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EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
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EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. The manual is divided into chapters and each chapter is divided into sections.
EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
GENERAL INFORMATION IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER ........... 1-1 MODEL LABEL..................1-1 FEATURES....................1-2 OUTLINE OF THE FI SYSTEM ............... 1-2 FI SYSTEM....................1-3 IMMOBILIZER SYSTEM ................. 1-4 INSTRUMENT FUNCTION ..............1-5 IMPORTANT INFORMATION ............... 1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-8 REPLACEMENT PARTS.................
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
FEATURES EAS20170 FEATURES EAS5UXB014 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
FEATURES EAS5UXB016 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator is installed in the fuel rail, and maintains the fuel pressure that is applied to the fuel injector at 387 – 397 kPa (3.87 –...
FEATURES EAS5UXB016 IMMOBILIZER SYSTEM To help prevent theft, the XJR1300 is equipped with an “immobilizer system” that electronically pre- vents engine starting. The key has a built-in microchip transponder that disables illegal duplicate keys by dual checking of code between key and immobilizer unit and between immobilizer unit and ECU, thereby improving se- curity.
FEATURES Odometer and trip meter modes EAS5UXB003 INSTRUMENT FUNCTION Multi-function display EWA5UXB001 WARNING Be sure to stop the motorcycle before mak- ing any setting change to the multi-function display. 1. Odometer/Trip meter/Fuel trip meter Pushing the “SELECT” button switches the dis- play between the odometer mode “ODO”...
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FEATURES Fuel meter Self-diagnosis devices 1. Error code display 1. Fuel level warning indicator 2. Fuel meter This model is equipped with a self-diagnosis de- vice for various electrical circuits. The fuel meter indicates the amount of fuel in the If any of those circuits are defective, the engine fuel tank.
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FEATURES ECA5UXB016 CAUTION: If the multi-function display indicates an er- ror code, the vehicle should be checked as soon as possible in order to avoid engine damage.
Oil bearings liberally when installing, if appropri- EAS20200 ate. REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...
IMPORTANT INFORMATION ECA13300 CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfac- 1. Bearings EAS20240 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Al- ways replace piston pin clips after one use. When installing a circlip “1”, make sure the sharp-edged corner “2”...
CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: Lead NOTE: Coupler If there is no continuity, clean the terminals. Connector When checking the wire harness, perform 2.
SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 5WMG (EUR) 5WMJ (OCE) Dimensions Overall length 2175 mm (85.6 in) Overall width 765 mm (30.1 in) Overall height 1115 mm (43.9 in) Seat height 795 mm (31.3 in) Wheelbase 1500 mm (59.1 in) Ground clearance 125 mm (4.92 in) Minimum turning radius...
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Air cooled 4-stroke, DOHC Displacement 1251.0 cm Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 79.0 × 63.8 mm (3.11 × 2.51 in) Compression ratio 9.70 :1 Standard compression pressure (at sea level) 1050 kPa/400 r/min (149.3 psi/400 r/min) (10.5 kgf/cm /400 r/min)
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ENGINE SPECIFICATIONS Volume 33.90–34.70 cm (2.07–2.12 cu.in) Warpage limit 0.20 mm (0.0079 in) Camshaft Drive system Chain drive (center) Camshaft cap inside diameter 25.000–25.021 mm (0.9843–0.9851 in) Camshaft journal diameter 24.967–24.980 mm (0.9830–0.9835 in) Camshaft-journal-to-camshaft-cap clearance 0.020–0.054 mm (0.0008–0.0021 in) Camshaft lobe dimensions Intake A 35.849–35.949 mm (1.4114–1.4153 in)
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ENGINE SPECIFICATIONS Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve margin thickness D (intake) 0.80–1.20 mm (0.0315–0.0472 in) Valve margin thickness D (exhaust) 0.80–1.20 mm (0.0315–0.0472 in) Valve stem diameter (intake) 5.475–5.490 mm (0.2156–0.2161 in) Limit 5.445 mm (0.2144 in)
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ENGINE SPECIFICATIONS kgf) Installed compression spring force (exhaust) 61.70–72.50 N (13.87–16.30 lbf) (6.29–7.39 kgf) 2.5 °/1.7 mm (2.5 °/0.067 in) Spring tilt (intake) 2.5 °/1.7 mm (2.5 °/0.067 in) Spring tilt (exhaust) Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Outer spring Free length (intake) 41.10 mm (1.62 in)
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ENGINE SPECIFICATIONS Piston Piston-to-cylinder clearance 0.015–0.040 mm (0.0006–0.0016 in) Limit 0.15 mm (0.0059 in) Diameter D 78.970–78.985 mm (3.1090–3.1096 in) Height H 5.0 mm (0.20 in) Offset 1.00 mm (0.0394 in) Offset direction Intake side Piston pin bore inside diameter 18.004–18.015 mm (0.7088–0.7093 in) Limit 18.045 mm (0.7104 in)
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ENGINE SPECIFICATIONS Dimensions (B × T) 1.20 × 3.00 mm (0.05 × 0.12 in) End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in) Limit 0.75 mm (0.0295 in) Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in) Limit 0.100 mm (0.0039 in) Oil ring Dimensions (B ×...
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ENGINE SPECIFICATIONS Transmission Transmission type Constant mesh 5-speed Primary reduction system Spur gear Primary reduction ratio 98/56 (1.750) Secondary reduction system Chain drive Secondary reduction ratio 38/17 (2.235) Operation Left foot operation Gear ratio 40/14 (2.857) 36/18 (2.000) 33/21 (1.571) 31/24 (1.292) 29/26 (1.115) Main axle runout limit...
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle 25.30 ° Caster angle Trail 100.0 mm (3.94 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Wheel travel 130.0 mm (5.12 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
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CHASSIS SPECIFICATIONS Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 5.5 mm (0.22 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 5.5 mm (0.22 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter 15.00 mm (0.59 in) Caliper cylinder inside diameter 30.23 mm (1.19 in)
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CHASSIS SPECIFICATIONS Maximum Compression damping adjusting positions Minimum Standard Maximum Rear suspension Type Swingarm Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 91.0 mm (3.58 in) Spring free length 205.0 mm (8.07 in) Installed length 186.0 mm (7.32 in) Optional spring available Enclosed gas/air pressure (STD) 1200 kPa (170.7 psi) (12.0 kgf/cm...
TIGHTENING TORQUE EAS20320 TIGHTENING TORQUE EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- A.
LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips All O-ring Bearings Crankshaft big end Crankshaft journals Con rod bolt Piston surfaces Piston pins Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Valve lifter surfaces Camshaft lobes and camshaft journals Oil pump rotors (inner and outer) and oil pump shaft...
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Push rod Yamaha bond No. 1215 Crankcase mating surface (Three Bond No. 1215®) Yamaha bond No. 1215 Cylinder head cover gasket (Three Bond No. 1215®) Cylinder head plug Yamaha bond No. 1215 Breather grommet (Three Bond No.
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LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Swingarm head pipe bearing Swingarm head pipe left/right thrust cover oil seal lip Engine bracket bearing Crankcase rear end left side bearing 2-23...
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LUBRICATION POINTS AND LUBRICANT TYPES 2-24...
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CABLE ROUTING K. Apply protective film to the frame side. (Left 1. Clutch hose side only) 2. Gusset L. Fasten the seat lock cable to the seat rail with a 3. Protector band. Face the band clasp downwards and the 4.
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CABLE ROUTING I. Route the fuel tank drain hose and fuel tank 1. Reservoir tank breather hose (total of 2 hoses) through the 2. Speed sensor lead engine cable guide. 3. Starter motor cable J. Fasten together with a band, the generator 4.
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CABLE ROUTING I. Route the sub harness past the front side of the 1. Throttle cable starting circuit cutoff relay. 2. Ignition coil #1, #4 J. Fasten the wire harness to the seat rail immedi- 3. Horn (right side) ately to the back of the seat rail side cover 4.
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CABLE ROUTING 1. Meter leads 2. Handle crown 3. Left handlebar switch lead 4. Clutch hose 5. Left front flasher lead 6. Immobilizer unit lead 7. Left main switch lead 8. Atmospheric temperature sensor lead 9. Wire harness 10. Right front flasher lead 11.
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CABLE ROUTING 1. Breather assembly 2. Fuel return hose 3. Breather hose 1 4. Clip 5. Fuel hoses 6. Pressure regulator 7. Breather hose 2 8. Vacuum hose 9. Air induction system hose A. Direct the claw of the clip upwards on the left of the vehicle.
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ..... 3-1 ENGINE ......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODIES........3-6 ADJUSTING THE EXHAUST GAS VOLUME ......... 3-8 CHECKING THE ENGINE IDLING SPEED ..........3-9 ADJUSTING THE THROTTLE CABLE FREE PLAY ......
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LUBRICATING THE REAR SUSPENSION..........3-32 ELECTRICAL SYSTEM................. 3-33 CHECKING AND CHARGING THE BATTERY ........3-33 CHECKING THE FUSES ................ 3-33 REPLACING THE HEADLIGHT BULB............ 3-33 ADJUSTING THE HEADLIGHT BEAM ........... 3-33...
