Download  Print this page

Yamaha XJR1300 2007 Service Manual

Hide thumbs
Most useful pages: More

Advertisement

Table of Contents
2007
XJR1300(W)
SERVICE MANUAL
5WM-28197-E0

Advertisement

Table of Contents

   Summary of Contents for Yamaha XJR1300 2007

  • Page 1 2007 XJR1300(W) SERVICE MANUAL 5WM-28197-E0...
  • Page 3 EAS20040 XJR1300(W) 2007 SERVICE MANUAL ©2007 by Yamaha Motor Co., Ltd. First edition, February 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 5 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.
  • Page 6: Symbols

    EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.
  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER ........... 1-1 MODEL LABEL..................1-1 FEATURES....................1-2 OUTLINE OF THE FI SYSTEM ............... 1-2 FI SYSTEM....................1-3 IMMOBILIZER SYSTEM ................. 1-4 INSTRUMENT FUNCTION ..............1-5 IMPORTANT INFORMATION ............... 1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-8 REPLACEMENT PARTS.................
  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
  • Page 11: Features

    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.
  • Page 12: Fi System

    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 –...
  • Page 13: Immobilizer System

    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.
  • Page 14: Instrument Function

    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”...
  • Page 15 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.
  • Page 16 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.
  • Page 17: Important Information

    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...
  • Page 18: Circlips

    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”...
  • Page 19: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: Lead NOTE: Coupler If there is no continuity, clean the terminals. Connector When checking the wire harness, perform 2.
  • Page 20: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pocket tester 1-10, 5-31, 90890-03112 5-35, 6-8, 7-83, 7-85, 7-86, Analog pocket tester 7-90, 7-91, YU-03112-C 7-93, 7-94, 7-95, 7-96, 7-97, 7-98, 7-99 Timing light 3-11 90890-03141 Inductive clamp timing light YU-03141 Digital circuit tester 6-8, 6-10 90890-03174...
  • Page 22 5-20 90890-04101 Valve lapping tool YM-A8998 Tappet adjusting tool 90890-04110 Valve adjustment tool YM-33966 Ignition checker 7-92 90890-06754 Opama pet-4000 spark checker YM-34487 Yamaha bond No. 1215 (Three Bond 5-63 No.1215®) 90890-85505 Digital tachometer 3-7, 3-9, 3-11 90890-06760 YU-39951-B 1-13...
  • Page 23: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................ 2-9 ELECTRICAL SPECIFICATIONS ..............2-12 TIGHTENING TORQUE................. 2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-15 ENGINE ....................2-15 CHASSIS ....................2-18 LUBRICATION POINTS AND LUBRICANT TYPES ........2-21 ENGINE ....................2-21 CHASSIS ....................
  • Page 24: General Specifications

    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...
  • Page 25: Engine Specifications

    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)
  • Page 26 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)
  • Page 27 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)
  • Page 28 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)
  • Page 29 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)
  • Page 30 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 ×...
  • Page 31 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...
  • Page 32: Chassis Specifications

    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)
  • Page 33 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)
  • Page 34 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...
  • Page 35: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Digital 5.0 °/1070 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer TBDF55/DENSO Transistorized coil ignition 248–372 Ω Crankshaft position sensor resistance Ignition coil Model/manufacturer 83R/MORIC Minimum ignition spark gap 6.0 mm (0.24 in) 1.92–2.88 Ω...
  • Page 36 ELECTRICAL SPECIFICATIONS 12 V, 1.7 W × 2 Turn signal indicator light 12 V, 1.7 W × 1 Oil level warning light 12 V, 1.7 W × 1 High beam indicator light 12 V, 1.7 W × 1 Engine trouble warning light Immobilizer system indicator light Electric starting system System type...
  • Page 37 ELECTRICAL SPECIFICATIONS Fuel injection system fuse 15.0 A Backup fuse 7.5 A Spare fuse 15.0 A Spare fuse 7.5 A 2-14...
  • Page 38: Tightening Torque

