Yamaha 2011 FZ8NA(C) Service Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Motorcycle
  5. 2011 FZ8NA(C)
  6. Service manual

Yamaha 2011 FZ8NA(C) Service Manual

Motorcycle yamaha 2011 fz8na(c)
Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
Table of Contents

Advertisement

Quick Links

Download this manual
2011
SERVICE MANUAL
FZ8NA(C)
LIT-11616-24-07
39P-28197-10

Advertisement

Table of Contents
loading

Related Manuals for Yamaha 2011 FZ8NA(C)

Summary of Contents for Yamaha 2011 FZ8NA(C)

  • Page 1 2011 SERVICE MANUAL FZ8NA(C) LIT-11616-24-07 39P-28197-10...
  • Page 2 EAS20050 FZ8NA(C) SERVICE MANUAL ©2010 by Yamaha Motor Corporation, U.S.A. First edition, November 2010 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-24-07...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 4: How To Use This Manual

    EAS20091 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...

  • Page 5: Symbols

    EAS20101 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine Gear oil mounted Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM 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 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ...............1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS.................1-7 GASKETS, OIL SEALS AND O-RINGS..........1-7 LOCK WASHERS/PLATES AND COTTER PINS ........1-7 BEARINGS AND OIL SEALS ..............1-8 CIRCLIPS ....................1-8 BASIC SERVICE INFORMATION..............1-9...

  • 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 EAS39P1101 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 12: Fi System

    FEATURES EAS39P1102 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm², 47.0 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus- ing the fuel to be injected into the intake manifold only during the time the passage remain open.

  • Page 13: Instrument Functions

    FEATURES EAS39P1103 Tachometer INSTRUMENT FUNCTIONS Multi-function meter unit 1. Tachometer 2. Tachometer red zone The electric tachometer allows the rider to 1. Fuel meter monitor the engine speed and keep it within 2. Coolant temperature display the ideal power range. 3.
  • Page 14 FEATURES 5. Push the “RESET” button to set the min- Fuel meter utes. 6. Push the “SELECT” button and then release it to start the clock. Odometer and tripmeter modes 1. Fuel meter The fuel meter indicates the amount of fuel in the fuel tank.
  • Page 15 FEATURES Self-diagnosis device 1. Error code display This model is equipped with a self-diagnosis device for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light will come on and the display will indicate an error code. ECA11590 If the display indicates an error code, the vehicle should be checked as soon as pos-...

  • Page 16: Important Information

    EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...

  • Page 17: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20231 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

  • Page 18: Basic Service Information

    BASIC SERVICE INFORMATION EAS30380 Screw type BASIC SERVICE INFORMATION 1. Remove: • Quick fastener EAS30390 QUICK FASTENERS To remove the quick fastener, loosen the screw Rivet type with a screwdriver, then pull the fastener out. 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out.
  • Page 19 BASIC SERVICE INFORMATION ECA16770 ECA16750 When connecting the battery leads to the When disconnecting the battery leads from battery, be sure to connect the positive bat- the battery, be sure to disconnect the nega- tery lead first, then the negative battery tive battery lead first, then the positive bat- lead.
  • Page 20 BASIC SERVICE INFORMATION ECA16630 ECA14371 Electrical components are very sensitive to Never insert the tester probes into the cou- and can be damaged by static electricity. pler terminal slots. Always insert the Therefore, never touch the terminals and be probes from the opposite end “a” of the sure to keep the contacts clean.
  • Page 21 BASIC SERVICE INFORMATION ECA16780 • When disconnecting a coupler, release the coupler lock, hold both sections of the coupler securely, and then disconnect the coupler. • There are many types of coupler locks; therefore, be sure to check the type of coupler lock before disconnecting the coupler.
  • Page 22 BASIC SERVICE INFORMATION 5. Check: • Continuity (with the pocket tester) Pocket tester 90890-03112 Analog pocket tester YU-03112-C • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (3). • As a quick remedy, use a contact revitalizer available at most part stores.

  • Page 23: 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 inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 Steering nut wrench 3-20, 4-60 90890-01403 Exhaust flange nut wrench YU-A9472 Damper rod holder 4-52, 4-53 90890-01423 Damping rod holder YM-01423 Oil filter wrench 3-24 90890-01426 YU-38411...
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller attachment (M10) 4-54, 4-56 90890-01436 Universal damping rod bleeding tool set YM-A8703 Rod puller 4-54, 4-56 90890-01437 Universal damping rod bleeding tool set YM-A8703 Fork spring compressor 4-51, 4-56 90890-01441 YM-01441 Fork seal driver 4-54...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pivot shaft wrench 90890-01518 Frame spanner socket YM-01518 Compression gauge 90890-03081 Engine compression tester YU-33223 Vacuum gauge 90890-03094 Vacuummate YU-44456 Pocket tester 1-13, 8-99, 8- 90890-03112 100, 8-101, 8- Analog pocket tester 105, 8-106, 8- YU-03112-C 107, 8-108, 8-...
  • Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Digital circuit tester 5-43, 7-13, 8- 90890-03174 110, 8-112, 8- Model 88 Multimeter with tachometer 117, 8-118 YU-A1927 Fuel pressure adapter 90890-03176 YM-03176 Thickness gauge 3-5, 5-21, 5-51 90890-03180 Feeler gauge set YU-26900-9 Test harness- speed sensor (3P) 8-113, 8-117...
  • Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor 5-25, 5-31 90890-04019 YM-04019 Middle driven shaft bearing driver 6-13 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Mechanical seal installer 6-13 90890-04078 Water pump seal installer YM-33221-A Universal clutch holder 5-49, 5-53...
  • Page 29 Valve guide reamer (ø4) 5-27 90890-04113 Valve guide reamer (4.0 mm) YM-04113 Extension 90890-04136 Camshaft wrench 5-14, 5-17 90890-04162 YM-04162 Ignition checker 8-109 90890-06754 Oppama pet-4000 spark checker YM-34487 Yamaha bond No.1215 5-19, 5-34, 5-67 (Three bond No.1215®) 90890-85505 1-20...
  • Page 30 SPECIAL TOOLS 1-21...

  • Page 31: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-9 ELECTRICAL SPECIFICATIONS...............2-12 TIGHTENING TORQUES................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-14 ENGINE TIGHTENING TORQUES ............2-15 CHASSIS TIGHTENING TORQUES ............2-19 LUBRICATION POINTS AND LUBRICANT TYPES ........2-22 ENGINE ....................2-22 CHASSIS ....................2-24 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-25 ENGINE OIL LUBRICATION CHART ...........2-25 LUBRICATION DIAGRAMS ..............2-27 COOLING SYSTEM DIAGRAMS ...............2-37...

  • Page 32: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 39P2 (USA) 39P3 (California) Dimensions Overall length 2140 mm (84.3 in) Overall width 770 mm (30.3 in) Overall height 1065 mm (41.9 in) Seat height 815 mm (32.1 in) Wheelbase 1460 mm (57.5 in) Ground clearance 140 mm (5.51 in) Minimum turning radius...

  • Page 33: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 779 cm³ Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 68.0 × 53.6 mm (2.68 × 2.11 in) Compression ratio 12.0 : 1 Standard compression pressure (at sea level) 1480 kPa/350 r/min (14.8 kgf/cm²/350 r/min, 210.5 psi/350 r/min) Minimum–Maximum...
  • Page 34 ENGINE SPECIFICATIONS Radiator core Width 222.6 mm (8.76 in) Height 360.0 mm (14.17 in) Depth 22.0 mm (0.87 in) Water pump Water pump type Single suction centrifugal pump 65/43 × 25/32 (1.181) Reduction ratio Impeller shaft tilt limit 0.15 mm (0.006 in) Spark plug(s) Manufacturer/model NGK/CR9E...
  • Page 35 ENGINE SPECIFICATIONS Valve, valve seat, valve guide Valve clearance (cold) Intake 0.10–0.17 mm (0.0039–0.0067 in) Exhaust 0.25–0.29 mm (0.0098–0.0114 in) Valve dimensions Valve head diameter A (intake) 25.90–26.10 mm (1.0197–1.0276 in) Valve head diameter A (exhaust) 21.90–22.10 mm (0.8622–0.8701 in) Valve face width B (intake) 1.210–2.490 mm (0.0476–0.0980 in) Valve face width B (exhaust)
  • Page 36 ENGINE SPECIFICATIONS Free length (exhaust) 38.62 mm (1.52 in) Limit 36.69 mm (1.44 in) Installed length (intake) 33.00 mm (1.30 in) Installed length (exhaust) 33.00 mm (1.30 in) Spring rate K1 (intake) 24.99 N/mm (2.55 kgf/mm, 142.69 lb/in) Spring rate K2 (intake) 37.28 N/mm (3.80 kgf/mm, 212.87 lb/in) Spring rate K1 (exhaust) 24.99 N/mm (2.55 kgf/mm, 142.69 lb/in)
  • Page 37 ENGINE SPECIFICATIONS End gap (installed) 0.25–0.35 mm (0.0098–0.0138 in) Limit 0.60 mm (0.0236 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring Ring type Taper Dimensions (B × T) 0.80 × 2.50 mm (0.03 × 0.10 in) End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in) Limit...
  • Page 38 ENGINE SPECIFICATIONS Plate quantity 7 pcs Clutch spring free length 52.50 mm (2.07 in) Limit 49.88 mm (1.96 in) Spring quantity 6 pcs Transmission Transmission type Constant mesh 6-speed Primary reduction system Gear Primary reduction ratio 1.512 (65/43) Secondary reduction system Chain Secondary reduction ratio 2.875 (46/16)
  • Page 39 ENGINE SPECIFICATIONS Air induction system Reed valve bending limit 0.4 mm (0.016 in) 18–22 Ω at 20 °C (68 °F) Solenoid resistance Idling condition Engine idling speed 1150–1250 r/min 4.0–5.0 % Intake vacuum 30.0 kPa (225 mmHg, 8.9 inHg) 90.0–110.0 °C (194.00–230.00 °F) Water temperature 75.0–95.0 °C (167.00–203.00 °F) Oil temperature...

  • Page 40: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 25°00’ Trail 109.0 mm (4.29 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 130.0 mm (5.12 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 41 CHASSIS SPECIFICATIONS Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter 16.00 mm (0.63 in) Caliper cylinder inside diameter 30.20 mm (1.19 in) 27.00 mm (1.06 in) Recommended fluid DOT 4 Rear brake Type Hydraulic single disc brake...
  • Page 42 CHASSIS SPECIFICATIONS Optional spring available Enclosed gas/air pressure (STD) 1200 kPa (12.0 kgf/cm², 170.7 psi) Spring preload adjusting positions Minimum Standard Maximum Drive chain Type/manufacturer 525V10/DAIDO Number of links Drive chain slack 20.0–30.0 mm (0.79–1.18 in) 15-link length limit 239.3 mm (9.42 in) Shift pedal Installed shift rod length 304.1–306.1 mm (11.97–12.05 in)

  • Page 43: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system 5.0 °/1200 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer TBDFD0/DENSO Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 1.19–1.61 Ω Primary coil resistance Secondary coil resistance 8.50–11.50 kΩ...
  • Page 44 ELECTRICAL SPECIFICATIONS Armature coil 0.0100–0.2000 Ω at 20 °C (68 °F) Commutator resistance Above 1 MΩ at 20 °C (68 °F) Insulation resistance Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force 6.02–6.51 N (614–664 gf, 21.65–23.41 ozf) Mica undercut (depth) 0.70 mm (0.03 in) Starter relay...

  • Page 45: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20331 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.

  • Page 46: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Cylinder head nut See TIP. Cylinder head bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Cylinder head plug 42 Nm (4.2 m·kgf, 30 ft·lbf) Camshaft caps bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head cover bolt...
  • Page 47 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe and muffler bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Exhaust pipe and exhaust pipe 20 Nm (2.0 m·kgf, 14 ft·lbf) bracket bolt Muffler and muffler bracket bolt 48 Nm (4.8 m·kgf, 35 ft·lbf) Crankcase stud bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Crankcase bolt (main journal)
  • Page 48 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Shift rod locknut (front) 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Left Shift rod locknut (rear) 8 Nm (0.8 m·kgf, 5.8 ft·lbf) thread Shift rod joint bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Shift arm bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) Neutral switch...
  • Page 49 TIGHTENING TORQUES 2-18...

  • Page 50: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Upper bracket pinch bolt 26 Nm (2.6 m·kgf, 19 ft·lbf) Steering stem nut 115 Nm (11.5 m·kgf, 83 ft·lbf) Upper handlebar holder bolt 24 Nm (2.4 m·kgf, 17 ft·lbf) Lower handlebar holder nut 32 Nm (3.2 m·kgf, 23 ft·lbf) Lower bracket pinch bolt...
  • Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Relay arm nut (relay arm and 40 Nm (4.0 m·kgf, 29 ft·lbf) connecting arm) Main frame and rear frame nut 42 Nm (4.2 m·kgf, 30 ft·lbf) Clutch cable locknut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Throttle cable locknut 4.5 Nm (0.45 m·kgf, 3.3 ft·lbf) Rear shock absorber assembly...
  • Page 52 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front wheel axle 65 Nm (6.5 m·kgf, 47 ft·lbf) Front wheel axle pinch bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Front brake caliper bolt 40 Nm (4.0 m·kgf, 29 ft·lbf) Front side reflector nut 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Front brake disc bolt 18 Nm (1.8 m·kgf, 13 ft·lbf)

  • Page 53: Lubrication Points And Lubricant Types

    Transmission gears (wheel and pinion) Main axle and drive axle Shift forks and shift fork guide bars Three bond Cylinder head cover mating surface No.1541C® Yamaha bond Cylinder head cover semicircular No.1215 (Three bond No.1215®) Yamaha bond Crankcase mating surface No.1215 (Three bond...
  • Page 54 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond Left crankcase cover (three mating surface) No.1215 (Three bond No.1215®) Yamaha bond Crankcase cover (lead grommet) No.1215 (Three bond No.1215®) 2-23...

