Yamaha FZS6W Service Manual
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Yamaha FZS6W Service Manual

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FZS6W
FZS6WC
SERVICE MANUAL
LIT-11616-20-60
4S8-28197-10

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Summary of Contents for Yamaha FZS6W

  • Page 1 FZS6W FZS6WC SERVICE MANUAL LIT-11616-20-60 4S8-28197-10...
  • Page 2 EAS20050 FZS6W/FZS6WC SERVICE MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. First edition, Octover 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed inU.S.A. P/N LIT-11616-20-60...
  • 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

    EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20100 16.Replace the part SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6.

  • 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 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 CHECKING THE CONNECTIONS ...............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 EAS4S81003 OUTLINE OF 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 EAS4S81004 FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 250 kPa (2.5 kg/cm ). Accordingly, when the energiz- ing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 13: Instrument Functions

    FEATURES EAS4S81005 Tachometer INSTRUMENT FUNCTIONS 1. Tachometer 2. Tachometer red zone. 1. Coolant temperature display/air intake tem- The electric tachometer allows the rider to perature display monitor the engine speed and keep it within 2. Speedometer the ideal power range. 3.
  • Page 14 “E” (Empty), “F” (Full) and symbol “ ” will flash eight times, then go off for approximately 3 seconds. If this occurs, have a Yamaha dealer check the electrical cir- cuit. Coolant temperature mode 1. Odometer/tripmeter/fuel reserve tripmeter Push the “SELECT”...
  • Page 15 FEATURES 4. Push the “RESET” button to select the NOTE: desired brightness level. • Even if the air intake temperature is set to be 5. Push the “SELECT” button to confirm the displayed, the coolant temperature warning selected brightness level. The display will light comes on when the engine overheats.

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

  • Page 18: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead NOTE: • Coupler • If there is no continuity, clean the terminals. •...

  • Page 19: 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 20 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-26, 4-53 90890-01403 Spanner wrench YU-33975 Damper rod holder 4-45, 4-47 90890-01294 Damping rod holder set YM-01300 T-handle 4-45, 4-47 90890-01326 YM-01326 Oil filter wrench 3-13 90890-01426 YU-38411 Fork seal driver weight 4-47, 4-48 90890-01367 Replacement hammer...
  • Page 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pocket tester 1-9, 5-38, 8-65, 90890-03112 8-66, 8-67, 8-71, Analog pocket tester 8-72, 8-73, 8-74, YU-03112-C 8-75, 8-76, 8-77, 8-78, 8-79, 8-80, 8-81, 8-82 Pressure gauge 3-14, 7-6 90890-03153 YU-03153 Oil pressure adapter H 3-14 90890-03139 Fuel pressure adapter...
  • Page 22 5-23 90890-04113 Valve guide reamer (4.0 mm) YM-04113 Ignition checker 8-74 90890-06754 Opama pet-4000 spark checker YM-34487 Yamaha bond No. 1215 5-32, 5-35, 5- (Three bond No.1215®) 58, 6-12 90890-85505 Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927...

  • Page 23: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-9 ELECTRICAL SPECIFICATIONS...............2-12 TIGHTENING TORQUES................2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-15 ENGINE TIGHTENING TORQUES ............2-16 CHASSIS TIGHTENING TORQUES ............2-20 LUBRICATION POINTS AND LUBRICANT TYPES ........2-22 ENGINE ....................2-22 CHASSIS ....................2-23 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-25 ENGINE OIL LUBRICATION CHART ...........2-25 LUBRICATION DIAGRAMS ..............2-27 COOLING SYSTEM DIAGRAMS ...............2-39...

  • Page 24: General Specifications

    Ground clearance 145 mm (5.71 in) Minimum turning radius 2800 mm (110.2 in) Weight With oil and fuel 207.0 kg (456 lb) (FZS6W) 208.0 kg (459 lb) (FZS6WC) Maximum load 189 kg (417 lb) (FZS6WC) 190 kg (419 lb) (FZS6W)

  • Page 25: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 600.0 cm³ Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 65.5 × 44.5 mm (2.58 × 1.75 in) Compression ratio 12.20 :1 Standard compression pressure (at sea level) 1550 kPa/400 r/min (220.5 psi/400 r/min) (15.5 kgf/cm²/400 r/min) Minimum–maximum...
  • Page 26 ENGINE SPECIFICATIONS Water pump Water pump type Single suction centrifugal pump 86/44 × 31/31 (1.955) Reduction ratio Max. impeller shaft tilt 0.15 mm (0.006 in) Spark plug (s) Manufacturer/model NGK/CR9EK Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Cylinder head Volume 10.33–10.93 cm³...
  • Page 27 ENGINE SPECIFICATIONS Valve dimensions Valve head diameter A (intake) 24.90–25.10 mm (0.9803–0.9882 in) Valve head diameter A (exhaust) 21.90–22.10 mm (0.8622–0.8701 in) Valve face width B (intake) 1.140–1.980 mm (0.0449–0.0780 in) Valve face width B (exhaust) 1.140–1.980 mm (0.0449–0.0780 in) Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit...
  • Page 28 ENGINE SPECIFICATIONS Limit 1.6 mm (0.06 in) Valve spring Inner spring Free length (intake) 37.04 mm (1.46 in) Limit 35.20 mm (1.39 in) Free length (exhaust) 41.79 mm (1.65 in) Limit 39.70 mm (1.56 in) Installed length (intake) 30.02 mm (1.18 in) Installed length (exhaust) 36.12 mm (1.42 in) Spring rate K1 (intake)
  • Page 29 ENGINE SPECIFICATIONS Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in) Limit 16.043 mm (0.6316 in) Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in) Limit 15.971 mm (0.6288 in) Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 in) Limit 0.072 mm (0.0028 in)
  • Page 30 ENGINE SPECIFICATIONS Crankshaft Width A 51.850–52.550 mm (2.04–2.06 in) Width B 268.80–270.00 mm (10.58–10.63 in) Runout limit C 0.030 mm (0.0012 in) Big end side clearance D 0.160–0.262 mm (0.0063–0.0103 in) Big end radial clearance 0.028–0.052 mm (0.0011–0.0020 in) Small end free play 0.32–0.50 mm (0.01–0.02 in) Journal oil clearance (using plastigauge®) 0.034–0.058 mm (0.0013–0.0023 in)
  • Page 31 0290 x 4 Manufacturer DENSO Throttle body Type/quantity 36EIDW-B1/1 (FZS6W) 36EIDW-B4/1 (FZS6WC) Manufacturer MIKUNI ID mark 5VX1 03 (FZS6W) 5VX4 12 (FZS6WC) Throttle valve size Throttle position sensor Resistance 4.0–6.0 kΩ Output voltage (at idle) 0.63-0.73 V Adjusted by tachometer Idling condition Engine idling speed 1250–1350 r/min...

  • Page 32: Chassis Specifications

    225 kPa (33 psi) (2.25 kgf/cm²) (2.25 bar) Rear 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Loading condition 90–189 kg (198–417 lb) (FZS6WC) 90–190 kg (198–419 lb) (FZS6W) Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar)
  • Page 33 CHASSIS SPECIFICATIONS Front disc brake Disc outside diameter × thickness 298.0 × 5.0 mm (11.73 × 0.20 in) Brake disc thickness limit 4.5 mm (0.18 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer)
  • Page 34 CHASSIS SPECIFICATIONS Rear suspension Type Swingarm (monocross) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 50.0 mm (1.97 in) Spring free length 185.0 mm (7.28 in) Installed length 172.0 mm (6.77 in) Spring rate K1 127.40 N/mm (727.45 lb/in) (12.99 kgf/mm) Spring stroke K1 0.0–50.0 mm (0.00–1.97 in) Optional spring available...

  • Page 35: Electrical Specifications

    Ignition system type DC. TCI Advancer type Digital 5.0 °/1300 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer FUA0016/MITSUBISHI (FZS6W) FUA0017/MITSUBISHI (FZS6WC) Ignition coil Model/manufacturer JO383/DENSO Minimum ignition spark gap 6.0 mm (0.24 in) 1.53–2.07 Ω at 20°C (68°F) Primary coil resistance Secondary coil resistance 12.0–18.0 kΩ...
  • Page 36 ELECTRICAL SPECIFICATIONS Indicator light Neutral indicator light Turn signal indicator light Oil level warning light High beam indicator light Coolant temperature warning light Engine trouble warning light Electric starting system System type Constant mesh Starter motor Model/manufacturer SM-14/MITSUBA Power output 0.60 kW 0.0012–0.0022 Ω...
  • Page 37 ELECTRICAL SPECIFICATIONS Fuel injection system relay Model/manufacturer G8R-30Y-R/OMRON 162–198 Ω Resistance Thermo unit Model/manufacturer 8CC/MITSUBISHI 290.0–354.0 Ω Resistance at 80°C Fuses Main fuse 30.0 A Headlight fuse 20.0 A Taillight fuse 10.0 A Signaling system fuse 10.0 A Ignition fuse 10.0 A Radiator fan fuse 20.0 A...

  • Page 38: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 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 39: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plugs 18 Nm (1.8 m·kg, 13 ft·lb) Cylinder head bolt See NOTE Cylinder head bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft caps bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft cap oil check bolt...
  • Page 40 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Catalyst pipe and catalyst pipe 20 Nm (2.0 m·kg, 14 ft·lb) stay bolt Muffler joint bolt 20 Nm (2.0 m·kg, 14 ft·lb) NOTE Catalyst joint bolt 20 Nm (2.0 m·kg, 14 ft·lb) NOTE Exhaust pipe stay bolt 20 Nm (2.0 m·kg, 14 ft·lb)
  • Page 41 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size sensor 45 Nm (4.5 m·kg, 33 ft·lb) Shift shaft spring stopper screw 22 Nm (2.2 m·kg, 16 ft·lb) Left Shift rod nut 7 Nm (0.7 m·kg, 5.0 ft·lb) thread Shift rod nut 7 Nm (0.7 m·kg, 5.0 ft·lb) Shift rod joint 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 42 TIGHTENING TORQUES Cylinder head tightening sequence. Crankcase tightening sequence. 2-19...

  • Page 43: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Upper bracket pinch bolt 30 Nm (3.0 m·kg, 22 ft·lb) Steering stem nut 110 Nm (11 m·kg, 80 ft·lb) Upper bracket and upper handle- 23 Nm (2.3 m·kg, 17 ft·lb) bar holder Lower bracket pinch bolt –...
  • Page 44 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Seat lock and frame 7 Nm (0.7 m·kg, 5.0 ft·lb) Licence plate light screw 4 Nm (0.4 m·kg, 2.9 ft·lb) Rear reflector bolt 4 Nm (0.4 m·kg, 2.9 ft·lb) Flap and bracket 6 7 Nm (0.7 m·kg, 5.0 ft·lb) Blacket 6 and rear frame 19 Nm (1.9 m·kg, 14 ft·lb)

  • Page 45: Lubrication Points And Lubricant Types

    Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Yamaha bond Cylinder head cover mating surface No.1215 Yamaha bond Cylinder head cover semicircular No.1215 Yamaha bond Crankcase mating surface No.1215...

  • Page 46: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Sidestand pivoting point and metal-to-metal moving parts Link and sidestand switch contact point...
  • Page 47 LUBRICATION POINTS AND LUBRICANT TYPES 2-24...