    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.
  • Page 39 TIGHTENING TORQUE Thread Item Q’ty Tightening torque Remarks size Timing chain guide stopper 2 bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) OIL pump asembly screw 7 Nm (0.7 m•kg, 5.1 ft•lb) Oil pump bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Oil strainer housing bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Oil filter bolt...
  • Page 40 TIGHTENING TORQUE Thread Item Q’ty Tightening torque Remarks size Cover 2 screw 3 Nm (0.3 m•kg, 2.2 ft•lb) Cover 1 bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Clutch cover bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Cover screw 4 Nm (0.4 m•kg, 2.9 ft•lb) Crankcase bolt 12 Nm (1.2 m•kg, 8.7 ft•lb) Crankcase bolt...
  • Page 41: Chassis

    TIGHTENING TORQUE Thread Item Q’ty Tightening torque Remarks size Speed sensor screw 10 Nm (1.0 m•kg, 7.2 ft•lb) Fuel rail screw 5 Nm (0.5 m•kg, 3.6 ft•lb) Pressure regulator 4 Nm (0.4 m•kg, 2.9 ft•lb) EAS20350 CHASSIS Thread Item Q’ty Tightening torque Remarks size...
  • Page 42 TIGHTENING TORQUE Thread Item Q’ty Tightening torque Remarks size Damper rod assembly 23 Nm (2.3 m•kg, 17 ft•lb) Rear shock absorber lower bolt 23 Nm (2.3 m•kg, 17 ft•lb) Rear shock absorber upper bolt 30 Nm (3.0 m•kg, 22 ft•lb) Seal guard bolt 7 Nm (0.7 m•kg, 5.1 ft•lb) Chain case bolt...
  • Page 43 TIGHTENING TORQUE Thread Item Q’ty Tightening torque Remarks size Front brake caliper bolt 40 Nm (4.0 m•kg, 29 ft•lb) Front brake disc bolt 18 Nm (1.8 m•kg, 13 ft•lb) Front caliper bleed screw 6 Nm (0.6 m•kg, 4.3 ft•lb) Front brake hose union bolt 30 Nm (3.0 m•kg, 22 ft•lb) Tension bar bolt and nut 23 Nm (2.3 m•kg, 17 ft•lb)
  • Page 44: Lubrication Points And Lubricant Types

    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...
  • Page 45: Chassis

    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.
  • Page 46 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...
  • Page 47 LUBRICATION POINTS AND LUBRICANT TYPES 2-24...
  • Page 48: Lubrication Diagrams

    LUBRICATION DIAGRAMS EAS28860 LUBRICATION DIAGRAMS 2-25...
  • Page 49 LUBRICATION DIAGRAMS 1. Relief valve 2. Bypass valve 3. Oil filter element 4. Oil pump 5. Camshaft (intake) 6. Camshaft (exhaust) 7. Oil strainer housing 8. Oil strainer 2-26...
  • Page 50 LUBRICATION DIAGRAMS 2-27...
  • Page 51 LUBRICATION DIAGRAMS 1. Drive axle 2. Push rod 3. Main axle 4. Camshaft 5. Crankshaft 2-28...
  • Page 52 LUBRICATION DIAGRAMS 2-29...
  • Page 53 LUBRICATION DIAGRAMS 1. Nozzle 2. Bypass valve 3. Oil filter element 4. Relief valve 2-30...
  • Page 54: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-31...
  • Page 55 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.
  • Page 56 CABLE ROUTING 2-33...
  • Page 57 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.
  • Page 58 CABLE ROUTING 2-35...
  • Page 59 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.
  • Page 60 CABLE ROUTING 2-37...
  • Page 61 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.
  • Page 62 CABLE ROUTING 2-39...
  • Page 63 CABLE ROUTING 1. Sub-wire harness 2. Vacuum hose 3. Fuel injector coupler 4. Fuel hoses 5. Throttle body (12P) coupler 6. Wire harness 7. Intake air pressure sensor 8. Sub-throttle motor lead 9. Engine temperature sensor lead 10. ISC motor lead 11.
  • Page 64 CABLE ROUTING 2-41...
  • Page 65 CABLE ROUTING 1. Vacuum hose 1 2. Vacuum hose 2 3. Fuel hose 1 4. Fuel hose 2 5. Engine temperature sensor 6. ISC motor 7. Sub-throttle position sensor 8. Sub-throttle motor 9. Joint 10. Plug 11. Intake air pressure sensor 12.
  • Page 66 CABLE ROUTING 2-43...
  • Page 67 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.
  • Page 68 CABLE ROUTING 2-45...
  • Page 69 CABLE ROUTING 1. Fuel pump Comp. 2. Clamp 3. Pipe 2 4. Pipe 4 5. Rollover valve 6. Fuel hoses 7. Pipe 5 8. Clamp 9. Pipe 3 10. Plug 11. Fuel hose 2 12. Fuel hose 1 13. Frame 14.
  • Page 70 CABLE ROUTING 2-47...
  • Page 71: Periodic Checks And Adjustments