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 50000 km, repeat the maintenance intervals starting from 10000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)
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PERIODIC MAINTENANCE ODOMETER READING (× 1000 km) ANNUA ITEM CHECK OR MAINTENANCE JOB CHECK Check chain slack, alignment and condition. Drive chain Adjust and lubricate chain with Every 1000 km and after washing the vehicle or riding in the rain a special O-ring chain lubri- cant thoroughly.
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PERIODIC MAINTENANCE EAS36771 NOTE: Air filter This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
ENGINE EAS20470 ENGINE EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center 2.
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ENGINE Cylinder #2 180° Cylinder #4 360° Cylinder #3 540° LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3. Adjust: Valve clearance MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM NOTE: a. Align the intake and exhaust valve lifter slots If the valve clearance is incorrect, record the with each other. measured reading. b. Install the tappet adjusting tool “1” between Measure the valve clearance in the following the camshaft and the valve lifter “2”.
ENGINE f. Round off the original valve pad number ac- cording to the following table. Last digit Available valve pads 0 or 2 EXAMPLE: When the valve pad installed was 248 (thick- ness 2.48 mm) d. Remove the valve pad “4” from the valve lift- Applied number = 250 er.
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ENGINE 1. Stand the vehicle on a level surface. Engine idling speed NOTE: 970–1170 r/min Place the vehicle on the center stand. 7. Adjust: 2. Remove: SYNCHRONIZING THE THROTTLE BOD- FUEL TANK Refer to “FUEL TANK” on page 6-1. Vacuum hose “1” MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a.
ENGINE Refer to “ADJUSTING THE THROTTLE CA- BLE FREE PLAY” on page 3-9. Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 11.Install: FUEL TANK Refer to “FUEL TANK” on page 6-1. EAS20600 ADJUSTING THE EXHAUST GAS VOLUME NOTE: NOTE: The selected cylinder number appears on the Be sure to set the CO density level to standard, clock LCD.
ENGINE EAS20590 CHECKING THE ENGINE IDLING SPEED NOTE: Prior to checking the engine idling speed, the throttle body synchronization should be adjusted properly, the air filter element should be clean, and the engine should have adequate compres- sion. 1. Start the engine and let it warm up until it reaches specified oil temperature.
ENGINE Manufacturer/model NGK/DPR8EA-9 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM 4. Check: Handlebar side Electrode “1” a. Loosen the locknut “1”. Damage/wear → Replace the spark plug. b. Turn the adjusting nut “2” in direction “a” or Insulator “2” “b” until the specified throttle cable free play Abnormal color →...
ENGINE 8. Connect: Spark plug Spark plug cap EAS20700 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. NOTE: 1.
ENGINE c. If the compression pressure is above the Compression gauge maximum specification, check the cylinder 90890-03081 head, valve surfaces and piston crown for Engine compression tester carbon deposits. YU-33223 Carbon deposits → Eliminate. Extension d. If the compression pressure is below the min- 90890-04082 imum specification, pour a teaspoonful of en- gine oil into the spark plug bore and measure...
ENGINE ECA13360 CAUTION: Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of CD or higher and do not use oils labeled “ENERGY CONSERVING II”.
ENGINE d. Install the new oil filter element, oil filter ele- 8. Install: ment cover and union bolt. O-ring Engine oil filler cap NOTE: Align the projection on the oil filter case with 9. Start the engine, warm it up for several min- utes, and then turn it off.
ENGINE NOTE: Place the vehicle on a suitable stand. the system was disassembled, a clutch hose was loosened or removed, 2. Check: the clutch fluid level is very low, Clutch fluid level clutch operation is faulty. Below the minimum level mark “a” → Add the NOTE: recommended clutch fluid to the proper level.
ENGINE h. Tighten the bleed screw and then release the Side cover (right) clutch lever. Refer to “GENERAL CHASSIS” on page 4-1. i. Repeat steps (e) to (h) until all of the air bub- bles have disappeared from the clutch fluid in the plastic hose.
ENGINE MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Turn the main switch to “ON”. b. Check the EXUP pully position. c. Remove right side cover d. Loosen both locknuts “1”. e. Turn both adjusting bolts “2” to adjust free play in EXUP cable. Direction “a” Increase EXUP cable free play Direction “b”...
CHASSIS EAS21140 CHASSIS Brake pedal position 40.0 mm (1.57 in) EAS21160 ADJUSTING THE FRONT BRAKE 1. Adjust: Brake lever position (distance “a” from the throttle grip to the brake lever) NOTE: While pushing the clutch lever forward, turn the adjusting dial “1” until the clutch lever is in the desired position.
CHASSIS system. Air in the brake system will consid- tion, leading to poor brake performance. erably reduce braking performance and When refilling, be careful that water does could result in loss of control and possibly not enter the brake fluid reservoir. Water an accident.
CHASSIS 2. Check: EAS21280 CHECKING THE FRONT BRAKE HOSES Brake hose clamp The following procedure applies to all of the Loose → Tighten the clamp bolt. brake hoses and brake hose clamps. 3. Hold the vehicle upright and apply the brake 1.
CHASSIS LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21350 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA13100 WARNING Bleed the hydraulic brake system whenever: the system is disassembled. a brake hose is loosened, disconnected or A. Front replaced. B. Rear the brake fluid level is very low. brake operation is faulty. d.
CHASSIS EAS21390 ADJUSTING THE DRIVE CHAIN SLACK LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL NOTE: The drive chain slack must be checked at the EAS21380 tightest point on the chain. ADJUSTING THE SHIFT PEDAL NOTE: ECA13550 CAUTION: The shift pedal position is determined by the in- A drive chain that is too tight will overload stalled shift rod length “a”.
CHASSIS EAS21510 Direction “a” CHECKING AND ADJUSTING THE Drive chain is tightened. STEERING HEAD Direction “b” 1. Stand the vehicle on a level surface. Drive chain is loosened. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.
CHASSIS NOTE: Set the torque wrench at a right angle to the steering nut wrench. Steering nut wrench 90890-01403 Spanner wrench YU-33975 Lower ring nut (initial tightening torque) 52 Nm (5.2 m•kg, 38 ft•lb) LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 5. Install: Upper bracket Refer to “STEERING HEAD” on page 4-50. Handlebar Refer to “HANDLEBAR”...
CHASSIS EAS21580 ADJUSTING THE FRONT FORKS The following procedure applies to both of the front fork legs. EWA13150 WARNING Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. Securely support the motorcycle so that there is no danger of it falling over.
CHASSIS there is no danger of it falling over. Always adjust both rear shock absorber as- LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL semblies evenly. Uneven adjustment can Compression damping result in poor handling and loss of stability. ECA13590 Spring preload CAUTION: ECA13590 Never go beyond the maximum or minimum CAUTION: adjustment positions.
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CHASSIS Rebound damping Minimum (soft) 36 click(s) out* Standard 10 click(s) out* Maximum (hard) 1 click(s) out* *With the adjusting knob fully turned d. Tighten the bleed screw. Lock screw 0.1 Nm (0.01 m•kg, 0.07 ft•lb) ECA5UXB004 CAUTION: Do not strike to insert with unreasonable force a flat head screwdriver in the spring seat adjustment hole.
CHASSIS Tire air pressure (measured on cold tires) Loading condition 0–90 kg (0–198 lb) Front 250 kPa (36 psi) (2.50 kgf/cm (2.50 bar) Rear 250 kPa (36 psi) (2.50 kgf/cm (2.50 bar) Loading condition 90–205 kg (198–452 lb) Front LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 250 kPa (36 psi) (2.50 kgf/cm (2.50 bar) EAS21660...
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Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. 3-31...
CHASSIS EAS21670 EAS21710 CHECKING THE WHEELS LUBRICATING THE PEDAL The following procedure applies to both of the Lubricate the pivoting point and metal-to-metal wheels. moving parts of the pedal. 1. Check: Recommended lubricant Wheel Lithium-soap-based grease Damage/out-of-round → Replace. EWA13260 EAS21720 WARNING LUBRICATING THE SIDESTAND...
ELECTRICAL SYSTEM EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” on page 7-79. EAS21770 CHECKING THE FUSES Refer to “ELECTRICAL COMPONENTS” on page 7-79. 4. Install: EAS21780 REPLACING THE HEADLIGHT BULB Headlight bulb 1. Disconnect: Secure the new headlight bulb with the head- Headlight unit “1”...
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ELECTRICAL SYSTEM LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 2. Adjust: Headlight beam (horizontally) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Turn the adjusting screw “2” in direction “a” or “b”. Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3-34...
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CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEEL..................... 4-2 REMOVING THE FRONT WHEEL............4-4 DISASSEMBLING THE FRONT WHEEL ..........4-4 CHECKING THE FRONT WHEEL ............4-4 ASSEMBLING THE FRONT WHEEL ............4-5 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-5 INSTALLING THE FRONT WHEEL (DISC) ..........4-6 REAR WHEEL ....................
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HANDLEBAR ....................4-38 REMOVING THE HANDLEBAR .............. 4-39 CHECKING THE HANDLEBAR .............. 4-39 INSTALLING THE HANDLEBAR ............4-39 FRONT FORK....................4-41 REMOVING THE FRONT FORK LEGS ..........4-44 DISASSEMBLING THE FRONT FORK LEGS ........4-44 CHECKING THE FRONT FORK LEGS ..........4-45 ASSEMBLING THE FRONT FORK LEGS ..........
