL PUMP 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Removing the fuel pump Remove the parts in the order listed. Seat/cover Refer to “SEAT AND SIDE COVERS” in chapter 3. Fuel tank Refer to “FUEL TANK”...
  • Page 351: Removing The Fuel Pump

    TRANSFER GEAR CASE REMOVING THE FUEL PUMP 1. Remove: • fuel pump CAUTION: • Do not drop the fuel pump or give it a strong shock. • Do not touch the base section of the fuel sender. INSTALL THE FUEL PUMP 1.
  • Page 352: Sub Fuel Tank

    TRANSFER GEAR CASE SUB FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • 28 Nm (2.8 m kg, 20 ft • • Order Job/Part Q’ty Remarks Removing the sub fuel tank Remove the parts in the order listed. Fuel pump Refer to “FUEL PUMP”.
  • Page 353 TRANSFER GEAR CASE 50 Nm (5.0 m kg, 36 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the transfer gear case Remove the parts in the order listed. Seat/right side cover Refer to “SEAT AND SIDE COVERS”...
  • Page 354 TRANSFER GEAR CASE 50 Nm (5.0 m kg, 36 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Oil seal Transfer gear case Dowel pin Bearing Bearing housing For installation, reverse the removal procedure.
  • Page 355 TRANSFER GEAR CASE 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Disassembling the oil tank Remove the parts in the order listed. Oil temperature sensor Oil tank left cover Oil tank left cover gasket...
  • Page 356: Removing The Middle Driven Shaft

    TRANSFER GEAR CASE REMOVING THE MIDDLE DRIVEN SHAFT NOTE: Loosen the middle drive gear nut before remove the drive sprocket. 1. Straighten the lock washer tab. 2. Loosen: • middle drive gear nut 1 NOTE: When loosening the middle drive gear nut, press down on the brake pedal so the middle drive gear does not move.
  • Page 357: Checking The Oil Strainer

    TRANSFER GEAR CASE CHECKING THE OIL STRAINER 1. Check: • oil strainer Damage → Replace. Contaminants → Clean with engine oil. CHECKING THE OIL PUMP 1. Check: • oil pump housing 1 • oil pump cover 2 Cracks/damage/wear → Replace the defec- tive part(-s).
  • Page 358: Checking The Oil Pipe

    TRANSFER GEAR CASE CHECKING THE OIL PIPE 1. Check: • oil pipe Damage → Replace. EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2.
  • Page 359: Installing The Transfer Gear Case

    TRANSFER GEAR CASE 4. Check: • oil pump operation Refer to “CHECKING THE OIL PUMP”. INSTALLING THE TRANSFER GEAR CASE 1. Install: • middle driven shaft 1 • middle drive gear 2 • primary chain 3 (into the transfer gear case) •...
  • Page 360 TRANSFER GEAR CASE 4. Install: • lock washer • middle drive gear nut 1 100 Nm (10.0 m • kg, 72 ft • lb) 5. Bend the lock washer tab along a flat side of the nut. 6. Remove: • drive sprocket nut 7.
  • Page 361: Crankcase

    CRANKCASE CRANKCASE Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Camshafts Refer to “CAMSHAFTS”. Pistons Refer to “CYLINDERS AND PISTONS”. Shift shaft Refer to “SHIFT SHAFT AND STOPPER LEVER”. Generator rotor Refer to “GENERATOR AND STARTER CLUTCH”.
  • Page 362 CRANKCASE Order Job/Part Q’ty Remarks Engine oil pump driven gear Left crankcase Dowel Joint pipe Right crankcase For installation, reverse the removal procedure. 5 - 94...
  • Page 363 CRANKCASE Order Job/Part Q’ty Remarks Removing the baffle plate and Remove the parts in the order listed. bearings Crankshaft Refer to “CRANKSHAFT AND CON- NECTING RODS”. Transmission Refer to “TRANSMISSION”. Baffle plate Oil seal Bearing For installation, reverse the removal procedure.
  • Page 364: Disassembling The Crankcase

    CRANKCASE EAS00386 DISASSEMBLING THE CRANKCASE NOTE: Loosen the generator shaft bolt before remov- ing the generator rotor. 1. Remove: • generator shaft bolt 1 NOTE: While the holding the generator rotor 2 with the primary sheave holder 3, loosen the gen- erator shaft bolt.
  • Page 365: Checking The Crankcase

    CRANKCASE 3. Turn: • shift drum segment NOTE: Turn the shift drum segment 1 to the position shown in the illustration. In this position, the shift drum segment’s teeth will not contact the crankcase during crankcase separation. 4. Remove: • right crankcase CAUTION: •...
  • Page 366: Checking The Bearings And Oil Seals

    CRANKCASE EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1. Check: • bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement → Replace. 2. Check: • oil seals Damage/wear → Replace. CHECKING THE OIL DELIVERY PIPE 1.
  • Page 367: Assembling The Crankcase

    CRANKCASE EAS00416 ASSEMBLING THE CRANKCASE 1. Apply: • sealant (onto the crankcase mating surfaces) ® Quick Gasket ACC-11001-05-01 NOTE: Do not allow any sealant to come into contact with the oil gallery. 2. Install: • dowel pins 1 • joint pipe 2 3.
  • Page 368 CRANKCASE 4. Install: È • holder • crankcase bolts NOTE: • Lubricate the bolt threads with engine oil. • Tighten each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. • Tighten the bolts in numerical order (refer to the numbers in the illustration).
  • Page 369 CRANKCASE 9. Install: • washer • generator shaft bolt 1 28 Nm (2.8 m • kg, 20 ft • lb) NOTE: ® • Apply locking agent (LOCTITE ) to the threads of the generator shaft bolt. • While holding the generator rotor 2 with the primary sheave holder 3, tighten the gener- ator shaft bolt.
  • Page 370: Engine Oil Pump