    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 ......
  • Page 72 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...
  • Page 73: Periodic Maintenance

    The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 50000 km, repeat the maintenance intervals starting from 10000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)
  • Page 74 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.
  • Page 75 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.
  • Page 76: Engine

    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.
  • Page 77 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”.
  • Page 78: Synchronizing The Throttle Bodies

    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.
  • Page 79 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.
  • Page 80: Adjusting The Exhaust Gas Volume

    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.
  • Page 81: Checking The Engine Idling Speed

    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.
  • Page 82: Checking The Spark Plugs

    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 →...
  • Page 83: Checking The Ignition Timing

    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.
  • Page 84: Checking The Engine Oil Level

    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...
  • Page 85: Changing The Engine Oil

    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”.
  • Page 86: Measuring The Engine Oil Pressure

    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.
  • Page 87: Adjusting The Clutch Lever

    ENGINE Engine oil pressure Possible causes Leaking oil pas- sage Faulty oil filter Above specification Oil viscosity too high 7. Remove: Pressure gauge Oil pressure adapter 5. Install: 8. Install: Oil pressure gauge “1” Main gallery bolt Adapter “2” Main gallery bolt 12 Nm (1.2 m•kg, 8.7 ft•lb) Pressure gauge 90890-03153...
  • Page 88: Bleeding The Hydraulic Clutch System

    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.
  • Page 89: Replacing The Air Filter Element

    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.
  • Page 90: Checking The Crankcase Breather Hose

    ENGINE Cracks/damage → Replace. 1. Check: Loose connection → Connect properly. Exhaust pipe Muffler ECA14940 CAUTION: Cracks/damage → Replace. Make sure the fuel tank breather hose is Gasket Exhaust gas leaks → Replace. routed correctly. 2. Check: Tightening torque Exhaust pipe nut “1” 25 Nm (2.5 m•kg, 18 ft•lb) Exhaust pipe bolt “2”...
  • Page 91: Adjusting The Exup Cables

    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”...
  • Page 92: Chassis

    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.
  • Page 93: Checking The Brake Fluid Level

    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.
  • Page 94: Checking The Front Brake Hoses

    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.
  • Page 95: Bleeding The Hydraulic Brake System

    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.
  • Page 96: Adjusting The Shift Pedal

    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”.
  • Page 97: Lubricating The Drive Chain

    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.
  • Page 98: Checking The Front Fork

    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”...
  • Page 99: Adjusting The Front Forks

    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.
  • Page 100: Adjusting The Rear Shock Absorber Assembly

    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.
  • Page 101 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.
  • Page 102: Checking The Tires

    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...
  • Page 103 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...
  • Page 104: Checking The Wheels

    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...
  • Page 105: Electrical System

    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”...
  • Page 106 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...
  • Page 107 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 ....................
  • Page 108 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 ..........
  • Page 109 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.
  • Page 110 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 •...
  • Page 111 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.
  • Page 112: Front Wheel

    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.
  • Page 113: Assembling The Front Wheel

    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.
  • Page 114: Installing The Front Wheel (disc)

    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.
  • Page 115 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.
  • Page 116: Rear Wheel

    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.
  • Page 117 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...
  • Page 118 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...
  • Page 119: Removing The Rear Wheel (disc)

    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.
  • Page 120: Assembling The Rear Wheel

    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.
  • Page 121 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...
  • Page 122: Front Brake