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GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the passenger seat and side cover 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Seat Side cover (left/right) Grab bar Rear fender cover For installation, reverse the removal proce- dure.
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FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 72 Nm (7.2 m kg, 52 ft • • 20 Nm (2.0 m kg, 15 ft • • 18 Nm (1.8 m kg, 13 ft • • 40 Nm (4.0 m kg, 29 ft •...
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FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Spacer Oil seal Bearing For assembly, reverse the disassembly pro- cedure.
FRONT WHEEL EAS21900 NOTE: REMOVING THE FRONT WHEEL To prevent damaging the wheel, place a rag “2” 1. Stand the vehicle on a level surface. between the screwdriver and the wheel surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
FRONT WHEEL Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE 4. Check: NOTE: Wheel bearings Front wheel turns roughly or is loose → Re- After replacing the tire, wheel or both, the front wheel static balance should be adjusted.
FRONT WHEEL LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 4. Check: Front wheel static balance MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (d) through (f) several times un- til all the marks come to rest at the same spot. g.
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FRONT WHEEL 3. Install: Right brake caliper Left brake caliper Brake caliper bolt 40 Nm (4.0 m•kg, 29 ft•lb) EWA13530 WARNING Proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “CA- BLE ROUTING” on page 2-31.
REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel 150 Nm (15.0 m kg, 109 ft • • Order Job/Parts to remove Q’ty Remarks Chain adjuster Washers Left chain puller Wheel axle Right chain puller Rear wheel assembly Spacer (left) Spacer (right) For installation, reverse the removal proce- dure.
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REAR WHEEL Removing the brake disc and rear wheel sprocket 23 Nm (2.3 m kg, 17 ft • • 69 Nm (6.9 m kg, 50 ft • • Order Job/Parts to remove Q’ty Remarks Brake disc Rear wheel sprocket Rear wheel drive hub Rear wheel drive hub damper Oil seal Bearing...
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REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Spacer Bearing For assembly, reverse the disassembly pro- cedure. 4-10...
REAR WHEEL EAS22040 EAS22080 REMOVING THE REAR WHEEL (DISC) DISASSEMBLING THE REAR WHEEL 1. Stand the vehicle on a level surface. 1. Remove: EWA13120 Oil seals WARNING Wheel bearings Securely support the vehicle so that there is Refer to “DISASSEMBLING THE FRONT no danger of it falling over.
REAR WHEEL ter, and knock in the bearing. ECA5UXB005 CAUTION: Do not tap in the bearing at an angle. NOTE: Knock in the bearing so that dimension “a” is 7 mm, as in the illustration. a. Tooth face b. Correct 1.
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REAR WHEEL Wheel axle nut 150 Nm (15.0 m•kg, 109 ft•lb) 3. Adjust: Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-24. Drive chain slack 20.0–30.0 mm (0.79–1.18 in) 4-13...
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks Clip Pad pin Pad support Brake pad/Brake pad shim For installation, reverse the removal proce- dure. 4-14...
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FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “BLEEDING THE HYDRAULIC Drain the brake fluid BRAKE SYSTEM”...
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FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Master cylinder boots Circlip Master cylinder kit Spring For assembly, reverse the disassembly pro- cedure. 4-16...
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FRONT BRAKE Removing the front brake caliper 40 Nm (4.0 m kg, 29 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “BLEEDING THE HYDRAULIC Drain the brake fluid BRAKE SYSTEM”...
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FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kg, 4.3 ft ¥ ¥ Order Job/Parts to remove Q’ty Remarks Clip Pad pin Pad support Brake pad/Brake pad shim Brake caliper piston Brake caliper dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: Never disassemble brake components un- less absolutely necessary. If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.
FRONT BRAKE 5. Adjust: Brake disc deflection MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc “1”. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 2.
FRONT BRAKE 6. Check: Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-23. EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake caliper.
FRONT BRAKE a piece of wood “a”. replace the dust seals and piston seals. b. Blow compressed air into the brake hose joint opening “b” to force out the left side piston from the brake caliper. EWA5UXB002 WARNING Never try to pry out the brake caliper piston. 2.
FRONT BRAKE (brake master cylinder body) Obstruction→Blow out with compressed air. 6. Check: Brake lever operation Soft or spongy feeling → Bleed the brake 2. Check: system. Brake master cylinder kit “1” Damage/scratches/wear → Replace. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
FRONT BRAKE First, tighten the upper bolt, then the lower bolt. EAS22520 ASSEMBLING THE FRONT BRAKE MASTER 2. Install: CYLINDER Copper washers EWA13520 Brake hose WARNING Union bolt Before installation, all internal brake com- ponents should be cleaned and lubricated Brake hose union bolt with clean or new brake fluid.
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FRONT BRAKE vapor lock. ECA13540 CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-23. 5. Check: Brake fluid level Below the minimum level mark “a”...
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 40 Nm (4.0 m kg, 29 ft • • 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper Clip Pad pin Pad support Brake pad Brake caliper shim...
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REAR BRAKE Removing the rear brake master cylinder 30 Nm (3.0 m kg, 22 ft • • 30 Nm (3.0 m kg, 22 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “BLEEDING THE HYDRAULIC Drain the brake fluid...
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REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder boots Circlip Brake master cylinder kit Spring For assembly, reverse the disassembly pro- cedure. 4-29...
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REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “BLEEDING THE HYDRAULIC Drain the brake fluid BRAKE SYSTEM”...
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REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Clip Pad pin Pad support Brake pad/Brake pad shim Brake caliper piston Brake caliper dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
REAR BRAKE 4. Install: 6. Check: Brake pad shims Brake pedal operation Soft or spongy feeling → Bleed the brake (onto the brake pads) Brake pads system. Pad support Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-23. NOTE: Always install new brake pads, brake pad shims, EAS22590 and a brake pad spring as a set.
REAR BRAKE MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM EWA13610 WARNING a. Secure the right side brake caliper piston with Whenever a brake caliper is disassembled, a waste cloth. replace the brake caliper piston/dust seals. b. Blow compressed air into the brake hose joint opening to force out the left side piston from EAS22650 the brake caliper.
REAR BRAKE the brake fluid and could cause vapor lock. Brake hose union bolt ECA13540 30 Nm (3.0 m•kg, 22 ft•lb) CAUTION: Brake fluid may damage painted surfaces EWA13530 WARNING and plastic parts. Therefore, always clean up Proper brake hose routing is essential to in- any spilt brake fluid immediately.
REAR BRAKE Cracks/damage/wear → Replace. container under the master cylinder and the end of the brake hose. EAS22710 CHECKING THE REAR BRAKE MASTER CYLINDER 1. Check: Brake master cylinder “1” Damage/scratches/wear → Replace. Brake fluid delivery passages “2” (brake master cylinder body) Obstruction→Blow out with compressed air.
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REAR BRAKE sure safe vehicle operation. Refer to “CA- and plastic parts. Therefore, always clean up BLE ROUTING” on page 2-31. any spilt brake fluid immediately. ECA14160 3. Bleed: CAUTION: Brake system When installing the brake hose onto the Refer to “BLEEDING THE HYDRAULIC brake master cylinder, make sure the brake BRAKE SYSTEM”...
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 26 Nm (2.6 m kg, 19 ft • • 26 Nm (2.6 m kg, 19 ft •...
HANDLEBAR EAS22860 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: Handlebar grip “1” NOTE: Blow compressed air between the handlebar EAS22930 and the handlebar grip, and gradually push the INSTALLING THE HANDLEBAR...
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HANDLEBAR 3. Install: 6. Install: Handlebar grip Left handlebar switch “1” MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM NOTE: a. Apply a thin coat of rubber adhesive onto the Align the projection on the left handlebar switch left end of the handlebar. with the hole “a” on the handlebar. b.
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 30 Nm (3.0 m kg, 22 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 •...
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FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft • • 20 Nm (2.0 m kg, 15 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Valve stem lock nut...
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FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft • • 20 Nm (2.0 m kg, 15 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks For assembly, reverse the disassembly pro- cedure.
FRONT FORK Nut “1” EAS22960 REMOVING THE FRONT FORK LEGS Spring guide “2” The following procedure applies to both of the Push rod “3” front fork legs. Spacer “4” 1. Stand the vehicle on a level surface. Front fork spring EWA13120 WARNING Securely support the vehicle so that there is...
FRONT FORK Damper rod assembly Tapered spindle “3” Spring “4” NOTE: Damper rod assembly “5” While holding the damper rod with the damper rod holder “2”, loosen the damper rod assembly bolt. Damper rod holder 90890-01513 EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
FRONT FORK NOTE: When assembling the front fork leg, be sure to replace the following parts: Slide metal Piston metal Oil seal Dust seal Before assembling the front fork leg, make sure all of the components are clean. 1. Install: 3.
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FRONT FORK 5. Install: 4. Install: Stopper ring Slide metal “1” Dust seal “1” Oil seal washer “2” (with the fork seal driver “2” and attachment Oil seal “3” “3”) (with the fork seal driver “4” and attachment “5”) Frok seal driver weight 90890-01367 Frok seal driver weight Replacement hammer...