  • Page 55: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings, seal lip and bearing lip Tube guide (throttle grip) inner surface and throttle cables Brake lever pivot bolt and metal-to-metal moving parts Clutch lever pivot bolt, metal-to-metal moving parts and clutch cable end Engine mount bolts (rear upper and lower) Engine mount bolts (front left and right) Relay arm, connecting rod and rear shock absorber collar...

  • Page 56: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-25...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter 6. Main gallery 7. AC magneto drive gear shower 8. Shift fork (upper) 9. Main axle 10.Mission shower 11.Drive axle 12.AC magneto axle 13.Crankshaft 14.Piston cooler...

  • Page 58: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil delivery pipe 2. Oil level switch 3. Oil filter cartridge 4. Crankshaft 2-28...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil cooler 5. Relief valve 6. Oil pipe 7. Oil strainer 8. Oil pump 2-30...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil level switch 3. Oil pump 4. Oil strainer 5. Oil pipe 6. Oil cooler 2-32...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil pipe 3. Drive axle 2-34...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Main gallery 5. Crankshaft 2-36...

  • Page 68: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-37...
  • Page 69 COOLING SYSTEM DIAGRAMS 1. Thermostat 2. Water pump 3. Radiator 4. Radiator fan 5. Oil cooler 2-38...
  • Page 70 COOLING SYSTEM DIAGRAMS 2-39...
  • Page 71 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat 2-40...

  • Page 72: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING Handlebar (front view) 2-41...
  • Page 73 CABLE ROUTING 1. Clutch cable 2. Left handlebar switch lead 3. Main switch lead 4. Horn lead 5. Lower headlight stay 6. Throttle cable (return side) 7. Throttle cable (pull side) 8. Brake hose 9. Wire harness 10.Right handlebar switch lead 11.Throttle cables A.
  • Page 74 CABLE ROUTING Handlebar (right side view) 2-43...
  • Page 75 CABLE ROUTING 1. Wire harness 2. Throttle cable 3. Radiator inlet hose 4. Right radiator fan motor lead 5. Coolant reservoir hose 6. Right handlebar switch lead 7. Throttle cables 8. Throttle cable (return side) 9. Throttle cable (pull side) 10.Radiator stay 11.Clutch cable A.
  • Page 76 CABLE ROUTING Engine (right side view) 2-45...
  • Page 77 CABLE ROUTING 1. Cable guide 2. Fuel tank breather hose 3. Fuel tank drain hose 4. Brake fluid reservoir hose 5. Rear brake light switch lead 6. Frame 7. Rear brake light switch stay 8. Right rider footrest bracket 9. Rear brake light switch A.
  • Page 78 CABLE ROUTING Engine (right side view) For California only 2-47...
  • Page 79 CABLE ROUTING 1. Rear brake light switch lead 2. Brake fluid reservoir hose 3. Fuel tank drain hose 4. Frame 5. Rear brake light switch stay 6. Right rider footrest bracket 7. Rear brake light switch A. Route the fuel tank drain hose further inward of the vehicle than the brake fluid reservoir.
  • Page 80 CABLE ROUTING Handlebar (left side view) 2-49...
  • Page 81 CABLE ROUTING 1. Main switch lead 2. Left handlebar switch lead 3. Clutch cable 4. Clutch cable swaging metal 5. Left radiator fan motor lead 6. Water pump breather hose 7. Radiator stay 8. Horn 9. Right handlebar switch lead 10.Meter bracket 11.Brake hose 12.Throttle cables...
  • Page 82 CABLE ROUTING Engine (left side view) 2-51...
  • Page 83 CABLE ROUTING Q. Back of the vehicle 1. Water pump breather hose R. Outside of the vehicle 2. Oil level switch lead 3. Sidestand switch lead 4. O sensor lead 5. Coolant reservoir tank drain hose 6. Water pump inlet pipe 7.
  • Page 84 CABLE ROUTING Rear frame (left side view) 2-53...
  • Page 85 CABLE ROUTING 1. Wire harness 2. Starter motor lead 3. Battery negative lead 4. Seat lock cable 5. Ground lead 6. AC magneto lead 7. Rectifier/regulator lead 8. Rectifier/regulator bracket 9. Fuel tank drain hose 10.Fuel tank breather hose 11.Rear brake light switch lead 12.Brake fluid reservoir hose 13.Coolant reservoir tank drain hose 14.Speed sensor lead...
  • Page 86 CABLE ROUTING Rear frame (left side view) For California only 2-55...
  • Page 87 CABLE ROUTING 1. Oil level switch lead 2. Sidestand switch lead 3. O sensor lead 4. Waterproof coupler 5. Battery negative lead 6. Wire harness 7. Starter motor lead 8. Rectifier/regulator lead 9. AC magneto lead 10.Fuel tank drain hose 11.Rear brake light switch lead 12.Brake fluid reservoir hose 13.Coolant reservoir tank drain hose...
  • Page 88 CABLE ROUTING Frame (top view) 2-57...
  • Page 89 CABLE ROUTING K. Route each lead between the frame and 1. Throttle cables ECU (engine control unit) holder. 2. Wire harness L. Route the left handlebar switch lead cou- 3. Right handlebar switch lead pler under the main switch lead and 4.
  • Page 90 CABLE ROUTING Frame (top view) 2-59...
  • Page 91 CABLE ROUTING N. Route the main fuse lead so that the 1. Air filter case drain hose branch of the lead comes to the top of the 2. Pickup coil lead vehicle. 3. Speed sensor lead coupler O. To the rectifier/regulator 4.
  • Page 92 CABLE ROUTING Frame (top view) For California only 2-61...
  • Page 93 CABLE ROUTING 1. Ignition coil sub-wire harness 2. Fuel injection system sub-wire harness 3. Pickup coil lead 4. Starter motor lead 5. Oil level switch lead 6. Fuel tank breather hose (fuel tank to roll- over valve) 7. Waterproof coupler 8.
  • Page 94 CABLE ROUTING Frame (top view) 2-63...
  • Page 95 CABLE ROUTING L. Order insignificant-starter motor lead and 1. Atmospheric pressure sensor seat lock cable. 2. Battery positive lead M. Push the wire harness firmly to the end. 3. Radiator fan motor relay N. Route the engine stop switch lead on the 4.
  • Page 96 CABLE ROUTING Fuel tank (left and bottom view) 2-65...
  • Page 97 CABLE ROUTING 1. Frame 2. Fuel tank cover 3. Fuel tank breather hose 4. Fuel tank drain hose 5. Fuel tank 6. Fuel pump 7. Clip 8. Fuel hose 9. Fuel hose connector cover A. Install the fuel tank drain hose with the white paint marks facing to the left of the vehicle.
  • Page 98 CABLE ROUTING Front brake, rear brake 2-67...
  • Page 99 CABLE ROUTING 1. Horn 2. Lower bracket 3. Front fork assembly 4. Front brake hose 5. Brake hose holder 6. Front brake master cylinder 7. Swingarm 8. Rear brake hose 9. Clamp A. Install the brake pipe to touch the projec- tion on the brake caliper (both left and right).
  • Page 100 CABLE ROUTING Canister (top view) For California only 2-69...
  • Page 101 CABLE ROUTING 1. Fuel pump bracket 2. Fuel tank breather hose (fuel tank to roll- over valve) 3. Fuel hose 4. Rectifier/regulator 5. Rear frame 6. Fuel tank drain hose 7. Canister purge hose 8. Frame 9. Cap 10.Waterproof coupler 11.Rectifier/regulator bracket 12.Grommet A.
  • Page 102 CABLE ROUTING Canister (left side view) For California only 2-71...
  • Page 103 CABLE ROUTING 1. Fuel tank breather hose (fuel tank to roll- over valve) 2. Fuel tank 3. Fuel tank drain hose 4. Fuel pump bracket 5. Rear frame 6. Canister purge hose 7. Frame 8. Canister purge hose stay 9. Clamp 10.Damper 11.Rectifier/regulator bracket 12.Canister...
  • Page 104 CABLE ROUTING Canister (right side view) For California only 2-73...
  • Page 105 CABLE ROUTING 1. Fuel tank breather hose (fuel tank to roll- over valve) 2. Canister purge hose 3. Brake fluid reservoir 4. Fuel tank breather hose (rollover valve to canister) 5. Rollover valve 6. Rear frame 7. Clamp 8. Rectifier/regulator bracket A.
  • Page 106 CABLE ROUTING 2-75...

  • Page 107: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .....3-2 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS............3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5 CHECKING THE CRANKCASE BREATHER HOSE ......3-8 ADJUSTING THE ENGINE IDLING SPEED ..........3-8 SYNCHRONIZING THE THROTTLE BODIES ........3-9 CHECKING THE THROTTLE BODY JOINTS ........3-10...
  • Page 108 CHECKING THE FRONT BRAKE LIGHT SWITCH ......3-28 ADJUSTING THE REAR BRAKE LIGHT SWITCH ......3-28 CHECKING AND LUBRICATING THE CABLES ........3-28 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-29 CHECKING AND CHARGING THE BATTERY........3-29 CHECKING THE FUSES..............3-29 REPLACING THE HEADLIGHT BULB ..........3-29 ADJUSTING THE HEADLIGHT BEAM ..........3-31...

  • Page 110: Periodic Maintenance

    • From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. • Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service.

  • Page 111: General Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE EAS39P2302 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) 1 month 6 months 12 months 18 months 24 months...
  • Page 112 Front and rear √ √ √ √ √ √ 25 * • Check operation. brake switches • Apply Yamaha chain and √ √ √ √ √ √ 26 * Control cables cable lube or engine oil thor- oughly. • Check operation.

  • Page 113: Checking The Fuel Line

    PERIODIC MAINTENANCE EAS21030 EAS20680 CHECKING THE FUEL LINE CHECKING THE SPARK PLUGS The following procedure applies to all of the The following procedure applies to all of the fuel, vacuum and breather hoses. spark plugs. 1. Remove: 1. Remove: • Rider seat •...

  • Page 114: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE 7. Install: 3. Remove: • Spark plugs • Pickup rotor cover “1” • Ignition coils Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Before installing the spark plug, clean the spark plug and gasket surface. 8. Install: • Radiator upper bolt •...
  • Page 115 PERIODIC MAINTENANCE Cylinder #2 180° Cylinder #4 360° Cylinder #3 540° ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: • Camshaft • Refer to “CAMSHAFTS” on page 5-11. • When removing the timing chain and cam- shafts, fasten the timing chain with a wire to •...
  • Page 116 PERIODIC MAINTENANCE b. Calculate the difference between the speci- Valve pad range Nos. 120–240 fied valve clearance and the measured 1.20–2.40 mm valve clearance. Valve pad thickness (0.047–0.094 in) Example: 25 thicknesses in Specified valve clearance = 0.11–0.20 mm Available valve pads 0.05 mm (0.002 in) (0.004–0.008 in) increments...

  • Page 117: Checking The Crankcase Breather Hose

    PERIODIC MAINTENANCE h. Measure the valve clearance again. EAS20610 ADJUSTING THE ENGINE IDLING SPEED If the valve clearance is still out of specifi- cation, repeat all of the valve clearance Prior to adjusting the engine idling speed, the adjustment steps until the specified clear- throttle bodies synchronization should be ance is obtained.

  • Page 118: Synchronizing The Throttle Bodies

    PERIODIC MAINTENANCE • Clean the throttle bodies only if they can- 2. Remove: not be synchronized using the air screw. • Rider seat Refer to “CHECKING AND CLEANING Refer to “GENERAL CHASSIS” on page THE THROTTLE BODIES” on page 7-10. 4-1.

  • Page 119: Checking The Throttle Body Joints

    PERIODIC MAINTENANCE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Start the engine, warm it up for several • After each step, rev the engine two or three minutes, and then let it run at the specified times, each time for less than a second, and engine idling speed.

  • Page 120: Checking The Exhaust System

    PERIODIC MAINTENANCE EAS21090 CHECKING THE CANISTER (for California only) 1. Remove: • Rider seat • Left side cover • Right side cover Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank 3. Install: Refer to “FUEL TANK” on page 7-1. •...

  • Page 121: Adjusting The Clutch Cable Free Play

    PERIODIC MAINTENANCE 2. Remove: • Air filter case cover “1” When installing the air filter element into the air Refer to “GENERAL CHASSIS” on page filter case cover, make sure that the sealing 4-1. surfaces are aligned to prevent any air leaks. 5.

  • Page 122: Checking The Brake Operation

    PERIODIC MAINTENANCE Drive on the dry road, operate the front and rear brakes separately and check to see if the brakes are operating properly. EAS21240 CHECKING THE BRAKE FLUID LEVEL 1. Stand the vehicle on a level surface. • Place the vehicle on a suitable stand. •...

  • Page 123: Adjusting The Front Disc Brake

    PERIODIC MAINTENANCE • Refill with the same type of brake fluid EWA39P2301 WARNING that is already in the system. Mixing brake fluids may result in a harmful chemical • After adjusting the brake lever position, reaction, leading to poor brake perfor- make sure the pin on the brake lever mance.

  • Page 124: Checking The Rear Brake Pads

    PERIODIC MAINTENANCE EWA13070 WARNING After adjusting the brake pedal position, check that the end of the adjusting bolt “c” is visible through the hole “d”. c. Tighten the locknut “1” to specification. Locknut 18 Nm (1.8 m·kgf, 13 ft·lbf) EWA39P1302 WARNING EAS21350 A soft or spongy feeling in the brake pedal...