    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...
  • Page 123 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”...
  • Page 124 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...
  • Page 125 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”...
  • Page 126 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.
  • Page 127: Introduction

    FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: Never disassemble brake components un- less absolutely necessary. If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.
  • Page 128: Replacing The Front Brake Pads

    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.
  • Page 129: Removing The Front Brake Calipers

    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.
  • Page 130: Checking The Front 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.
  • Page 131: Installing The Front Brake Calipers

    FRONT BRAKE 2. Install: Brake caliper Brake hose holder Brake caliper bolt 40 Nm (4.0 m•kg, 29 ft•lb) Refer to “REPLACING THE FRONT BRAKE PADS” on page 4-20. 3. Add the recommended brake fluid to the proper level. Brake master cylinder reservoir 3.
  • Page 132: Removing The Front Brake Master Cylinder

    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”...
  • Page 133: Assembling The Front Brake Master Cylinder

    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.
  • Page 134 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”...
  • Page 135: Rear Brake

    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...
  • Page 136 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...
  • Page 137 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...
  • Page 138 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”...
  • Page 139 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.
  • Page 140: Introduction

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit 4.5 mm (0.18 in) EWA14100 WARNING Disc brake components rarely require disas- 5. Adjust: Brake disc deflection sembly. Therefore, always follow these pre- ventive measures: Refer to “CHECKING THE FRONT BRAKE DISC” on page 4-19. Never disassemble brake components un- less absolutely necessary.
  • Page 141: Removing The Rear Brake Caliper

    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.
  • Page 142: Checking The Rear Brake Caliper

    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.
  • Page 143: Removing The Rear Brake Master Cylinder

    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.
  • Page 144: Checking The Rear Brake Master Cylinder

    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.
  • Page 145 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”...
  • Page 146: Handlebar

    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 •...
  • Page 147: Removing The Handlebar

    HANDLEBAR EAS22860 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: Handlebar grip “1” NOTE: Blow compressed air between the handlebar EAS22930 and the handlebar grip, and gradually push the INSTALLING THE HANDLEBAR...
  • Page 148 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.
  • Page 149: Front Fork

    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 •...
  • Page 150 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...
  • Page 151 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.
  • Page 152: Removing The Front Fork Legs

    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...
  • Page 153: Checking The Front Fork Legs

    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.
  • Page 154: Assembling 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.
  • Page 155 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...
  • Page 156 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.
  • Page 157: Installing The Front Fork Legs

    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.
  • Page 158: Steering Head

    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 •...
  • Page 159 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 •...
  • Page 160: Removing The Lower Bracket

    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.
  • Page 161 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)
  • Page 162: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 163: Handling The Rear Shock Absorber And Gas Cylinder

    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.
  • Page 164: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23320 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Install: Rear shock absorber assembly NOTE: With the rear shock absorber assembly, tighten in the order: left/right lower bolts, then upper bolts. Rear shock absorber assembly lower bolt 30 Nm (3.0 m•kg, 22 ft•lb) Rear shock absorber assembly upper bolt...
  • Page 165: Swingarm

    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 •...
  • Page 166: Removing The Swingarm

    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.
  • Page 167 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”...
  • Page 168: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain 85 Nm (8.5 m kg, 62 ft • • Order Job/Parts to remove Q’ty Remarks Loosen Drive sprocket nut Refer to “ENGINE REMOVAL” on page 5-1. Refer to “REAR SHOCK ABSORBER Rear shock absorber ASSEMBLY”...
  • Page 169: Removing The Drive Chain

    CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
  • Page 170: Checking The Drive Sprocket

    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.
  • Page 171 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 ............
  • Page 172 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.........
  • Page 173 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...
  • Page 174: Engine Removal

    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 •...
  • Page 175 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 •...
  • Page 176 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 • •...
  • Page 177: Installing The Engine

    ENGINE REMOVAL 3. Install: EAS23720 INSTALLING THE ENGINE Shift arm “1” 1. Install: Engine bracket bolt (rear upper) “1” Shift arm mounting bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) Engine bracket bolt (rear upper) “2” Engine mounting nut (rear upper) “3” NOTE: Engine bracket bolt (front) “4”...
  • Page 178 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.
  • Page 179: Camshafts