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FRONT FORK 8. Fill the fork oil with the specified amount of minutes until the oil has settled and the air the recommended. bubbles have dispersed. Front fork leg ECA5UXB007 CAUTION: Recommended oil Be sure to fill to the top of the inner tube with Suspension oil 01 or equivalent fork oil and remove air.
FRONT FORK Refer to “ADJUSTING THE FRONT FORKS” bracket pinch bolts. on page 3-27. NOTE: c. Measure the distance from the adjuster “5” Check that the top end of the inner tube is level bottom end to the adjuster “6” bottom end. with the upper bracket’s top end.
STEERING HEAD EAS23090 STEERING HEAD Remove headlight and meters 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
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STEERING HEAD Removing the lower bracket 110 Nm (11.0 m kg, 80 ft • • 52 Nm (5.2 m kg, 38 ft • • Return fully 18 Nm (1.8 m kg, 13 ft • • 40 Nm (4.0 m kg, 29 ft •...
STEERING HEAD 3. Replace: EAS23100 REMOVING THE LOWER BRACKET Bearings 1. Stand the vehicle on a level surface. Bearing races EWA13120 MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM WARNING a. Remove the bearing races from the steering Securely support the vehicle so that there is head pipe with a long rod “1” and hammer. no danger of it falling over.
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STEERING HEAD Lower bearing Bearing races Recommended lubricant Lithium-soap-based grease 2. Install: Lower ring nut “1” Rubber washer “2” Upper ring nut “3” Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-25. 3. Install: Upper bracket Steering stem nut Steering stem nut 110 Nm (11.0 m•kg, 80 ft•lb)
REAR SHOCK ABSORBER ASSEMBLY EAS23170 EAS23220 HANDLING THE REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER AND GAS CYLINDER ASSEMBLY EWA13750 1. Stand the vehicle on a level surface. WARNING EWA13120 WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Securely support the vehicle so that there is Before handling the rear shock absorber or no danger of it falling over.
SWINGARM EAS23330 SWINGARM Removing the swingarm 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5 ft • • 125 Nm (12.5 m kg, 90 ft •...
SWINGARM EAS23340 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle the suitable stand so that the rear wheel is elevated. 2.
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SWINGARM Spacers Oil seals Thrust cover Swingarm Pivot shaft 3. Install: Rear shock absorber assembly Rear wheel Refer to “REAR SHOCK ABSORBER AS- SEMBLY” on page 4-54 and “REAR WHEEL” on page 4-8. 4. Adjust: Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...
CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
CHAIN DRIVE c. Remove the drive chain from the kerosene Drive chain and completely dry it. Recommended lubricant ECA5C11003 Engine oil or chain lubricant CAUTION: suitable for O-ring chains This vehicle has a drive chain with small rub- ber O-rings “1” between the drive chain side EAS23460 plates.
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ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE..............5-4 CAMSHAFTS....................5-5 REMOVING THE CAMSHAFTS.............. 5-7 CHECKING THE CAMSHAFTS .............. 5-7 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET..5-9 CHECKING THE TIMING CHAIN GUIDES ..........5-9 CHECKING THE TIMING CHAIN TENSIONER........5-9 INSTALLING THE CAMSHAFTS ............
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CHECKING THE CLUTCH BOSS ............5-46 CHECKING THE PRESSURE PLATE ............ 5-46 CHECKING THE CLUTCH PUSH RODS ..........5-46 INSTALLING THE CLUTCH ..............5-46 DISASSEMBLING THE CLUTCH MASTER CYLINDER ......5-48 CHECKING THE CLUTCH MASTER CYLINDER........5-48 ASSEMBLING THE CLUTCH MASTER CYLINDER ......5-48 INSTALLING THE CLUTCH MASTER CYLINDER.........
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INSTALLING THE CRANKSHAFT ............5-76 TRANSMISSION.................... 5-77 CHECKING THE SHIFT FORKS............. 5-81 CHECKING THE SHIFT FORKS............. 5-81 CHECKING THE TRANSMISSION ............5-81 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ......5-82 INSTALLING THE TRANSMISSION ............5-82...
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 20 Nm (2.0 m kg, 15 ft • • 20 Nm (2.0 m kg, 15 ft •...
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ENGINE REMOVAL Removing the starter motor, generator and drive chain 10 Nm (1.0 m kg, 7.2 ft • • 85 Nm (8.5 m kg, 62 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 25 Nm (2.5 m kg, 18 ft •...
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ENGINE REMOVAL Removing the engine 48 Nm (4.8 m kg, 35 ft • • 48 Nm (4.8 m kg, 35 ft • • 88 Nm (8.8 m kg, 64 ft • • 88 Nm (8.8 m kg, 64 ft • •...
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CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “AIR INDUCTION SYSTEM” on Air induction system page 6-13.
CAMSHAFTS Removing the camshafts 12 Nm (1.2 m kg, 8.7 ft • • 20 Nm (2.0 m kg, 15 ft • • 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 15 ft •...
CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: Timing plate cover 2. Align: “T” mark on timing plate (align with crankshaft position sensor station- ary pointer) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- 6.
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CAMSHAFTS Camshaft lobe dimension limit Intake A 35.849–35.949 mm (1.4114–1.4153 in) Limit 35.749 mm (1.4074 in) Intake B 28.010–28.110 mm (1.1023–1.1067 in) Limit 27.910 mm (1.0988 in) 4. Measure: Exhaust A Camshaft-journal-to-camshaft-cap clearance 35.950–36.050 mm Out of specification → Measure the camshaft (1.4154–1.4193 in) Limit journal diameter.
CAMSHAFTS a. Tooth face b. Correct LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 1. Timing chain roller 5. Measure: 2. Camshaft sprockets Camshaft journal diameter “a” Out of specification → Replace the camshaft. EAS23950 CHECKING THE TIMING CHAIN GUIDES Within specification → Replace the cylinder 1. Check: head and the camshaft caps as a set.
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CAMSHAFTS d. Install the camshaft caps “3”. 2. Install: Intake camshaft NOTE: Make sure each camshaft cap is installed in its Exhaust camshaft original place. Refer to the identification marks MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM as follows: a. Turn the crankshaft clockwise. “I”:Intake b. When piston #1 is at TDC on the compres- “E”:Exhaust sion stroke, align the “T”...
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CAMSHAFTS Camshaft cap bolt 12 Nm (1.2 m•kg, 8.7 ft•lb) NOTE: Tighten the camshaft cap bolts in a crisscross pattern, working from the inside out. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3. Install: Timing chain guide (exhaust side) 4. Install: LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Timing chain tensioner 5. Turn: Timing chain tensioner gasket Crankshaft MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM...
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CAMSHAFTS Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-4. 10.Install: Timing plate cover 5-12...
CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 35 Nm (3.5 m kg, 25 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 •...
CYLINDER HEAD Damage/scratches → Replace. EAS24120 REMOVING THE CYLINDER HEAD 3. Measure: 1. Remove: Cylinder head warpage Cylinder head nuts Out of specification → Resurface the cylinder NOTE: head Loosen the nuts in the proper sequence as shown. Warpage limit 0.20 mm (0.0079 in) Loosen each nut 1/2 of a turn at a time.
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CYLINDER HEAD 2. Install: Cylinder head NOTE: Pass the timing chain through the timing chain cavity. 3. Tighten: Cylinder head nuts Cylinder head nuts 35 Nm (3.5 m•kg, 25 ft•lb) NOTE: Lubricate the cylinder head nuts with engine oil. Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages.
VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs 1 2 3 Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-13. Valve pad Valve lifter Valve cotter Valve spring retainer Valve spring (inner) Valve spring (outer) Intake valve...
VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
VALVES AND VALVE SPRINGS so that it can be reinstalled in its original place. 2. Replace: Valve guide NOTE: EAS24290 To ease valve guide removal and installation, CHECKING THE VALVES AND VALVE and to maintain the correct fit, heat the cylinder GUIDES head to 100°C in an oven.
VALVES AND VALVE SPRINGS Valve stem end Mushroom shape or diameter larger than the body of the valve stem → Replace the valve. 5. Measure: Valve margin thickness “a” Out of specification → Replace the valve. Valve margin thickness “a” 0.8 mm–1.2 mm (0.0315–0.0472 in) c.
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VALVES AND VALVE SPRINGS 2. Check: NOTE: Valve seat After replacing the cylinder head or replacing the Pitting/wear → Replace the cylinder head. valve and valve guide, the valve seat and valve 3. Measure: face should be lapped. Valve seat width “a” MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Out of specification →...
VALVES AND VALVE SPRINGS 1. Measure: Valve spring free length “a” Out of specification → Replace the valve spring. Valve spring free length Inner Free length (intake) 39.65 mm (1.56 in) Free length (exhaust) 39.65 mm (1.56 in) Outer e. Apply a fine lapping compound to the valve Free length (intake) face and repeat the above steps.
VALVES AND VALVE SPRINGS b. Installed length EAS24340 INSTALLING THE VALVES 3. Measure: The following procedure applies to all of the Valve spring tilt “a” valves and related components. Out of specification → Replace the valve 1. Deburr: spring. Valve stem end (with an oil stone) Spring tilt limit Inner...