  • Page 125: Checking The Front Brake Hoses

    PERIODIC MAINTENANCE EWA13110 WARNING After bleeding the hydraulic brake system, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21280 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose holders. 1. Check: • Brake hose “1” Cracks/damage/wear →...

  • Page 126: Checking The Wheels

    PERIODIC MAINTENANCE 2. Check: • Brake hose holder “2” Loose → Tighten the holder bolt. EWA13180 WARNING • The tire pressure should only be checked and regulated when the tire temperature 3. Hold the vehicle upright and apply the rear equals the ambient air temperature.

  • Page 127: Checking The Wheel Bearings

    EAS39P1309 CHECKING THE SWINGARM OPERATION given if a tire combination other than one 1. Check: approved by Yamaha is used on this vehi- cle. • Swingarm operation Swingarm not working properly → Check Front tire the swingarm.

  • Page 128: Lubricating The Drive Chain

    PERIODIC MAINTENANCE keep the drive chain slack within the speci- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ fied limits. a. Loosen both locknuts “1”. b. Turn both adjusting bolts “2” in direction “a” or “b” until the specified drive chain slack is The drive chain slack must be checked at the obtained.

  • Page 129: Checking And Adjusting The Steering Head

    PERIODIC MAINTENANCE engine oil or chain lubricant that is suitable for O-ring chains. Do not use any other lubricants • Set the torque wrench at a right angle to the on the drive chain since they may contain sol- steering nut wrench. vents that could damage the O-rings.

  • Page 130: Lubricating The Brake Lever

    PERIODIC MAINTENANCE 2. Adjust: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Installed shift rod length 5. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Upper bracket a. Loosen both locknuts “1”. Refer to “HANDLEBAR” on page 4-44. b. Turn the shift rod “2” in direction “a” or “b” to EAS39P1303 obtain the correct shift pedal position.

  • Page 131: Checking The Front Fork

    PERIODIC MAINTENANCE EAS21531 EAS21590 CHECKING THE FRONT FORK ADJUSTING THE REAR SHOCK 1. Stand the vehicle on a level surface. ABSORBER ASSEMBLY EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there Securely support the vehicle so that there is no danger of it falling over.

  • Page 132: Checking The Connecting Arm And Relay Arm

    PERIODIC MAINTENANCE Recommended brand YAMALUBE Type SAE 10W-30, SAE 10W-40, SAE 10W-50, SAE 15W-40, SAE 20W-40 or SAE 20W-50 Recommended engine oil grade API service SG type or higher, JASO standard MA ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS39P1312 CHECKING THE CONNECTING ARM AND RELAY ARM Refer to “CHECKING THE CONNECTING ARM AND RELAY ARM”...
  • Page 133 PERIODIC MAINTENANCE c. Tighten the new oil filter cartridge to speci- fication with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 m·kgf, 12 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • Engine oil drain bolt (along with the gasket Engine oil drain bolt 4.

  • Page 134: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE EAS20820 MEASURING THE ENGINE OIL PRESSURE 1. Check: • Engine oil level Below the minimum level mark “a” → Add the recommended engine oil to the proper level. 5. Measure: • Engine oil pressure (at the following conditions) Oil pressure 230.0 kPa/5000 r/min (2.30 kgf/ cm²/5000 r/min, 33.4 psi/5000...

  • Page 135: Checking The Cooling System

    PERIODIC MAINTENANCE 2. Check: • Water pump outlet pipe “10” Cracks/damage → Replace. • Coolant level The coolant level should be between the Refer to “RADIATOR” on page 6-1, “OIL maximum level mark “a” and minimum COOLER” on page 6-5, “THERMOSTAT” level mark “b”.
  • Page 136 PERIODIC MAINTENANCE 3. Remove: 8. Drain: • Coolant reservoir tank • Coolant 4. Disconnect: (from the engine and radiator) • Coolant reservoir hose 9. Install: 5. Drain: • Coolant drain bolt • Coolant (along with the copper washer (from the coolant reservoir) 6.

  • Page 137: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE • Use only distilled water. However, if dis- EAS21330 ADJUSTING THE REAR BRAKE LIGHT tilled water is not available, soft water SWITCH may be used. • If coolant comes into contact with painted The rear brake light switch is operated by surfaces, immediately wash them with movement of the brake pedal.

  • Page 138: Adjusting The Throttle Cable Free Play

    PERIODIC MAINTENANCE 2. Check: c. Tighten the locknut “1”. • Cable operation Rough movement → Lubricate. Recommended lubricant Engine oil or a suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device.
  • Page 139 PERIODIC MAINTENANCE 2. Remove: 6. Remove: • Headlight bolt “1” • Headlight bulb holder “1” 3. Remove: EWA13320 • Headlight bolts “1” WARNING • Headlight unit “2” Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 140: Adjusting The Headlight Beam

    PERIODIC MAINTENANCE 12. Install: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Headlight bolts 2. Adjust: • Headlight beam (horizontally) Headlight bolt ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 7 Nm (0.7 m·kgf, 5.1 ft·lbf) a. Turn the adjusting screw “1” in direction “a” or “b”. 13. Install: • Headlight side covers Direction “a”...

  • Page 141: Chassis

    CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEEL ....................4-5 REMOVING THE FRONT WHEEL ............4-7 CHECKING THE FRONT WHEEL............4-7 DISASSEMBLING THE FRONT WHEEL ..........4-7 ASSEMBLING THE FRONT WHEEL .............4-8 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-8 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ....4-9 REAR WHEEL ....................4-11 REMOVING THE REAR WHEEL ............4-14 CHECKING THE REAR WHEEL ............4-14...
  • Page 142 HANDLEBAR....................4-44 REMOVING THE HANDLEBAR ............4-46 CHECKING THE HANDLEBAR............4-46 INSTALLING THE HANDLEBAR ............4-46 FRONT FORK .....................4-49 REMOVING THE FRONT FORK LEGS ..........4-51 DISASSEMBLING THE FRONT FORK LEGS ........4-51 CHECKING THE FRONT FORK LEGS..........4-52 ASSEMBLING THE FRONT FORK LEGS ...........4-52 INSTALLING THE FRONT FORK LEGS ..........4-56 STEERING HEAD..................4-58 REMOVING THE LOWER BRACKET ..........4-60 CHECKING THE STEERING HEAD ............4-60...
  • Page 144 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery Order Job/Parts to remove Q’ty Remarks Passenger seat Rider seat Tool kit Battery negative lead Battery positive lead Main fuse Battery band Battery Battery seat For installation, reverse the removal proce- dure.

  • Page 145: General Chassis

    GENERAL CHASSIS Removing the headlight and meter assembly Order Job/Parts to remove Q’ty Remarks Headlight top cover Left headlight side panel Right headlight side panel Headlight assembly Headlight sub-wire harness coupler Disconnect. Left turn signal/position light lead connector Disconnect. Right turn signal/position light lead connector Disconnect.
  • Page 146 GENERAL CHASSIS Removing the rear cover Order Job/Parts to remove Q’ty Remarks Passenger seat/rider seat Refer to “GENERAL CHASSIS” on page 4-1. Left side cover Right side cover Tail/brake light lead coupler Disconnect. Upper tail cover Tail/brake light bracket Tail/brake light assembly Left turn signal light lead coupler Disconnect.
  • Page 147 GENERAL CHASSIS Removing the air filter case 2.0 Nm (0.20 m kgf, 1.5 ft Ibf) Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case cover Air filter Crankcase breather hose Disconnect.
  • Page 148 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Brake hose holder Front brake caliper Reflector bracket Reflector Wheel axle pinch bolt Loosen. Wheel axle Collar Front wheel Front brake disc For installation, reverse the removal proce- dure.

  • Page 149: Front Wheel

    FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer Wheel bearing For assembly, reverse the disassembly pro- cedure.

  • Page 150: Front Wheel

    FRONT WHEEL EAS21900 3. Measure: REMOVING THE FRONT WHEEL • Radial wheel runout “1” 1. Stand the vehicle on a level surface. • Lateral wheel runout “2” EWA13120 Over the specified limits → Replace. WARNING Radial wheel runout limit Securely support the vehicle so that there 1.0 mm (0.04 in) is no danger of it falling over.

  • Page 151: Assembling The Front Wheel

    FRONT WHEEL b. Install the spacer. c. Install the new wheel bearing (left side). Place a suitable washer “1” between the socket “2” and the bearing so that both the inner race “3” and outer race “4” are pressed at the same time, and then press the bearing until the inner race makes contact with the spacer “5”.

  • Page 152: Installing The Front Wheel (Front Brake Discs)

    FRONT WHEEL c. Turn the front wheel 90° so that the “X ” c. If the heavy spot does not stay in that posi- tion, install a heavier weight. mark is positioned as shown. d. Repeat steps (b) and (c) until the front d.
  • Page 153 FRONT WHEEL Check that wheel axle end “a” is flush with front folk surface “b” and then tighten the wheel axle pinch bolt. If end “a” is not flush with sur- face “b”, align the ends manually or with a plastic hammer.

  • Page 154: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Rear brake caliper Refer to “REAR BRAKE” on page 4-31. Locknut Loosen. Adjusting bolt Loosen. Wheel axle nut Washer Wheel axle Left adjusting block Right adjusting block Rear wheel Brake caliper bracket For installation, reverse the removal proce-...
  • Page 155 REAR WHEEL Removing the brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Collar Rear brake disc Collar Rear wheel sprocket Rear wheel drive hub Rear wheel drive hub damper Collar Oil seal Bearing Rear wheel For installation, reverse the removal proce- dure.
  • Page 156 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer Wheel bearing For assembly, reverse the disassembly pro- cedure. 4-13...

  • Page 157: Removing The Rear Wheel

    REAR WHEEL EAS22040 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 158: Checking And Replacing The Rear Wheel Sprocket

    REAR WHEEL EAS14B1003 CHECKING AND REPLACING THE REAR ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ WHEEL SPROCKET 1. Check: EAS22140 • Rear wheel sprocket ASSEMBLING THE REAR WHEEL More than 1/4 tooth “a” wear → Replace 1. Install: the drive chain sprockets as a set. • Wheel bearings Bent teeth →...
  • Page 159 REAR WHEEL 2. Check: A. Left side • Rear brake disc B. Right side Refer to “CHECKING THE REAR BRAKE 5. Install: DISC” on page 4-37. • Rear brake caliper 3. Lubricate: • Rear brake caliper retaining bolts • Oil seal lips 6.
  • Page 160 REAR WHEEL 4-17...

  • Page 161: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake hose holder Front brake caliper Reflector bracket Reflector Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw...
  • Page 162 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Right rear view mirror Refer to “HANDLEBAR” on page 4-44. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm...
  • Page 163 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-20...
  • Page 164 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. Brake hose union bolt Brake hose gasket Brake hose Front brake caliper...
  • Page 165 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro-...

  • Page 166: Introduction

    FRONT BRAKE EAS22220 d. Hold the dial gauge at a right angle against INTRODUCTION the brake disc surface. EWA14100 e. Measure the deflection 1.5 mm (0.06 in) WARNING below the edge of the brake disc. Disc brake components rarely require dis- assembly.

  • Page 167: Replacing The Front Brake Pads

    FRONT BRAKE 3. Measure: • Brake pad wear limit “a” Out of specification → Replace the brake pads as a set. Brake lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake lining thickness d. Measure the brake disc deflection. (outer) e.

  • Page 168: Removing The Front Brake Calipers

    FRONT BRAKE d. Install the brake pads and brake pad EAS22300 REMOVING THE FRONT BRAKE CALIPERS spring. The following procedure applies to both of the brake calipers. The arrow mark “a” on the brake pad spring must point in the direction of disc rotation. Before removing the brake caliper, drain the brake fluid from the entire brake system.

  • Page 169: Checking The Front Brake Calipers

    FRONT BRAKE EWA39P1401 EWA13611 WARNING WARNING • Never try to pry out the brake caliper pis- Whenever a brake caliper is disassembled, tons. replace the brake caliper piston dust seals • Do not loosen the bolts “4”. and brake caliper piston seals. c.

  • Page 170: Removing The Front Brake Master Cylinder

    FRONT BRAKE EWA13530 • Refill with the same type of brake fluid WARNING that is already in the system. Mixing brake fluids may result in a harmful chemical Proper brake hose routing is essential to reaction, leading to poor brake perfor- insure safe vehicle operation.

  • Page 171: Checking The Front Brake Master Cylinder

    FRONT BRAKE 1. Disconnect: • Brake light switch connectors (from the front brake light switch) 2. Remove: • Brake hose union bolt “1” • Brake hose gaskets “2” • Brake hose “3” To collect any remaining brake fluid, place a container under the master cylinder and the 4.
  • Page 172 FRONT BRAKE • Align the end of the front brake master cylin- der holder with the punch mark “b” on the handlebar. • First, tighten the upper bolt, then the lower bolt. • There should be more than 11 mm (0.43 in) for clearance between the right handlebar switch and the front brake master cylinder holder.
  • Page 173 FRONT BRAKE 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. 4-30...

  • Page 174: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Rear brake caliper Brake pad Brake pad shim Brake pad insulator Brake pad spring Bleed screw For installation, reverse the removal proce- dure.
  • Page 175 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Right side cover Refer to “GENERAL CHASSIS” on page 4-1. Drain.
  • Page 176 REAR BRAKE Removing the rear brake master cylinder 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) Order Job/Parts to remove Q’ty Remarks Right footrest assembly Rear brake light switch Rear brake master cylinder assembly For installation, reverse the removal proce- dure.
  • Page 177 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Brake master cylinder kit Hose joint Bushing Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-34...
  • Page 178 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Brake hose union bolt Brake hose gasket Brake hose Rear brake caliper For installation, reverse the removal proce- dure. 4-35...
  • Page 179 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Brake pad Brake pad shim Brake pad insulator Brake pad spring Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.