  • Page 48: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-25...
  • Page 49 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil filter 5. Oil cooler 6. Main axle 7. Mission cooler 8. Drive axle 9. Main gallery 10.Piston cooler 11.Intake camshaft 12.Exhaust camshaft 2-26...

  • Page 50: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27...
  • Page 51 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil level switch 2. Oil cooler 3. Relief valve 2-28...
  • Page 52 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 53 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Exhaust camshaft 3. Intake camshaft 4. Oil strainer 2-30...
  • Page 54 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 55 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil strainer 3. Oil level switch 4. Oil pump 2-32...
  • Page 56 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil pump 3. Relief valve 2-34...
  • Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 2-36...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 2-38...

  • Page 62: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-39...
  • Page 63 COOLING SYSTEM DIAGRAMS 1. Radiator 2. Oil cooler 2-40...
  • Page 64 COOLING SYSTEM DIAGRAMS 2-41...
  • Page 65 COOLING SYSTEM DIAGRAMS 1. Water pump 2. Oil cooler 3. Radiator 2-42...
  • Page 66 COOLING SYSTEM DIAGRAMS 2-43...
  • Page 67 COOLING SYSTEM DIAGRAMS 1. Oil cooler 2. Water pump 2-44...
  • Page 68 COOLING SYSTEM DIAGRAMS 2-45...
  • Page 69 COOLING SYSTEM DIAGRAMS 1. Radiator 2. Thermostat 2-46...

  • Page 70: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-47...
  • Page 71 CABLE ROUTING 1. Left handlebar switch lead 2. Main switch lead 3. Clutch cable 4. Throttle cables 5. Right handlebar switch lead A. Clamp the right and left handlebar switch leads and handlebars. Point the tip of the clamp downward in front of the handlebar. B.
  • Page 72 CABLE ROUTING 2-49...
  • Page 73 CABLE ROUTING 1. Rear brake light switch lead 2. Neutral switch lead 3. Fuel tank breather hose 4. Crankshaft position sensor lead 5. Right handlebar switch lead 6. O sensor lead 7. Bracket 8. Fuel tank drain hose 9. Rear brake reservoir hose A.
  • Page 74 CABLE ROUTING 2-51...
  • Page 75 CABLE ROUTING M. Coupler should not run on the relay assem- 1. Main switch lead bly. 2. Stay assembly N. To the tail/brake light 3. Left handlebar switch lead O. To the license plate light 4. Clutch cable P. To the rear right turn signal light 5.
  • Page 76 CABLE ROUTING 2-53...
  • Page 77 CABLE ROUTING Q. Clamp the neutral switch lead, tail/brake 1. Right handlebar switch lead light lead and O sensor lead. Point the 2. Throttle cables clamp opening to the rear side. 3. Battery positive lead R. Push the wire harness in the groove of the 4.
  • Page 78 CABLE ROUTING 2-55...
  • Page 79 CABLE ROUTING 1. Fuel pump assembly 2. Fuel tank breather hose 3. Fuel tank drain hose 4. Fuel hose 5. Clip 6. Clamp 7. Fuel tank protector 8. Charge hose (FZS6WC) 9. Roll over valve (FZS6WC) A. Air opening. B. Install the O-ring with its lip pointed upward.
  • Page 80 CABLE ROUTING FZS6WC 2-57...
  • Page 81 CABLE ROUTING 1. Clip 2. Roll over valve assembly 3. Canister hose 4. Balance hose 5. Clamp 6. Canister assembly 7. Upper bracket 8. Hose 9. Canister bracket 10.Fuel tank drain hose 11.Roll over valve hose A. Front side B. Point the paint marking upward. C.
  • Page 82 CABLE ROUTING 2-59...

  • Page 83: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 ENGINE......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODIES ........3-6 ADJUSTING THE ENGINE IDLING SPEED ..........3-8 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-8 CHECKING THE SPARK PLUGS............3-9 MEASURING THE COMPRESSION PRESSURE .......3-10 CHECKING THE ENGINE OIL LEVEL ..........3-12 CHANGING THE ENGINE OIL.............3-12 MEASURING THE ENGINE OIL PRESSURE ........3-13...
  • Page 84 ELECTRICAL SYSTEM................3-32 REPLACING THE HEADLIGHT BULBS..........3-32 ADJUSTING THE HEADLIGHT BEAMS ..........3-32...

  • Page 86: Periodic Maintenance

    Air induction sys- √ √ age. • Replace any damaged parts if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. General maintenance and lubrication chart INITIAL ODOMETER READINGS 600 mi...
  • Page 87 PERIODIC MAINTENANCE 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 30 months •...
  • Page 88 25 * and switches • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.

  • Page 89: Engine

    ENGINE EAS20470 ENGINE EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead 4.
  • Page 90 ENGINE • When removing the timing chain and cam- Valve clearance measuring sequence shafts, fasten the timing chain with a wire to Cylinder #1 → #2 → #4 → #3 retrieve it if it falls into the crankcase. 6. Adjust: •...

  • Page 91: Synchronizing The Throttle Bodies

    ENGINE • Since valve pads of various sizes are origi- • Lubricate the valve lifter with molybdenum nally installed, the valve pad number must be disulfide oil. rounded in order to reach the closest equiva- • The valve lifter must turn smoothly when lent to the original.
  • Page 92 ENGINE • Air filter case ECA14900 CAUTION: Refer to "GENERAL CHASSIS" on page 4- Do not use the throttle valve adjusting 3. Install: screws to adjust the throttle body syncroni- • Vacuum gauge “1” zation. (onto the synchronizing hose “2”) Vacuum gauge Vacuum gauge 90890-03094...

  • Page 93: Adjusting The Engine Idling Speed

    ENGINE Throttle cable free play Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 3.0–5.0 mm (0.12–0.20 in) 11. Install: EAS20630 • Fuel tank ADJUSTING THE THROTTLE CABLE FREE Refer to "FUEL TANK" on page 7-1. PLAY • Seat NOTE: Refer to "GENERAL CHASSIS" on page 4- Prior to adjusting the throttle cable free play, the engine idling speed and throttle bodies synchronization should be adjusted properly.

  • Page 94: Checking The Spark Plugs

    ENGINE b. Turn the adjusting nut “3” in direction “a” or 4. Install: “b” to take up any slack on the decelerator • Battery cable. Refer to "GENERAL CHASSIS" on page 4- 1 and "CHECKING AND CHARGING THE Direction “a” BATTERY"...

  • Page 95: Measuring The Compression Pressure

    ENGINE 8. Install: • Spark plugs Spark plug 18 Nm (1.8 m·kg, 13 ft·lb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: • Spark plug caps 10. Install: A. Right side #1, #2 and #3 •...
  • Page 96 ENGINE • Battery ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Refer to "GENERAL CHASSIS" on page 4- a. Set the main switch to “ON”. 1 and "CHECKING AND CHARGING THE b. With the throttle wide open, crank the BATTERY" on page 8-68. engine until the reading on the compres- •...

  • Page 97: Checking The Engine Oil Level

    ENGINE • Heat protector plate • Battery box bracket • Battery box Refer to "GENERAL CHASSIS" on page 4- • Battery Refer to "GENERAL CHASSIS" on page 4- 1 and "CHECKING AND CHARGING THE BATTERY" on page 8-68. • Air filter case Refer to "GENERAL CHASSIS"...

  • Page 98: Measuring The Engine Oil Pressure

    ENGINE Oil filter cartridge 17 Nm (1.7 m·kg, 12 ft·lb) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Check: • Engine oil drain bolt gasket 7. Install: • Engine oil drain bolt (along with the new gasket) Engine oil drain bolt 4. Drain: 43 Nm (4.3 m·kg, 31 ft·lb) •...

  • Page 99: Adjusting The Clutch Cable Free Play

    ENGINE ECA13410 Engine oil pressure CAUTION: 240 kPa (34.1 psi) (2.4 kg/cm When the engine is cold, the engine oil will Engine speed have a higher viscosity, causing the engine Approx 6,600 r/min oil pressure to increase. Therefore, be sure Oil temperature to measure the engine oil pressure after 75.0–85.0 °C (167.00–185.00...

  • Page 100: Cleaning The Air Filter Element

    ENGINE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: EAS20950 • Clutch cable free play CLEANING THE AIR FILTER ELEMENT ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. Remove: • Seat Handlebar side Refer to "GENERAL CHASSIS" on page 4- a. Turn the adjusting bolt “1” in direction “a” or “b” until the specified clutch cable free play •...

  • Page 101: Checking The Throttle Body Joints

    ENGINE ECA4S81008 Refer to "GENERAL CHASSIS" on page 4- CAUTION: • Fuel tank Never operate the engine without the air fil- Refer to "FUEL TANK" on page 7-1. ter element installed. Unfiltered air will 2. Check: cause rapid wear of engine parts and may •...

  • Page 102: Checking The Exhaust System

    ENGINE ECA13450 Exhaust pipe nut CAUTION: 20 Nm (2.0 m·kg, 15 ft·lb) Make sure the crankcase breather hose is Catalytic converter joint bolt routed correctly. 20 Nm (2.0 m·kg, 15 ft·lb) Muffler joint bolt 20 Nm (2.0 m·kg, 15 ft·lb) Muffler stay bolt 20 Nm (2.0 m·kg, 15 ft·lb) Exhaust pipe stay bolt...

  • Page 103: Checking The Cooling System

    ENGINE ECA13470 CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.
  • Page 104 ENGINE 3. Remove: Coolant drain bolt (water pump) • Radiator cap lock bolt “1” 10 Nm (1.0 m·kg, 7.2 ft·lb) • Radiator cap “2” 8. Install: • Coolant reservoir 9. Fill: EWA13030 • Cooling system WARNING (with the specified amount of the recom- A hot radiator is under pressure.
  • Page 105 ENGINE ECA13480 CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.

  • Page 106: Chassis

    CHASSIS EAS21140 EAS21190 CHASSIS ADJUSTING THE REAR DISC BRAKE 1. Check: • Brake pedal position EAS21160 ADJUSTING THE FRONT DISC BRAKE (distance “a” from the top of the rider foot- 1. Adjust: rest to the top of the brake pedal) •...

  • Page 107: Checking The Brake Fluid Level

    CHASSIS Locknut 18 Nm (1.8 m·kg, 13 ft·lb) EWA4S81005 WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system.

  • Page 108: Checking The Rear Brake Pads

    CHASSIS EAS21290 CHECKING THE REAR BRAKE HOSE 1. Check: • Brake hose Cracks/damage/wear → Replace. EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: 2. Check: • Rear brake pad •...

  • Page 109: Bleeding The Hydraulic Brake System

    CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21340 BLEEDING THE HYDRAULIC BRAKE SYS- EWA13100 WARNING Bleed the hydraulic brake system when- ever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. A. Front •...

  • Page 110: Adjusting The Shift Pedal

    CHASSIS EWA13110 EAS21390 ADJUSTING THE DRIVE CHAIN SLACK WARNING NOTE: After bleeding the hydraulic brake system, The drive chain slack must be checked at the check the brake operation. tightest point on the chain. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ECA13550 CAUTION: EAS21370 ADJUSTING THE SHIFT PEDAL A drive chain that is too tight will overload 1.