    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 •...
  • Page 180: Removing The Camshafts

    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.
  • Page 181 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.
  • Page 182: Checking The Timing Chain And Camshaft Sprocket

    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.
  • Page 183 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”...
  • Page 184 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...
  • Page 185 CAMSHAFTS Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-4. 10.Install: Timing plate cover 5-12...
  • Page 186: Cylinder Head

    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 •...
  • Page 187: Removing The Cylinder Head

    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.
  • Page 188 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.
  • Page 189: Valves And Valve Springs

    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...
  • Page 190: Removing The Valves

    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.
  • Page 191: Checking The Valves And Valve Guides

    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.
  • Page 192: Checking The Valve Seats

    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.
  • Page 193 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 →...
  • Page 194: Checking The Valve Springs

    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.
  • Page 195: Checking The Valve Lifters

    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...
  • Page 196 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.
  • Page 197: Cylinder And Piston

    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...
  • Page 198: Removing The 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.
  • Page 199: Checking The Piston Rings

    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”...
  • Page 200: Checking The Piston Pin

    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 →...
  • Page 201 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.
  • Page 202 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.
  • Page 203: Generator

    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...
  • Page 204: Checking The Generator

    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.
  • Page 205 GENERATOR b. Measure the stator coil resistances. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 5-32...
  • Page 206: Timing Plate

    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”...
  • Page 207: Electric Starter

    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.
  • Page 208: Checking The Starter Motor

    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”...
  • Page 209: Assembling The Starter Motor

    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.
  • Page 210: Clutch

    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.
  • Page 211 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...
  • Page 212 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.
  • Page 213 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...
  • Page 214 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...
  • Page 215 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...
  • Page 216 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...
  • Page 217: Removing The Clutch

    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”...
  • Page 218: Checking The Clutch Plates

    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.
  • Page 219: Checking The Clutch Boss

    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.
  • Page 220 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.
  • Page 221: Disassembling The Clutch Master Cylinder

    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 →...
  • Page 222: Installing The Clutch Master Cylinder

    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.
  • Page 223: Disassembling The Clutch Release Cylinder

    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.
  • Page 224: Assembling The Clutch Release Cylinder

    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.
  • Page 225 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”...
  • Page 226: Oil Pump

    OIL PUMP EAS24910 OIL PUMP Removing the oil pump 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Clutch Refer to “CLUTCH” on page 5-37. Oil pump drive gear Collar Washer...
  • Page 227 OIL PUMP Disassembling the oil pump 7 Nm (0.7 m kg, 5.2 ft • • Order Job/Parts to remove Q’ty Remarks Rotor housing Inner rotor Outer rotor Dowel pin Dowel pin Housing Inner rotor Outer rotor Dowel pin Pump shaft Pump cover For installation, reverse the removal proce- dure.
  • Page 228: Disassembling The Oil Pump

    OIL PUMP EAS24950 DISASSEMBLING THE OIL PUMP 1. Remove: Screw Oil pump drive gear “1” Oil pump driven gear “2” Oil pump housing “3” Oil pump housing cover “4” EAS24960 CHECKING THE OIL PUMP 1. Check: 1. Inner rotor Oil pump drive gear “1” 2.
  • Page 229: Installing The Oil Pump

    OIL PUMP Recommended lubricant Engine oil 2. Install: Oil pump shaft “1” (to the oil pump cover “2”) Pin “3” Inner rotor “4” Outer rotor “5” Pin “6” Oil pump housing “7” Oil pump cover screw 7 Nm (0.7 m•kg, 5.1 ft•lb) NOTE: When installing the inner rotor, align the pin “3”...
  • Page 230: Shift Shaft

    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...
  • Page 231: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: Shift shaft “1” Shift shaft lever Bends/damage/wear → Replace. Shift shaft lever spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: Stopper lever “1” 2. Install: Bends/damage → Replace. Washer “1”...
  • Page 232: Oil Pan

    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...
  • Page 233: Removing The Oil Pan

