EAS00010 YZF-R6R/YZF-R6SR YZF-R6RC/YZF-R6SRC SERVICE MANUAL 2002 by Yamaha Motor Corporation, U.S.A. First edition, December 2002 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A.
EAS00030 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
EAS00008 1 2 GEN INFO SYMBOLS SPEC 3 4 CHK ADJ CHAS 5 6 COOL ENG 7 8 FI ELEC Symbols 10 to 17 indicate the following. 10 9 10 11 12 13 14 15 16 17 TRBL SHTG 11 12 13 14 15 16 17 18 19 20 21 24 The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter.
EAS00012 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 CHK ADJ 3 CHAS 4 ENG 5 COOL 6 FI 7 ELEC 8 TRBL SHTG 9
CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTLINE OF FI SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM . . .
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE PADS . . . . . . . . . . .
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . .
REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . .
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE LIFTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE VALVES . .
OIL PAN AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL DELIVERY PIPE AND OIL PIPE . . . . . . . . . CHECKING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 6 COOLING SYSTEM RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 CHECKING THE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 CHECKING THE BULBS AND BULB SOCKETS . . . . . . . . . . . . . . . . . TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULBS . . . . .
FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46 8-46 8-47 8-48 8-50 SELF-DIAGNOSIS . . .
UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 FAULTY LIGHTING OR SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . HEADLIGHT DOES NOT COME ON . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . TAIL /BRAKE LIGHT DOES NOT COME ON . . . . . . . . . . . . . . . . . . TAIL /BRAKE LIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL DOES NOT COME ON . . .
MOTORCYCLE IDENTIFICATION GEN INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
FEATURES GEN INFO EAS00896 FEATURES OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber.
FEATURES GEN INFO EAS00897 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 284 kPa (2.84 kg/cm2) higher than the intake manifold pressure. Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
FEATURES 1 2 3 4 GEN INFO INSTRUMENT FUNCTION Multi-function display The multi-function display is equipped with the following: S a speedometer (which shows the riding speed) S an odometer (which shows the total distance traveled) S two tripmeters (which show the distance traveled since they were last set to zero) S a fuel reserve tripmeter (which shows the distance traveled since the fuel level warning light came on) S a clock S a self-diagnosis device S a display brightness and engine speed warning lig
FEATURES 1 2 3 4. 5. GEN INFO Display brightness and shift timing indicator light control mode This mode cycles through five control functions, allowing you to make the following settings in the order listed below. 1. Display brightness: This function allows you to adjust the brightness of the multi-function display to suit the outside lighting conditions. 2.
FEATURES GEN INFO To set the shift timing indicator light activation function NOTE: S The indicator light activation function can be set between 10,000 and 16,000 r/min. S From 10,000 r/min to 12,000 r/min, the indicatar light can be set in increments of 500 r/min. S From 12,000 r/min to 16,000 r/min, the indicatar light can be set in increments of 200 r/min. 1. Push the “RESET” button to select the desired engine speed for activating the indicator light. 2.
IMPORTANT INFORMATION GEN INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
IMPORTANT INFORMATION GEN INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease.
CHECKING THE CONNECTIONS GEN INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead S coupler S connector 2. Check: S lead S coupler S connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect several times. 3. Check: S all connections Loose connection ! Connect properly. NOTE: If the pin 1 on the terminal is flattened, bend it up. 4.
GEN INFO SPECIAL TOOLS EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. NOTE: S For U.S.A.
SPECIAL TOOLS Tool No. 90890-01426 YU-38411 Rod puller 90890-01437 YM-01437 Rod puller attachment 90890-01436 Fork seal driver 90890-01367 YM-33963 Fork seal driver attachment 90890-01374 YM-8020-A Vacuum gauge 90890-03094 YU-08030 Compression gauge 90890-03081 YU-33223 Adapter 90890-04136 90890-03112 YU-3112 Oil pressure gauge 90890-03153 YU-03153 Adapter 90890-03139 Tool name/Function Oil filter wrench This tool is needed to loosen or tighten the oil filter cartridge.
SPECIAL TOOLS Tool No. 90890-04044 YM-04044 Tool name/Function Piston ring compressor This tool is used to compress piston rings when installing the cylinder. Carburetor angle driver 90890-03158 Valve spring compressor 90890-04019 YM-04019 Attachment 90890-04108 YM-01253 Middle driven shaft bearing driver 90890-04058 YM-4058 Mechanical seal installer 90890-04078 YM-33221 This tool is used to turn the pilot screw when adjusting the engine idling speed.