  • Page 111: Lubricating The Drive Chain

    CHASSIS EAS21500 Direction “a” CHECKING AND ADJUSTING THE STEER- Drive chain is tightened. ING HEAD Direction “b” 1. Stand the vehicle on a level surface. Drive chain is loosened. EWA13120 WARNING NOTE: Securely support the vehicle so that there To maintain the proper wheel alignment, adjust is no danger of it falling over.
  • Page 112 CHASSIS c. Loosen the lower ring nut “4” completely • Steering head tension and then tighten it to specification with a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ steering nut wrench. NOTE: EWA13140 Make sure all of the cables and wires are prop- WARNING erly routed. Do not overtighten the lower ring nut.

  • Page 113: Checking The Front Fork

    CHASSIS EAS21530 Spring preload CHECKING THE FRONT FORK ECA13590 1. Stand the vehicle on a level surface. CAUTION: EWA13120 Never go beyond the maximum or minimum WARNING adjustment positions. Securely support the vehicle so that there 1. Adjust: is no danger of it falling over. •...
  • Page 114 Rear 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Maximum load* 189 kg (417 lb) (FZS6WC) 190 kg (419 lb) (FZS6W) * Total weight of rider, passenger, cargo and accessories EWA13190 WARNING It is dangerous to ride with a worn-out tire.
  • Page 115 No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehi- cle. 1. Tire tread depth 2. Side wall Front tire 3.

  • Page 116: Checking The Wheels

    CHASSIS EAS21670 EAS21710 CHECKING THE WHEELS LUBRICATING THE PEDAL The following procedure applies to both of the Lubricate the pivoting point and metal-to-metal wheels. moving parts of the pedal. 1. Check: Recommended lubricant • Wheel Damage/out-of-round → Replace. Lithium-soap-based grease EWA13260 WARNING EAS21720...
  • Page 117 ELECTRICAL SYSTEM EAS21750 adversely affected. If the headlight bulb ELECTRICAL SYSTEM gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. EAS21790 REPLACING THE HEADLIGHT BULBS 6. Install: The following procedure applies to both of the •...
  • Page 118 ELECTRICAL SYSTEM 3-33...
  • Page 119 CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEEL ....................4-5 REMOVING THE FRONT WHEEL ............4-7 CHECKING THE FRONT WHEEL............4-7 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-8 INSTALLING THE FRONT WHEEL ............4-9 REAR WHEEL ....................4-10 REMOVING THE REAR WHEEL ............4-13 CHECKING THE REAR WHEEL ............4-13 CHECKING THE REAR WHEEL DRIVE HUB ........4-13 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ..4-14 ADJUSTING THE REAR WHEEL STATIC BALANCE......4-14...
  • Page 120 INSTALLING THE HANDLEBAR ............4-40 FRONT FORK.....................4-43 REMOVING THE FRONT FORK LEGS ..........4-45 DISASSEMBLING THE FRONT FORK LEGS ........4-45 CHECKING THE FRONT FORK LEGS..........4-46 ASSEMBLING THE FRONT FORK LEGS ...........4-47 INSTALLING THE FRONT FORK LEGS ..........4-49 STEERING HEAD..................4-51 REMOVING THE LOWER BRACKET ..........4-53 CHECKING THE STEERING HEAD ............4-53 INSTALLING THE STEERING HEAD...........4-54 REAR SHOCK ABSORBER ASSEMBLY ..........4-55...

  • Page 122: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat Order Job/Parts to remove Q’ty Remarks Seat For installation, reverse the removal proce- dure.
  • Page 123 GENERAL CHASSIS Removing the cowlings Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Right front cowling inner panel (with cowling) Front turn signal light coupler Disconnect. Front cowling Front cowling inner panel (center) Rear view mirrors Windshield...
  • Page 124 GENERAL CHASSIS Removing the air filter case and battery Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel Refer to "GENERAL CHASSIS"...
  • Page 125 GENERAL CHASSIS Removing the battery box Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK"...

  • Page 126: Front Wheel

    FRONT WHEEL EAS21880 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Brake hose holder Reflector stay Reflector Front brake caliper Front wheel axle pinch bolt Loosen. Front wheel axle Collar Front wheel Front brake disc For installation, reverse the removal proce- dure.
  • Page 127 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure.

  • Page 128: Removing The Front Wheel

    FRONT WHEEL EAS21900 REMOVING THE FRONT 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. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.

  • Page 129: Adjusting The Front Wheel Static Balance

    FRONT WHEEL • Adjust the front wheel static balance with the brake disc installed. 1. Remove: • Balancing weight(s) 2. Find: • Front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ c. Remove the wheel bearings “3” with a gen- a.

  • Page 130: Installing The Front Wheel

    FRONT WHEEL 1. Lubricate: • Wheel axle • Oil seal lips Recommended lubricant Lithium-soap-based grease 2. Install: • Coller • Wheel axle NOTE: NOTE: Install the tire and wheel with the mark “1” Start with the lightest weight. pointing in the direction of wheel rotation. b.

  • Page 131: Rear Wheel

    REAR WHEEL EAS22030 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Rear brake caliper Locknut Loosen. Adjusting nut Loosen. Rear wheel axle nut Washer Rear wheel axle Washer Drive chain puller Rear wheel Rear brake caliper bracket For installation, reverse the removal proce- dure.
  • Page 132 REAR WHEEL Removing the rear brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel For installation, reverse the removal proce- dure.
  • Page 133 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly pro- cedure. 4-12...

  • Page 134: Removing The Rear Wheel

    REAR WHEEL EAS22040 • Rear wheel drive hub “2” REMOVING THE REAR WHEEL • Rear wheel drive hub damper 1. Stand the vehicle on a level surface. • Right collar EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 135: Checking And Replacing The Rear Wheel Sprocket

    REAR WHEEL EAS22120 EAS22150 CHECKING AND REPLACING THE REAR ADJUSTING THE REAR WHEEL STATIC WHEEL SPROCKET BALANCE 1. Check: NOTE: • Rear wheel sprocket • After replacing the tire, wheel or both, the More than 1/4 tooth “a” wear → Replace rear wheel static balance should be adjusted.

  • Page 136: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks Brake hose holder Reflector stay Reflector Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw For installation, reverse the removal proce- dure.
  • Page 137 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-24. Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Brake lever Front brake light switch lead coupler Disconnect.
  • Page 138 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Master cylinder kit Spring Master cylinder Push rod For assembly, reverse the disassembly pro- cedure. 4-17...
  • Page 139 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-24. Union bolt Copper washer Brake hose Reflector stay Reflector Brake caliper For installation, reverse the removal proce- dure.
  • Page 140 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure. 4-19...

  • Page 141: Introduction

    FRONT BRAKE EAS22220 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ INTRODUCTION a. Place the vehicle on a suitable stand so EWA14100 that the front wheel is elevated. WARNING b. Before measuring the front brake disc Disc brake components rarely require dis- deflection, turn the handlebar to the left or assembly.

  • Page 142: Replacing The Front Brake Pads

    FRONT BRAKE NOTE: Brake disc bolt Always install new brake pads and a brake pad 18 Nm (1.8 m·kg, 13 ft·lb) spring as a set. LOCTITE® ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ d. Measure the brake disc deflection. a. Connect a clear plastic hose “1” tightly to e.

  • Page 143: Removing The Front Brake Calipers

    FRONT BRAKE Below the minimum level mark “c” → Add • Brake caliper pistons “1” the recommended brake fluid to the proper • Brake caliper piston seals “2” level. Refer to "CHECKING THE BRAKE FLUID LEVEL" on page 3-22. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.

  • Page 144: Assembling The Front Brake Calipers

    FRONT BRAKE 1. Install: Recommended brake component replace- ment schedule • Brake caliper seals • Brake caliper pistons Every two years and Brake fluid whenever the brake is EAS22440 disassembled INSTALLING THE FRONT BRAKE CALI- PERS 1. Check: The following procedure applies to both of the •...

  • Page 145: Removing The Front Brake Master Cylinder

    FRONT BRAKE EWA13090 EAS22490 REMOVING THE FRONT BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. NOTE: Other brake fluids may cause the rubber Before removing the front brake master cylin- seals to deteriorate, causing leakage and der, drain the brake fluid from the entire brake poor brake performance.

  • Page 146: Assembling The Front Brake Master Cylinder

    FRONT BRAKE Recommended fluid DOT 4 1. Install: • Master cylinder kit • Circlip EAS22530 INSTALLING THE FRONT BRAKE MASTER 2. Check: CYLINDER • Brake master cylinder kit “1” 1. Install: Damage/scratches/wear → Replace. • Brake master cylinder “1” Brake master cylinder holder bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE:...
  • Page 147 FRONT BRAKE ECA4S81013 ECA13540 CAUTION: CAUTION: When installing the brake hose onto the Brake fluid may damage painted surfaces brake master cylinder, make sure that the and plastic parts. Therefore, always clean brake pipe touches the projection “b” on up any spilt brake fluid immediately. the brake master cylinder.

  • Page 148: 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 shim Brake pad Brake screw Brake pad spring For installation, reverse the removal proce- dure.
  • Page 149 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-24. Brake fluid reservoir cap Rear brake fluid reservoir diaphragm holder Rear brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose Union bolt...
  • Page 150 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Spring Brake master cylinder body For installation, reverse the removal proce- dure. 4-29...
  • Page 151 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-24. Union bolt Copper washer Brake hose Rear brake caliper For installation, reverse the removal proce- dure.
  • Page 152 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 spring Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.

  • Page 153: Introduction

    REAR BRAKE EAS22560 4. Adjust: INTRODUCTION • Brake disc deflection EWA14100 Refer to "CHECKING THE FRONT BRAKE WARNING DISCS" on page 4-20. Disc brake components rarely require dis- Brake disc bolt assembly. Therefore, always follow these 30 Nm (3.0 m·kg, 22 ft·lb) preventive measures: LOCTITE®...

  • Page 154: Removing The Rear Brake Caliper

    REAR BRAKE b. Loosen the bleed screw and push the 5. Check: brake caliper pistons into the brake caliper • Brake pedal operation with your finger. Soft or spongy feeling → Bleed the brake c. Tighten the bleed screw. system. Refer to "BLEEDING THE HYDRAULIC Bleed screw BRAKE SYSTEM"...

  • Page 155: Checking The Rear Brake Caliper

    REAR BRAKE Scratches/wear → Replace the brake cali- per assembly. • Brake caliper body “3” Cracks/damage → Replace the brake cali- per assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose joint opening “a”...

  • Page 156: Installing The Rear Brake Caliper

    REAR BRAKE 1. Install: • Brake pad shims (on to the brake pads) • Brake pads • Brake caliper seals • Brake caliper • Brake caliper piston Brake caliper bolt (front side) EAS22670 27 Nm (2.7 m·kg, 20 ft·lb) INSTALLING THE REAR BRAKE CALIPER Brake caliper bolt (rear side) 1.

  • Page 157: Removing The Rear Brake Master Cylinder

    REAR BRAKE EAS22720 CHECKING THE REAR BRAKE MASTER CYLINDER 1. Check: • Brake master cylinder “1” Damage/scratches/wear → Replace. • Brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. 7. Check: • Brake pedal operation Soft or spongy feeling →...