  • Page 180: Introduction

    REAR BRAKE EAS22561 INTRODUCTION Brake disc thickness limit EWA14101 4.5 mm (0.18 in) WARNING 5. Adjust: Disc brake components rarely require dis- • Brake disc deflection assembly. Therefore, always follow these Refer to “CHECKING THE FRONT preventive measures: BRAKE DISCS” on page 4-23. •...
  • Page 181 REAR BRAKE 2. Install: • Brake pad insulators • Brake pad shims (onto the brake pads) • Brake pad spring (into the rear brake caliper) • Brake pads Always install new brake pads, brake pad insu- lators, brake pad shims, and brake pad spring as a set.

  • Page 182: Removing The Rear Brake Caliper

    REAR BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose 6. Check: joint opening “a” to force out the piston from • Brake pedal operation Soft or spongy feeling → Bleed the brake the brake caliper. EWA13550 system. WARNING Refer to “BLEEDING THE HYDRAULIC •...

  • Page 183: Assembling The Rear Brake Caliper

    REAR BRAKE 1. Check: • Whenever a brake caliper is disassem- • Brake caliper piston “1” bled, replace the brake caliper piston dust Rust/scratches/wear → Replace the seal and brake caliper piston seal. brake caliper piston. • Brake caliper cylinder “2” Recommended fluid Scratches/wear →...

  • Page 184: Removing The Rear Brake Master Cylinder

    REAR BRAKE 2. Remove: 5. Bleed: • Rear brake caliper • Brake system 3. Install: Refer to “BLEEDING THE HYDRAULIC • Brake pad insulators BRAKE SYSTEM” on page 3-15. • Brake pad shims 6. Check: (onto the brake pads) • Brake fluid level Below the minimum level mark “a”...

  • Page 185: Checking The Rear Brake Master Cylinder

    REAR BRAKE EAS22720 • Never use solvents on internal brake CHECKING THE REAR BRAKE MASTER components. CYLINDER 1. Check: Recommended fluid • Brake master cylinder DOT 4 Damage/scratches/wear → Replace. • Brake fluid delivery passages 1. Install: (brake master cylinder body) •...
  • Page 186 REAR BRAKE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake perfor- mance.
  • Page 187 HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Rear view mirror Front brake light switch connector Disconnect. Front master cylinder holder Front brake master cylinder assembly Right handlebar switch Throttle cable housing Throttle cable Disconnect. Grip end Throttle grip Clutch switch coupler Disconnect.
  • Page 188 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Upper handlebar holder Handlebar Lower handlebar holder For installation, reverse the removal proce- dure. 4-45...

  • Page 189: 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” Blow compressed air between the left handle- EAS22931 INSTALLING THE HANDLEBAR bar and the handlebar grip, and gradually push...
  • Page 190 HANDLEBAR 3. Tighten: 7. Install: • Lower handlebar holder nuts • Throttle cable clamp “1” Lower handlebar holder nut • Using side “a” of the master cylinder as a 32 Nm (3.2 m·kgf, 23 ft·lbf) guide, install the clamp between side “a” and protector “2”...
  • Page 191 HANDLEBAR ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 12. Adjust: a. Apply a thin coat of rubber adhesive onto • Clutch cable free play the end of the left handlebar. Refer to “ADJUSTING THE CLUTCH b. Side the handlebar grip over the end of the CABLE FREE PLAY” on page 3-12. left handlebar.

  • Page 192: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Front wheel Refer to “FRONT WHEEL” on page 4-5. Front fender Band Left side only. Upper bracket pinch bolt Loosen.
  • Page 193 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Fork spring Locknut Outer tube Dust seal Oil seal clip Oil seal Washer Damper rod assembly bolt Copper washer...

  • Page 194: Removing The Front Fork Legs

    FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS Fork spring compressor The following procedure applies to both of the 90890-01441 front fork legs. YM-01441 1. Stand the vehicle on a level surface. Rod holder EWA13120 90890-01434 WARNING Damper rod holder double ended Securely support the vehicle so that there YM-01434...

  • Page 195: Checking The Front Fork Legs

    FRONT FORK ECA39P1404 Do not scratch the outer tube. 2. Measure: • Spring free length “a” Out of specification → Replace. Fork spring free length 4. Remove: 286.1 mm (11.26 in) • Damper rod assembly bolt Limit • Damper rod assembly 280.4 mm (11.04 in) While holding the damper rod with the damper rod holder “1”, loosen the damper rod assem-...
  • Page 196 FRONT FORK - Oil seal clip Damper rod holder - Dust seal 90890-01423 - Copper washer Damping rod holder - O-ring YM-01423 • Before assembling the front fork leg, make sure all of the components are clean. 1. Install: • Damper rod assembly “1” ECA39P1406 Allow the damper rod assembly to slide slowly down the inner tube “2”...
  • Page 197 FRONT FORK 5. Install: • Outer tube (to the inner tube) 6. Install: • Washer • Oil seal “1” (with the fork seal driver “2”) Fork seal driver 90890-01442 Adjustable fork seal driver (36– 9. Fill: 46 mm) • Front fork leg YM-01442 (with the specified amount of the recom- mended fork oil)
  • Page 198 FRONT FORK 11. After filling the front fork leg, slowly stroke 14. Install: the damper rod “1” up and down (at least • Fork spring “1” ten times) to distribute the fork oil. • Spacer “2” • Locknut “3” • Cap bolt “4” Be sure to stroke the damper rod slowly because the fork oil may spurt out.

  • Page 199: Installing The Front Fork Legs

    FRONT FORK g. Pull up the rod puller and install the rod holder “2” between the locknut “3” and the spacer “4”. Rod puller 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M10) 90890-01436 k. Remove the rod holder and fork spring Universal damping rod bleeding compressor.
  • Page 200 FRONT FORK EWA13680 WARNING Make sure the brake hoses are routed prop- erly. 4-57...

  • Page 201: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Meter assembly Refer to “GENERAL CHASSIS” on page 4-1. Handlebar Refer to “HANDLEBAR”...
  • Page 202 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Lock washer Upper ring nut Rubber washer Lower ring nut Lower bracket Bearing cover Lower bearing dust seal Upper bearing Lower bearing For installation, reverse the removal proce- dure.

  • Page 203: Removing The Lower Bracket

    STEERING HEAD EAS23110 2. Check: REMOVING THE LOWER BRACKET • Bearings “1” 1. Stand the vehicle on a level surface. • Bearing races “2” EWA13120 Damage/pitting → Replace the bearings WARNING and bearing races as a set. Securely support the vehicle so that there is no danger of it falling over.

  • Page 204: Installing The Steering Head

    STEERING HEAD Temporarily tighten the upper and lower bracket pinch bolts. 5. Tighten: • Steering stem nut Steering stem nut 115 Nm (11.5 m·kgf, 83 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage →...

  • Page 205: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Left side cover Refer to “GENERAL CHASSIS” on page 4-1. Right side cover Refer to “GENERAL CHASSIS” on page 4-1. Brake fluid reservoir bolt Refer to “REAR BRAKE”...

  • Page 206: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that EWA13740 the rear wheel is elevated. WARNING This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Relay arm and swingarm bolt “1” the rear shock absorber, read and make •...

  • Page 207: Checking The Connecting Arm And Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY EAS23261 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arm “1” • Relay arms “2” Damage/wear → Replace. 3. Frame 4. Swingarm A. Left side B. Right side 3. Install: 2. Check: • Rear shock absorber assembly •...
  • Page 208 REAR SHOCK ABSORBER ASSEMBLY 3. Frame 4. Swingarm A. Left side B. Right side 4. Tighten: • Rear shock absorber assembly upper nut • Rear shock absorber assembly lower nut • Frame and connecting arm nut • Relay arm and swingarm nut •...

  • Page 209: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear brake caliper Refer to “REAR BRAKE” on page 4-31. Rear wheel Refer to “REAR WHEEL” on page 4-11. Refer to “REAR SHOCK ABSORBER Relay arm ASSEMBLY” on page 4-62. Drive chain Refer to “CHAIN DRIVE”...

  • Page 210: Removing The Swingarm

    SWINGARM EAS23350 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. Place the vehicle on a suitable stand so that the rear wheel is elevated. 2.

  • Page 211: Installing The Swingarm

    SWINGARM 4. Check: • Dust covers “1” • Spacer “2” • Oil seals “3” Damage/wear → Replace. • Collar “4” Damage/scratches → Replace. • Bearings “5” Damage/pitting → Replace. A. Left side B. Right side EAS23380 INSTALLING THE SWINGARM 3. Install: 1.

  • Page 212: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks Drive sprocket Refer to “ENGINE REMOVAL” on page 5-3. Drive chain For installation, reverse the removal proce- dure. 4-69...

  • Page 213: 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. Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 214: Checking The Drive Sprocket

    CHAIN DRIVE to clean the drive chain. High-pressure 5. Lubricate: methods could force dirt or water into the • Drive chain drive chain’s internals, and solvents will Recommended lubricant deteriorate the O-rings. A coarse brush Chain lubricant suitable for O- can also damage the O-rings.
  • Page 215 CHAIN DRIVE 4. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-18. Drive chain slack 20.0–30.0 mm (0.79–1.18 in) ECA13550 b. After riveting, make sure the diameter A drive chain that is too tight will overload between the edges “b”...
  • Page 216 CHAIN DRIVE 4-73...

  • Page 217: Engine

    ENGINE ENGINE INSPECTION..................5-1 MEASURING THE COMPRESSION PRESSURE .........5-1 ENGINE REMOVAL ..................5-3 INSTALLING THE ENGINE ..............5-8 INSTALLING THE DRIVE SPROCKET ..........5-10 CAMSHAFTS....................5-11 REMOVING THE CAMSHAFTS ............5-13 CHECKING THE CAMSHAFTS ............5-14 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET..5-15 CHECKING THE TIMING CHAIN GUIDES ..........5-15 CHECKING THE TIMING CHAIN TENSIONER ........5-16 INSTALLING THE CAMSHAFTS ............5-17 CYLINDER HEAD..................5-20...
  • Page 218 CLUTCH......................5-45 REMOVING THE CLUTCH..............5-49 CHECKING THE FRICTION PLATES ..........5-50 CHECKING THE CLUTCH PLATES.............5-50 CHECKING THE CLUTCH SPRINGS ..........5-51 CHECKING THE CLUTCH HOUSING ..........5-51 CHECKING THE CLUTCH BOSS ............5-51 CHECKING THE PRESSURE PLATE ..........5-51 CHECKING THE PULL LEVER SHAFT AND PULL ROD....5-52 INSTALLING THE CLUTCH..............5-52 SHIFT SHAFT .....................5-55 CHECKING THE SHIFT SHAFT ............5-56...
  • Page 219 TRANSMISSION..................5-84 REMOVING THE TRANSMISSION ............5-89 CHECKING THE SHIFT FORKS ............5-89 CHECKING THE SHIFT DRUM ASSEMBLY........5-90 CHECKING THE TRANSMISSION ............5-90 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ......5-91 INSTALLING THE TRANSMISSION.............5-91...

  • Page 220: Engine Inspection

    ENGINE INSPECTION EAS14B1052 5. Measure: ENGINE INSPECTION • Compression pressure Out of specification → Refer to steps (c) EAS20710 and (d). MEASURING THE COMPRESSION PRES- SURE Standard compression pres- The following procedure applies to all of the sure (at sea level) cylinders.
  • Page 221 ENGINE INSPECTION 6. Install: • Spark plug Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) 7. Install: • Ignition coils...

  • Page 222: Engine Removal

    ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the drive sprocket Order Job/Parts to remove Q’ty Remarks Loosen. Drive chain Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-18. Locknut Shift rod Shift arm Joint Drive sprocket cover Plate Drive sprocket nut Washer Drive sprocket For installation, reverse the removal proce-...
  • Page 223 ENGINE REMOVAL Removing the muffler and exhaust pipe Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Drive sprocket cover Refer to “ENGINE REMOVAL” on page 5-3. sensor coupler Disconnect.
  • Page 224 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Throttle bodies Refer to “THROTTLE BODIES” on page 7-6. Thermostat assembly Refer to “THERMOSTAT” on page 6-7. Oil cooler Refer to “OIL COOLER”...
  • Page 225 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Stator coil assembly lead coupler Disconnect. Crankshaft position sensor lead coupler Disconnect. Oil level switch lead coupler Disconnect. Neutral switch connector Disconnect. Speed sensor coupler Disconnect. For installation, reverse the removal proce- dure.
  • Page 226 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Right front engine mounting bolt 1 Left front engine mounting bolt Upper engine mounting bolt/nut Lower engine mounting bolt/nut Engine mounting adjust bolt Loosen. Engine For installation, reverse the removal proce- dure.

  • Page 227: Installing The Engine

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Right front engine mounting bolt 2 “1” Refer to “CYLINDER HEAD” on page 5- 6. Install: • Left front engine mounting bolt “1” (temporarily tighten) • Right front engine mounting bolt 1 “2” (temporarily tighten) 2.
  • Page 228 ENGINE REMOVAL Pivot shaft wrench 90890-01518 Frame spanner socket YM-01518 Pivot shaft wrench adapter 90890-01476 9. Tighten: • Left front engine mounting bolt “1” • Right front engine mounting bolt 1 “2” Left front engine mounting bolt 45 Nm (4.5 m·kgf, 33 ft·lbf) Right front engine mounting bolt 1 45 Nm (4.5 m·kgf, 33 ft·lbf)

  • Page 229: Installing The Drive Sprocket

    ENGINE REMOVAL Align punch mark “a” of the shift arm “1” with alignment mark “b” of the crankcase. EAS39P1501 INSTALLING THE DRIVE SPROCKET 1. Install: • Drive sprocket • Washer • Drive sprocket nut “1” Drive sprocket nut 85 Nm (8.5 m·kgf, 61 ft·lbf) LOCTITE®...