    ENGINE OIL PUMP EAS00356 ENGINE OIL PUMP Order Job/Part Q’ty Remarks Removing the engine oil pump Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE” Oil strainer Engine oil pump assembly For installation, reverse the removal procedure. 5 - 102...
  • Page 371 ENGINE OIL PUMP Order Job/Part Q’ty Remarks Disassembling the engine oil pump Remove the parts in the order listed. Spring retainer Spring Relief valve Oil pump housing cover 1 Spring Collar Ball Oil pump outer rotor 1 Oil pump inner rotor 1 5 - 103...
  • Page 372 ENGINE OIL PUMP Order Job/Part Q’ty Remarks Oil pump housing cover 2 Oil pump shaft Oil pump inner rotor 2 Oil pump outer rotor 2 Oil seal Oil pump housing For assembly, reverse the disassembly procedure. 5 - 104...
  • Page 373: Checking The Oil Pump

    ENGINE OIL PUMP EAS00363 CHECKING THE OIL PUMP 1. Check: • oil pump housing 1 • oil pump housing covers 2 Cracks/damage/wear → Replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance a • outer-rotor-to-oil-pump-housing clearance Out of specification → Replace the oil pump.
  • Page 374: Checking The Oil Strainer

    ENGINE OIL PUMP 2. Check: • ball 1 • collar 2 • spring 3 • oil seal 4 Damage/wear → Replace the defective part(s). EAS00368 CHECKING THE OIL STRAINER 1. Check: • oil strainer 1 Damage → Replace. Contaminants → Clean with solvent. EAS00375 ASSEMBLING THE OIL PUMP 1.
  • Page 375: Installing The Oil Pump

    ENGINE OIL PUMP 2. Install: • oil pump housing 1 • oil seals 2 • oil pump outer rotor 2 3 • oil pump inner rotor 2 4 • pin 5 • oil pump shaft 6 • pins 7 • oil pump housing cover 2 8 2 Nm (0.2 m •...
  • Page 376: Installing The Oil Strainer

    ENGINE OIL PUMP EAS00378 INSTALLING THE OIL STRAINER 1. Install: • oil strainer 1 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: The arrow mark on the oil strainer cover must point towards the rear of the engine. 5 - 108...
  • Page 377: Crankshaft And Connecting Rods

    CRANKSHAFT AND CONNECTING RODS CRANKSHAFT AND CONNECTING RODS Order Job/Part Q’ty Remarks Removing the crankshaft and Remove the parts in the order listed. connecting rods Crankcase Separate. Refer to “CRANKCASE”. Crankshaft Generator shaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal...
  • Page 378: Removing The Crankshaft

    CRANKSHAFT AND CONNECTING RODS EAS00385 REMOVING THE CRANKSHAFT 1. Remove: • crankshaft journal bearing 1 NOTE: • Remove the crankshaft journal bearing with the bearing remover and installer 2 and bearing driver 3. Bearing remover and installer YM-28898 Bearing driver YM-04058 EAS00391 REMOVING THE CONNECTING RODS...
  • Page 379 CRANKSHAFT AND CONNECTING RODS 2. Check: • crankshaft journal surfaces • crankshaft pin surfaces • bearing surfaces Scratches/wear → Replace the crankshaft. • generator shaft drive gear 1 Damage/wear → Replace the crankshaft. 3. Measure: • crankshaft-pin-to-big-end-bearing clear- ance Out of specification → Replace the big end bearings.
  • Page 380 CRANKSHAFT AND CONNECTING RODS d. Assemble the connecting rod halves. NOTE: • Do not move the connecting rod or crank- shaft until the clearance measurement has been completed. • Lubricate the bolts threads and nut seats with molybdenum disulfide grease. •...
  • Page 381 CRANKSHAFT AND CONNECTING RODS CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle. • Tighten the bolt until it is the specified angle. NOTE: When using a hexagonal bolt note that the angle from one corner to another is 60°. h.
  • Page 382 CRANKSHAFT AND CONNECTING RODS 4. Select: • big end bearings (P NOTE: • The numbers a stamped into the crankshaft web and the numbers b on the connecting rods are used to determine the replacement big end bearing sizes. • “P ”...
  • Page 383 CRANKSHAFT AND CONNECTING RODS 5. Measure: • crankshaft journal diameter a Out of specification → Replace the crank- shaft. Crankshaft journal diameter 49.968 ~ 49.980 mm (1.9672 ~ 1.9677 in) NOTE: Measure the diameter of each crankshaft jour- nal at two places. 6.
  • Page 384: Installing The Connecting Rods

    CRANKSHAFT AND CONNECTING RODS 7. Calculate: • crankshaft journal-to-crankshaft journal bearing clearance Out of specification → Replace the crank- shaft and crankshaft journal bearings as a set. NOTE: Calculate the clearance by subtracting the crankshaft journal diameter from the crank- shaft journal bearing inside diameter.
  • Page 385 CRANKSHAFT AND CONNECTING RODS 3. Install: • big end bearings • connecting rods • connecting rod caps (onto the crankshaft pins) NOTE: • Align the projections a on the big end bear- ings with the notches b in the connecting rods and connecting rod caps.
  • Page 386: Installing The Crankshaft

    CRANKSHAFT AND CONNECTING RODS WARNING When the bolts are tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and per- form the procedure again. CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle.
  • Page 387: Transmission