  • Page 158: Assembling The Rear Brake Master Cylinder

    REAR BRAKE EAS22730 ASSEMBLING THE REAR BRAKE MASTER Recommended fluid CYLINDER DOT 4 EWA13520 WARNING EWA13090 WARNING • Before installation, all internal brake com- • Use only the designated brake fluid. ponents should be cleaned and lubricated Other brake fluids may cause the rubber with clean or new brake fluid.
  • Page 159 REAR BRAKE Brake pedal position 25.8 mm (1.02 in) 6. Adjust: • Rear brake light operation timing Refer to "ADJUSTING THE REAR BRAKE LIGHT SWITCH" on page 3-23. 4-38...

  • Page 160: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Grip end Handlebar grip Clutch switch connector Disconnect. Left handlebar switch Clutch cable Clutch lever Right handlebar switch Throttle grip Throttle cable Front brake light switch connector Disconnect. Front brake master cylinder holder Front brake master cylinder Upper handlebar holder...

  • Page 161: Removing The Handlebars

    HANDLEBAR EAS22860 REMOVING THE HANDLEBARS 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” NOTE: Blow compressed air between the left handle- EAS22880 CHECKING THE HANDLEBAR bar and the handlebar grip, and gradually push...
  • Page 162 HANDLEBAR 2. Install: • Handlebar “1” • Upper handlebar holders “2” • Upper handlebar holder caps “3” (Stan- dard) Upper handlebar holder bolt 23 Nm (2.3 m·kg, 17 ft·lb) 4. Install: • Brake master cylinder “1” • Brake master cylinder holder “2” Refer to "INSTALLING THE FRONT BRAKE MASTER CYLINDER"...
  • Page 163 HANDLEBAR NOTE: Align the projection “a” on the left handlebar switch with the hole “b” on the handlebar. 7. Install: • Handlebar grip • Grip end Grip end 26 Nm (2.6 m·kg, 19 ft·lb) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto the left end of the handlebar.

  • Page 164: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks Front wheel Refer to "FRONT WHEEL" on page 4-5. Front brake calipers Refer to "FRONT BRAKE" on page 4-15. Front fender Cap bolt Loosen. Upper bracket pinch bolt Loosen.
  • Page 165 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Spacer Washer Front fork spring Dust seal Oil seal clip Damper rod assembly bolt Copper washer Damper rod assembly Oil seal Washer Inner tube Outer tube bushing Inner tube bushing Oil flow stopper...

  • Page 166: Removing The Front Fork Legs

    FRONT FORK EAS22970 (with a flat-head screwdriver) REMOVING THE FRONT FORK LEGS ECA14180 The following procedure applies to both of the CAUTION: front fork legs. Do not scratch the inner tube. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.

  • Page 167: Checking The Front Fork Legs

    FRONT FORK ECA14190 CAUTION: • Excessive force will damage the oil seal and bushing. A damaged oil seal or bush- ing must be replaced. • Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged. 3.

  • Page 168: Assembling The Front Fork Legs

    FRONT FORK Recommended lubricant Suspension oil 01 or eqivalent 3. Tighten: • Damper rod assembly bolt “1” Damper rod assembly bolt 23 Nm (2.3 m·kg, 17 ft·lb) LOCTITE® EAS23020 NOTE: ASSEMBLING THE FRONT FORK LEGS While holding the damper rod assembly with The following procedure applies to both of the the damper rod holder “2”...
  • Page 169 FRONT FORK NOTE: Adjust the oil seal clip so that it fits into the outer tube’s groove. 5. Install: • Washer • Oil seal “1” (with the fork seal driver and adapter) 7. Install: ECA14220 CAUTION: • Dust seal “1” (with the fork seal driver weight) Make sure the numbered side of the oil seal faces up.

  • Page 170: Installing The Front Fork Legs

    FRONT FORK 9. Measure: • Front fork leg oil level “a” Out of specification → Correct. Level 134.0 mm (5.28 in) NOTE: • While filling the front fork leg, keep it upright. • After filling, slowly pump the front fork leg up and down to distribute the fork oil.
  • Page 171 FRONT FORK 4-50...

  • Page 172: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Front wheel Refer to "FRONT WHEEL" on page 4-5. Front fender Refer to "FRONT FORK" on page 4-43. Front fork Refer to "FRONT FORK" on page 4-43. Handlebar Refer to "HANDLEBAR"...
  • Page 173 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Upper bearing Lower bearing Dust seal Bearing outer race For installation, reverse the removal proce- dure. 4-52...

  • Page 174: Removing The Lower Bracket

    STEERING HEAD EAS23110 REMOVING THE LOWER BRACKET 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: • Steering stem nut • Washer 3. Replace: •...

  • Page 175: Installing The Steering Head

    STEERING HEAD 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing • Bearing races Recommended lubricant Lithium-soap-based grease 2. Install: •...

  • Page 176: 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 Seat Refer to "GENERAL CHASSIS" on page 4-1. Side cover Refer to "GENERAL CHASSIS" on page 4-1. Rear brake caliper Refer to "REAR BRAKE"...

  • Page 177: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 • Seat HANDLING THE REAR SHOCK ABSORBER • Side cover EWA13740 Refer to "GENERAL CHASSIS" on page 4- WARNING This rear shock absorber contains highly • Rear wheel compressed nitrogen gas. Before handling Refer to "REAR WHEEL" on page 4-10. the rear shock absorber, read and make 3.

  • Page 178: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY • Bushings Damage/wear → Replace. • Dust seals Damage/wear → Replace. • Bolts Bends/damage/wear → Replace. 4. Install: EAS23300 • Rear wheel INSTALLING THE REAR SHOCK Refer to "REAR WHEEL" on page 4-10. ABSORBER ASSEMBLY 5. Adjust: 1.

  • Page 179: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Muffler assembly Refer to "ENGINE REMOVAL" on page 5-1. Catalyst assembly Refer to "ENGINE REMOVAL" on page 5-1. Exhaust pipe assembly Refer to "ENGINE REMOVAL" on page 5-1. Rear brake caliper Refer to "REAR BRAKE"...
  • Page 180 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 4-59...

  • Page 181: Removing The Swingarm

    SWINGARM EAS23340 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2.

  • Page 182: Installing The Swingarm

    SWINGARM EAS23380 INSTALLING THE SWINGARM 1. Lubricate: • Bearings • Spacers • Dust covers • Pivot shaft “1” Recommended lubricant Lithium-soap-based grease 2. Install: • Swingarm • Pivot shaft nut “2” Pivot shaft nut 120 Nm (12.0 m·kg, 87 ft·lb) 3.

  • Page 183: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks Drive sprocket cover Refer to "ENGINE REMOVAL" on page 5-1. Refer to "REMOVING THE SWINGARM" on Swingarm page 4-60. Rear fender Drive chain Chain protector For installation, reverse the removal proce- dure.

  • Page 184: Removing The Drive Chain

    CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: 2. Check: Place the vehicle on a suitable stand so that •...

  • Page 185: Checking The Drive Sprocket

    CHAIN DRIVE More than 1/4 tooth “a” wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. a. Correct 1. Drive chain roller 2. Drive chain sprocket EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to "CHECKING AND REPLACING THE REAR WHEEL SPROCKET"...
  • Page 186 CHAIN DRIVE 4-65...

  • Page 187: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-6 CAMSHAFTS....................5-8 REMOVING THE CAMSHAFTS ............5-10 CHECKING THE CAMSHAFTS ............5-11 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET..5-12 CHECKING THE TIMING CHAIN GUIDES ..........5-12 CHECKING THE TIMING CHAIN TENSIONER ........5-13 INSTALLING THE CAMSHAFTS ............5-13 CYLINDER HEAD..................5-16 REMOVING THE CYLINDER HEAD ............5-17 CHECKING THE CYLINDER HEAD ............5-17...
  • Page 188 CHECKING THE OIL NOZZLES ............5-44 ASSEMBLING THE OIL PUMP ............5-44 INSTALLING THE OIL PUMP ...............5-45 INSTALLING THE OIL STRAINER ............5-45 INSTALLING THE OIL PAN ..............5-45 CLUTCH......................5-46 REMOVING THE CLUTCH..............5-49 CHECKING THE FRICTION PLATES ..........5-49 CHECKING THE CLUTCH PLATES.............5-50 CHECKING THE CLUTCH SPRINGS ..........5-50 CHECKING THE CLUTCH HOUSING ..........5-50 CHECKING THE CLUTCH BOSS ............5-50 CHECKING THE PRESSURE PLATE ..........5-51...

  • Page 190: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the drive sprocket Order Job/Parts to remove Q’ty Remarks Loosen Drive chain Refer to "ADJUSTING THE SHIFT PEDAL" on page 3-25. Locknut Shift rod Shift arm Drive sprocket cover Drive sprocket nut Lock washer Drive sprocket For installation, reverse the removal proce- dure.
  • Page 191 ENGINE REMOVAL Removing the exhaust pipe Order Job/Parts to remove Q’ty Remarks Exhaust pipe assembly Exhaust pipe gasket Catalytic converter pipe Muffler cover Muffler For installation, reverse the removal proce- dure.
  • Page 192 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK"...
  • Page 193 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Starter motor lead Disconnect. Stator coil assembly coupler Disconnect. Oil level switch connector Disconnect. Neutral switch coupler Disconnect. Speed sensor coupler Disconnect. For assembly, reverse the removal proce- dure.
  • Page 194 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Right front engine mounting bolt Left front engine mounting bolt Self-locking nut Rear engine mounting bolt Engine For installation, reverse the removal proce- dure.

  • Page 195: Installing The Engine

    ENGINE REMOVAL EAS23720 NOTE: INSTALLING THE ENGINE First tighten the lower self-locking nut. 1. Install: • Rear engine mounting bolts “1” NOTE: Lubricate the rear engine mounting bolt threads with engine oil. 4. Tighten: • Left front engine mounting bolts “5” Left front engine mounting bolt 55 Nm (5.5 m·kg, 40 ft·lb) 2.
  • Page 196 ENGINE REMOVAL NOTE: • Before installing, make sure to align the punch mark “a” of the shift shaft with the punch mark “b” of the shift arm. • Align the bottom edge of the shift pedal with the mark on the frame-to-swingarm bracket.

  • Page 197: Camshafts

    CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty Remarks Battery Refer to "GENERAL CHASSIS" on page 4-1. Air filter case Refer to "GENERAL CHASSIS" on page 4-1. Battery box Refer to "FUEL TANK" on page 7-1. Battery box bracket Refer to "GENERAL CHASSIS"...
  • Page 198 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Pickup rotor cover Refer to "PICKUP ROTOR" on page 5-33. Camshaft sprocket bolt Timing chain tensioner Timing chain tensioner gasket Timing chain guide (exhaust side) Intake camshaft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft...

  • Page 199: Removing The Camshafts

    CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: • Pickup rotor cover Refer to "PICKUP ROTOR" on page 5-33. 2. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b.

  • Page 200: Checking The Camshafts

    CAMSHAFTS 8. Remove: • Camshaft sprockets EAS23850 CHECKING THE CAMSHAFTS 1. Check: • Camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: 3. Measure: • Camshaft lobe dimensions “a” and “b” • Camshaft runout Out of specification → Replace the cam- Out of specification →...