  • Page 230: Camshafts

    CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Throttle bodies Refer to “THROTTLE BODIES” on page 7-6. Refer to “AIR INDUCTION SYSTEM” on Air cut-off valve page 7-15.
  • Page 231 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Refer to “CRANKSHAFT POSITION SEN- Pickup rotor cover SOR” on page 5-39. Disconnect. Clutch cable (engine side) Refer to “CLUTCH” on page 5-45. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Exhaust camshaft cap Intake camshaft...

  • Page 232: Removing The Camshafts

    CAMSHAFTS EAS23810 ECA13720 REMOVING THE CAMSHAFTS 1. Remove: To prevent damage to the cylinder head, • Pickup rotor cover camshafts or camshaft caps, loosen the Refer to “CRANKSHAFT POSITION camshaft cap bolts in stages and in a criss- SENSOR” on page 5-39. cross pattern, working from the outside in.

  • Page 233: Checking The Camshafts

    CAMSHAFTS Camshaft wrench 90890-04162 YM-04162 EAS23850 CHECKING THE CAMSHAFTS 1. Check: • Camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • Camshaft lobe dimensions “a” and “b” 3. Measure: Out of specification → Replace the cam- • Camshaft runout shaft.

  • Page 234: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFTS b. Position strip of Plastigauge® “1” onto the camshaft journal as shown. EAS23870 CHECKING THE TIMING CHAIN AND CAM- c. Install the dowel pins and camshaft caps. SHAFT SPROCKET 1. Check: • Timing chain • Tighten the camshaft cap bolts in stages and Damage/stiffness →...

  • Page 235: Checking The Timing Chain Tensioner

    CAMSHAFTS EAS23960 b. Squeeze the timing chain tensioner clip “2”, CHECKING THE TIMING CHAIN TEN- and then push the timing chain tensioner SIONER rod “3” into the timing chain tensioner hous- 1. Remove: ing. • Timing chain tensioner housing “1” •...

  • Page 236: Installing The Camshafts

    CAMSHAFTS Camshaft wrench 90890-04162 YM-04162 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS24000 INSTALLING THE CAMSHAFTS 1. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b. When piston #1 is at TDC, align the “T” mark “a”...
  • Page 237 CAMSHAFTS “EL”: Exhaust left side camshaft cap mark 7. Install: “ER”: Exhaust right side camshaft cap mark • Timing chain tensioner gasket • Make sure the arrow mark “a” on each cam- • Timing chain tensioner “1” shaft points towards the right side of the •...
  • Page 238 • Apply bond TB1541C® onto the mating sur- faces “a” of the cylinder head cover and cyl- inder head cover gasket. • Apply bond Yamaha bond No.1215 (Three bond No.1215®) onto the mating surfaces “b” of the cylinder head cover gasket and cylin- der head.

  • Page 239: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-3. Intake camshaft Refer to “CAMSHAFTS” on page 5-11. Exhaust camshaft Refer to “CAMSHAFTS” on page 5-11. Coolant pipe Fast idle plunger inlet hose Coolant temperature sensor Right front engine mounting bolt 2...

  • Page 240: Removing The Cylinder Head

    CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAM- SHAFTS” on page 5-13. 2. Remove: • Cylinder head nuts • Cylinder head bolts • Loosen the nuts in the proper sequence as ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 241 CYLINDER HEAD 5. Install: 2. Install: • Exhaust camshaft • Intake camshaft • Cylinder head gasket “1” Refer to “INSTALLING THE CAM- • Dowel pins SHAFTS” on page 5-17. 3. Install: • Cylinder head • Washers • Cylinder head nuts •...
  • Page 242 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-20. Intake valve lifter Intake valve pad Intake valve cotter Intake valve spring retainer Intake valve spring Intake valve Intake valve stem seal...
  • Page 243 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve spring retainer Exhaust valve spring Exhaust valve Exhaust valve stem seal Exhaust valve spring seat Exhaust valve guide For installation, reverse the removal proce- dure.

  • Page 244: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. 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 245: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 2. Replace: • Valve guide EAS24290 CHECKING THE VALVES AND VALVE GUIDES To ease valve guide removal and installation, The following procedure applies to all of the and to maintain the correct fit, heat the cylinder valves and valve guides.

  • Page 246: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 6. Measure: • Valve stem runout After replacing the valve guide, reface the Out of specification → Replace the valve. valve seat. • When installing a new valve, always replace Valve guide remover (ø4) the valve guide. 90890-04111 •...
  • Page 247 VALVES AND VALVE SPRINGS Valve seat width After replacing the cylinder head or replacing Valve seat width (intake) the valve and valve guide, the valve seat and 0.90–1.10 mm (0.0354–0.0433 valve face should be lapped. Limit ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1.60 mm (0.06 in) a.

  • Page 248: Checking The Valve Springs

    VALVES AND VALVE SPRINGS h. Install the valve into the cylinder head. 2. Measure: Press the valve through the valve guide • Compressed valve spring force “a” Out of specification → Replace the valve and onto the valve seat to make a clear impression.

  • Page 249: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 3. Install: EAS24320 CHECKING THE VALVE LIFTERS • Valve spring seat “1” The following procedure applies to all of the • Valve stem seal “2” valve lifters. • Valve “3” 1. Check: • Valve spring “4” •...
  • Page 250 VALVES AND VALVE SPRINGS “2” and the valve spring compressor attach- 7. Install: ment “3”. • Valve pad • Valve lifter Valve spring compressor 90890-04019 • The valve lifter must move smoothly when YM-04019 rotated with a finger. Valve spring compressor •...

  • Page 251: Generator

    GENERATOR EAS24480 GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Left side cover Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Drain.
  • Page 252 GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Bearing housing Collar Bearing Starter clutch idler gear Idler gear shaft Bearing For installation, reverse the removal proce- dure. 5-33...

  • Page 253: Removing The Generator

    • Generator rotor and starter clutch assem- bly “1” 3. Apply: • Sealant 3. Remove: (onto the stator coil lead grommet “1”) • Idle gear shaft bolt “1” Yamaha bond No.1215 • Washer (Three bond No.1215®) • Idle shaft 90890-85505 • Idle gear “2” 5-34...
  • Page 254 GENERATOR 4. Install: • Generator rotor cover gasket • Generator rotor cover “1” Generator rotor cover bolt (M8) 22 Nm (2.2 m·kgf, 16 ft·lbf) Generator rotor cover bolt (M6) 12 Nm (1.2 m·kgf, 8.7 ft·lbf) • First tighten the M8 bolts and then tighten the M6 bolts.

  • Page 255: Starter Clutch

    STARTER CLUTCH EAS24550 STARTER CLUTCH Removing the starter clutch Order Job/Parts to remove Q’ty Remarks Spacer O-ring Washer Starter clutch drive gear Collar Washer Driven gear Damper Starter clutch assembly plate Starter clutch assembly Generator rotor For installation, reverse the removal proce- dure.

  • Page 256: Removing The Starter Clutch

    STARTER CLUTCH EAS24560 REMOVING THE STARTER CLUTCH 1. Remove: • Spacer “1” • O-ring “2” • Washer “3” EAS5D01018 CHECKING THE DAMPER 1. Check: • Dampers “1” Damage/wear → Replace. 2. Remove: • Starter clutch drive gear “1” • Collar “2” •...

  • Page 257: Installing The Starter Clutch

    STARTER CLUTCH 3. Check: 2. Install: • Starter clutch gear’s contacting surfaces • Generator rotor “1” Damage/pitting/wear → Replace the • Dampers “2” starter clutch gear. • Driven gear “3” 4. Check: • Starter clutch operation • Be sure to install the damper to the driven ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 258: Crankshaft Position Sensor

    CRANKSHAFT POSITION SENSOR EAS24520 CRANKSHAFT POSITION SENSOR Removing the crankshaft position sensor Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-23.

  • Page 259: Removing The Crankshaft Position Sensor

    CRANKSHAFT POSITION SENSOR EAS24530 REMOVING THE CRANKSHAFT POSITION SENSOR 1. Disconnect: • Crankshaft position sensor lead coupler 2. Remove: • Crankshaft position sensor • O-rings • Pickup rotor cover “1” Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.

  • Page 260: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Throttle bodies Refer to “THROTTLE BODIES” on page 7-6. Right throttle body joint Refer to “THROTTLE BODIES”...
  • Page 261 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Front cover Starter motor yoke Armature assembly Gasket Brush holder set Rear cover For assembly, reverse the disassembly pro- cedure. * When replacing any of the front cover, starter motor yoke, armature assembly, and rear cover, replace the starter motor assembly.

  • Page 262: Checking The Starter Motor

    ELECTRIC STARTER EAS24791 b. If any resistance is out of specification, CHECKING THE STARTER MOTOR replace the starter motor. 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.

  • Page 263: Assembling The Starter Motor

    ELECTRIC STARTER 2. Connect: • Starter motor lead “3” 6. Check: • Gear teeth Damage/wear → Replace the starter motor. 7. Check: • Bearing • Oil seal Damage/wear → Replace the starter motor. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: •...
  • Page 264 CLUTCH EAS25061 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-23. Clutch cable Disconnect. Clutch cover Clutch cover gasket Dowel pin Oil filler cap For installation, reverse the removal proce- dure.
  • Page 265 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the removal proce- dure. 5-46...
  • Page 266 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Compression spring Pressure plate Pull rod Bearing Friction plate 1 Green paint mark. Clutch plate 1 Friction plate 2 Purple paint mark. Clutch boss nut Washer Clutch boss Wire circlip Clutch plate 2 Friction plate 3 Clutch damper spring...
  • Page 267 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Thrust plate Clutch housing Bearing For installation, reverse the removal proce- dure. 5-48...

  • Page 268: Clutch

    CLUTCH EAS30712 4. Remove: REMOVING THE CLUTCH • Clutch plate 1 “1” 1. Remove: • Friction plate 2 • Clutch cover “1” • Gasket Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 269: Checking The Friction Plates

    CLUTCH 7. Remove: EAS25100 CHECKING THE FRICTION PLATES • Clutch boss nut The following procedure applies to all of the • Washer friction plates. • Clutch boss assembly 1. Check: • Thrust plate • Friction plate 8. Remove: Damage/wear → Replace the friction •...

  • Page 270: Checking The Clutch Springs

    CLUTCH 2. Measure: EAS25150 CHECKING THE CLUTCH HOUSING • Clutch plate warpage 1. Check: (with a surface plate and thickness gauge • Clutch housing dogs “1”) Damage/pitting/wear → Deburr the clutch Out of specification → Replace the clutch housing dogs or replace the clutch hous- plates as a set.

  • Page 271: Checking The Pull Lever Shaft And Pull Rod

    CLUTCH 3. Install: EAS25220 CHECKING THE PULL LEVER SHAFT AND • Wire circlip “1” PULL ROD 1. Check: • Pull lever shaft pinion gear teeth “1” • Pull rod teeth “2” Damage/wear → Replace the pull rod and pull lever shaft as a set. 4.
  • Page 272 CLUTCH • Stake the clutch boss nut at a cutout “a” in 7. Install: the main axle. • Friction plate 1 “1” • While holding the clutch boss assembly “1” with the universal clutch holder “3”, tighten • Install the last friction plate shifting half the clutch boss nut.
  • Page 273 CLUTCH 9. Install: • Dowel pins • Clutch cover gasket • Clutch cover “1” Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) • Apply engine oil onto the bearing. • Apply locking agent (LOCTITE®) to the threads of only the clutch cover bolt “a” 11.

  • Page 274: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Clutch assembly Refer to “CLUTCH” on page 5-45. Shift arm and shift rod Refer to “ENGINE REMOVAL” on page 5-3. Circlip Washer Shift shaft Washer Shift shaft spring...

  • Page 275: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear → Replace. • Shift shaft spring “2” • Collar “3” Damage/wear → Replace. 2. Install: • Bearing • Washer • Collar • Shift shaft spring “1” •...

  • Page 276: Oil Pump

    OIL PUMP EAS24921 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Drive sprocket cover Refer to “ENGINE REMOVAL” on page 5-3. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”...
  • Page 277 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Dowel pin Drain pipe Oil strainer Oil pipe Oil delivery pipe Relief valve assembly Oil/water pump assembly drive chain guide Collar Oil/water pump assembly drive sprocket Washer Oil/water pump assembly drive chain Dowel pin...
  • Page 278 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil/water pump driven sprocket Circlip Oil pump housing Bearing Oil pump rotor assembly For assembly, reverse the disassembly pro- cedure. 5-59...

  • Page 279: Removing The Oil Pan

    OIL PUMP EAS24930 EAS24960 REMOVING THE OIL PAN CHECKING THE OIL PUMP 1. Remove: 1. Check: • Oil level switch “1” • Oil pump driven gear “1” • Oil pan “2” • Oil pump housing “2” Cracks/damage/wear → Replace the •...

  • Page 280: Checking The Relief Valve

    OIL PUMP EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes. 1. Check: • Oil delivery pipe “1” • Oil pipe “2” Damage → Replace. Obstruction → Wash and blow out with compressed air.

  • Page 281: Installing The Oil/Water Pump

    OIL PUMP 4. Check: Recommended lubricant • Oil pump operation Engine oil Refer to “CHECKING THE OIL PUMP” on page 5-60. 2. Install: • Pin “1” EAS25030 INSTALLING THE OIL/WATER PUMP • Inner rotor “2” 1. Install: • Outer rotor “3” •...