SPECIAL TOOLS Tool No. 90890-06756 YB-35956 90890-85505 ACC-1100105-01 Tool name/Function Vacuum/pressure pump gauge set This tool used to measure the vacuum pressure. Yamaha bond No. 1215 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Maximum load (except motorcycle) Standard Limit 5SL3 (USA except for CAL) 5SL4 (CAL) 5SL7 (USA except for CAL) 5SL8 (CAL) SSS 2,025 mm (79.7 in) 690 mm (27.2 in) 1,090 mm (42.9 in) 820 mm (32.3 in) 1,380 mm (54.3 in) 135 mm (5.3 in) 3,400 mm (133.
ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Engine Engine type Displacement Cylinder arrangement Bore stroke Compression ratio Engine idling speed Vacuum pressure at engine idling speed Standard compression pressure (at sea level) Fuel Recommended fuel Fuel tank capacity Total (including reserve) Reserve only Engine oil Lubrication system Recommended oil Standard Liquid-cooled, 4-stroke, DOHC 600 cm3 (36.61 cu.in) Forward-inclined parallel 4-cylinder 65.5 44.5 mm (2.58 1.75 in) 12.
ENGINE SPECIFICATIONS Item SPEC Standard Oil filter Oil filter type Bypass valve opening pressure Oil pump Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Cooling system Radiator capacity Radiator cap opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Max. impeller shaft tilt Limit Formed 80 X 120 kPa (0.8 X 1.2 kg/cm2, 0.8 X 1.2 bar, 11.6 X 17.4 psi) SSS SSS Trochoid 0.03 X 0.
ENGINE SPECIFICATIONS Item SPEC Standard Limit Chain drive (right) 23.008 X 23.029 mm (0.9058 X 0.9067 in) 22.967 X 22.980 mm (0.9042 X 0.9047 in) 0.028 X 0.062 mm (0.0011 X 0.0024 in) SSS SSS SSS 0.08 mm (0.0031 in) Measurement A 33.45 X 33.55 mm (1.317 X 1.321 in) Measurement B 25.12 X 25.22 mm (0.989 X 0.993 in) 33.40 mm (1.315 in) 25.07 mm (0.
ENGINE SPECIFICATIONS Item Standard Timing chain Model/number of links Tensioning system Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions Head Diameter Exhaust Valve guide inside diameter Intake Exhaust Valve-stem-to-valve-guide clearance Intake Limit RH2015 /120 Automatic SSS SSS 0.13 X 0.20 mm (0.0051 X 0.0079 in) 0.23 X 0.30 mm (0.0091 X 0.
ENGINE SPECIFICATIONS Item Valve springs Free length Intake (inner) Intake (outer) Exhaust Installed length (valve closed) Intake (inner) Intake (outer) Exhaust Compressed spring force (installed) Intake (inner) SPEC Standard Limit 35.7 mm (1.41 in) 40.3 mm (1.59 in) 41.7 mm (1.64 in) 33.9 mm (1.33 in) 38.3 mm (1.50 in) 39.6 mm (1.56 in) 30 mm (1.18 in) 32.5 mm (1.28 in) 36.1 mm (1.42 in) SSS SSS SSS 61.5 X 70.7 N (6.27 X 7.21 kg, 13.83 X 15.89 lb) 139.1 X 160.1 N (14.18 X 16.33 kg, 31.27 X 35.
ENGINE SPECIFICATIONS Item Piston Piston-to-cylinder clearance SPEC Standard 0.010 X 0.035 mm (0.0004 X 0.0014 in) Limit Diameter D 65.475 X 65.490 mm (2.5778 X 2.5783 in) 0.055 mm (0.0022 in) SSS Height H Piston pin bore (in the piston) Diameter 4 mm (0.16 in) SSS 16.002 X 16.013 mm (0.6300 X 0.6304 in) 0.5 mm (0.0197 in) Intake side 16.043 mm (0.6316 in) SSS SSS 15.991 X 16.000 mm (0.6296 X 0.6299 in) 0.002 X 0.022 mm (0.0001 X 0.0009 in) 15.971 mm (0.6288 in) 0.072 mm (0.