  • Page 201: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFTS NOTE: • Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clear- ance with the Plastigauge®. Camshaft cap bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) EAS23870 d.

  • Page 202: Checking The Timing Chain Tensioner

    CAMSHAFTS • Timing chain guide (top side) “3” Damage/wear → Replace the defective part(s). ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • Timing chain tensioner cap bolt EAS23970 CHECKING THE TIMING CHAIN TEN- • Aluminum washer SIONER • Gasket 1. Check: Damage/wear → Replace the defective •...
  • Page 203 CAMSHAFTS NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. ECA4S81016 CAUTION: • Lubricate the camshaft cap bolts with the engine oil. • The camshaft cap bolts must be tightened evenly or damage to the cylinder head, 3.
  • Page 204 CAMSHAFTS 10. Measure: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Valve clearance 7. Turn: Out of specification → Adjust. • Crankshaft Refer to "ADJUSTING THE VALVE (several full turns clockwise) CLEARANCE" on page 3-4. 8. Check: • “T” mark “a” Make sure the “T” mark on the pickup rotor is aligned with the crankcase mating sure face “b”.

  • Page 205: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Intake camshaft Refer to "CAMSHAFTS" on page 5-8. Exhaust camshaft Refer to "CAMSHAFTS" on page 5-8. Cylinder head Cylinder head gasket Dowel pin For installation, reverse the removal proce- dure.

  • Page 206: Removing The Cylinder Head

    CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: • Cylinder head bolts NOTE: • Loosen the bolts in the proper sequence as shown. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Loosen each bolts 1/2 of a turn at a time. a. Place a straightedge “1” and a thickness After all of the bolts are fully loosened, gauge “2”...
  • Page 207 CYLINDER HEAD NOTE: Pass the timing chain through the timing chain cavity. 3. Tighten: • Cylinder head bolts “1” – “10” Cylinder head bolt (1st) 19 Nm (1.9 m·kg, 14 ft·lb) Cylinder head bolt (2 nd) 50 Nm (5.0 m·kg, 36 ft·lb) •...
  • Page 208 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 5-16. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring outer Intake valve spring inner Intake valve stem seal...

  • Page 209: Valves And Valve Springs

    VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-20...

  • Page 210: Removing The Valves

    VALVES AND VALVE SPRINGS EAS24280 • Valve cotters “1” REMOVING THE VALVES NOTE: The following procedure applies to all of the Remove the valve cotters by compressing the valves and related components. valve springs with the valve spring compressor NOTE: “2”...

  • Page 211: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS EAS24290 NOTE: CHECKING THE VALVES AND VALVE To ease valve guide removal and installation, GUIDES and to maintain the correct fit, heat the cylinder The following procedure applies to all of the head to 100°C (212°F) in an oven. valves and valve guides.

  • Page 212: Checking The Valve Seats

    VALVES AND VALVE SPRINGS Out of specification → Replace the valve. Valve guide remover (ø4) NOTE: 90890-04111 • When installing a new valve, always replace Valve guide remover (4.0 mm) the valve guide. YM-04111 • If the valve is removed or replaced, always Valve guide installer (ø4) replace the oil seal.
  • Page 213 VALVES AND VALVE SPRINGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b. Apply molybdenum disulfide oil onto the a. Apply Mechanic’s blueing dye (Dykem) “b” valve stem. onto the valve face. c. Install the valve into the cylinder head. b. Install the valve into the cylinder head. d.

  • Page 214: 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” and onto the valve seat to make a clear Out of specification → Replace the valve impression.

  • Page 215: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • Valve stem end (with an oil stone) 3. Measure: • Valve spring tilt “a” Out of specification → Replace the valve spring.
  • Page 216 VALVES AND VALVE SPRINGS ECA13800 CAUTION: Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad “1” • Valve lifter “2” (with the recommended lubricant) NOTE: b. Smaller pitch • Lubricate the valve lifter and valve pad with 4.

  • Page 217: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS4S81014 GENERATOR AND STARTER CLUTCH Removing the generator and starter clutch Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Drain Coolant Refer to "CHANGING THE COOLANT"...
  • Page 218 GENERATOR AND STARTER CLUTCH Removing the generator and starter clutch Order Job/Parts to remove Q’ty Remarks Idler gear shaft Idler gear Starter clutch drive gear For installation, reverse the removal proce- dure. 5-29...

  • Page 219: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS24490 ECA13880 REMOVING THE GENERATOR CAUTION: 1. Remove: To protect the end of the crankshaft, place • Seat an appropriate sized socket between the Refer to "GENERAL CHASSIS" on page 4- flywheel puller set’s center bolt and the crankshaft.

  • Page 220: Checking The Starter Clutch

    GENERATOR AND STARTER CLUTCH otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch drive gear counterclockwise “B”, it should turn freely, otherwise the starter clutch is faulty and must be replaced. EAS24570 CHECKING THE STARTER CLUTCH 1.

  • Page 221: Installing The Generator

    GENERATOR AND STARTER CLUTCH Yamaha bond No. 1215 ® (Three bond No.1215 90890-85505 EAS24500 INSTALLING THE GENERATOR 1. Install: • Generator rotor • Washer • Generator rotor bolt 4. Install: NOTE: • Stator coil • Clean the tapered portion of the crankshaft 5.

  • Page 222: Pickup Rotor

    PICKUP ROTOR EAS4S81015 PICKUP ROTOR Removing the pickup rotor Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel Refer to "GENERAL CHASSIS"...

  • Page 223: Removing The Pickup Rotor

    PICKUP ROTOR EAS4S81041 REMOVING THE PICKUP ROTOR 1. Remove: • Pickup rotor cover “1” NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EAS4S81042 INSTALLING THE PICKUP ROTOR 1.
  • Page 224 PICKUP ROTOR 3. Apply: • Sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 90890-85505 ® (Three Bond No.1215 4. Install: • Pickup rotor cover gasket • Pickup rotor cover NOTE: • When installing the pickup rotor cover, align the timing chain guide (intake side) pin “1”...

  • Page 225: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel Refer to "GENERAL CHASSIS"...
  • Page 226 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Lock washer Oil seal Bearing Washer set Starter motor rear cover Washer set O-ring Brush holder Armature assembly Starter motor yoke O-ring For assembly, reverse the disassembly pro- cedure.

  • Page 227: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 a. Measure the armature assembly resis- CHECKING THE STARTER MOTOR tances with the pocket tester. 1. Check: • Commutator Pocket tester Dirt → Clean with 600 grit sandpaper. 90890-03112 2. Measure: Analog pocket tester • Commutator diameter “a” YU-03112-C Out of specification →...

  • Page 228: Assembling The Starter Motor

    ELECTRIC STARTER NOTE: Align the match marks “a” on the starter motor yoke with the match marks “b” on the starter motor front and rear covers. 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing •...

  • Page 229: Oil Pump

    OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to "CHANGING THE ENGINE OIL" on page 3-12. Drain. Coolant Refer to "CHANGING THE COOLANT" on page 3-18. Exhaust pipe assembly Refer to "ENGINE REMOVAL"...
  • Page 230 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Relief valve assembly For installation, reverse the removal proce- dure. 5-41...
  • Page 231 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump rotor housing Oil pump driven sprocket For assembly, reverse the removal proce- dure. 5-42...

  • Page 232: Removing The Oil Pan

    OIL PUMP EAS24930 REMOVING THE OIL PAN Inner-rotor-to-outer-rotor-tip 1. Remove: clearance • Oil level switch “1” 0.030–0.090 (0.0012– • Oil pan “2” 0.0035 in) • Oil pan gasket Limit • Dowel pins 0.15 mm (0.0059 in) Outer-rotor-to-oil-pump-hous- NOTE: ing clearance Loosen each bolt 1/4 of a turn at a time, in 0.030–0.080 (0.0012–...

  • Page 233: Checking The Oil Delivery Pipes

    OIL PUMP Damage/wear → Replace. • Oil nozzle passage Obstruction → Blow out with compressed air. EAS24980 CHECKING THE OIL DELIVERY PIPES 1. Check: • Oil delivery pipe “1” • Oil pipe “2” EAS25010 Damage → Replace. ASSEMBLING THE OIL PUMP Obstruction →...

  • Page 234: Installing The Oil Pump

    OIL PUMP EAS25050 INSTALLING THE OIL PAN 1. Install: • Oil pipe • Oil delivery pipe 2. Install: • Dowel pins • Gasket • Oil pan “1” Oil pan bolt 3. Check: 12 Nm (1.2 m·kg, 8.7 ft·lb) • Oil pump operation •...

  • Page 235: Clutch

    3-12. Drain Coolant Refer to "CHANGING THE COOLANT" on page 3-18. Coolant hose Clutch cable Clutch cable holder Clutch cover Clutch cover gasket Dowel pin For installation, reverse the removal proce- dure. * Yamaha bond No.1215 (Three Bond No.1215®) 5-46...
  • Page 236 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Washer Pull lever Pull lever spring Washer Oil seal Bearing Pull lever shaft Washer For installation, reverse the removal proce- dure. 5-47...
  • Page 237 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Compression spring Pressure plate Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Clutch plate 2 Clutch boss nut Lock washer Clutch boss Thrust plate For assembly, reverse the removal proce- dure.

  • Page 238: Removing The Clutch

    CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: • Clutch cable holder “1” • Clutch cover “2” • Gasket NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 239: Checking The Clutch Plates

    CLUTCH Clutch spring free length 55.00 mm (2.17 in) Minimum length 54.00 mm (2.13 in) Limit 52.3 mm (2.06 in) EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: • Clutch plate Damage →...

  • Page 240: Checking The Pressure Plate

    CLUTCH EAS25270 NOTE: INSTALLING THE CLUTCH Pitting on the clutch boss splines will cause 1. Install: erratic clutch operation. • Thrust plate “1” • Clutch boss “2” • Lock washer “3” • Clutch boss nut “4” EAS25170 CHECKING THE PRESSURE PLATE 1.
  • Page 241 CLUTCH 5. Install: NOTE: • Friction plates Tighten the clutch spring bolts in stages and in • Clutch plates a crisscross pattern. NOTE: First, install a friction plate and then alternate between a clutch plate and a friction plate. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a Install the clutch plate and friction plate as shown in the illustration.

  • Page 242: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Drive sprocket cover Refer to "ENGINE REMOVAL" on page 5-1. Shift shaft cover Shift shaft cover gasket Dowel pin Oil seal Shift shaft Shift shaft spring Collar Stopper lever spring...

  • Page 243: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear → Replace. • Shift shaft spring “2” Damage/wear → Replace. 2. Install: • Shift shaft cover NOTE: Lubricate the oil seal lips with lithium-soap- based grease. EAS25430 CHECKING THE STOPPER LEVER 1.

  • Page 244: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to "ENGINE REMOVAL" on page 5-1. Cylinder head Refer to "CYLINDER HEAD" on page 5-16. Refer to "GENERATOR AND STARTER Generator CLUTCH" on page 5-28. Refer to "GENERATOR AND STARTER Starter clutch CLUTCH"...
  • Page 245 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Plate For installation, reverse the removal proce- dure. 5-56...