  • Page 282: Installing The Oil Pan

    OIL PUMP 5. Install: • Relief valve assembly “1” • O-ring • Oil strainer “2” • O-ring Oil strainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® • Oil pipe “3” • O-rings 3. Install: Oil pipe bolt • Oil/water pump assembly drive chain 10 Nm (1.0 m·kgf, 7.2 ft·lbf) guide “1”...
  • Page 283 OIL PUMP • Tighten the oil pan bolts in stages and in a crisscross pattern. • Lubricate the oil level switch O-ring with lith- ium-soap-based grease. 5-64...

  • Page 284: Crankcase

    Crankshaft position sensor SOR” on page 5-39. Oil/water pump assembly Refer to “OIL PUMP” on page 5-57. Refer to “ELECTRIC STARTER” on page 5- Starter motor Oil return pipe Speed sensor Neutral switch * Yamaha bond No.1215 (Three bond No.1215®) 5-65...
  • Page 285 Separating the crankcase Order Job/Parts to remove Q’ty Remarks Crankcase breather hose Ventilation chamber cover Ventilation chamber cover gasket Left side cover O-ring Lower crankcase Dowel pin For installation, reverse the removal proce- dure. * Yamaha bond No.1215 (Three bond No.1215®) 5-66...

  • Page 286: Disassembling The Crankcase

    (0.08–0.12 in) of the crankshaft journal • Lower crankcase bearings. ECA13900 • For area “a”, apply Yamaha bond No.1215 (Three Bond No.1215®) twice. For shaded Tap on one side of the crankcase with a area “b”, degrease the area and then apply soft-face hammer.
  • Page 287 CRANKCASE 5. Install: Crankcase bolt “1”–“10” • Lower crankcase “1” 1st: 20 Nm (2.0 m·kgf, 14 ft·lbf) (onto the upper crankcase “2”) 2nd*: 20 Nm (2.0 m·kgf, 14 ECA13980 ft·lbf) 3rd: 56–61° Before tightening the crankcase bolts, Crankcase bolt “11”–“16” make sure the transmission gears shift cor- 24 Nm (2.4 m·kgf, 17 ft·lbf) rectly when the shift drum assembly is...
  • Page 288 CONNECTING RODS AND PISTONS EAS39P1503 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-65. Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston...

  • Page 289: Connecting Rods And Pistons

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

  • Page 290: Checking The Piston Rings

    CONNECTING RODS AND PISTONS 2. Measure: • Piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cylinder. Then, find the average of the mea- surements.

  • Page 291: Checking The Piston Pin

    CONNECTING RODS AND PISTONS Piston ring side clearance Piston ring end gap Top ring Top ring 0.030–0.065 (0.0012– 0.25–0.35 mm (0.0098–0.0138 0.0026 in) Limit Limit 0.115 mm (0.0045 in) 0.60 mm (0.0236 in) 2nd ring 2nd ring 0.020–0.055 (0.0008– 0.35–0.50 mm (0.0138–0.0197 0.0022 in) Limit Limit...

  • Page 292: Checking The Connecting Rods

    CONNECTING RODS AND PISTONS EAS39P1504 CHECKING THE CONNECTING RODS 1. Measure: • Crankshaft-pin-to-big-end-bearing clear- ance Out of specification → Replace the big end bearings. Crankshaft-pin-to-big-end-bear- ing clearance 0.034–0.058 (0.0013– 0.0023 in) 3. Measure: Limit • Piston pin bore inside diameter “b” 0.09 mm (0.0035 in) Out of specification →...
  • Page 293 CONNECTING RODS AND PISTONS To install the big end bearing, care should be taken not to install it at an angle and the posi- tion should not be out of alignment. d. Assemble the connecting rod halves. ECA39P1501 Tighten the connecting rod bolts using the plastic-region tightening angle method.
  • Page 294 CONNECTING RODS AND PISTONS h. Put a mark “1” on the corner of the con- k. Remove the connecting rod and big end necting rod bolt “2” and the connecting rod bearings. cap “3”. Measure the compressed Plastigauge® width on the crankshaft pin. If the crank- shaft-pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings.

  • Page 295: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS 2. Tighten: • Connecting rod bolts ECA14B1042 Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts. Install by carrying out the following procedures in order to assemble in the most suitable con- EAS26190 dition.
  • Page 296 CONNECTING RODS AND PISTONS • Install the piston pin clips, so that the clip ends are 3 mm (0.12 in) “c” or more from the cutout in the piston. • Reinstall each piston into its original cylinder. a. Side machined face b.
  • Page 297 CONNECTING RODS AND PISTONS 7. Lubricate: • Crankshaft pins • Connecting rod big end bearing inner sur- face (with the recommended lubricant) Recommended lubricant Engine oil 8. Check: 11. Tighten: • Cylinder stud bolts • Connecting rod bolts “1” Cylinder stud bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) 9.
  • Page 298 CONNECTING RODS AND PISTONS EWA13400 WARNING If the connecting rod bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Instead, replace the connecting rod bolt with a new one and perform the procedure again. ECA13950 Do not use a torque wrench to tighten the connecting rod bolt to the specified angle.

  • Page 299: Crankshaft

    CRANKSHAFT EAS25950 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Lower crankcase Refer to “CRANKCASE” on page 5-65. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS” on page 5-70. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Washer Timing chain drive sprocket Straight key...

  • Page 300: Removing The Crankshaft Assembly

    CRANKSHAFT EAS25980 2. Check: REMOVING THE CRANKSHAFT ASSEMBLY • Crankshaft journal surfaces 1. Remove: • Crankshaft pin surfaces • Crankshaft assembly • Bearing surfaces • Crankshaft journal bearings Scratches/wear → Replace the crank- shaft. Identify the position of each crankshaft journal 3.
  • Page 301 CRANKSHAFT Do not put the Plastigauge® over the oil hole in the crankshaft journal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Select: • Crankshaft journal bearings (J –J e. Install the crankshaft journal lower bear- ings “1” into the lower crankcase and assemble the crankcase halves. •...

  • Page 302: Installing The Crankshaft

    CRANKSHAFT EAS26200 INSTALLING THE CRANKSHAFT 1. Install: • Crankshaft journal upper bearings (into the upper crankcase) • Crankshaft journal lower bearings (into the lower crankcase) • Crankshaft • Align the projections “a” on the crankshaft journal bearings “1” with the notches “b” in the crankcase.
  • Page 303 TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Lower crankcase Refer to “CRANKCASE” on page 5-65. Drive axle assembly Oil seal Bearing Washer Shift fork guide bar retainer Spring Shift fork guide bar Shift fork “L”...
  • Page 304 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Oil pipe Oil baffle plate Bearing For installation, reverse the removal proce- dure. 5-85...
  • Page 305 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks When installing secondary pinion gear “1”, 2nd pinion gear install the gear with groove “a” facing to the toothed lock washer. Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer...
  • Page 306 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer Collar...
  • Page 307 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Collar Bearing Circlip Drive axle For assembly, reverse the disassembly pro- cedure. 5-88...

  • Page 308: Transmission

    TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift fork guide bar retainers “2” • Shift fork guide bars • Shift fork “L” and “R” • Shift drum assembly • Shift fork “C” EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks.

  • Page 309: Checking The Shift Drum Assembly

    TRANSMISSION 3. Check: • Shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift forks and shift fork guide bar as a set. 2. Measure: • Drive axle runout (with a centering device and dial gauge “1”) Out of specification →...

  • Page 310: Assembling The Main Axle And Drive Axle

    TRANSMISSION 4. Check: • Transmission gear engagement • With the toothed lock washer retainer “1” in (each pinion gear to its respective wheel the groove “a” in the axle, align the projection gear) “c” on the retainer with an axle spline “b”, and Incorrect →...
  • Page 311 TRANSMISSION Shift fork guide bar retainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® • The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”, “C”, “L”. •...
  • Page 312 TRANSMISSION 5-93...

  • Page 313: Cooling System

    COOLING SYSTEM RADIATOR ....................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR ..............6-3 OIL COOLER ....................6-5 CHECKING THE OIL COOLER..............6-6 INSTALLING THE OIL COOLER ............6-6 THERMOSTAT ....................6-7 CHECKING THE THERMOSTAT............6-9 ASSEMBLING THE THERMOSTAT ASSEMBLY ........6-9 INSTALLING THE THERMOSTAT ASSEMBLY ........6-10 WATER PUMP ....................6-11 DISASSEMBLING THE WATER PUMP..........6-12 CHECKING THE WATER PUMP ............6-12 ASSEMBLING THE WATER PUMP............6-12...
  • Page 314 RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Drive sprocket cover Refer to “ENGINE REMOVAL”...
  • Page 315 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Radiator fan motor coupler Disconnect. Radiator Radiator fan motor Water pump breather hose 2 Disconnect. Water pump inlet pipe For installation, reverse the removal proce- dure.

  • Page 316: Radiator

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. Straighten any flattened fins with a thin, flat- head screwdriver. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.
  • Page 317 RADIATOR b. Apply 122.7 kPa (1.23 kgf/cm², 17.8 psi) of pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3.

  • Page 318: Oil Cooler

    OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-26. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-23. Water jacket joint inlet hose Oil cooler inlet hose Oil cooler union bolt Washer...

  • Page 319: Checking The Oil Cooler

    OIL COOLER EAS26420 • Crankcase CHECKING THE OIL COOLER (with the specified amount of the recom- 1. Check: mended engine oil) • Oil cooler Refer to “CHANGING THE ENGINE OIL” Cracks/damage → Replace. on page 3-23. 2. Check: 4. Check: •...

  • Page 320: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Throttle body assembly Refer to “THROTTLE BODIES”...
  • Page 321 THERMOSTAT Disassembling the thermostat assembly Order Job/Parts to remove Q’ty Remarks Thermostat housing cover Thermostat Thermostat housing For assembly, reverse the disassembly pro- cedure.

  • Page 322: Checking The Thermostat

    THERMOSTAT EAS26450 CHECKING THE THERMOSTAT If the accuracy of the thermostat is in doubt, 1. Check: replace it. A faulty thermostat could cause seri- • Thermostat ous overheating or overcooling. Does not open at 71–85 °C (159.8–185.0 °F) → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 323: Installing The Thermostat Assembly

    THERMOSTAT EAS26480 INSTALLING THE THERMOSTAT ASSEM- 1. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-26. 2. Check: • Cooling system Leaks → Repair or replace any faulty part.

  • Page 324: Water Pump

    WATER PUMP EAS26500 WATER PUMP Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Oil/water pump assembly Refer to “OIL PUMP” on page 5-57. Oil pump rotor Refer to “OIL PUMP” on page 5-57. Water pump cover Impeller shaft (along with the impeller) Water pump seal Oil seal Bearing...

  • Page 325: Disassembling The Water Pump

    WATER PUMP EAS26520 EAS26541 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Water pump seal “1” • Water pump housing cover “1” • Impeller “2” Cracks/damage/wear → Replace. Remove the water pump seal from the inside •...
  • Page 326 WATER PUMP ECA14080 Never lubricate the water pump seal sur- face with oil or grease. Install the water pump seal with the special tools. Mechanical seal installer 90890-04078 Water pump seal installer 4. Measure: YM-33221-A • Impeller shaft tilt Out of specification → Repeat steps (3) Middle driven shaft bearing driver and (4).

  • Page 327: Fuel System

    FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK COVER ..........7-3 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP...............7-3 CHECKING THE FUEL PUMP BODY ............7-3 CHECKING THE FUEL PUMP OPERATION .........7-4 CHECKING THE ROLLOVER VALVE (for California only) .....7-4 INSTALLING THE FUEL PUMP..............7-4 INSTALLING THE FUEL TANK...............7-4 INSTALLING THE FUEL TANK COVER ..........7-5...
  • Page 328 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank cover Fuel hose connector cover Fuel hose connector Disconnect. Fuel sender coupler Disconnect. Fuel pump coupler Disconnect.

  • Page 329: Fuel Tank

    FUEL TANK Removing the canister (for California only) Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Left side cover Refer to “GENERAL CHASSIS” on page 4-1. Right side cover Refer to “GENERAL CHASSIS” on page 4-1. Brake fluid reservoir bolt Refer to “REAR BRAKE”...
  • Page 330 FUEL TANK EAS39P1713 EWA39P1702 REMOVING THE FUEL TANK COVER WARNING 1. Remove: Cover fuel hose connection with a cloth • Fuel tank cover “1” when disconnecting them. Residual pres- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ sure in the fuel lines could cause fuel to a. Remove the bolts. spurt out when removing the hose.
  • Page 331 FUEL TANK EAS26690 CHECKING THE FUEL PUMP OPERATION 1. Check: • Fuel pump operation Refer to “CHECKING THE FUEL PRES- SURE” on page 7-5. EAS39P2701 CHECKING THE ROLLOVER VALVE (for California only) 1. Check: • Rollover valve Damage/faulty → Replace. A.
  • Page 332 FUEL TANK EAS39P1714 INSTALLING THE FUEL TANK COVER 1. Install: • Fuel tank cover ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert projections “a” under the fuel tank cover bracket while inserting projection “b” into the hole of the fuel tank cover bracket. d. Connect the pressure gauge “2” and fuel pressure adapter “3”...