    OIL PAN “a” facing forward. EAS5UXB005 REMOVING THE OIL PAN 1. Remove: Oil level switch Oil pan Gasket Dowel pins EAS24970 CHECKING THE RELIEF VALVE 1. Check: Relief valve body “1” Relief valve “2” Spring “3” 2. Install: Cover “4” Oil strainer “1”...
  • Page 234: Crankcase

    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 •...
  • Page 235: Disassembling The Crankcase

    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...
  • Page 236 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”...
  • Page 237 CRANKCASE M10×50mm bolt “16”, “17” M6 ×110mm bolt “18” M6 ×95mm bolt “19”, “ 21” M6 ×40mm bolt “20”, “ 23” M6 ×50mm bolt “22”, “ 26” M6 ×65mm bolt “25”, “ 37” M6 ×30mm bolt “27” M8×55mm bolt “28”, “30” M6 ×125mm bolt “24”...
  • Page 238: Starter Clutch

    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...
  • Page 239: Checking The Starter Clutch

    STARTER CLUTCH EAS24570 CHECKING THE STARTER CLUTCH 1. Check: Starter clutch rollers “1” Damage/wear → Replace. Starter clutch gear “2” Starter clutch drive gear “3” Starter clutch idle gear “4” Burrs/chips/roughness/wear → Replace the defective part(s). LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS24580 CHECKING THE STARTER CLUTCH SHAFT 1.
  • Page 240 STARTER CLUTCH 5-67...
  • Page 241: Crankshaft Assembly

    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.
  • Page 242 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...
  • Page 243: Removing The Crankshaft Assembly

    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.
  • Page 244 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.
  • Page 245 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-...
  • Page 246 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...
  • Page 247: Checking The Hy-vo Chain

    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”...
  • Page 248: Installing The Crankshaft Journal Bearing

    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.
  • Page 249: Installing The Crankshaft

    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.
  • Page 250: Transmission

    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.
  • Page 251 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...
  • Page 252 TRANSMISSION Disassembling the transmission Order Job/Parts to remove Q’ty Remarks Plate washer 1st wheel gear/Collar Plate washer 4th wheel gear Circlip Plate washer 3rd wheel gear/Collar Plate washer 5th wheel gear Circlip Plate washer 2nd wheel gear/Collar Drive axle 2nd Pinion gear 5th Pinion gear/Collar Plate washer 3rd Pinion gear...
  • Page 253 TRANSMISSION Disassembling the transmission Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-80...
  • Page 254: Checking The Shift Forks

    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.
  • Page 255: Installing The Shift Forks And Shift Drum

    TRANSMISSION 4. Check: EAS26350 INSTALLING THE TRANSMISSION Transmission gear engagement 1. Install: (each pinion gear to its respective wheel Main axle assembly “1” gear) Rough operation → Reassemble the trans- Drive axle assembly “2” mission axle assemblies. 5. Check: Transmission gear movement Rough movement →...
  • Page 256 TRANSMISSION 2. Check: Transmission gear movement Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly. 5-83...
  • Page 257 FUEL SYSTEM FUEL TANK....................6-1 REMOVING THE FUEL TANK ..............6-2 REMOVING THE FUEL PUMP ............... 6-2 CHECKING THE FUEL PUMP BODY............. 6-2 INSTALLING THE FUEL PUMP .............. 6-2 INSTALLING THE FUEL TANK............... 6-2 THROTTLE BODIES ..................6-4 CHECKING THE INJECTORS ..............6-7 CHECKING THE THROTTLE BODIES ...........
  • Page 258: Fuel Tank

    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.
  • Page 259: Removing The Fuel Tank

    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...
  • Page 260 FUEL TANK fuel hose end in the direction of the arrow.
  • Page 261: Throttle Bodies

    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 •...
  • Page 262 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 •...
  • Page 263 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...
  • Page 264: Checking The Injectors

    THROTTLE BODIES EAS26980 CHECKING THE INJECTORS 1. Check: Injectors Damage → Replace. EAS26990 CHECKING THE THROTTLE BODIES 1. Check: Throttle bodies Rust/scratches/wear→Replace the throttle body assembly. d. Connect the pressure gauge “3” and adapter 2. Check: “4” to the fuel injection pipe. Fuel passages Contaminants →...
  • Page 265: Adjusting The Throttle Position Sensor