  • Page 246: Disassembling The Crankcase

    CRANKCASE EAS25550 NOTE: DISASSEMBLING THE CRANKCASE Identify the position of each crankshaft jour- 1. Place the engine upside down. nal lower bearing so that it can be reinstalled 2. Remove: in its original place. • Crankcase bolts NOTE: EAS25580 • Loosen each bolt 1/4 of a turn at a time, in CHECKING THE CRANKCASE stages and in a crisscross pattern.

  • Page 247: Assembling The Crankcase

    Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces) 6. Install: • Crankcase bolts Yamaha bond No. 1215 (Three bond No. 1215®) NOTE: 90890-85505 • Lubricate the bolt threads with engine oil. • Install a washer on bolts “1”–”10”...
  • Page 248 CRANKCASE 5-59...

  • Page 249: Crankshaft

    CRANKSHAFT EAS25950 CRANKSHAFT Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to "CRANKCASE" on page 5-55. Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring...
  • Page 250 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to "CRANKCASE" on page 5-55. Connecting rods caps Refer to "CRANKSHAFT" on page 5-60. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing For installation, reverse the removal proce- dure.

  • Page 251: Removing The Connecting Rods And Pistons

    CRANKSHAFT 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” • Big end bearings NOTE: Identify the position of each bigend bearing so that it can be reinstalled in its original place.

  • Page 252: Checking The Cylinder And Piston

    CRANKSHAFT EAS24390 CHECKING THE CYLINDER AND PISTON Piston size “P” 1. Check: Standard • Piston wall 65.475–65.490 mm (2.5778– • Cylinder wall 2.5783 in) Vertical scratches → Replace the cylinder, and replace the piston and piston rings as a set. 2.

  • Page 253: Checking The Piston Pins

    CRANKSHAFT Top ring Top ring Ring side clearance End gap (installed) 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 Ring side clearance End gap (installed) 0.030–0.065 (0.0012– 0.70–0.80 mm (0.0276–0.0315 0.0026 in) Limit...

  • Page 254: Checking The Big End Bearings

    CRANKSHAFT end bearings must be installed in their orig- Piston pin bore inside diameter inal positions. 16.002–16.013 mm (0.6300– a. Clean the big end bearings, crankshaft 0.6304 in) pins, and the inside of the connecting rod Limit halves. 16.043 mm (0.6316 in) b.
  • Page 255 CRANKSHAFT j. Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi- tion. k. Tighten the connecting rod bolts. Connecting rod bolt 15 Nm (1.5 m·kg, 11 ft·lb) + 120°...
  • Page 256 CRANKSHAFT If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings. p. After the installation, check that the section show “a” is flush with each other by touch- ing the surface. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Side machined face “a” 2.

  • Page 257: Installing The Connecting Rod And Piston

    CRANKSHAFT • Make sure that the “Y” mark “a” on the con- necting rod faces left when the arrow mark “b” on the piston is pointing up as shown. • Reinstall each piston into its original cylinder (numbering order starting from the left: #1 to #4).
  • Page 258 CRANKSHAFT 6. Install: • Big end bearings • Connecting rod cap (onto the connecting rod) NOTE: • Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. • Make sure that the characters “a” on both the connecting rod and connecting rod cap are aligned.

  • Page 259: Checking The Crankshaft

    CRANKSHAFT ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ with a new one and perform the proce- ECA14980 dure again. CAUTION: • If they are not flush with each other, remove the connecting rod bolt and big Tighten the connecting rod bolts using the end bearing and restart from step “7”. In plastic-region tightening angle method.
  • Page 260 CRANKSHAFT ECA4S81028 NOTE: CAUTION: • Align the projections “a” of the crankshaft Do not interchange the crankshaft journal journal lower bearings with the notches “b” in bearings. To obtain the correct crankshaft- the lower crankcase. journal- to-crankshaft-journal-bearing • Do not move the crankshaft until the clear- clearance and prevent engine damage, the ance measurement has been completed.

  • Page 261: Installing The Crankshaft

    CRANKSHAFT “2” respectively, than the bearing size for “J ” is: “J ” (crankcase) – “J ” (crankshaft web) – 1 = 6 – 2 – 1 = 3 (brown) CRANKSHAFT JOURNAL BEARING COLOR CODE White Blue Black Brown Green g.
  • Page 262 CRANKSHAFT • Be sure to install each crankshaft journal upper bearing in its original place. 2. Install: • Crankshaft 3. Install: • Lower crankcase Refer to "CRANKCASE" on page 5-55. 5-73...

  • Page 263: Transmission

    TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to "CRANKCASE" on page 5-55. Drive axle assembly Circlip Oil seal Bearing Shift drum retainer Shift fork guide bar Spring Shift fork-L Shift fork-R...
  • Page 264 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Bearing 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Main axle Bearing housing Bearing For installation, reverse the removal proce-...
  • Page 265 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Washer Collar 3rd wheel gear Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer 2nd wheel gear...
  • Page 266 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-77...

  • Page 267: Removing The Transmission

    TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Main axle assembly “1” (with the Torx® wrench) 2. Check: • Shift fork guide bar Roll the shift fork guide bar on a flat sur- face. Bends → Replace. EWA12840 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a.

  • Page 268: Checking The Transmission

    TRANSMISSION • Shift drum bearing “2” • Transmission gears Damage/pitting → Replace the shift drum Blue discoloration/pitting/wear → Replace assembly. the defective gear(s). • Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). EAS26300 CHECKING THE TRANSMISSION 1. Measure: 4.
  • Page 269 TRANSMISSION • Install shift fork-C into the groove in the 3rd 4. Check: and 4th pinion gear on the main axle. • Transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly. 3. Install: • Shift fork-R “1” •...
  • Page 270 TRANSMISSION 5-81...

  • Page 271: Cooling System

    COOLING SYSTEM RADIATOR....................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR ..............6-3 OIL COOLER ....................6-4 CHECKING THE OIL COOLER..............6-5 INSTALLING THE OIL COOLER ............6-5 THERMOSTAT ....................6-6 CHECKING THE THERMOSTAT............6-7 INSTALLING THE THERMOSTAT ASSEMBLY ........6-7 WATER PUMP ....................6-9 DISASSEMBLING THE WATER PUMP..........6-11 CHECKING THE WATER PUMP ............6-11 ASSEMBLING THE WATER PUMP............6-12 INSTALLING THE WATER PUMP ............6-13...
  • Page 272 RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK"...
  • Page 273 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Coolant reservoir drain hose For installation, reverse the removal proce- dure.

  • Page 274: Checking The 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. NOTE: 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 275 OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Radiator assembly Refer to "RADIATOR" on page 6-1. Coolant reservoir Refer to "RADIATOR" on page 6-1. Drain. Engine oil Refer to "CHANGING THE ENGINE OIL" on page 3-12.

  • Page 276: Oil Cooler

    OIL COOLER EAS26420 (with the specified amount of the recom- CHECKING THE OIL COOLER mended coolant) 1. Check: Refer to "CHANGING THE COOLANT" on • Oil cooler page 3-18. Cracks/damage → Replace. • Crankcase (with the specified amount of the recom- mended engine oil) Refer to "CHANGING THE ENGINE OIL"...

  • Page 277: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK"...

  • Page 278: Checking The Thermostat

    THERMOSTAT EAS26450 2. Check: CHECKING THE THERMOSTAT • Thermostat housing cover “1” 1. Check: • Cracks/damage → Replace. • Thermostat “1” Does not open at 71–85°C (160–185°F) → Replace. EAS26490 INSTALLING THE THERMOSTAT ASSEM- 1. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Thermostat a. Suspend the thermostat “3” in a container NOTE: “4”...
  • Page 279 THERMOSTAT 5. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to "CHECKING THE RADIATOR" on page 6-3.

  • Page 280: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump Order Job/Parts to remove Q’ty Remarks It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Drain. Coolant Refer to "CHANGING THE COOLANT" on page 3-18.
  • Page 281 WATER PUMP Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Water pump cover O-ring Impeller shaft Circlip Water pump seal Oil seal Bearing Water pump housing O-ring Copper washer For assembly, reverse the disassembly pro- cedure. 6-10...

  • Page 282: Disassembling The Water Pump

    WATER PUMP EAS26510 DISASSEMBLING THE WATER PUMP 1. Remove: • Water pump cover • O-ring • Circlip • Impeller shaft 2. Remove: • Water pump seal “1” NOTE: 5. Remove: Remove the water pump seal from the inside • Rubber damper holder “5” of the water pump housing “2”.

  • Page 283: Assembling The Water Pump

    CAUTION: • Before installing the water pump seal, apply Make sure the rubber damper and rubber Yamaha bond No.1215 or Quick Gasket “2” damper holder are flush with the impeller. to the water pump housing “3”. Impeller shaft tilt limit Mechanical seal installer 0.15 mm (0.006 in)

  • Page 284: Installing The Water Pump

    WATER PUMP • Water pump outlet hose “2” • Copper washer NOTE: • Install the radiator outlet hose with white “a” mark positioned outside. • Install the hose clamp with its screw head pointed to the inner side. 1. Straightedge 2.

  • Page 285: Fuel System

    FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP...............7-2 CHECKING THE FUEL PUMP BODY ............7-2 CHECKING THE FUEL PUMP OPERATION .........7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK...............7-3 THROTTLE BODIES..................7-4 CHECKING THE INJECTORS ...............7-6 CHECKING THE THROTTLE BODIES ..........7-6 CHECKING THE FUEL PRESSURE............7-6 ADJUSTING THE THROTTLE POSITION SENSOR ......7-6...
  • Page 286 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel Refer to "GENERAL CHASSIS"...

  • Page 287: Fuel Tank

    FUEL TANK EAS26630 EAS26670 REMOVING THE FUEL TANK CHECKING THE FUEL PUMP BODY 1. Extract the fuel in the fuel tank through the 1. Check: fuel tank cap with a pump. • Fuel pump body Obstruction → Clean. 2. Remove: Cracks/damage →...

  • Page 288: Installing The Fuel Tank

    2. Install: • Fuel sender coupler • Fuel pump coupler • Fuel tank breather hose (FZS6W) • Fuel tank drain hose NOTE: There is a white paint mark on the fuel tank breather hose (FZS6W).
  • Page 289 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel Refer to "GENERAL CHASSIS"...

  • Page 290: Throttle Bodies

    THROTTLE BODIES Removing the injectors Order Job/Parts to remove Q’ty Remarks Throttle position sensor coupler Disconnect. Intake air pressure sensor coupler Disconnect. Cylinder #1 injector coupler Disconnect. Cylinder #2 injector coupler Disconnect. Cylinder #3 injector coupler Disconnect. Cylinder #4 injector coupler Disconnect.

  • Page 291: Checking The Injectors

    THROTTLE BODIES EAS26980 CHECKING THE INJECTORS Pressure gauge 1. Check: 90890-03153 • Injectors YU-03153 Damage → Replace. Fuel pressure adapter 90890-03176 EAS26990 YM-03176 CHECKING THE THROTTLE BODIES 1. Check: • Throttle bodies Cracks/damage → Replace the throttle bodies as a set. 2.
  • Page 292 THROTTLE BODIES • Positive tester probe Yellow “1” • Negative tester probe Black/Blue “2” Digital circuit tester 90890-03174 Model 88 maltimeter with tachometer YU-A1927 c. Measure the throttle position sensor volt- age. d. Adjust the throttle position sensor angle so that the voltage is within the specified range.
  • Page 293 THROTTLE BODIES...