    TRANSMISSION EAS00419 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum assembly, and shift forks Crankcase Separate. Refer to “CRANKCASE”. Shift fork guide bar Shift fork “L” Shift fork “R” Shift fork “C” Shift drum assembly Drive axle assembly Main axle assembly...
  • Page 388 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle Remove the parts in the order listed. assembly Circlip Washer 5th pinion gear 2nd/3rd pinon gear Circlip Washer 4th pinon gear Main axle/1st pinon gear For assembly, reverse the disassembly procedure. 5 - 120...
  • Page 389 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle Remove the parts in the order listed. assembly 5th wheel gear Circlip Washer 2nd wheel gear Circlip Washer 1st wheel gear 4th wheel gear Circlip Washer 3rd wheel gear Drive axle For assembly, reverse the disassembly procedure.
  • Page 390: Checking The Shift Forks

    TRANSMISSION EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower 1 • shift fork pawl 2 Bends/damage/scoring/wear → Replace the shift fork. 2. Check: • shift fork guide bar Roll the shift fork guide bar on a flat surface.
  • Page 391: Checking The Shift Drum Assembly

    TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • shift drum grooves Damage/scratches/wear → Replace the shift drum assembly. • shift drum segment 1 Damage/wear → Replace the shift drum assembly. • shift drum bearing 2 Damage/pitting → Replace the shift drum assembly.
  • Page 392: Installing The Transmission

    TRANSMISSION 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 5. Check: • transmission gear movement Rough movement → Replace the defective part(s). 6. Check: • circlips Bends/damage/looseness → Replace. EAS00428 INSTALLING THE TRANSMISSION 1.
  • Page 393 TRANSMISSION 2. Check: • transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly. 5 - 125...
  • Page 394: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Linear control valve 8 Spark plug E Decompression solenoid 2 Intake air pressure sensor 2 9 Relay unit F Crankshaft position sensor 3 Intake air temperature sensor 0 ECU G Cylinder identification sensor 4 Intake air pressure sensor 1 A Battery H Ignition coil...
  • Page 395: Wiring Diagram

    FUEL INJECTION SYSTEM WIRING DIAGRAM 6 - 2...
  • Page 396 FUEL INJECTION SYSTEM 3 Main switch 4 Battery 6 Main fuse A Fuel injection system relay B Fuel pump E Crankshaft position sensor F Throttle position sensor G Intake air pressure sensor 1 H Intake air pressure sensor 2 I Atmospheric pressure sensor J Cylinder identification sensor K Lean angle cut-off switch L Speed sensor...
  • Page 397: Ecu's Self-diagnostic Function

    FUEL INJECTION SYSTEM ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control sys- tem is operating normally. If this function detects a malfunction in the system, it immediately oper- ates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 398 FUEL INJECTION SYSTEM Engine trouble warning light indication and FI system operating conditions (normal mode) Warning light ECU’s operating FI operating condition Starting and driving indication condition ON and OFF *1 Self-diagnostic func- FI function in operation Able tion in operation Blinking *2 Warning control when Operation stopped...
  • Page 399 FUEL INJECTION SYSTEM Function to check for blown warning light bulb The engine trouble warning light illuminates 1 for 1.4 seconds after the main switch has been turned “ON” and while the starter switch is being pressed. If the warning light does not illuminate under these conditions, a problem may have possibly occurred, such as a blown warning light bulb.
  • Page 400 FUEL INJECTION SYSTEM * Table of self-diagnostic fault code numbers displayed on meter Able/ Able/ Able/ Able/ Symptom unable to unable to Symptom unable to unable to start drive start drive No normal signals are received Faulty intake air pressure sensor from the cylinder identification pipe system 2;...
  • Page 401: Substitute Characteristics Operation Control (fail-safe Action)

    FUEL INJECTION SYSTEM SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the motorcycle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with substitute characteristic operation instructions that are appropriate for the type of the malfunction.
  • Page 402: Troubleshooting