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VALVES AND VALVE SPRINGS NOTE: Recommended lubricant Make sure each valve is installed in its original Molybdenum disulfide oil place. Install the valve spring with the larger pitch “a” facing up. 7. Install: Valve pad Valve lifter a. Larger pitch NOTE: b.
CYLINDER AND PISTON EAS24370 CYLINDER AND PISTON Removing the cylinder and piston 20 Nm (2.0 m kg, 15 ft • • Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-13. Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston...
CYLINDER AND PISTON Vertical scratches → Rebore or replace the EAS24380 REMOVING THE PISTON cylinder, and replace the piston and piston 1. Remove: rings as a set. Piston pin clips “1” 2. Measure: Piston pin “2” Piston-to-cylinder clearance Piston “3” MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM ECA13810 a.
CYLINDER AND PISTON piston ring side clearance Top ring Ring side clearance 0.045–0.080 mm (0.0018–0.0032 Limit 0.100 mm (0.0039 in) 2nd ring Ring side clearance 0.030–0.070 mm (0.0012–0.0028 b. 5 mm (0.20 in) from the bottom edge of the piston Limit 0.100 mm (0.0039 in) Piston diameter “D”...
CYLINDER AND PISTON piston ring end gap Top ring End gap (installed) 0.20–0.35 mm (0.0079–0.0138 in) Limit 0.60 mm (0.0236 in) 2nd ring End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in) Limit 0.75 mm (0.0295 in) 4. Calculate: Oil ring Piston-pin-to-piston-pin-bore clearance End gap (installed) Out of specification →...
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CYLINDER AND PISTON A. Exhaust side B. Intake side 3. Install: Cylinder gasket “1” Dowel pins “2” 2. Install: Piston “1” Piston pin “2” Piston pin clips “3” NOTE: Apply engine oil the piston pin. Make sure the arrow mark “a” on the piston points towards the exhaust side of the engine.
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CYLINDER AND PISTON 4. Lubricate: Piston Piston rings Cylinder (Apply recommended lubricant) Recommended lubricant Engine oil 5. Offset: Piston ring end gap a. Top ring b. Lower oil ring rail c. Upper oil ring rail d. 2nd ring A. Forward 6.
GENERATOR EAS24480 GENERATOR Generator Disassembly 7 Nm (0.7 m kg, 5 ft • • 25 Nm (2.5 m kg, 18 ft • • Order Job/Parts to remove Q’ty Remarks “ENGINE REMOVAL” on page Refer to Generator End cover Brush holder Regulator Rectifier cover Rectifier...
GENERATOR EAS5UXB004 CHECKING THE GENERATOR Brush use limit 4.7mm (0.19 in) 1. Remove: Brush spring force End cover 5.10–5.69 N (18.36–20.48 oz) 2. Measure: (520–580 gf) Stator coil resistance Out of specification → Replace the stator coil. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Stator coil resistance a.
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GENERATOR b. Measure the stator coil resistances. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 5-32...
TIMING PLATE EAS5UXB001 TIMING PLATE Removing the timing plate 45 Nm (4.5 m kg, 33 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks “GENERAL CHASSIS”...
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor Refer to “ENGINE REMOVAL” on page 5-1. Front bracket Washer kit Rear bracket Washer kit Brush holder/Brush1 Armature coil Stator assembly For assembly, reverse the disassembly pro- cedure.
ELECTRIC STARTER EAS24790 MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM CHECKING THE STARTER MOTOR a. Measure the resistance “1” and mica “2” re- 1. Check: sistance with the pocket tester. Commutator Dirt → Clean with 600 grit sandpaper. Pocket tester 2. Measure: 90890-03112 Analog pocket tester Commutator diameter “a”...
ELECTRIC STARTER Brush spring force 7.65–10.01 N (27.54–36.03 oz) (780–1021 gf) EAS24810 INSTALLING THE STARTER MOTOR 1. Install: Starter motor Starter motor bolts 7. Check: Gear teeth Starter motor Damage/wear → Replace the gear. 10 Nm (1.0 m•kg, 7.2 ft•lb) EAS24800 2.
CLUTCH EAS25060 CLUTCH Removing the crankcase cover 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Drain the engine oil. Refer to “ENGINE” on page 3-4. Crankcase cover (right) Crankcase cover gasket (right) Dowel pin For installation, reverse the removal proce- dure.
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CLUTCH Removing the clutch 70 Nm (7.0 m kg, 51 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Pressure plate 2 Clutch spring Clutch spring seat Pressure plate 1 Short clutch push rod Ball Long clutch push rod O-ring...
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CLUTCH Removing the clutch 70 Nm (7.0 m kg, 51 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Thrust plate Spacer Bearing Primary driven gear For installation, reverse the removal proce- dure.
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CLUTCH Removing the clutch master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Drain the clutch fluid Refer to “ENGINE” on page 3-4. Clutch lever Clutch switch lead Clutch switch...
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CLUTCH Disassembling the clutch master cylinder Order Job/Parts to remove Q’ty Remarks Master cylinder boot Circlip Master cylinder kit Spring For assembly, reverse the disassembly pro- cedure. 5-41...
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CLUTCH Removing the clutch release cylinder 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Drain the clutch fluid Refer to “ENGINE” on page 3-4. Clutch release cylinder bolt (long)/(short) Clutch hose union bolt Copper washer...
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CLUTCH Disassembling the clutch release cylinder Order Job/Parts to remove Q’ty Remarks Clutch release cylinder Piston seals Clutch release cylinder piston Piston seals Spring For assembly, reverse the disassembly pro- cedure. 5-43...
CLUTCH EAS25070 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: Clutch boss nut “1” NOTE: While holding the clutch boss “3” with the uni- versal clutch holder “2”, loosen the clutch boss nut. There is a built-in damper between the clutch boss “3”...
CLUTCH Damage → Replace. 2. Check: Clutch spring seat Damage → Replace. 3. Measure: Clutch spring free height Out of specification → Replace the clutch spring plate. Clutch spring height 6.78 mm (0.27 in) Limit 6.40 mm (0.25 in) A. Friction plate 1 (narrow) B.
CLUTCH EAS25160 CHECKING THE CLUTCH BOSS Long clutch push rod bending limit 1. Check: 0.3 mm (0.0118 in) Clutch boss splines Damage/pitting/wear → Replace the clutch boss. NOTE: Pitting on the clutch boss spline will cause errat- ic clutch operation. EAS25250 INSTALLING THE CLUTCH 1.
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CLUTCH 3. Install: NOTE: Friction plate 1 (narrow) “1” Insert the rounded end of the long clutch push Spring seat plate “2” rod into the clutch boss first. Spring “3” Clutch plate “4” Wire circlip “5” NOTE: Install spring “3” as shown in the illustration. 7.
CLUTCH Recommended clutch component replacement schedule Every two years and Clutch fluid whenever the clutch is dis- assembled 1. Check: Clutch master cylinder body “1” Cracks/damage → Replace the clutch mas- ter cylinder. Clutch fluid delivery passage “2” (clutch master cylinder body) Obstruction →...
CLUTCH with clean or new clutch fluid. Clutch hose union bolt Never use solvents on internal clutch com- 30 Nm (3.0 m•kg, 22 ft•lb) ponents as they will cause the piston seals to swell and distort. EWA13360 Whenever a clutch master cylinder is dis- WARNING assembled, replace the piston seals.
CLUTCH is already in the system. Mixing clutch flu- ids may result in a harmful chemical reac- tion, leading to poor clutch performance. When refilling, be careful that water does not enter the clutch fluid reservoir. Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock.
CLUTCH Clutch hose union bolt 30 Nm (3.0 m•kg, 22 ft•lb) EWA13360 WARNING Proper clutch hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING” on page 2-31. EAS25340 ASSEMBLING THE CLUTCH RELEASE CYLINDER EWA5UXB007 WARNING Before installation, all internal clutch com- ponents must be cleaned and lubricated with clean or new clutch fluid.
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CLUTCH 3. Bleed: Clutch system Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-16. 4. Check: Clutch fluid level Below the minimum level mark “a” → Add the recommended clutch fluid to the proper level. Refer to “CHECKING THE CLUTCH FLUID LEVEL”...
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Oil pump Refer to “OIL PUMP” on page 5-53. Drive sprocket cover Refer to “ENGINE REMOVAL” on page 5-1. Circlip Plate washer Shift shaft...
OIL PAN EAS5UXB002 OIL PAN REMOVING THE OIL PAN 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks “ENGINE REMOVAL” on page Refer to Engine Oil level switch/O-ring Oil pan Dowel pin...
CRANKCASE EAS25540 CRANKCASE Separating the crankcase 12 Nm (1.2 m kg, 8.7 ft • • 35 Nm (3.5 m kg, 25 ft • • 24 Nm (2.4 m kg, 17 ft • • 35 Nm (3.5 m kg, 25 ft •...
Obstruction → Blow out with compressed air. EAS25650 ASSEMBLING THE CRANKCASE 1. Lubricate: Crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: Yamaha bond No. 1215 (Three Bond No. 1215®) (onto the crankcase mating surfaces) 5-62...
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CRANKCASE Yamaha bond No. 1215 (Three Bond No.1215®) 90890-85505 NOTE: Apply a thin, even layer of Yamaha Bond 1215 to the upper crankcase No application required “1”(slanted line sec- tion) Apply all around the top and bottom case tight- ening bolts (star mark “a”) “2”...