  • Page 333: Throttle Bodies

    THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Disconnect.
  • Page 334 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty Remarks Coolant temperature sensor coupler Disconnect. Throttle bodies Throttle body joint For installation, reverse the removal proce- dure.
  • Page 335 THROTTLE BODIES Removing the injectors Order Job/Parts to remove Q’ty Remarks Fuel injection system sub-wire harness Hose joint Negative pressure hose (Thin) Negative pressure hose (Thick) Hose joint For California only Canister purge hose For California only Intake air pressure sensor Throttle position sensor Sub-throttle position sensor Idle adjust screw wire...
  • Page 336 THROTTLE BODIES EAS39P1710 battery terminal before checking the REMOVING THE FUEL HOSE (THROTTLE injectors. BODY SIDE) ECA39P1701 1. Remove: • Fuel tank • When checking the injectors, do not allow Refer to “REMOVING THE FUEL TANK” any foreign material to enter or adhere to on page 7-3.
  • Page 337 THROTTLE BODIES 1. Check: EAS39P1706 CHECKING AND CLEANING THE THROT- • Injector pressure TLE BODIES ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the injector pressure adapter “1” Before cleaning the throttle bodies, check the to the fuel rail joint “2”, and then connect an following items: air compressor “3”...
  • Page 338 THROTTLE BODIES ECA39P1703 EWA14B1022 WARNING Observe the following precautions; other- When cleaning the throttle bodies, be care- wise, the throttle bodies may not operate ful not to injure yourself on the throttle properly. valves or other components of the throttle •...
  • Page 339 THROTTLE BODIES g. Make sure that there are no carbon depos- EAS39P1711 INSTALLING THE FUEL HOSE (THROTTLE its or other foreign materials in any of the BODY SIDE) passages “a” in each throttle body, in the 1. Connect: space “b” between the throttle valve shaft •...
  • Page 340 THROTTLE BODIES c. Connect the throttle position sensor, sub- EAS39P1708 ADJUSTING THE SUB-THROTTLE POSI- throttle position sensor and sub-throttle TION SENSOR servo motor to the wire harness. EWA39P1701 d. Set the main switch to “OFF” and set the WARNING engine stop switch to “ ”.
  • Page 341 THROTTLE BODIES • Positive tester probe Green/yellow (wire harness color) • Negative tester probe Black/blue (wire harness color) d. Set the main switch to “ON” and fully close the sub-throttle valves. e. Measure the sub-throttle position sensor voltage. f. Adjust the sub-throttle position sensor angle so that the voltage is within the spec- ified range.

  • Page 342: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-15...
  • Page 343 AIR INDUCTION SYSTEM 1. Air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover) 7-16...
  • Page 344 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Radiator Refer to “RADIATOR”...
  • Page 345 AIR INDUCTION SYSTEM EAS27060 1. Check: CHECKING THE AIR INDUCTION SYSTEM • Hoses Loose connections → Connect properly. Air injection Cracks/damage → Replace. The air induction system burns unburned 2. Check: exhaust gases by injecting fresh air (second- • Reed valve ary air) into the exhaust port, reducing the •...
  • Page 346 AIR INDUCTION SYSTEM • Reed valve assembly Install the reed valve assembly so that the open side turns to the exhaust side of the engine. A. Exhaust side 2. Install: • Reed valve cover Reed valve cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE®...

  • Page 347: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM..................8-1 CIRCUIT DIAGRAM................8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION .....8-3 TROUBLESHOOTING ................8-5 ELECTRIC STARTING SYSTEM..............8-7 CIRCUIT DIAGRAM................8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-9 TROUBLESHOOTING ................8-11 CHARGING SYSTEM .................8-13 CIRCUIT DIAGRAM................8-13 TROUBLESHOOTING ................8-15 LIGHTING SYSTEM ...................8-17 CIRCUIT DIAGRAM................8-17 TROUBLESHOOTING ................8-19 SIGNALING SYSTEM.................8-21 CIRCUIT DIAGRAM................8-21 TROUBLESHOOTING ................8-23...
  • Page 348 ELECTRICAL COMPONENTS..............8-93 CHECKING THE SWITCHES...............8-97 CHECKING THE BULBS AND BULB SOCKETS.......8-100 CHECKING THE FUSES..............8-101 CHECKING AND CHARGING THE BATTERY........8-102 CHECKING THE RELAYS..............8-105 CHECKING THE TURN SIGNAL RELAY ...........8-106 CHECKING THE RELAY UNIT (DIODE) ..........8-107 CHECKING THE IGNITION COILS ............8-108 CHECKING THE CRANKSHAFT POSITION SENSOR .....8-109 CHECKING THE LEAN ANGLE SENSOR .........8-109 CHECKING THE STARTER MOTOR OPERATION......8-110 CHECKING THE STATOR COIL............8-110...

  • Page 350: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 351 IGNITION SYSTEM 1. Main switch 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 12.Relay unit 13.Starting circuit cut-off relay 15.Neutral switch 16.Sidestand switch 19.Lean angle sensor 22.Cylinder identification sensor 23.Crankshaft position sensor 24.ECU (engine control unit) 25.Ignition coil #1 26.Ignition coil #2 27.Ignition coil #3 28.Ignition coil #4...
  • Page 352 IGNITION SYSTEM EAS39P1804 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
  • Page 353 IGNITION SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. ECU (engine control unit) 9. Sidestand switch 10.Relay unit (diode) 11.Neutral switch 12.Battery negative lead...
  • Page 354 IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Fuel tank 4. Radiator 1. Check the fuses. NG→ (Main and ignition) Replace the fuse(s).
  • Page 355 IGNITION SYSTEM 8. Check the main switch. NG→ Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-97. OK↓ 9. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-97. OK↓...

  • Page 356: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 357 ELECTRIC STARTING SYSTEM 1. Main switch 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 10.Starter relay 11.Starter motor 12.Relay unit 13.Starting circuit cut-off relay 15.Neutral switch 16.Sidestand switch 53.Right handlebar switch 55.Engine stop switch 56.Start switch 58.Left handlebar switch 59.Clutch switch 80.Ignition fuse...
  • Page 358 ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 359 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.
  • Page 360 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Fuel tank 4. Air filter case 5. Throttle bodies 1. Check the fuses. NG→ (Main and ignition) Replace the fuse(s).
  • Page 361 ELECTRIC STARTING SYSTEM 8. Check the main switch. NG→ Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-97. OK↓ 9. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-97. OK↓...

  • Page 362: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-13...
  • Page 363 CHARGING SYSTEM 2. Rectifier/regulator 3. AC magneto 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 8-14...
  • Page 364 CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 1. Check the fuse. NG→ (Main) Replace the fuse. Refer to “CHECKING THE FUSES” on page 8-101. OK↓...
  • Page 365 CHARGING SYSTEM 8-16...

  • Page 366: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-17...
  • Page 367 LIGHTING SYSTEM 1. Main switch 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 24.ECU (engine control unit) 42.Meter assembly 49.High beam indicator light 51.Meter light 58.Left handlebar switch 60.Dimmer switch 69.Headlight 70.License plate light 71.Tail/brake light 72.Headlight relay (on/off) 78.Headlight fuse 80.Ignition fuse 8-18...
  • Page 368 LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Headlight assembly 4. Fuel tank 1.
  • Page 369 LIGHTING SYSTEM 7. Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-17. OK↓ Replace the ECU or meter assembly. 8-20...

  • Page 370: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21...
  • Page 371 SIGNALING SYSTEM 1. Main switch 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 12.Relay unit 15.Neutral switch 18.Fuel sender 21.Speed sensor 24.ECU (engine control unit) 39.Coolant temperature sensor 42.Meter assembly 43.Oil level warning light 44.Neutral indicator light 45.Tachometer 46.Multi-function meter 50.Turn signal indicator light...
  • Page 372 SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3.
  • Page 373 SIGNALING SYSTEM 3. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-21. OK↓ This circuit is OK. The tail/brake light fails to come on. NG→ 1. Check the tail/brake light bulb and socket.
  • Page 374 SIGNALING SYSTEM 3. Check the turn signal relay. NG→ Refer to “CHECKING THE TURN Replace the turn signal relay. SIGNAL RELAY” on page 8-106. OK↓ 4. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring.
  • Page 375 SIGNALING SYSTEM The fuel level warning light fails to come on. 1. Check the fuel sender. NG→ Refer to “CHECKING THE FUEL Replace the fuel pump assembly. SENDER” on page 8-112. OK↓ 2. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM”...
  • Page 376 COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-27...
  • Page 377 COOLING SYSTEM 1. Main switch 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 24.ECU (engine control unit) 39.Coolant temperature sensor 73.Radiator fan motor relay 74.Right radiator fan motor fuse 75.Right radiator fan motor 76.Left radiator fan motor fuse 77.Left radiator fan motor 80.Ignition fuse 8-28...
  • Page 378 COOLING SYSTEM EAS27320 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Fuel tank 4. Air filter case 5. Throttle bodies 1. Check the fuses. NG→ (Main, ignition and radiator fan motor) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
  • Page 379 COOLING SYSTEM 7. Check the entire cooling system’s NG→ wiring. Properly connect or repair the cooling Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-27. OK↓ Replace the ECU. 8-30...

  • Page 380: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-31...
  • Page 381 FUEL INJECTION SYSTEM 1. Main switch 4. Backup fuse 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 9. Fuel injection system fuse 12.Relay unit 14.Fuel pump relay 15.Neutral switch 16.Sidestand switch 17.Fuel pump 19.Lean angle sensor 20.Atmospheric pressure sensor 21.Speed sensor 22.Cylinder identification sensor 23.Crankshaft position sensor...
  • Page 382 FUEL INJECTION SYSTEM EAS27351 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 engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 383 FUEL INJECTION SYSTEM ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.
  • Page 384 FUEL INJECTION SYSTEM EAS30580 The engine operation is not normal, but the TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1. Check the operation of the following sen- engine trouble warning light comes on. sors and actuators in the diagnostic mode.
  • Page 385 FUEL INJECTION SYSTEM EAS27411 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ON”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.
  • Page 386 FUEL INJECTION SYSTEM EAS27462 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part have been completed, reset the meter display according to the reinstatement method.
  • Page 387 FUEL INJECTION SYSTEM Fault code No. Cylinder identification sensor: no normal signals are received from Item the cylinder identification sensor. Unable to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause...
  • Page 388 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from the Item crankshaft position sensor. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause...
  • Page 389 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: open or short circuit detected. (no nor- Item mal signals are received from the intake air pressure sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:03 Meter display Displays the intake air pressure.
  • Page 390 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: open or short circuit detected. (no nor- Item mal signals are received from the intake air pressure sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:03 Meter display Displays the intake air pressure.
  • Page 391 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged or Item detached hose). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:03 Meter display Displays the intake air pressure. Set the engine stop switch to “ ”, and then operate the throttle Procedure while pushing the start switch “...
  • Page 392 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: open or short circuit detected. (no normal Item signals are received from the throttle position sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:01 Throttle position sensor Meter display •...
  • Page 393 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: open or short circuit detected. (no normal Item signals are received from the throttle position sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:01 Throttle position sensor Meter display •...
  • Page 394 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: stuck throttle position sensor detected. Item (signal from throttle position sensor will not change.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:01 Throttle position sensor Meter display •...
  • Page 395 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the blue/yellow lead Item of the ECU is detected. (no normal signals are received from the sidestand switch.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.
  • Page 396 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the blue/yellow lead Item of the ECU is detected. (no normal signals are received from the sidestand switch.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.
  • Page 397 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor or atmospheric pressure sensor: when Item the main switch is set to “ON”, the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ greatly. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 398 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor or atmospheric pressure sensor: when Item the main switch is set to “ON”, the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ greatly. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 399 FUEL INJECTION SYSTEM Fault code No. Coolant temperature sensor: open or short circuit detected. (no nor- Item mal signals are received from the coolant temperature sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:06 Meter display Displays the coolant temperature.
  • Page 400 FUEL INJECTION SYSTEM Fault code No. Intake air temperature sensor: open or short circuit detected. (no Item normal signals are received from the intake air temperature sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:05 Meter display Displays the intake air temperature.
  • Page 401 FUEL INJECTION SYSTEM Fault code No. Intake air temperature sensor: open or short circuit detected. (no Item normal signals are received from the intake air temperature sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:05 Meter display Displays the intake air temperature.
  • Page 402 FUEL INJECTION SYSTEM Fault code No. Atmospheric pressure sensor: open or short circuit detected. (no Item normal signals are received from the atmospheric pressure sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:02 Meter display Displays the atmospheric pressure.
  • Page 403 FUEL INJECTION SYSTEM Fault code No. Atmospheric pressure sensor: open or short circuit detected. (no Item normal signals are received from the atmospheric pressure sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:02 Meter display Displays the atmospheric pressure.
  • Page 404 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 405 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 406 FUEL INJECTION SYSTEM Fault code No. Latch up detected. Item No normal signals are received from the lean angle sensor. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. d:08 Lean angle sensor output voltage Meter display •...
  • Page 407 FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#1 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 408 FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#1 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 409 FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#2 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 410 FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#2 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 411 FUEL INJECTION SYSTEM Fault code No. Cylinder-#3 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#3 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 412 FUEL INJECTION SYSTEM Fault code No. Cylinder-#3 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#3 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 413 FUEL INJECTION SYSTEM Fault code No. Cylinder-#4 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#4 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 414 FUEL INJECTION SYSTEM Fault code No. Cylinder-#4 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#4 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 415 FUEL INJECTION SYSTEM Fault code No. Injector: open circuit detected. (no normal signals are received from Item the injector.) Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 416 FUEL INJECTION SYSTEM Fault code No. Injector: open circuit detected. (no normal signals are received from Item the injector.) Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 417 FUEL INJECTION SYSTEM Fault code No. Injector: open circuit detected. (no normal signals are received from Item the injector.) Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
  • Page 418 FUEL INJECTION SYSTEM Fault code No. Lean angle sensor: open or short circuit detected. (no normal sig- Item nals are received from the lean angle sensor.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. d:08 Lean angle sensor output voltage Meter display •...
  • Page 419 FUEL INJECTION SYSTEM Fault code No. Lean angle sensor: open or short circuit detected. (no normal sig- Item nals are received from the lean angle sensor.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. d:08 Lean angle sensor output voltage Meter display •...
  • Page 420 FUEL INJECTION SYSTEM Fault code No. A. no normal signals are received from the speed sensor. B. open or short circuit is detected in the neutral circuit of the neu- Item tral switch. C. open or short circuit is detected in the clutch circuit of the clutch switch.
  • Page 421 FUEL INJECTION SYSTEM A. Speed sensor system malfunction Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection → Connect Connection of speed sensor Check in the diagnostic code (meter) coupler it securely, or repair/replace (Code No. d07). With the rear Check the connection of the the wire harness.
  • Page 422 FUEL INJECTION SYSTEM B. Neutral switch sensor system malfunction Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection → Recon- Connection of neutral switch Start the engine. coupler nect or repair the coupler. Ride the vehicle at a low Check the connection of the speed (approx.
  • Page 423 FUEL INJECTION SYSTEM Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Shift drum (that detects the Check the gear shift drum Start the engine. neutral position) malfunction (that detects the neutral posi- Ride the vehicle at a low tion).
  • Page 424 FUEL INJECTION SYSTEM Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Open or short circuit → Continuity of leads between Start the engine. clutch switch and relay unit Replace the wire harness. Ride the vehicle at a low coupler Yellow/black–Yellow/black speed (approx.
  • Page 425 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector, Item fuel pump and main relay. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:09, d:50 Fuel system voltage (battery voltage) Meter display Approximately 12.0 d:09...
  • Page 426 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector, Item fuel pump and main relay. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:09, d:50 Fuel system voltage (battery voltage) Meter display Approximately 12.0 d:09...
  • Page 427 FUEL INJECTION SYSTEM Fault code No. Item Incorrect voltage is supplied to the ECU. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Charging system malfunction Check the charging system.
  • Page 428 FUEL INJECTION SYSTEM Fault code No. Sub-throttle position sensor: open or short circuit detected. (no nor- Item mal signals are received from the sub-throttle position sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display —...
  • Page 429 FUEL INJECTION SYSTEM Fault code No. Sub-throttle servo motor: stuck sub-throttle servo motor detected. Item signal from sub-throttle position sensor will not change. (sub-throt- tle servo motor will not start.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 430 FUEL INJECTION SYSTEM Fault code No. Sub-throttle servo motor: stuck sub-throttle servo motor detected. Item signal from sub-throttle position sensor will not change. (sub-throt- tle servo motor will not start.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 431 FUEL INJECTION SYSTEM Fault code No. Engine idling stop: engine has been left idling. (The ECU automati- Item cally stops the engine after 20 minutes if it is left idling.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 432 FUEL INJECTION SYSTEM Fault code No. Er-1 ECU internal malfunction (output signal error): no signals are Item received from the ECU. Able to start engine (Unable if ECU Failure) Fail-safe system Able to drive vehicle (Unable if ECU Failure) Diagnostic code No. —...
  • Page 433 FUEL INJECTION SYSTEM Fault code No. Er-2 ECU internal malfunction (output signal error): no signals are Item received from the ECU within the specified duration. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display —...
  • Page 434 FUEL INJECTION SYSTEM Fault code No. Er-3 ECU internal malfunction (output signal error): data from the ECU Item cannot be received correctly. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure —...
  • Page 435 FUEL INJECTION SYSTEM Fault code No. Er-4 ECU internal malfunction (input signal error): non-registered data Item has been received from the meter. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure —...
  • Page 436 FUEL INJECTION SYSTEM EAS30660 DIAGNOSTIC CODE TABLE The following tables contain information about diagnostic code numbers that do not have a corre- sponding fault code number. (These items are not listed in “TROUBLESHOOTING DETAILS”.) Diag- nostic Item Meter display/Actuation Procedure code d:48 Air induction system sole-...
  • Page 437 FUEL INJECTION SYSTEM Diag- nostic Item Meter display/Actuation Procedure code d:63 Malfunction code reinstate- ment (for fault code No. d24 only) • No malfunction code — • Malfunction code exists Fault code No. d24 To reinstate, set the engine • (If more than one code stop switch from “...