  • Page 294: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM...
  • Page 295 AIR INDUCTION SYSTEM 1. Air cut-off valve 2. Reed valve 3. To air filter case A. To cylinder #1 and #2 B. To cylinder #3 and #4 7-10...
  • Page 296 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS"...

  • Page 297: Checking The Air Induction System

    AIR INDUCTION SYSTEM EAS27060 A. From the air filter case CHECKING THE AIR INDUCTION SYSTEM B. To the reed valve 1. Check: Air injection • Hoses The air induction system burns unburned Loose connections → Connect properly. exhaust gases by injecting fresh air (second- Cracks/damage →...
  • Page 298 AIR INDUCTION SYSTEM 7-13...

  • Page 299: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM..................8-1 CIRCUIT DIAGRAM................8-1 TROUBLESHOOTING ................8-3 ELECTRIC STARTING SYSTEM..............8-5 CIRCUIT DIAGRAM................8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-7 TROUBLESHOOTING ................8-8 CHARGING SYSTEM .................8-11 CIRCUIT DIAGRAM................8-11 TROUBLESHOOTING ................8-13 LIGHTING SYSTEM ...................8-15 CIRCUIT DIAGRAM................8-15 TROUBLESHOOTING ................8-17 SIGNALING SYSTEM.................8-19 CIRCUIT DIAGRAM................8-19 TROUBLESHOOTING ................8-21 COOLING SYSTEM..................8-27 CIRCUIT DIAGRAM................8-27 TROUBLESHOOTING ................8-29...
  • Page 300 CHECKING THE RELAY UNIT (DIODE) ..........8-72 CHECKING THE SPARK PLUG CAPS ..........8-73 CHECKING THE IGNITION COILS ............8-74 CHECKING THE CRANKSHAFT POSITION SENSOR .......8-75 CHECKING THE LEAN ANGLE SENSOR ...........8-75 CHECKING THE STARTOR MOTOR OPERATION ......8-75 CHECKING THE STATOR COIL............8-76 CHECKING THE RECTIFIER/REGULATOR ........8-76 CHECKING THE HORN ...............8-77 CHECKING THE ENGINE OIL LEVEL GAUGE ........8-77 CHECKING THE FUEL SENDER ............8-78...

  • Page 302: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 303 IGNITION SYSTEM 1. Main switch 6. Main fuse 9. Battery 10.Starting circuit cut-off relay 11.Sidestand switch 12.Neutral switch 17.Lean angle sensor 18.Crankshaft position sensor 21.ECU (engine control unit) 28.Cylinder-#1/#4 ignition coil 29.Cylinder-#2/#3 ignition coil 30.Spark plug 46.Engine stop switch 53.Ignition fuse 60.Clutch switch...

  • Page 304: Troubleshooting

    IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Side cowlings NG→ 1. Check the fuses. (Main and ignition) Replace the fuse(s). Refer to "CHECKING THE FUSES"...
  • Page 305 IGNITION SYSTEM 8. Check the engine stop switch. NG→ Refer to "CHECKING THE Replace the right handlebar switch. SWITCHES" on page 8-63. OK↓ 9. Check the neutral switch. NG→ Refer to "CHECKING THE Replace the neutral switch. SWITCHES" on page 8-63. OK↓...

  • Page 306: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 307 ELECTRIC STARTING SYSTEM 1. Main switch 6. Main fuse 7. Starter relay 8. Starter motor 9. Battery 10.Starting circuit cut-off relay 11.Sidestand switch 12.Neutral switch 46.Engine stop switch 47.Start switch 53.Ignition fuse 60.Clutch switch...

  • Page 308: Starting Circuit Cut-Off System Operation

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

  • Page 309: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Front cowling inner panel 3. Fuel tank 4. Left side cover 1. Check the fuses. NG→ (Main and ignition) Replace the fuse(s).
  • Page 310 ELECTRIC STARTING SYSTEM 8. Check the neutral switch. NG→ Refer to "CHECKING THE Replace the neutral switch. SWITCHES" on page 8-63. OK↓ 9. Check the sidestand switch. NG→ Refer to "CHECKING THE Replace the sidestand switch. SWITCHES" on page 8-63. OK↓...
  • Page 311 ELECTRIC STARTING SYSTEM 8-10...

  • Page 312: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11...
  • Page 313 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 6. Main fuse 9. Battery 8-12...

  • Page 314: Troubleshooting

    CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Front cowling inner panel 3. Fuel tank NG→ 1. Check the fuse. (Main) Replace the fuse. Refer to "CHECKING THE FUSES" on page 8-67.
  • Page 315 CHARGING SYSTEM 8-14...

  • Page 316: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15...
  • Page 317 LIGHTING SYSTEM 1. Main switch 6. Main fuse 9. Battery 21.ECU (engine control unit) 39.High beam indicator light 52.Headlight fuse 54.Tail fuse 57.License plate light 58.Tail/brake light 61.Dimmer switch 66.Headlight relay 67.Headlight (high beam) 68.Headlight (low beam) 8-16...

  • Page 318: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Front cowling inner panel 3. Fuel tank 4.
  • Page 319 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 8-15. OK↓ This circuit is OK. 8-18...

  • Page 320: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19...
  • Page 321 SIGNALING SYSTEM 1. Main switch 6. Main fuse 9. Battery 10.Starting circuit cut-off relay 12.Neutral switch 13.Fuel pump 21.ECU (engine control unit) 32.Fuel level warning light 33.Oil level warning light 34.Neutral indicator light 35.Tachometer 36.Multi-function meter 40.Left turn signal indicator light 41.Right turn signal indicator light 42.Meter light 43.Oil level switch...

  • Page 322: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Front cowling inner panel 3.
  • Page 323 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 8-19. OK↓ This circuit is OK. The tail/brake light fails to come on. NG→ 1. Check the tail/brake light bulb and socket.
  • Page 324 SIGNALING SYSTEM 3. Check the hazard switch. NG→ Refer to "CHECKING THE Replace the left handlebar switch. SWITCHES" on page 8-63. OK↓ 4. Check the turn signal/hazard relay. NG→ The turn signal relay is faulty and must Refer to "CHECKING THE be replaced.
  • Page 325 SIGNALING SYSTEM 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 8-19. OK↓ This circuit is OK. The oil level warning light fails to come. NG→ 1.
  • Page 326 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 8-19. OK↓ This circuit is OK. The speedometer fails to operate. NG→ 1. Check the speed sensor. Refer to "CHECKING THE SPEED Replace the speed sensor.
  • Page 327 SIGNALING SYSTEM 8-26...

  • Page 328: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-27...
  • Page 329 COOLING SYSTEM 1. Main switch 6. Main fuse 9. Battery 20.Coolant temperature sensor 21.ECU (engine control unit) 36.Multi-function meter 48.Radiator fan motor fuse 49.Radiator fan motor relay 50.Radiator fan motor 53.Ignition fuse 8-28...

  • Page 330: Troubleshooting

    COOLING SYSTEM EAS27320 TROUBLESHOOTING NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Front cowling inner panel 3. Fuel tank 4. Side cover NG→ 1. Check the fuses. (Main, ignition and radiator fan motor) Replace the fuse(s). Refer to "CHECKING THE FUSES" on page 8-67.
  • Page 331 COOLING SYSTEM 8-30...

  • Page 332: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-31...
  • Page 333 FUEL INJECTION SYSTEM 1. Main switch 5. Fuel injection system fuse 6. Main fuse 9. Battery 10.Starting circuit cut-off relay 11.Sidestand switch 12.Neutral switch 13.Fuel pump 14.Throttle position sensor 15.Intake air pressure sensor 16.O sensor 17.Lean angle sensor 18.Crankshaft position sensor 19.Intake air temperature sensor 20.Coolant temperature sensor 21.ECU (engine control unit)

  • Page 334: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 335: Fail-Safe Actions (Substitute Characteristics Operation Control)

    FUEL INJECTION SYSTEM EAS27362 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU 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 336 FUEL INJECTION SYSTEM Able / Able / Fault Item Symptom unable to unable to code No. start drive Able Able Malfunction detected in the pri- (depending (depending Ignition coil (#2, #3) mary wire of the ignition coil (#2, on the num- on the num- (faulty ignition) #3).

  • Page 337: Troubleshooting Method

    FUEL INJECTION SYSTEM Able / Able / Fault Item Symptom unable to unable to code No. start drive ECU internal malfunc- Data from the ECU cannot be Er-3 tion Unable Unable received correctly. (output signal error) ECU internal malfunc- Non-registered data has been Er-4 tion Unable...

  • Page 338: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS27411 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 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 339 FUEL INJECTION SYSTEM NOTE: If the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ ” again. 9. Turn the main switch to “OFF” to cancel the diagnostic mode. Diagnostic code table Fault Diagnostic code...
  • Page 340 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Latch up detected. • The vehicle has overturned. No normal signal is • Defective lean angle sensor. received from the lean • Malfunction in ECU. angle sensor. •...
  • Page 341 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in communication line. Data from the ECU cannot Er-3 • Malfunction in meter unit. — be received correctly. • Malfunction in ECU. Non-registered data has •...
  • Page 342 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code EEPROM fault code display • Not fault • Fault detected 01 to 02 (Fault detection cyl- inder) — 01: #1 and #4 02: #2 and #3 • (If plural cylinders are defective, the display alter- nates every two seconds.) Malfunction history code...
  • Page 343 FUEL INJECTION SYSTEM Actuator operation table Diag- nostic Item Actuation Checking method code Actuates the ignition coils #1, #4 for five times every sec- Check the spark five times. Ignition coil #1/#4 ond. • Connect an ignition Illuminates the engine trou- checker.