STARTER CLUTCH EAS24550 STARTER CLUTCH Removing the starter clutch 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Separate Crankcase Refer to “CRANKCASE” on page 5-61. Bearing housing O-ring Oil seal...
CRANKSHAFT ASSEMBLY EAS25970 CRANKSHAFT ASSEMBLY Removing the crankshaft assembly Order Job/Parts to remove Q’ty Remarks Refer to “STARTER CLUTCH” on page Starter clutch 5-65. Crankshaft assembly Oil seal (left) Cover Timing chain HY-VO chain Crankshaft plane bearing Upper guide For installation, reverse the removal proce- dure.
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CRANKSHAFT ASSEMBLY Removing the connecting rod 36 Nm (3.6 m kg, 26 ft • • Order Job/Parts to remove Q’ty Remarks Connecting bolt Connecting rod Connecting rod cap Connecting rod bearing For installation, reverse the removal proce- dure. 5-69...
CRANKSHAFT ASSEMBLY EAS25980 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: Crankshaft assembly “1” Crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place. 2.
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CRANKSHAFT ASSEMBLY Crankcase bolt “1”–“15”, “28”, “30”(M8) 24 Nm (2.4 m•kg, 17 ft•lb) Crankcase bolt “16”17“, ”32“, ”34“(M10) 35 Nm (3.5 m•kg, 25 ft•lb) Crankcase bolt “18”–“27”, “29”, “31” “35”–“37” (M6) 12 Nm (1.2 m•kg, 8.7 ft•lb) NOTE: d. Put a piece of Plastigauge® “2” on each Tighten the bolts in the tightening sequence crankshaft journal.
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CRANKSHAFT ASSEMBLY of the bearings. 16 1412 11 13 15 17 283032 33 34 35 36 A. Upper crankcase B. Lower crankcase g. Remove the lower crankcase and the crank- shaft journal lower bearings. h. Measure the compressed Plastigauge® width “e” on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft journal bear-...
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CRANKSHAFT ASSEMBLY 4. Measure: d. Assemble the connecting rod halves. Crankshaft pin-to-big end bearing clearance NOTE: Out of specification → Replace the big end Do not move the connecting rod and crank- bearings. shaft until the clearance measurement has been completed. Crankshaft pin-to-big end bearing Lubricate the bolt threads and nut seats with clearance...
CRANKSHAFT ASSEMBLY Bearing color code Blue Black Brown EAS26110 CHECKING THE HY-VO CHAIN 1. Check: HY-VO chain “1” Damage/stiffness → Replace the HY-VO LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL chain and sprockets as a set. 5. Select: Big end bearings (P –P NOTE: The numbers “A” stamped into the crankshaft web and the numbers “1”...
CRANKSHAFT ASSEMBLY 4. Align: Bolt heads “1” (with the connecting rod caps) NOTE: Align the projections “a” on the big end bear- ings with the notches “b” in the connecting rod and connecting rod cap. 5. Tighten: Be sure to reinstall each big end bearing in its Connecting rod nuts original place.
CRANKSHAFT ASSEMBLY crankcase, fasten it with a wire. EAS26200 INSTALLING THE CRANKSHAFT 1. Install: Crankshaft journal upper bearings (into the upper crankcase) NOTE: Align the projections “a” on the crankshaft jour- nal upper bearings with the notches “b” in the upper crankcase.
TRANSMISSION EAS26240 TRANSMISSION REMOVING THE TRANSMISSION Order Job/Parts to remove Q’ty Remarks Separate Crankcase Refer to “CRANKCASE” on page 5-61. Main axle assembly Oil seal Bearing Drive axle assembly Collar O-ring Oil seal Circlip Bearing For installation, reverse the removal proce- dure.
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TRANSMISSION Removing the shift drum assembly Order Job/Parts to remove Q’ty Remarks Shift fork guide bar Shift fork 1 (L) Shift fork 2 (C) Shift fork 3 (R) Stopper plate Shift cam For installation, reverse the removal proce- dure. 5-78...
TRANSMISSION EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to checks and adjustments of all shift fork related parts. 1. Check: Shift fork cam follower “1” Shift fork pawl “2” Bends/damage/scoring/wear → Replace the shift fork. EAS26300 CHECKING THE TRANSMISSION 1.
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 19 Nm (1.9 m kg, 14 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat/side cover (right/left) 4-1.
FUEL TANK Contaminants → Clean the fuel pump pas- EAS26630 REMOVING THE FUEL TANK sage. 1. Extract the fuel in the fuel tank through the Rust/scratches/wear→Replace fuel fuel tank cap with a pump. pump assembly. 2. Remove: Fuel return hose EAS26710 INSTALLING THE FUEL PUMP Fuel hose...
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FUEL TANK fuel hose end in the direction of the arrow.
THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 3 Nm (0.3 m kg, 2.2 ft •...
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THROTTLE BODIES Removing the throttle bodies 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 3 Nm (0.3 m kg, 2.2 ft •...
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THROTTLE BODIES Removing the fuel hoses and injectors 4 Nm (0.4 m kg, 2.9 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks Fuel return hose Fuel hose 1/fuel hose 2...
THROTTLE BODIES Vacuum pressure increase → → → → Fuel pressure too low. Vacuum pressure decrease → → → → Fuel pressure too high. Faulty → Replace the pressure regulator. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS27020 ADJUSTING THE THROTTLE POSITION g. After adjusting the throttle position sensor an- SENSOR gle, tighten the throttle position sensor bolt.
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THROTTLE BODIES d. Check the sub-throttle position sensor overall resistance . Out of specification → Replace the sub-throt- tle position sensor. Resistance 4.0–6.0 kΩ e. Connect the pocket tester (Ω × 1k) to the throttle position sensor as shown. Tester positive lead → → → → c.
THROTTLE BODIES Sub-throttle position sensor out- put voltage 0.91–1.01 V i. Loosen the sub-throttle position sensor bolt. j. Adjust the sub-throttle position sensor angle so that the output voltage is within the speci- fied range. k. After adjusting the sub-throttle position sen- sor angle, tighten the sub-throttle position sensor bolt.
THROTTLE BODIES sub-throttle servo motor. b. Execute diagnostic mode, and make a visual inspection of sub-throttle valve operation (Code No. 56). Operate the sub-throttle valve in the full open direction for five seconds, stop for two seconds, and operate in the full close direction for five seconds.
AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 6-13...
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AIR INDUCTION SYSTEM 1. Air filter case 2. Air induction system hose (Air filter case—Air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (Air cut-off valve—Cyl- inder head) 5. Exhaust port 6-14...
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AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 6-1. Spark plug cap Air induction system solenoid coupler Disconnect.
AIR INDUCTION SYSTEM EAS27060 EAS27070 CHECKING THE AIR INDUCTION SYSTEM INSTALLING THE AIR INDUCTION SYSTEM Air induction system 1. Install: The air induction system burns unburned ex- Reed valves haust gases by injecting fresh air (secondary air) Reed valve stoppers into the exhaust port, reducing the emission of 2.
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ELECTRICAL SYSTEM IGNITION SYSTEM ..................7-1 CIRCUIT DIAGRAM ................7-1 TROUBLE SHOOTING ................7-3 ELECTRIC STARTING SYSTEM ..............7-5 CIRCUIT DIAGRAM ................7-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......7-7 TROUBLE SHOOTING ................7-9 CHARGING SYSTEM..................7-11 CIRCUIT DIAGRAM ................7-11 TROUBLE SHOOTING ................
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CHECKING AND CHARGING THE BATTERY ........7-87 CHECKING THE RELAYS ..............7-90 CHECKING THE TURN SIGNAL RELAY ..........7-90 CHECKING THE DIODE ................. 7-91 CHECKING THE IGNITION SPARK GAP..........7-92 CHECKING THE SPARK PLUG CAPS........... 7-93 CHECKING THE IGNITION COIL ............7-93 CHECKING THE CRANKSHAFT POSITION SENSOR......
IGNITION SYSTEM EAS27140 TROUBLE SHOOTING The ignition system fails to operate. (no spark or intermittent spark). NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Fuel tank 3.Headlight unit 4.Left side cover 1. Check the fuse (Main fuse, Ignition fuse) NG→ Replace the fuse(s).
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IGNITION SYSTEM 10.Check the sidestand switch. Refer to NG→ Replace the sidestand switch. “CHECKING THE SWITCHES” on page 7-81 OK↓ 11.Check the clutch switch. Refer to NG→ Replace the clutch switch. “CHECKING THE SWITCHES” on page 7-81 OK↓ 12.Check the relay unit (starting circuit Replace the relay unit (starting circuit cut-off cut-off relay).
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed).
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ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main 3. Main switch 4. Ignition 5. Engine stop switch 6. Starting circuit cut-off relay 7.
ELECTRIC STARTING SYSTEM EAS27190 TROUBLE SHOOTING The starter motor fails to turn. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Fuel tank 3.Headlight unit 1. Check the fuse (Main fuse, Ignition fuse) NG→ Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 7-86 OK↓...