    FUEL INJECTION SYSTEM TROUBLESHOOTING Diagnosis mode troubleshooting 1 (self-diagnostic malfunction detected) By entering a diagnostic code in the ECU through the use of the “SELECT” and “RESET” buttons on the tachometer, the sensor output values can be displayed and the actuators can be operated in accordance with the code that has been entered.
  • Page 403 FUEL INJECTION SYSTEM Verifying the operation of various sensors and actuators 1. Disconnect the wiring harness coupler from the fuel pump. 2. Turn the engine stop switch “OFF”. TRIP mile · Turn the engine stop switch “ON” if diag- nostic code numbers 03 and 09 are shown.
  • Page 404 FUEL INJECTION SYSTEM Erase the codes appearing on the meter upon the completion of the operation (reinstating the ECU). * Verify reinstatement procedures detailed in the troubleshooting details in order to carry out the reinstatement opera- tion that is applicable to the malfunctioning item.
  • Page 405 FUEL INJECTION SYSTEM Self-diagnostic fault codes, symptoms, and probable causes Diagnostic code indication Code No. Symptom Probable cause of malfunction Diagnostic code No normal signals are received from • Open or short circuit in wiring sub lead. the cylinder identification sensor. •...
  • Page 406 FUEL INJECTION SYSTEM Code No. Symptom Probable cause of malfunction Diagnostic code Atmospheric pressure sensor - open • Open or short circuit in wiring harness. or short circuit detected. • Defective atmospheric pressure sensor. • Improperly installed sensor. • Malfunction in ECU. Intake air pressure sensor 2 - open or •...
  • Page 407 FUEL INJECTION SYSTEM Sensor operation data display verification table NOTE: • Check the intake temperature, engine temperature, and oil temperature as close as possible to the area in which the respective sensor is mounted. • If it is not possible to check it with an atmospheric pressure gauge, judge it by using 760 mmHg as the standard.
  • Page 408 FUEL INJECTION SYSTEM Data displayed on meter Diag code Item Description of action (reference value) Malfunction history • Displays the total number of codes that are being detected 00 ~ 21 code erasure through self diagnosis and the fault codes in the past his- (00) Displays when there is no tory.
  • Page 409 FUEL INJECTION SYSTEM Actuator operation verification table Data displayed on meter Diag code Item Description of action (reference value) Ignition coil #1 After 1 second has elapsed from the time the engine stop Check that spark is generated, switch has been turned from OFF to ON, it actuates ignition 5 times with the engine stop coils #1 for five times every second and illuminates the engine switch ON.
  • Page 410 FUEL INJECTION SYSTEM Troubleshooting The condition of the engine is poor or the engine trouble warning light comes on. * The engine trouble warning light may not come on even if the condition of the engine is poor. The engine trouble warning light comes on. The engine trouble warning light does not come on.
  • Page 411 FUEL INJECTION SYSTEM Troubleshooting details Troubleshooting the self-diagnostic fault code Code No. Symptom No normal signals are received from the cylinder identification sensor. Used diagnostic code No. 1.Inspection operation item Operation item and countermeasure Reinstatement method 2.Defective cylinder identification sensor. Replace if defective.
  • Page 412 FUEL INJECTION SYSTEM Code No. Symptom Intake air pressure sensor 1 - open or short circuit detected. Used diagnostic code No. 03 (intake air pressure sensor 1) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Open or short circuit in wiring harness or Repair or replace if there is an open or short Reinstated by turn- sub lead.
  • Page 413 FUEL INJECTION SYSTEM Code No. Symptom 1 Intake air pressure sensor 1 - pipe system malfunction (clogged or detached hose). 2 Intake air pressure sensor 1 - open or short circuit detected. 3 Stuck throttle position sensor detected. Used diagnostic code No.
  • Page 414 FUEL INJECTION SYSTEM Code No. Symptom Throttle position sensor - open or short circuit detected. Used diagnostic code No. 01 (throttle position sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Installed state of throttle position sensor. Check the installed area for looseness or Reinstated by turn- pinching.
  • Page 415 FUEL INJECTION SYSTEM Code No. Symptom 1 Stuck throttle position sensor detected. 2 Intake air pressure sensor - pipe system malfunction (clogged or detached hose). Used diagnostic code No. 01 (throttle position sensor) No. 03 (intake air pressure sensor 1) No.
  • Page 416 FUEL INJECTION SYSTEM Code No. Symptom Open circuit is detected in the input line from the sidestand switch to the ECU. Used diagnostic code No. 20 (sidestand switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Open or short circuit in wiring harness or Repair or replace if there is an open or short If the transmission...
  • Page 417 FUEL INJECTION SYSTEM Code No. Symptom Open or short circuit detected from the atmospheric pressure sensor. Used diagnostic code No. 02 (atmospheric pressure sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Installed state of atmospheric pressure sen- Check the installed area for looseness or Reinstated by turn- pinching.
  • Page 418 FUEL INJECTION SYSTEM Code No. Symptom 1 Intake air pressure sensor 2 - pipe system malfunction (clogged or detached hose). 2 Intake air pressure sensor 2 - open or short circuit detected. 3 Stuck throttle position sensor detected. Used diagnostic code No.
  • Page 419 FUEL INJECTION SYSTEM Code No. Symptom Open or short circuit is detected from the oil temperature sensor. Used diagnostic code No. 10 (oil temperature sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Installed state of sensor Check the installed area for looseness or Reinstated by turn- pinching.
  • Page 420 FUEL INJECTION SYSTEM Code No. Symptom Electricity is not circulated to the decompression solenoid (open or short circuit in thermistor is detected) Used diagnostic code No. 55 (decompression solenoid) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Installed state of decompression solenoid Check the installed area for looseness or...
  • Page 421 FUEL INJECTION SYSTEM Code No. Symptom Faulty liner control valve or motor is detected. Used diagnostic code No. 54 (linear control valve) No. 10 (oil temperature sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1-1.Defective linear control valve Replace if defective.
  • Page 422 FUEL INJECTION SYSTEM Code No. Symptom Open or short circuit detected in the lean angle cut-off switch. Used diagnostic code No. 08 (lean angle cut-off switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Open or short circuit in lead wire. Repair or replace if there is an open or short Reinstated by turn- circuit.
  • Page 423 FUEL INJECTION SYSTEM Code No. Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 50 (fuel injection system relay) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Malfunction in ECU Fuel injection system relay is on. Reinstated by starting the engine 2.Open or short circuit in the wiring harness.
  • Page 424 FUEL INJECTION SYSTEM Diagnosis mode troubleshooting 2 (self-diagnostic malfunction not detected) Troubleshooting the sensors and actuator with no malfunctions detected, and special indications Even if the malfunctions of some of the sensors do not appear on the meter because they are not detected by the self-diagnostic function, they can be inspected in the diagnosis mode.
  • Page 425 FUEL INJECTION SYSTEM Symptom Engine cannot be started or difficult to start. (Fuel is not supplied to the cylinder.) Probable mal- • Open or short circuit in injector function area • Open or short circuit in wiring harness Inspection method 1 Inspection method 2 Inspection by diagnosis mode Inspection of a malfunction that cannot be identified in the...
  • Page 426 FUEL INJECTION SYSTEM Symptom The headlight does not turn ON or OFF. Probable mal- • Malfunction in the headlight relay function area • Malfunction in the headlight • Open or short circuit in the headlight wiring harness • Malfunction in the handlebar switch •...
  • Page 427 FUEL INJECTION SYSTEM Symptom Clock LCD displays “Er-2”. (No signals are received from the ECU within the specified duration.) Probable mal- • Improper operation of communication line function area • Malfunction in meter • Malfunction in ECU Inspection method 1 Inspection method 2 Inspection by diagnosis mode Inspection of a malfunction that cannot be identified in the...
  • Page 428 FUEL INJECTION SYSTEM Symptom Sidestand switch does not function (the engine does not stop when the stand is extended). Probable mal- • Short circuit in the input line to ECU function area • Malfunction in the starter circuit cut-off relay Inspection method 1 Inspection method 2 Inspection by diagnosis mode...
  • Page 429 FUEL INJECTION SYSTEM Symptom Engine trouble warning light blinks while the start switch is being pressed (to warn that the engine is unable to start). Probable mal- • Malfunction in Fuel injection system relay function area • Open circuit in wiring harness •...
  • Page 430: Throttle Bodies