  • Page 438: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-89...
  • Page 439 FUEL PUMP SYSTEM 1. Main switch 5. Main fuse 6. Frame ground 7. Engine ground 8. Battery 9. Fuel injection system fuse 12.Relay unit 14.Fuel pump relay 17.Fuel pump 24.ECU (engine control unit) 53.Right handlebar switch 55.Engine stop switch 80.Ignition fuse 8-90...
  • Page 440 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Fuel tank 4. Air filter case 1. Check the fuses. NG→ (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 441 FUEL PUMP SYSTEM 7. Check the entire fuel pump sys- NG→ tem’s wiring. Properly connect or repair the fuel Refer to “CIRCUIT DIAGRAM” on pump system’s wiring. page 8-89. OK↓ Replace the ECU. 8-92...
  • Page 442 ELECTRICAL COMPONENTS EAS27973 ELECTRICAL COMPONENTS 8-93...
  • Page 443 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Ignition coil 5. Main fuse 6. Battery 7. Fuse box 8. Fuel injection system fuse 9. Starter relay 10.Rectifier/regulator 11.Rear brake light switch 12.O sensor 13.Speed sensor 14.Sidestand switch 15.Oil level switch 16.Neutral switch...
  • Page 444 ELECTRICAL COMPONENTS 8-95...
  • Page 445 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. ECU (engine control unit) 3. Intake air pressure sensor 4. Fuel pump 5. Atmospheric pressure sensor 6. Relay unit 7. Lean angle sensor 8. Turn signal relay 9. Headlight relay 10.Radiator fan motor relay 11.Coolant temperature sensor 12.Crankshaft position sensor 13.Sub-throttle servo motor...

  • Page 446: Electrical Components

    ELECTRICAL COMPONENTS EAS27981 CHECKING THE SWITCHES 8-97...
  • Page 447 ELECTRICAL COMPONENTS 1. Clutch switch 2. Dimmer switch 3. Turn signal switch 4. Horn switch 5. Main switch 6. Oil level switch 7. Sidestand switch 8. Front brake light switch 9. Engine stop switch 10.Start switch 11.Neutral switch 12.Rear brake light switch 8-98...
  • Page 448 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
  • Page 449 ELECTRICAL COMPONENTS EAS27990 EWA13320 CHECKING THE BULBS AND BULB SOCK- WARNING Since the headlight bulb gets extremely Check each bulb and bulb socket for damage hot, keep flammable products and your or wear, proper connections, and also for conti- hands away from the bulb until it has nuity between the terminals.
  • Page 450 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Checking the condition of the bulb sockets b. If the pocket tester indicates “∞”, replace The following procedure applies to all of the the fuse.
  • Page 451 ELECTRICAL COMPONENTS 4. Install: will drop considerably. Therefore, take • Rider seat special care when charging the battery. Refer to “GENERAL CHASSIS” on page 4-1. Since VRLA (Valve Regulated Lead Acid) bat- teries are sealed, it is not possible to check the EAS28031 CHECKING AND CHARGING THE BATTERY charge state of the battery by measuring the...
  • Page 452 ELECTRICAL COMPONENTS • No charging is necessary when the open-cir- into the battery quickly and can cause cuit voltage equals or exceeds 12.8 V. battery overheating and battery plate damage. b. Check the charge of the battery, as shown • If it is impossible to regulate the charging in the charts and the following example.
  • Page 453 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Charging method using a variable-current Charging method using a constant voltage (voltage) charger charger a. Measure the open-circuit voltage prior to a. Measure the open-circuit voltage prior to charging. charging. Voltage should be measured 30 minutes after Voltage should be measured 30 minutes after the engine is stopped.
  • Page 454 ELECTRICAL COMPONENTS Starter relay 8. Check: • Battery terminals 1. Positive battery terminal Dirt → Clean with a wire brush. 2. Negative battery terminal Loose connection → Connect properly. 3. Positive tester probe 9. Lubricate: 4. Negative tester probe • Battery terminals Relay operation Recommended lubricant Continuity...
  • Page 455 ELECTRICAL COMPONENTS Relay unit (fuel pump relay) Radiator fan motor relay 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 1. Positive battery terminal 4. Negative tester probe 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3”...
  • Page 456 ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C The pocket tester or the analog pocket tester readings are shown in the following table. Continuity Positive tester probe b. Turn the main switch to “ON”. Sky blue “1” c. Measure the turn signal relay input voltage. Negative tester probe ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 457 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the wire harness. b. Connect the pocket tester (Ω × 1) to the c. Measure the primary coil resistance. relay unit terminal as shown. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ c. Check the relay unit (diode) for continuity. 2.
  • Page 458 ELECTRICAL COMPONENTS 3. Check: Pocket tester • Ignition spark gap 90890-03112 Out of specification → Replace. Analog pocket tester YU-03112-C Minimum ignition spark gap 6.0 mm (0.24 in) • Positive tester probe ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Gray “1” a. Connect the ignition checker “1” as shown. •...
  • Page 459 ELECTRICAL COMPONENTS • Positive tester probe Yellow/green (wire harness color) • Negative tester probe Black/blue (wire harness color) b. Check the starter motor operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28150 CHECKING THE STATOR COIL 1. Disconnect: c. Set the main switch to “ON”. • Stator coil coupler d.
  • Page 460 ELECTRICAL COMPONENTS b. Measure the stator coil resistance. c. Start the engine and let it run at approxi- mately 5000 r/min. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ d. Measure the rectifier/regulator input volt- age. EAS28170 CHECKING THE RECTIFIER/REGULATOR ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Check: 2. Check: • Rectifier/regulator input voltage •...
  • Page 461 ELECTRICAL COMPONENTS EAS28180 CHECKING THE HORN Oil level switch resistance 1. Check: Maximum level position resis- • Horn resistance tance Out of specification → Replace. 484–536 Ω Minimum level position resis- Horn resistance tance 1.066–1.114 Ω at 20 °C (68 °F) 114–126 Ω...
  • Page 462 ELECTRICAL COMPONENTS 3. Remove: • Fuel pump (from the fuel tank) 4. Check: • Fuel sender resistance Out of specification → Replace the fuel pump assembly. Sender unit resistance (full) 19.0–21.0 Ω EAS28241 Sender unit resistance (empty) CHECKING THE SPEED SENSOR 139.0–141.0 Ω...
  • Page 463 ELECTRICAL COMPONENTS e. Measure the voltage. With each full rotation 2. Check: of the rear wheel, the voltage reading • Coolant temperature sensor resistance Out of specification → Replace. should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
  • Page 464 ELECTRICAL COMPONENTS 3. Install: d. While slowly turning the throttle position • Coolant temperature sensor sensor shaft, check that the throttle posi- tion sensor resistance is within the speci- Coolant temperature sensor fied range. 18 Nm (1.8 m·kgf, 13 ft·lbf) The resistance does not change or it changes abruptly →...
  • Page 465 ELECTRICAL COMPONENTS c. Connect the pocket tester (Ω × 1 k) to the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ sub-throttle position sensor as shown. a. Remove the air induction system solenoid coupler from the air induction system sole- • Tester positive lead → noid. Green/yellow “3” b.

  • Page 466: Specifications

    ELECTRICAL COMPONENTS b. Connect the digital circuit tester (DCV) to b. Connect the pocket tester (DC 20 V) to the the test harness S-pressure sensor 5S7 test harness-speed sensor (3P). (3P). Pocket tester Digital circuit tester 90890-03112 90890-03174 Analog pocket tester Model 88 Multimeter with YU-03112-C tachometer...
  • Page 467 ELECTRICAL COMPONENTS ECA16730 2. Check: • Intake air temperature sensor resistance Out of specification → Replace. Pay attention to the installing direction of the test harness S-pressure sensor 5S7 Intake air temperature sensor (3P) coupler. resistance b. Connect the digital circuit tester (DCV) to 5.40–6.60 kΩ...
  • Page 468 ELECTRICAL COMPONENTS 8-119...

  • Page 469: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED ..........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING ..............9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ...................9-2 OVERHEATING ..................9-3 OVERCOOLING ..................9-3 POOR BRAKING PERFORMANCE ............9-3 FAULTY FRONT FORK LEGS ..............9-3 UNSTABLE HANDLING................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........9-4...
  • Page 470 TROUBLESHOOTING EAS28451 3. Throttle body (-ies) TROUBLESHOOTING • Deteriorated or contaminated fuel • Sucked-in air EAS28460 GENERAL INFORMATION Electrical system 1. Battery The following guide for troubleshooting does • Discharged battery not cover all the possible causes of trouble. It •...
  • Page 471 TROUBLESHOOTING Fuel system Shift shaft 1. Throttle body (-ies) • Improperly adjusted shift rod • Damaged or loose throttle body joint • Bent shift shaft • Improperly synchronized throttle bodies Shift drum and shift forks • Improperly adjusted engine idling speed •...
  • Page 472 TROUBLESHOOTING 2. Engine oil EAS28610 OVERCOOLING • Incorrect oil level • Incorrect oil viscosity (high) Cooling system • Deteriorated oil 1. Thermostat • Thermostat stays open EAS30480 OVERHEATING EAS28620 POOR BRAKING PERFORMANCE Engine • Worn brake pad 1. Clogged coolant passages •...
  • Page 473 TROUBLESHOOTING 3. Front fork leg(s) Tail/brake light bulb burnt out • Incorrect oil level • Wrong tail/brake light bulb • Unevenly tensioned fork spring (both • Faulty battery front fork legs) • Incorrectly adjusted rear brake light switch • Broken fork spring •...

  • Page 474: Wiring Diagram

    EAS28740 57. Rear brake light switch Blue/Black WIRING DIAGRAM 58. Left handlebar switch Blue/Red 59. Clutch switch FZ8NA(C) 2011 Blue/White 60. Dimmer switch 1. Main switch Blue/Yellow 61. Turn signal switch 2. Rectifier/regulator Orange/Black 62. Horn switch 3. AC magneto Orange/Green 63.
  • Page 477 WIRING DIAGRAM FZ8NA(C)
  • Page 478 WIRING DIAGRAM FZ8NA(C)

Table of Contents