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ELECTRIC STARTING SYSTEM OK↓ 11.Check the clutch switch. Refer to NG→ Replace the clutch switch. “CHECKING THE SWITCHES” on page 7-81 OK↓ 12.Check the start switch. Refer to NG→ Replace the right handlebar switch. “CHECKING THE SWITCHES” on page 7-81 OK↓...
CHARGING SYSTEM EAS27230 TROUBLE SHOOTING The battery is not being charged. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Fuel tank 3.Headlight unit 1. Check the fuse (Main fuse) NG→ Replace the fuse. Refer to “CHECKING THE FUSES” on page 7-86 OK↓...
LIGHTING SYSTEM EAS27260 TROUBLE SHOOTING Any of the following fail to light: Headlight, high beam indicator light, taillight, license plate light or meter light. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Fuel tank 3.Headlight unit 1. Check the each bulbs and bulb sockets condition.
SIGNALING SYSTEM EAS27290 TROUBLE SHOOTING Any of the following fail to light: Flasher light, brake light and indicator light. The horn fails to sound. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Fuel tank 3.Headlight unit 1. Check the fuse (Main, ignition, signal, taillight) NG→...
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SIGNALING SYSTEM The tail/brake light fails to come on. 1. Check the brake light switch. Refer to NG→ Replace the brake light switch “CHECKING THE SWITCHES” on page 7-81 OK↓ 2. Check the entire signaling system’s Properly connect or repair the signaling sys- wiring.
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SIGNALING SYSTEM The neutral indicator light fails to come on. 1. Check the neutral indicator light bulb Replace the neutral indicator light bulb, socket and socket. NG→ Refer to “CHECKING THE BULBS or both. AND BULB SOCKETS” on page 7-85 OK↓...
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SIGNALING SYSTEM The speedometer fails to operate. 1. Check the speed sensor. Refer to NG→ Replace the speed sensor. “CHECKING THE SPEED SENSOR” on page 7-96 OK↓ 2. Check the entire signaling system’s Properly connect or repair the signaling sys- wiring.
FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
FUEL INJECTION SYSTEM EAS27390 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
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FUEL INJECTION SYSTEM Fault Able / Able / code Item Symptom unable to unable to start drive Intake air pres- sure sensor 2 Intake air pressure sensor-open or short circuit is Able Able (open or detected. short-circuit) Intake air pres- Intake air pressure sensor-pipe system malfunction sure sensor 2 Able...
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FUEL INJECTION SYSTEM Fault Able / Able / code Item Symptom unable to unable to start drive Impos- Impos- Fuel system sible, sible, voltage Voltage supplied to the fuel injector and fuel pump dependi dependi (monitor volt- is not normal. ng on ng on age)
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FUEL INJECTION SYSTEM Fault Able / Able / code Item Symptom unable to unable to start drive ECU internal malfunction Non-registered data has been received from the Er-4 *Able *Able (input signal meter. error) *If multiple malfunctions have been detected for the ECU or immobilizer unit, you may not be able to start or drive the vehicle.
FUEL INJECTION SYSTEM The engine operation is not normal but the EAS27400 TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1. Check the operation of following sensors and engine trouble warning light comes on. actuators in the Diagnostic mode.
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FUEL INJECTION SYSTEM NOTE: The diagnostic monitoring code number ap- pears on the clock LCD (01–70). To decrease the selected diagnostic monitor- ing code number, press the RESET button. Press the RESET button for 1 second or longer to automatically decrease the diagnostic mon- itoring code numbers.
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FUEL INJECTION SYSTEM Diagnostic monitoring code table Fault Diagnostic code Symptom Probable cause of malfunction code No. Open circuit in wire harness. Defective crankshaft position sensor. No normal signals are Faulty timing plate. received from the crank- — Malfunction in ECU. shaft position sensor.
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FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Open circuit in wire harness. No normal signal is Defective O sensor. received from the O sen- — Malfunction in ECU. sor. Improperly installed O sensor. Open or short circuit in wire harness. Intake air pressure sensor Defective intake vacuum sensor 2.
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FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Open circuit in wire harness. No normal signals are received from the speed Defective speed sensor. sensor. Malfunction in ECU. Open circuit in wire harness. Open or short circuit is detected in the neutral Defective neutral switch.
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FUEL INJECTION SYSTEM Sensor operation table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “DIAGNOSTIC MONITORING MODE”. Diagnostic Item Meter display Checking method code No. Throttle angle Fully closed position 15–18 Check with throttle fully closed.
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FUEL INJECTION SYSTEM Diagnostic Item Meter display Checking method code No. EEPROM fault cylinder dis- — play No history History exists 01–04 (display defective cyl- inder number) (If more than one cylinder is defective, the display alternates every two sec- onds to show all the detected cylinder num- bers.
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FUEL INJECTION SYSTEM Diagnostic Item Meter display Checking method code No. Malfunction history code — re-display No malfunction code Malfunction code exists Fault detection code 24 (If code numbers more than one are detected, the display alternates every two seconds to show all the detected code numbers.
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FUEL INJECTION SYSTEM Diagnostic Item Actuation Checking method code No. Actuates the air induction system solenoid five times at one-second intervals. Illuminates the engine trou- Check the operating sound Air induction system sole- ble warning light light. of the air induction system noid (Light OFF: Air induction sys- solenoid five times.
FUEL INJECTION SYSTEM EAS27480 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Carry out check and maintenance on items or components that could be a cause of malfunction in accordance with the order. When the check and maintenance of malfunctioned part is completed, restore the meter display ac- cording to the “Reinstatement method”.
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FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor 1 open or short circuit detected. Diagnostic code No. Intake air pressure sensor 1 Reinstatement Order Item/components and probable cause Check or maintenance job method When error code Nos. 13 and 14 are displayed simultaneously, first check and repair No.13.
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FUEL INJECTION SYSTEM Intake air pressure sensor 1hose system malfunction (clogged Fault code No. Symptom or detached hose). Diagnostic code No. Intake air pressure sensor 1 Reinstatement Order Item/components and probable cause Check or maintenance job method When error code Nos. 13 and 14 are displayed simultaneously, first check and repair No.13.
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FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor-open or short circuit detected. Diagnostic code No. Throttle position sensor Reinstatement Order Item/components and probable cause Check or maintenance job method When error code Nos. 15 and 16 are displayed simultaneously, first check and repair No.15.
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FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Diagnostic code No. Throttle position sensor Reinstatement Order Item/components and probable cause Check or maintenance job method When error code Nos. 15 and 16 are displayed simultaneously, first check and repair No.15.
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FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor is stuck. Diagnostic code No. EXUP servo motor Reinstatement Order Item/components and probable cause Check or maintenance job method When error code Nos. 17 and 18 are displayed simultaneously, first check and repair No.17.
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FUEL INJECTION SYSTEM Open circuit is detected in the input line from the sidestand Fault code No. Symptom switch to the ECU. Diagnostic code No. Sidestand switch Reinstatement Order Item/components and probable cause Check or maintenance job method Connections. Execute the diagnostic monitor- If the transmis- Main wire harness ECU coupler sion is in gear,...
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FUEL INJECTION SYSTEM Fault code No. Symptom Intake air temperature sensor-open or short circuit detected. Diagnostic code No. Intake air temperature sensor Reinstatement Order Item/components and probable cause Check or maintenance job method When error code Nos. 22 and 37 are displayed simultaneously, first check and repair No.22.
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FUEL INJECTION SYSTEM Fault code No. Symptom sensor open or short circuit detected. Diagnostic code No. — — Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of O sensor. Check for looseness or pinch- Engine starts and races after ing.
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FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor 2 open or short circuit detected. Diagnostic code No. Intake air pressure sensor 2 Reinstatement Order Item/components and probable cause Check or maintenance job method When error code Nos. 25 and 37 are displayed simultaneously, first check and repair No.25.
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FUEL INJECTION SYSTEM Intake air pressure sensor 2 hose system malfunction (clogged Fault code No. Symptom or detached hose). Diagnostic code No. Intake air pressure sensor 2 Reinstatement Order Item/components and probable cause Check or maintenance job method When error code Nos. 26 and 37 are displayed simultaneously, first check and repair No.26.
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FUEL INJECTION SYSTEM Fault code No. Symptom Engine temperature sensor-open or short circuit detected. Diagnostic code No. Engine temperature sensor Reinstatement Order Item/components and probable cause Check or maintenance job method When error code Nos. 28 and 37 are displayed simultaneously, first check and repair No.28.
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FUEL INJECTION SYSTEM Malfunction detected in the primary lead of the ignition coil (#1 Fault code No. Symptom and #4). Diagnostic code No. Ignition coil (#1 and #4) Reinstatement Order Item/components and probable cause Check or maintenance job method Connection. Check the coupler for any pins Starting the Ignition coil (#1/#4) primary lead...
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FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling. Diagnostic code No. ISC (idle speed control) valve Reinstatement Order Item/components and probable cause Check or maintenance job method When error code Nos. 15 and 37 are displayed simultaneously, first check and repair No.15.
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FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling. Diagnostic code No. ISC (idle speed control) valve Reinstatement Order Item/components and probable cause Check or maintenance job method EFI fuse Check the EFI fuse. Starting the “CHECKING THE FUS- Refer to...