    FUEL INJECTION SYSTEM THROTTLE BODIES 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the throttle bodies Remove the parts in the order listed. Seat Refer to “SEAT AND SIDE COVERS” in chapter 3. Fuel tank/Air induction system cover/ Refer to “FUEL TANK”...
  • Page 431 FUEL INJECTION SYSTEM 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Throttle stop screw Throttle body joint screw Throttle bodies Throttle cable Disconnect. Throttle position sensor Refer to “FUEL INJECTION SYSTEM” in chapter 7. For installation, reverse the removal procedure.
  • Page 432 FUEL INJECTION SYSTEM 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the intake manifolds Remove the parts in the order listed. Engine temperature sensor coupler Disconnect. Injection sub-wire harness coupler Disconnect. Fuel hose Disconnect. Linear control valve outlet hose Disconnect.
  • Page 433 FUEL INJECTION SYSTEM 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the injectors Remove the parts in the order listed. Cylinder #1-injector coupler Disconnect. Cylinder #2-injector coupler Disconnect. Injector sub-wire harness Fuel pipe Injector joint 1 Injector joint 2 Injector For installation, reverse the removal...
  • Page 434: Checking The Injector

    FUEL INJECTION SYSTEM CAUTION: The throttle bodies should not be disas- sembled unnecessarily. CHECKING THE INJECTOR 1. Check: • injector Damage → Replace. CHECKING THE THROTTLE BODY 1. Check: • throttle body Cracks/damage → Replace the throttle bodies. 2. Check: •...
  • Page 435: Checking The Fuel Pump And Pressure Regulator Operation

    FUEL INJECTION SYSTEM CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: • pressure regulator operation M MMM M MMM M MMM M MMM M MMM a. Remove the air duct. Refer to “FUEL TANK” in chapter 3. b. Remove the fuel hose end clamp 1. c.
  • Page 436: Air Induction System

    AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.
  • Page 437: Air Cut-off Valve Assembly And Air Induction System Hoses

    AIR INDUCTION SYSTEM AIR CUT-OFF VALVE ASSEMBLY AND AIR INDUCTION SYSTEM HOSES 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the air cut-off valve Remove the parts in the order listed. assembly and hoses Fuel hose joint 1/air duct Refer to “FUEL TANK”...
  • Page 438: Reed Valves

    AIR INDUCTION SYSTEM REED VALVES 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the reed valves Remove the parts in the order listed. Air cut-off valve assembly/hoses A.I.S. vacuum hose Reed valve cover Reed valve assembly Reed valve case Pressure regulator A.I.S.
  • Page 439: Checking The Pressure Regulator

    AIR INDUCTION SYSTEM CHECKING THE PRESSURE REGULATOR 1. Check: • pressure regulator Damage → Replace. EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection → Connect properly. Cracks/damage → Replace. • pipes Cracks/damage → Replace. 2. Check: •...
  • Page 440: Elec

    – ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Ignition coil 2 7 Clutch switch C Decompression solenoid 2 Ignition coil 1 8 Atmospheric pressure sensor D Sidestand switch 3 Intake air pressure sensor 2 9 ECU E Crankshaft position sensor 4 Front brake light switch 0 Battery F Starter motor...
  • Page 441 – ELEC ELECTRICAL COMPONENTS 1 Intake air temperature sensor A Relay unit 2 Linear control valve B Speed sensor 3 Throttle position sensor C Lean angle cut-off switch 4 Engine temperature sensor D Oil temperature sensor 5 Spark plugs E Neutral switch 6 Fuse box F Stator coil assembly 7 Main fuse...
  • Page 442: Arrangement Of The Electrical Components And Couplers

    ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS 1 Speedometer coupler, tachometer couplers, right handlebar switch coupler and front turn signal/position connectors 2 Speedometer coupler, main switch coupler and left handlebar switch couplers 3 Headlight coupler 1 Rear turn signal light (left) connectors and license plate light connectors 2 Rear turn signal light (right) connectors...
  • Page 443 ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS 1 Linear control valve 9 Starter motor 2 Ignition coil 1 (rear cylinder) 0 Starter motor lead 3 Atmospheric pressure sensor A Rectifier/regulator coupler 4 Atmospheric pressure sensor coupler B Stator coil assembly coupler 5 Spark plug cap (ignition coil 2 - L spark plug lead) C Horn 1 connectors 6 Spark plug cap (ignition coil 1 - L spark plug lead)
  • Page 444 ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS 1 ECU coupler 2 ECU 3 Tail sub-wire harness coupler, decompression solenoid couplers, cylinder identification coupler, crankshaft position sensor coupler, speed sensor coupler, neutral switch connector and sidestand switch coupler 4 Fuel pump coupler 5 Horn 2 6 Horn 2 coupler 7 Lean angle cut-off switch coupler...
  • Page 445 ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS 1 ECU fuse 8 Battery positive lead 2 Fuse box 9 Headlight relay 3 Starter relay coupler 0 Battery negative lead 4 Main fuse A Horn 2 5 Starter relay B Startr motor lead 6 Turn signal relay C Relay unit 7 Battery...
  • Page 446 ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS 1 Spark plug cap (ignition coil 1 - R spark plug lead) 0 Rear brake light switch 2 Throttle position sensor A Stator coil 3 Intake air pressure sensor 1 coupler B Cylinder identification sensor 4 Engine temperature sensor coupler C Decompression solenoid...
  • Page 447: Checking Switch Continuity

    – ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1.
  • Page 448: Checking The Switches

    – ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace the switch. Improperly connected → Properly connect. Incorrect continuity reading →...
  • Page 449 – ELEC CHECKING THE SWITCHES 1 Dimmer switch 2 Horn switch 3 Turn signal switch 4 Clutch switch 5 Engine stop switch 6 Start switch 7 Front brake light switch 8 Main switch 9 Fuse 0 Rear brake light switch A Neutral switch B Sidestand switch 7 - 11...
  • Page 450: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
  • Page 451 – ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: • Be sure to hold the socket firmly when removing the bulb.
  • Page 452: Checking The Condition Of The Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester YU-03112 NOTE:...
  • Page 453: Checking The Leds

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE LEDs The following procedures applies to all of the LEDs. 1. Check: Dg Lg B • LED (for proper operation) Ch Y Improper operation → Replace. M MMM M MMM M MMM M MMM M MMM...
  • Page 454: Ignition System

    – ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM 7 - 16...
  • Page 455: Troubleshooting

    – ELEC IGNITION SYSTEM EAS00737 EAS00738 TROUBLESHOOTING 1. Main and ignition fuses The ignition system fails to operate (no • Check the main and ignition fuses for con- spark or intermittent spark). tinuity. Refer to “CHECKING THE FUSES” in Check: chapter 3.
  • Page 456 – ELEC IGNITION SYSTEM EAS00745 • Is the spark plug in good condition, is it of 5. Spark plug cap resistance the correct type, and is its gap within spec- ification? The following procedure applies to all of the spark plug caps. •...
  • Page 457 – ELEC IGNITION SYSTEM EAS00747 • Is the ignition coil OK? 6. Ignition coil resistance The following procedure applies to all of the ignition coils. • Disconnect the ignition coil leads from the Replace the ignition wire harness. coil. • Connect the pocket tester (Ω × 1) to the EAS00748 ignition coil as shown.
  • Page 458 – ELEC IGNITION SYSTEM EAS00749 12.Lean angle cut-off switch voltage 8. Main switch • Remove the lean angle cut-off switch. • Check the main switch for continuity. • Connect the pocket tester (Ω × 1) to the Refer to “CHECKING THE SWITCHES”. lean angle cut-off switch terminals as •...
  • Page 459 – ELEC IGNITION SYSTEM EAS00760 EAS00754 13.Relay unit (diode) 14.Wiring • Remove the relay unit from the wire har- • Check the entire ignition system’s wiring. ness. Refer to “CIRCUIT DIAGRAM”. • Connect the pocket tester (Ω × 1) to the •...
  • Page 460: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 7 - 22...
  • Page 461: Starting Circuit Cut-off System Operation

    – ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 462: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition and decompression solenoid fuses Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F)
  • Page 463 – ELEC ELECTRIC STARTING SYSTEM EAS00759 Positive tester probe → 4. Relay unit (starting circuit cut-off relay) sky blue 1 Negative tester probe → • Remove the relay unit from the wire har- black/yellow 2 ness. • Connect the pocket tester (Ω × 1) and bat- Positive tester probe →...
  • Page 464 – ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00750 6. Starter relay 8. Engine stop switch • Remove the starter relay. • Check the engine stop switch for continu- • Connect the pocket tester (Ω × 1) and bat- ity. tery (12 V) to the starter relay terminals as Refer to “CHECKING THE SWITCHES”.
  • Page 465 – ELEC ELECTRIC STARTING SYSTEM EAS00764 Decompression solenoid 12.Start switch resistance 1.2 Ω at 20 °C (68 °F) • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. • Check the decompression solenoid for • Is the start switch OK? continuity.
  • Page 466: Starter Motor

    – ELEC STARTER MOTOR EAS00767 STARTER MOTOR 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Starter motor lead Starter motor assembly For installation, reverse the removal procedure.
  • Page 467 – ELEC STARTER MOTOR Order Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed. Circlip Starter motor gear Starter motor rear cover Lock washer Washer set Refer to “ASSEMBLING THE STARTER Oil seal MOTOR”. Bearing Circlip Starter motor front cover Brush...
  • Page 468 – ELEC STARTER MOTOR Order Job/Part Q’ty Remarks Brush holder (along with the brushes) Brush seat (along with the brushes) Bearing Refer to “ASSEMBLING THE STARTER MOTOR”. Gasket Armature assembly Starter motor yoke For assembly, reverse the disassembly procedure. 7 - 30...
  • Page 469: Checking The Starter Motor

    – ELEC STARTER MOTOR EAS00770 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 27.5 mm (1.08 in) 3.
  • Page 470 – ELEC STARTER MOTOR 4. Measure: • armature assembly resistances (commuta- tor and insulation) Out of specification → Replace the starter motor. M MMM M MMM M MMM M MMM M MMM a. Measure the armature assembly resis- tances with the pocket tester. Pocket tester YU-03112 Armature coil...
  • Page 471: Assembling The Starter Motor

    – ELEC STARTER MOTOR EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: • bearing • brush seat 1 NOTE: Align the slot a on the brush seat with the tab b in the starter motor front cover. 2. Install: • brush holder (along with the brushes) 1 3.
  • Page 472 – ELEC STARTER MOTOR 6. Install: • gasket 1 • starter motor cover 2 • bolts NOTE: Align the match marks a on the starter motor yoke with the match marks b on the starter motor rear cover. 7. Install: •...
  • Page 473: Charging System

    – ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM Br/B Br/B (BLACK) (BLACK) L/W1 WIREHARNESS TAIL SUB-WIREHARNESS WIREHARNESS INJECTION SUB-WIREHARNESS (BLACK) (GRAY) L W/Y (BLACK) Br/L Br/L (BLACK) Br/L (GRAY) B/L Br/W (BLACK) (BLA å (BLACK) Br/B Br B L W/B (BLACK) (BLACK) (BLACK)
  • Page 474: Troubleshooting

    – ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse 2. battery Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F) 3.
  • Page 475 – ELEC CHARGING SYSTEM EAS00779 • Is the charging voltage within specifica- 5. Wiring tion? • Check the wiring connections of the entire charging system. Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly The charging circuit connected and without defects? is OK.
  • Page 476: Circuit Diagram

    – ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 7 - 38...
  • Page 477: Troubleshooting

    – ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery Any of the following fail to light: head- • Check the condition of the battery. light, high beam indicator light, taillight, Refer to “CHECKING AND CHARGING position light, license plate light or meter THE BATTERY”...
  • Page 478: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EAS00788 5. Headlight relay CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator • Remove the headlight relay from the wire light fail to come on. harness. • Connect the pocket tester (Ω × 1) and bat- 1.
  • Page 479 – ELEC LIGHTING SYSTEM EAS00789 Headlight 2. The tachometer and speedometer light fails Positive tester probe → to come on. yellow 1 or green 2 1. Tachometer and speedometer light LED Negative tester probe → black 3 • Check the LED of the tachometer and High beam indicator light speedometer light.
  • Page 480 – ELEC LIGHTING SYSTEM Speedometer assembly coupler 2. Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light assembly coupler (tail sub- wire harness side) as shown. Positive tester probe → blue 1 Dg Lg B Negative tester probe → black 2 Ch Y Br Ch Y Dg Lg B...
  • Page 481 – ELEC LIGHTING SYSTEM • Check the front turn signal/position light 2. Voltage bulb and socket for continuity. • Connect the pocket tester (DC 20 V) to the Refer to “CHECKING THE BULBS AND license plate light connectors (wire har- BULB SOCKETS”.
  • Page 482: Signaling System

    – ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 7 - 44...
  • Page 483 – ELEC SIGNALING SYSTEM 3 Main switch 4 Battery 5 Backup fuse (odometer and clock) 6 Main fuse 9 Relay unit B Fuel pump C Neutral switch P ECU X Tachometer [ Engine trouble warning light \ Neutral indicator light ] Speedometer _ Fuel level warning light a Left turn signal indicator light...
  • Page 484: Troubleshooting

    – ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to light: turn • Check the condition of the battery. signal light, brake light or an indicator Refer to “CHECKING AND CHARGING light. THE BATTERY” in chapter 3. •...
  • Page 485: Checking The Signaling System

    – ELEC SIGNALING SYSTEM EAS00796 3. Horn 1 CHECKING THE SIGNALING SYSTEM 1. The horn 1 fails to sound. • Disconnect the black connector at the horn 1 terminal. 1. Horn switch • Connect a jumper lead 1 to the horn 1 ter- •...
  • Page 486 – ELEC SIGNALING SYSTEM EAS00796 3. Horn 2 2. The horn 2 fails to sound. • Disconnect the horn 2 coupler at the horn 1. Horn switch • Check the horn switch for continuity. • Connect a jumper lead 1 to the brown ter- Refer to “CHECKING THE SWITCHES”.
  • Page 487 – ELEC SIGNALING SYSTEM EAS00799 2. Brake light switches 4. The turn signal light, turn signal indicator light or both fail to blink. • Check the brake light switches for continu- ity. 1. Turn signal light bulb and socket Refer to “CHECKING THE SWITCHES”. •...
  • Page 488 – ELEC SIGNALING SYSTEM 4. Voltage 5. Voltage • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness turn signal relay coupler (wire harness side) as shown.
  • Page 489 – ELEC SIGNALING SYSTEM • Set the main switch to “ON”. 6. Voltage • Set the turn signal switch to “ ” or “ ”. • Connect the pocket tester (DC 20 V) to the • Measure the voltage (DC 12 V) of the turn signal light connectors or speedome- chocolate 1 or dark green 2 at the turn ter assembly coupler (wire harness side)
  • Page 490 – ELEC SIGNALING SYSTEM EAS00803 3. Voltage 6. The fuel level indicator light fails to come • Connect the pocket tester (DC 20 V) to the speedometer assembly coupler (wire har- 1. Fuel level indicator light LED ness side) as shown. •...
  • Page 491 – ELEC SIGNALING SYSTEM 3. Voltage 2. Voltage • Connect the pocket tester (DC V 20) to the • Connect the pocket tester (DC 20 V) to the speedometer assembly coupler (wire har- speedometer assembly coupler (wire har- ness side) as shown. ness side) as shown.
  • Page 492: Fuel Injection System

    – ELEC FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM CIRCUIT DIAGRAM 7 - 54...
  • Page 493 – ELEC FUEL INJECTION SYSTEM 3 Main switch 4 Battery 6 Main fuse A Fuel injection system relay B Fuel pump E Crankshaft position sensor F Throttle position sensor G Intake air pressure sensor 1 H Intake air pressure sensor 2 I Atmospheric pressure sensor J Cylinder identification sensor K Lean angle cut-off switch...
  • Page 494: Troubleshooting