    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.
  • Page 266 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.
  • Page 267: Checking The Sub-throttle Servo Motor

    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.
  • Page 268: Fuel Supply System Air Bleeding

    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.
  • Page 269 THROTTLE BODIES 6-12...
  • Page 270: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 6-13...
  • Page 271 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...
  • Page 272 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.
  • Page 273: Checking The Air Induction System

    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.
  • Page 274 AIR INDUCTION SYSTEM 6-17...
  • Page 275 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 ................
  • Page 276 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......
  • Page 278: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 279 IGNITION SYSTEM 2. Main switch 3. Ignition fuse 4. Main fuse 7. Battery 13. Engine stop switch 15. Relay unit 16. Neutral switch 17. Sidestand switch 19. Ignition coil 1 20. Ignition coil 2 29. Crankshaft position sensor 30. Lean angle sensor 38.
  • Page 280: Trouble Shooting

    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).
  • Page 281 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).
  • Page 282: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 283 ELECTRIC STARTING SYSTEM 2. Main switch 3. Ignition fuse 4. Main fuse 7. Battery 8. Starter relay 9. Starter motor 13. Engine stop switch 14. Start switch 15. Relay unit 16. Neutral switch 17. Sidestand switch 65. Clutch switch...
  • Page 284: Starting Circuit Cut-off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed).
  • Page 285 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.
  • Page 286: Trouble Shooting

    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↓...
  • Page 287 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↓...
  • Page 288: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-11...
  • Page 289 CHARGING SYSTEM 1. Generator 2. Main switch 4. Main fuse 7. Battery 7-12...
  • Page 290: Trouble Shooting

    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↓...
  • Page 291 CHARGING SYSTEM 7-14...
  • Page 292: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-15...
  • Page 293 LIGHTING SYSTEM 2. Main switch 3. Ignition fuse 4. Main fuse 7. Battery 38. ECU 41. Meter light 44. Multi-function display 50. High beam indicator 53. Tail/brake light 54. Licence light 60. Pass switch 61. Dimmer switch 68. Headlight relay 69.
  • Page 294: Trouble Shooting

    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.
  • Page 295 LIGHTING SYSTEM 7-18...
  • Page 296: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-19...
  • Page 297 SIGNALING SYSTEM 2. Main switch 3. Ignition fuse 4. Main fuse 7. Battery 12. Front brake switch 15. Relay unit 16. Neutral switch 18. Fuel pump 31. Speed sensor 38. ECU 42. Speedometer 43. Tachometer 44. Multi-function display 45. Oil level warning light 47.
  • Page 298: Trouble Shooting

    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→...
  • Page 299 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.
  • Page 300 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↓...
  • Page 301 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.
  • Page 302: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 7-25...
  • Page 303 FUEL INJECTION SYSTEM 2. Main switch 3. Ignition fuse 4. Main fuse 5. Backup fuse 6. EFI fuse 7. Battery 13. Engine stop switch 14. Start switch 15. Relay unit 16. Neutral switch 17. Sidestand switch 18. Fuel pump 19. Ignition coil 1 20.
  • Page 304: Ecu Self-diagnostic Function

    FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 305: Fail-safe Actions (substitute Characteristics Operation Control)

    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.
  • Page 306 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...
  • Page 307 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)
  • Page 308 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.
  • Page 309: Troubleshooting Method

    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.
  • Page 310 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.
  • Page 311 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.
  • Page 312 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.
  • Page 313 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.
  • Page 314 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.
  • Page 315 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.
  • Page 316 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.
  • Page 317 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.
  • Page 318: Troubleshooting Details

    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”.
  • Page 319 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.
  • Page 320 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.
  • Page 321 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.
  • Page 322 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.
  • Page 323 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.
  • Page 324 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,...
  • Page 325 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.
  • Page 326 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.
  • Page 327 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.
  • Page 328 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.
  • Page 329 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.
  • Page 330 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...
  • Page 331 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.
  • Page 332 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...
  • Page 333 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.
  • Page 334 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...
  • Page 335 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...
  • Page 336 FUEL INJECTION SYSTEM Fault code No. Symptom Supplied power to the fuel injector and fuel pump is not