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FUEL INJECTION SYSTEM Fault code No. Symptom Injector-open circuit detected 36/37/38/ Diagnostic code No. Injector #1/#2/#3/#4 Reinstatement Order Item/components and probable cause Check or maintenance job method Connections. Check the coupler for any pins Start the Fuel injector coupler engine. that may have pulled out.
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FUEL INJECTION SYSTEM A. No normal signals are received from the speed sensor. Fault code No. Symptom B. Open or short circuit is detected in the neutral switch. Speed sensor Diagnostic code No. Neutral switch Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of speed sensor...
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FUEL INJECTION SYSTEM A. No normal signals are received from the speed sensor. Fault code No. Symptom B. Open or short circuit is detected in the neutral switch. Speed sensor Diagnostic code No. Neutral switch Reinstatement Order Item/components and probable cause Check or maintenance job method Installed condition of neutral switch...
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FUEL INJECTION SYSTEM Fault code No. Symptom Supplied power to the fuel injector and fuel pump is not normal. Diagnostic code No. Fuel system voltage Reinstatement Order Item/components and probable cause Check or maintenance job method Connections. Check the coupler for any pins Starting the Starting circuit cut-off relay coupler engine and...
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FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the ECU is not normal. Diagnostic code No. — — Reinstatement Order Item/components and probable cause Check or maintenance job method Connections. Check the coupler for any pins Starting the Wire harness ECU coupler engine and that may have pulled out.
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FUEL INJECTION SYSTEM Fault code No. Symptom Sub-throttle position sensor-open or short circuit detected. Diagnostic code No. Sub-throttle servo motor Reinstatement Order Item/components and probable cause Check or maintenance job method When error code Nos. 47 and 48 are displayed simultaneously, first check and repair No.47.
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FUEL INJECTION SYSTEM Fault code No. Symptom Sub-throttle servo motor is stuck. Diagnostic code No. Sub-throttle servo motor Reinstatement Order Item/components and probable cause Check or maintenance job method When error code Nos. 47 and 48 are displayed simultaneously, first check and repair No.47.
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FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Diagnostic code No. — — Reinstatement Order Item/components and probable cause Check or maintenance job method Connections. Check the coupler for any pins Reinstated Wire harness ECU coupler automatically that may have pulled out.
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FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic code No. — — Reinstatement Order Item/components and probable cause Check or maintenance job method Connections. Check the coupler for any pins Reinstated Wire harness ECU coupler automatically that may have pulled out.
FUEL PUMP SYSTEM EAS27600 TROUBLE SHOOTING The fuel pump fails to operate. NOTE: Before troubleshooting, remove the following part(s): 1.Seat 2.Side cover (right) 3.Headlight unit 1. Check the fuse (Main fuse, ignition fuse, EFI fuse) NG→ Replace the fuse(s). Refer to “CHECKING THE FUSES”...
IMMOBILIZER SYSTEM EAS27671 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: a code re-registering key (with a red bow) two standard keys (with a black bow) that can be re-registered with new codes a transponder (installed in the red key bow) an immobilizer unit the ECU...
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IMMOBILIZER SYSTEM Parts to be replaced Main switch/ Key registration immobilizer unit Accessory requirement Standard lock* and Main Immobilize switch r unit √ Standard key is lost New standard key All keys have been Code re-registering √ √ √ √ lost (including code key and standard re-registering key)
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IMMOBILIZER SYSTEM Standby mode: d. LED goes off a. Main switch “ON”. e. Standby mode ON b. Main switch “OFF”. f. Standby mode OFF c. LED lights Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
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IMMOBILIZER SYSTEM Standard key registration h. Standard key (2nd) a. Main switch “ON”. i. Registration mode b. Main switch “OFF”. c. LED lights A. Standard key (2nd) registration com- d. LED goes off plete e. Within 5 seconds B. When the 2nd standard key registration f.
IMMOBILIZER SYSTEM EAS27701 TROUBLE SHOOTING When the main switch is turned “ON”, the immobilizer system light goes on or flashes. 1. Check the fuse (Main, ignition and back up) NG→ Replace the fuse. Refer to “CHECKING THE FUSES” on page 7-86 OK↓...
IMMOBILIZER SYSTEM EAS27721 SELF-DIAGNOSIS FAULT CODE INDICATION When a system failure occurrs, the error code number is indicated in the LCD display of meter and the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code.
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IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Key code registra- Same standard key was Register another UNIT tion malfunction. attempted to be regis- standard key. tered two consecutive times. Undefinition code is Noise interference or Check the wire received.
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ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
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ELECTRICAL COMPONENTS Checking the condition of the bulbs EAS27990 CHECKING THE BULBS AND BULB The following procedure applies to all of the SOCKETS bulbs. NOTE: 1. Remove: Do not check any of the lights that use LEDs. Bulb EWA13320 Check each bulb and bulb socket for damage or WARNING wear, proper connections, and also for continu- Since the headlight bulb gets extremely hot,...
ELECTRICAL COMPONENTS check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. If the pocket tester indicates “∞”, replace the fuse. Checking the condition of the bulb sockets The following procedure applies to all of the bulb sockets.
ELECTRICAL COMPONENTS 4. Install: to check the charge state of the battery by mea- SEAT suring the specific gravity of the electrolyte. Refer to “GENERAL CHASSIS” on page 4-1. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery EAS28030 terminals.
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ELECTRICAL COMPONENTS be done with the battery mounted on the vehicle, disconnect the negative battery lead from the battery terminal.) To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
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ELECTRICAL COMPONENTS NOTE: NOTE: Set the charging voltage at 16–17 V.If the setting If the current is lower than the standard charging is lower, charging will be insufficient. If too high, current written on the battery, This type of bat- the battery will be over-charged.
ELECTRICAL COMPONENTS EAS28040 CHECKING THE RELAYS Result Continuity (between “3” and Check each switch for continuity with the pocket “4”) tester. If the continuity reading is incorrect, re- place the relay. Relay unit (fuel pump) Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1.
ELECTRICAL COMPONENTS Flasher relay input voltage DC 12V MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Connect the pocket tester (DC 20 V) to the Br/W flasher relay terminal. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Set the main switch to “ON”. c. Measure flasher relay applied voltage. Positive tester probe →...
ELECTRICAL COMPONENTS MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Continuity a. Disconnect the starting circuit cut-off relay Positive tester lead → Sky blue from the wire harness. “1” Negative tester lead → Sky blue/ b. Connect the pocket tester (Ω × 1) to the relay White “2” unit coupler as shown.
ELECTRICAL COMPONENTS c. Measure the spark plug cap resistance. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28100 CHECKING THE IGNITION COIL The following checking procedure applies to all of the ignition coils. 1. Check: Primary coil resistance Out of specification → Replace. 1. Ignition checker Primary coil resistance 2.
ELECTRICAL COMPONENTS 2. Check: Horn sound Faulty sound → Adjust or replace. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Connect a battery (12 V) to the horn. b. Turn the adjusting screw in direction “a” or “b” until the specified horn sound is obtained. c. Turn the lean angle sensor to 65°. d.
ELECTRICAL COMPONENTS b. Measure the oil level gauge resistance. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28210 CHECKING THE ENGINE TEMPERATURE SENSOR 1. Remove: Engine temperature sensor (From intake manifold) EWA14140 b. Immerse the engine temperature sensor in a WARNING container filled with coolant “2”. Handle the engine temperature sensor with NOTE: special care.
ELECTRICAL COMPONENTS Positive tester probe → White/Yellow “1” Negative tester probe → B/L Y Black/blue “2” L W/Y b. Check the throttle position sensor resistance. Out of specification → Replace the throttle position sensor. Resistance 4.0–6.0 kΩ b. Set the main switch to “ON”. c.
ELECTRICAL COMPONENTS Br/B Br/B R/W c. Measure the AI system solenoid resistance. b. Move the fuel sender float to the empty “3” and full “4” positions. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28410 CHECKING INTAKE AIR PRESSURE SENSORS 1 AND 2 1. Check: Intake air pressure sensor output voltage Out of specification →...
TROUBLESHOOTING Discharged battery EAS28450 TROUBLESHOOTING Faulty battery 2. Fuses EAS28460 GENERAL INFORMATION Blown, damaged or incorrect fuse Improperly installed fuse NOTE: The following guide for troubleshooting does not 3. Spark plug cover all the possible causes of trouble. It should Incorrect spark plug gap Incorrect spark plug heat range be helpful, however, as a guide to basic trouble-...
TROUBLESHOOTING 2. Air filter Incorrect connection Clogged air filter element Improperly grounded circuit Chassis Poor switch contacts (main switch) 1. Brake Burnt-out headlight bulb Dragging brake Headlight bulb burnt out Electrical system Wrong headlight bulb 1. Spark plug Faulty battery Incorrect spark plug gap Faulty rectifier/regulator Incorrect spark plug heat range...
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EAS28740 49.Left turn signal indicator light EAS28750 XJR1300(W) 2007 COLOR CODE 50.High beam indicator WIRING DIAGRAM Black 51.Oil level switch 1.Generator 52.Rear brake switch Brown 2.Main switch 53.Tail/brake light Chocolate 3.Ignition fuse 54.Licence light Dark green 4.Main fuse 55.Front left turn signal light Green 56.Front right turn signal light 5.Backup fuse...