    – ELEC FUEL INJECTION SYSTEM EAS00821 EAS00738 TROUBLESHOOTING 1. Main, ignition, ECU and fuel injection sys- tem fuses If the fuel injection system fails to oper- ate. • Check the main, ignition, ECU and fuel injection system fuses for continuity. Check: Refer to “CHECKING THE FUSES”...
  • Page 495 – ELEC FUEL INJECTION SYSTEM EAS00750 6. Cylinder #1-injector resistance 4. Engine stop switch • Disconnect the injection sub-wire harness • Check the engine stop switch for continu- coupler from the cylinder #1-injector. ity. • Connect the pocket tester (Ω × 1) to the Refer to “CHECKING THE SWITCHES”.
  • Page 496 – ELEC FUEL INJECTION SYSTEM EAS00817 7. Cylinder #2-injector resistance 8. Fuel pump resistance • Disconnect the injection sub-wire harness • Disconnect the fuel pump coupler from the coupler from the cylinder #2-injector. fuel pump. • Connect the pocket tester (Ω × 1) to the •...
  • Page 497 – ELEC FUEL INJECTION SYSTEM EAS00748 10.Cylinder identification sensor output volt- 9. Crankshaft position sensor resistance • Disconnect the crankshaft position sensor • Connect the pocket tester (DC 20 V) to the coupler from the wire harness. cylinder identification sensor coupler as •...
  • Page 498 – ELEC FUEL INJECTION SYSTEM 11.Speed sensor output voltage • Measure the speed sensor output voltage. • Connect the pocket tester (DC 20 V) to the speed sensor coupler as shown. Positive tester probe → white 1 Negative tester probe → black 2 •...
  • Page 499 – ELEC FUEL INJECTION SYSTEM 13.Intake air pressure sensor 1 output volt- 14.Intake air pressure sensor 2 output volt- • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the intake air intake air pressure sensor 1 cou- intake air intake air pressure sensor 2 cou- pler as shown.
  • Page 500 – ELEC FUEL INJECTION SYSTEM Positive tester probe → blue 1 Negative tester probe → black/blue 2 P B/L L • Measure the engine temperature sensor resistance. • Set the main switch to “ON”. Engine temperature sensor • Measure the atmospheric pressure sensor resistance 898 ~ 1,098 Ω...
  • Page 501 – ELEC FUEL INJECTION SYSTEM EAS00818 17.Oil temperature sensor resistance 18.Wiring • Remove the oil temperature sensor from • Check the entire fuel injection system’s the oil tank. wiring. • Connect the pocket tester (Ω × 100) to the Refer to “CIRCUIT DIAGRAM”. oil temperature sensor terminal as shown.
  • Page 502: Checking The Fuel Pump

    – ELEC FUEL INJECTION SYSTEM EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refueling. •...
  • Page 503 – ELEC FUEL INJECTION SYSTEM 1. Check: • throttle position sensor (installed on the throttle body) M MMM M MMM M MMM M MMM M MMM a. Disconnect the throttle position sensor cou- pler from the throttle position sensor. b. Connect the pocket tester (Ω × 1k) to the throttle position sensor.
  • Page 504 – ELEC FUEL INJECTION SYSTEM 2. Check: • throttle position sensor (removed from the throttle body) M MMM M MMM M MMM M MMM M MMM a. Disconnect the throttle position sensor cou- pler from the throttle position sensor. b. Remove the throttle position sensor from the throttle body.
  • Page 505 – ELEC FUEL INJECTION SYSTEM 3. Adjust: • throttle position sensor angle M MMM M MMM M MMM M MMM M MMM a. Disconnect the throttle position sensor cou- pler from the throttle position sensor. b. Connect the pocket tester (Ω × 1k) to the throttle position sensor.
  • Page 506: Starting Failures

    TRBL STARTING FAILURES SHTG EAS00844 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man- ual for checks, adjustments, and replacement of parts.
  • Page 507: Trbl Shtg

    STARTING FAILURES/ TRBL INCORRECT ENGINE IDLING SPEED SHTG ELECTRICAL SYSTEMS Battery Ignition system • Discharged battery • Faulty ECU • Faulty battery • Faulty crankshaft position sensor Fuse(s) • Broken generator rotor woodruff key • Blown, damaged or incorrect fuse Switches and wiring •...
  • Page 508: Poor Medium-and-high-speed Performance

    POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL FAULTY GEAR SHIFTING/FAULTY CLUTCH SHTG EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES”. ENGINE FUEL SYSTEM Air filter Fuel pump • Clogged air filter element • Faulty fuel pump EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT JUMPS OUT OF GEAR Refer to “CLUTCH DRAGS”.
  • Page 509: Overheating

    OVERHEATING/POOR BRAKING PERFORMANCE/ TRBL FAULTY FRONT FORK LEGS SHTG EAS00854 OVERHEATING ENGINE CHASSIS Cylinder head(s) and piston(s) Brake(s) • Heavy carbon buildup • Dragging brake Engine oil ELECTRICAL SYSTEMS • Incorrect oil level Spark plug(s) • Incorrect oil viscosity • Incorrect spark plug gap •...
  • Page 510: Unstable Handling

    TRBL UNSTABLE HANDLING SHTG EAS00862 UNSTABLE HANDLING Handlebar Rear shock absorber assembly(-ies) • Bent or improperly installed handlebar • Faulty rear shock absorber spring Steering head components • Leaking oil or gas • Improperly installed upper bracket Tire(s) • Improperly installed lower bracket •...
  • Page 511: Faulty Lighting Or Signaling System

    TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON TURN SIGNAL DOES NOT COME ON • Wrong headlight bulb • Faulty turn signal switch • Too many electrical accessories • Faulty turn signal relay •...
  • Page 512 XV1700P/XV1700PC WIRING DIAGRAM 1 Generator | Signaling system fuse 2 Rectifier/regulator } Decompression solenoid fuse 3 Main switch ~ ECU fuse 4 Battery å Fuel injection system fuse 5 Backup fuse (odometer and clock) 6 Main fuse 7 Starter relay...
  • Page 514 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
  • Page 515 XV1700P/XV1700PC WIRING DIAGRAM (For USA) (BLACK) (BLACK) WIRE HARNESS TAIL SUB-WIRE HARNESS WIRE HARNESS INJECTION SUB-WIRE HARNESS (BLUE) (BLUE) (BLACK) (GRAY) (BLACK) (BLACK) (BLACK) (GRAY) (BLACK) (BLACK) å (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (DARK GRAY) (GRAY) (BLACK) (BLACK)

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