  • Page 344: Troubleshooting Details

    FUEL INJECTION SYSTEM EAS27451 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 has been completed, reset the meter display according to the reinstatement method.
  • Page 345 FUEL INJECTION SYSTEM Fault code No. 13 Symptom Intake air pressure sensor-open or short circuit detected. Diagnostic code No. Intake air pressure sensor Item/components and probable Reinstate- Order Check or maintenance job cause ment method Open or short circuit in wire harness •...
  • Page 346 FUEL INJECTION SYSTEM Fault code No. 15 Symptom Throttle position sensor-open or short circuit detected. Diagnostic code No. Throttle position sensor Item/components and probable Reinstate- Order Check or maintenance job cause ment method Installed condition of throttle position Check the installed area for Turning the sensor.
  • Page 347 FUEL INJECTION SYSTEM Open circuit is detected in the input line from the side- Fault code No. 19 Symptom stand switch to the ECU. Diagnostic code No. Sidestand switch Item/components and probable Reinstate- Order Check or maintenance job cause ment method Connected state of connector •...
  • Page 348 FUEL INJECTION SYSTEM Intake air temperature sensor-open or short circuit Fault code No. 22 Symptom detected. Diagnostic code No. Intake air temperature sensor Item/components and probable Reinstate- Order Check or maintenance job cause ment method Installed condition of intake air tem- Check the installed area for Turning the perature sensor...
  • Page 349 FUEL INJECTION SYSTEM Latch up detected. Fault code No. 30 Symptom No normal signal is received from the lean angle sensor. Diagnostic code No. Lean angle sensor Item/components and probable Reinstate- Order Check or maintenance job cause ment method The vehicle has overturned. Raise the vehicle upright.
  • Page 350 FUEL INJECTION SYSTEM Malfunction detected in the primary wire of the ignition Fault code No. 34 Symptom coil (#2/#3). Diagnostic code No. Ignition coil (#2/#3) Item/components and probable Reinstate- Order Check or maintenance job cause ment method Connected state of connector •...
  • Page 351 FUEL INJECTION SYSTEM ANo normal signals are received from the speed sensor. Fault code No. 42 Symptom BOpen or short circuit is detected in the neutral switch. 07 Speed sensor Diagnostic code No. 21 Neutral switch Item/components and probable Reinstate- Order Check or maintenance job cause...
  • Page 352 FUEL INJECTION SYSTEM Fault code No. 43 Symptom The ECU is unable to monitor the battery voltage. Diagnostic code No. Fuel injection system relay Item/components and probable Reinstate- Order Check or maintenance job cause ment method Connected state of connector •...
  • Page 353 FUEL INJECTION SYSTEM Fault code No. 46 Symptom Power supply to the FI system relay is not normal. Diagnostic monitor- — — ing code No. Item/components and probable Reinstate- Order Check or maintenance job cause ment method Connected state of connector. •...
  • Page 354 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Diagnostic code No. — — Item/components and probable Reinstate- Order Check or maintenance job cause ment method Connected state of connector • Check the coupler for any pins Reinstated •...
  • Page 355 FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic code No. — — Item/components and probable Reinstate- Order Check or maintenance job cause ment method Connected state of connector • Check the coupler for any pins Reinstated •...

  • Page 356: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-55...
  • Page 357 FUEL PUMP SYSTEM 1. Main switch 5. Fuel injection system fuse 7. Main fuse 9. Battery 10.Starting circuit cut-off relay 13.Fuel pump 21.ECU (engine control unit) 46.Engine stop switch 53.Ignition fuse 8-56...

  • Page 358: Troubleshooting

    FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Front cowling inner panel3 3. Fuel tank NG→ 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 359 FUEL PUMP SYSTEM 8-58...

  • Page 360: Electrical Components

    ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-59...
  • Page 361 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Starter relay 4. Battery 5. Fuse box 6. Rear brake light switch 7. Neutral switch 8. Sidestand switch 9. Oil level switch 10.Radiator fan motor 11.Horn 12.Ignition coil 8-60...
  • Page 362 ELECTRICAL COMPONENTS 8-61...
  • Page 363 ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air temperature sensor 4. Fuel pump 5. Intake air pressure sensor 6. ECU (engine control unit) 7. Lean angle sensor 8. Starting circuit cut-off relay 9. Dimmer relay 10.Radiator fan motor relay 11.Turn signal relay 12.Rectifier/regulator...

  • Page 364: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-63...
  • Page 365 ELECTRICAL COMPONENTS 1. Main switch 2. Horn switch 3. Dimmer switch 4. Turn signal switch 5. Hazard switch 6. Clutch switch 7. Sidestand switch 8. Engine stop switch 9. Front brake light switch 10.Start switch 11.Oil level switch 12.Neutral switch 13.Rear brake light switch 14.Fuse 15.Left handlebar switch lead coupler...
  • Page 366 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 367: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EAS27990 • Avoid touching the glass part of the head- CHECKING THE BULBS AND BULB SOCK- light bulb to keep it free from oil, other- wise the transparency of the glass, the Check each bulb and bulb socket for damage life of the bulb, and the luminous flux will or wear, proper connections, and also for conti- be adversely affected.

  • Page 368: Checking The Leds

    ELECTRICAL COMPONENTS Checking the condition of the bulb sockets The following procedure applies to all of the bulb sockets. 1. Check: • Bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester c. When the jumper leads are connected to 90890-03112 the terminals the respective LED should Analog pocket tester...

  • Page 369: Checking And Charging The Battery

    ELECTRICAL COMPONENTS d. If the fuse immediately blows again, check • Avoid bodily contact with electrolyte as it the electrical circuit. can cause severe burns or permanent eye injury. Amperage Fuses Q’ty FIRST AID IN CASE OF BODILY CONTACT: rating EXTERNAL Main 30 A...
  • Page 370 ELECTRICAL COMPONENTS 2. Disconnect: EWA13300 WARNING • Battery leads (from the battery terminals) Do not quick charge a battery. ECA13640 ECA13670 CAUTION: CAUTION: First, disconnect the negative battery lead • Never remove the MF battery sealing “1”, and then positive battery lead “2”. caps.
  • Page 371 ELECTRICAL COMPONENTS NOTE: NOTE: Voltage should be measured 30 minutes after Voltage should be measured 30 minutes after the machine is stopped. the machine is stopped. b. Connect a charged and AMP meter to the b. Connect a charger and AMP meter to the battery and start charging.

  • Page 372: Checking The Relays

    ELECTRICAL COMPONENTS 9. Lubricate: 2. Negative battery terminal • Battery terminals 3. Positive tester probe 4. Negative tester probe Recommended lubricant Result Dielectric grease Continuity/No continuity 10. Install: (between “3” to “4”) • Fuel tank • Front cowling inner panel Relay unit (fuel pump relay) •...

  • Page 373: Checking The Turn Signal/Hazard Relay

    ELECTRICAL COMPONENTS Radiator fan motor b. Turn the main switch to “ON”. c. Measure the turn signal/hazard relay input voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: 1. Positive battery terminal • Turn signal/hazard relay output voltage 2. Negative battery terminal Out of specification → Replace. 3.

  • Page 374: Checking The Spark Plug Caps

    ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C Continuity Positive tester probe → Sky blue “1” → Negative tester probe ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Black/Yellow “2” a. Disconnect the relay unit coupler from the No continuity wire harness. Positive tester probe → Black/ b.

  • Page 375: Checking The Ignition Coils

    ELECTRICAL COMPONENTS EAS28100 CHECKING THE IGNITION COILS Pocket tester The following procedure applies to all of the 90890-03112 ignition coils. Analog pocket tester 1. Check: YU-03112-C • Primary coil resistance Out of specification → Replace. • Negative tester probe Spark plug lead “1” Primary coil resistance •...

  • Page 376: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS e. Crank the engine by pushing the starter Lean angle sensor output volt- switch and gradually increase the spark gap until a misfire occurs. 65°: 1.0–4.0 V ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS28120 a. Connect the lean angle sensor coupler to CHECKING THE CRANKSHAFT POSITION the wireharness.

  • Page 377: Checking The Stator Coil

    ELECTRICAL COMPONENTS • This check is likely to produce sparks, • Positive tester probe therefore, make sure no flammable gas or White “2” fluid is in the vicinity. • Negative tester probe White “3” b. Measure the stator coil resistance. b.

  • Page 378: Checking The Horn

    ELECTRICAL COMPONENTS EAS28180 CHECKING THE HORN 1. Check: • Horn resistance Out of specification → Replace. Horn resistance 1.01–1.11 Ω at 20°C (68°F) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the horn leads from the horn terminals. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Connect the pocket tester (Ω × 1) to the EAS28190 horn terminals.

  • Page 379: Checking The Fuel Sender

    ELECTRICAL COMPONENTS b. Measure the fuel sender resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Measure the pickup coil resistance. EAS28240 CHECKING THE SPEED SENSOR ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Check: • Speed sensor output voltage EAS28230 Out of specification → Replace. CHECKING THE FUEL SENDER 1. Remove: Output voltage reading cycle •...

  • Page 380: Checking The Radiator Fan Motor

    ELECTRICAL COMPONENTS EAS28250 CHECKING THE RADIATOR FAN MOTOR Pocket tester 1. Check: 90890-03112 • Radiator fan motor Analog pocket tester Faulty/rough movement → Replace. YU-03112-C ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the radiator fan motor coupler from the wire harness. b. Connect the battery (DC 12 V) as shown. •...

  • Page 381: Checking The Fuel Pump

    ELECTRICAL COMPONENTS • Throttle position sensor Pocket tester NOTE: 90890-03112 When installing the throttle position sensor, Analog pocket tester adjust its angle properly. Refer to "ADJUST- YU-03112-C ING THE THROTTLE POSITION SENSOR" on page 7-6. • Tester positive lead → Blue “1”...

  • Page 382: Checking The Air Induction System Solenoid

    ELECTRICAL COMPONENTS EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1. Check: • Intake air pressure sensor output voltage Out of specification → Replace. Intake air pressure sensor out- put voltage 3.75–4.25 V b. Measure the fuel pump resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
  • Page 383 ELECTRICAL COMPONENTS 2. Check: • Intake air temperature sensor resistance Out of specification → Replace. Intake pressure sensor resistance 2.2–2.7 kΩ at 20°C (68°F) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 100) to the intake air temperature sensor terminal as shown.
  • Page 384 ELECTRICAL COMPONENTS 8-83...

  • Page 385: 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 ..................9-2 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 386: Troubleshooting

    TROUBLESHOOTING EAS28450 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) NOTE: • Blown, damaged or incorrect fuse The following guide for troubleshooting does • Improperly installed fuse not cover all the possible causes of trouble. It 3.

  • Page 387: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING • Improper throttle cable free play • Foreign object between transmission gears • Flooded throttle body • Improperly assembled transmission • Faulty air induction system EAS28550 JUMPS OUT OF GEAR Electrical system 1. Battery Shift shaft • Discharged battery •...

  • Page 388: Overcooling

    TROUBLESHOOTING 2. Engine oil • Worn brake disc • Incorrect oil level • Air in hydraulic brake system • Incorrect oil viscosity • Leaking brake fluid • Inferior oil quality • Faulty brake caliper kit • Faulty brake caliper seal Cooling system •...

  • Page 389: Faulty Lighting Or Signaling System

    TROUBLESHOOTING • Faulty rear shock absorber spring • Incorrect connection • Leaking oil or gas • Damaged or faulty wire harness 6. Tire(s) • Improperly grounded circuit • Uneven tire pressures (front and rear) • Faulty battery • Incorrect tire pressure •...

  • Page 390: Wiring Diagram

    EAS28740 57. License plate light Red/Yellow WIRING DIAGRAM 58. Tail/brake light Sb/W Sky blue/White 59. Left handlebar switch FZS6W/FZS6WC White/Black 60. Clutch switch 1. Main switch White/Red 61. Dimmer switch 2. AC magneto White/Yellow 62. Hazard switch 3. Rectifier/regulator Yellow/Black 63.
  • Page 392 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 393 FZS6W/FZS6WC WIRING DIAGRAM Br/W G/W Br/W Y R/B R/L R/W L/R Y B G Y/L R/G P/W B/L G/B L G/W W Ch Dg Lg B/W MAIN HARNESS WIRE SUB LEAD2 MAIN HARNESS WIRE SUB LEAD1 MAIN HARNESS CORD HEAD LIGHT2...
  • Page 394 FZS6W/FZS6WC WIRING DIAGRAM MAIN HARNESS WIRE SUB LEAD2 MAIN HARNESS WIRE SUB LEAD1 MAIN HARNESS CORD HEAD LIGHT2 MAIN HARNESS CORD HEAD LIGHT1 FREE PUSH...

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