ENGINE SPECIFICATIONS Item Connecting rods Crankshaft-pin-to-big-end-bearing clearance Bearing color code SPEC Standard Limit 0.028 X 0.052 mm (0.0011 X 0.0020 in) 0.09 mm (0.0035 in) 1 = Blue 2 = Black 3 = Brown 4 = Green SSS Crankshaft Width A Width B Max. runout C 51.85 X 52.55 mm (2.04 X 2.06 in) 268.8 X 270.0 mm (10.58 X 10.63 in) SSS Big end side clearance D Big end radial clearance Small end free play Crankshaft-journal-to-crankshaftjournal-bearing clearance Bearing color code 0.160 X 0.
ENGINE SPECIFICATIONS Item Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratios 1st gear 2nd gear 3rd gear 4nd gear 5th gear 6th gear Max. main axle runout Max. drive axle runout SPEC Standard Limit Constant mesh, 6-speed Spur gear 86/44 (1.955) Chain drive 48/16 (3.000) Left-foot operation SSS SSS SSS SSS SSS SSS 37/13 (2.846) 37/19 (1.947) 28/18 (1.556) 32/24 (1.333) 25/21 (1.190) 26/24 (1.
ENGINE SPECIFICATIONS Item Throttle position sensor Resistance Output voltage (at idle) Throttle bodies Model (manufacturer) quantity Intake vacuum pressure Throttle cable free play lay (at the flange of the throttle grip) ID mark Throttle valve size Standard SPEC Limit 4.85 X 5.15 kΩ at 20_C (68_F) 0.63 X 0.73 V SSS 38EIS (MIKUNI) 4 24 kPa (180 mmHg, 7.0872 inHg) 6 X 8 mm (0 (0.24 24 X 0 0.
CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max.
CHASSIS SPECIFICATIONS Item Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 X 90 kg (0 X 198 lb) 90 X 193 kg (198 X 426 lb) (USA except for CAL) 90 X 192 kg (198 X 423 lb) (CAL) High-speed riding Min. tire tread depth Front brakes Brake type Operation Recommended fluid Brake lever free play Brake discs Diameter thickness Min. thickness Standard SSS SSS SSS 250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi) 290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi) SSS SSS 290 kPa (2.9 kgf/cm2, 2.9 bar, 41.
CHASSIS SPECIFICATIONS Item Front suspension Suspension type Front fork type Front fork travel Spring Free length Spacer length Installed length Spring rate (K1) Spring stroke (K1) Inner tube outer diameter Inner tube bending limit Optional spring available Fork oil Recommended oil Quantity (each front fork leg) Level (from the top of the inner tube, with the inner tube fully compressed, and without the fork spring) Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positi
CHASSIS SPECIFICATIONS Item Steering Steering bearing type Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Standard spring preload gas/air pressure Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum* Standard* Maximum* Compression damping adjusting positions Minimum* Standard* Maximum* *from the fully turn
ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit 12 V SSS DC. CDI 10_ BTDC at 1,300 r/min (USA except for CAL) 5_ BTDC at 1,300 r/min (CAL) 248 X 372 Ω at 20_C (68_F)/Gy-B SSS SSS F8T926 (MITSUBISHI) SSS Ignition coils Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance J0454 (DENSO) 6 mm (0.24 in) 0.17 X 0.23 Ω at 20_C (68_F) 4.8 X 7.
ELECTRICAL SPECIFICATIONS Item SPEC Standard Indicator light (voltage /wattage quantity) Neutral indicator light High beam indicator light Oil level indicator light Turn signal indicator light Fuel level warning light Coolant temparture indicator light Engine trouble warning light Shift timing indicator light Electric starting system System type Starter motor Model (manufacturer) Power output Brushes Overall length LED LED LED LED LED LED LED LED 1 1 1 2 1 1 1 1 Limit SSS SSS SSS SSS SSS SSS SSS SSS
ELECTRICAL SPECIFICATIONS Item SPEC Standard Limit Fuses (amperage quantity) Main fuse Fuel injection system fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan motor fuse Backup fuse (odometer and clock) Reserve fuse 40 A 1 15 A 1 20 A 1 15 A 1 15 A 1 15 A 1 10 A 1 40 A, 20 A, 15 A, 10 A Fuel level sender Model (manufacture) Sender unit resistance-full 5PW (DENSO) 750 X 1,100 Ω SSS SSS Starting circuit at-off relay Model (manufacture) Coil resistance G8R-30Y-R (OMRON) 162 X 198 Ω
CONVERSION TABLE/ GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MULTIPLIER ** mm 0.03937 = ** in 2 mm 0.03937 = 0.08 in This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.
TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Item Spark plugs Cylinder head Camshaft caps Cylinder head cover Camshaft cap oil check bolt Reed valve cover Air-cut valve stay Camshaft sprockets Connecting rod caps Generator rotor Timing chain tensioner Timing chain tensioner cap bolt Thermostat cover Coolant hose joint Water pump cover Water pump Radiator and frame Radiator stay and crankcase Oil pump cover Oil pump Oil pan Oil pan (center) Oil cooler Engine oil drain bolt Oil filt
TIGHTENING TORQUES Item Generator rotor cover Clutch cover Clutch cover Pickup coil rotor cover Clutch cable holder Pickup coil rotor cover Shift shaft cover Breather plate Stator coil Pickup rotor cover and clamp Drive sprocket cover Oil gallery bolt Generator rotor cover and stator coil lead clamp Breather hose cover Oil pipe Crankshaft position sensor Starter clutch Clutch pressure plate Clutch boss Drive sprocket Transmission bearing housing Shift drum retainer Shift shaft spring stopper Shift rod Shift
TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence.
SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Item Thread size Nm mSkg ftSlb Upper bracket and front fork Steering stem nut Handlebar and front fork Handlebar and upper bracket Lower ring nut Under bracket pinch bolt Main switch and upper bracket Front brake master cylinder cap stopper Front brake hose union bolts Front brake master cylinder and bracket Windshield and front cowling Front cowling and headlight assembly Headlight and front cowling stay Meter assembly and front cowling s
TIGHTENING TORQUES Item Rear brake hose union bolt Sidestand bracket and frame Front wheel axle shaft and bolt Rear wheel axle nut Front brake caliper and front fork Front brake disc and front wheel Rear brake disc and rear wheel Rear wheel sprocket and rear wheel drive hub Brake caliper bleed screw Pinch bolt (front wheel axle) SPEC Tightening Thread size Nm mSkg ftSlb M10 M10 M14 M24 M10 M6 M8 M10 M8 M8 30 61 91 110 40 18 30 100 6 18 3.0 6.1 9.1 11.0 4.0 1.8 3.0 10.0 0.6 1.
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Connecting rod bolts and nuts Crankshaft journals Camshaft lobes Camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Valve lifter surface Piston cooler (O-ring) Oil pump rotors (inner and outer) Oil pump housing Oil strainer Clutch (pull rod) Starter clutch idle gear i
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Front axle shaft Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear axle shaft Rear brake pedal shaft Sidestand pivoting point and metal-to-metal moving parts Link and sidestand switch contact point Sidestand hook and spring Throttle grip inner surface Brake lever pivoting point and me
COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 1 Radiator 2 Oil cooler 2-26 SPEC
COOLING SYSTEM DIAGRAMS 1 Water pump 2 Oil cooler 3 Radiator 2-27 SPEC
COOLING SYSTEM DIAGRAMS 1 Oil cooler 2 Water pump 2-28 SPEC
COOLING SYSTEM DIAGRAMS 1 Radiator 2 Thermostat 2-29 SPEC
ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART 2-30 SPEC
LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil level switch 2 Oil cooler 3 Relief valve 2-31 SPEC
LUBRICATION DIAGRAMS 1 2 3 4 Oil pump Exhaust camshaft Intake camshaft Oil strainer 2-32 SPEC
LUBRICATION DIAGRAMS 1 Oil cooler 2 Oil strainer 3 Oil level switch 4 Oil pump 2-33 SPEC
LUBRICATION DIAGRAMS 1 Main axle 2 Oil pump 3 Relief valve 2-34 SPEC
LUBRICATION DIAGRAMS 1 2 3 4 Cylinder head Intake camshaft Exhaust camshaft Crankshaft 2-35 SPEC
LUBRICATION DIAGRAMS 1 Main axle 2 Drive axle 2-36 SPEC
CABLE ROUTING SPEC CABLE ROUTING 1 2 3 4 5 6 7 8 9 Right handlebar switch lead Clutch cable Main switch lead and left handlebar switch lead Throttle cable (return side) Throttle cable (pull side) Front brake hoses Throttle cables Joint Under bracket A Pass the right handlebar switch lead inside the front brake hoses and over the throttle cables. B Install the throttle cables to the hook so that the pulling side of the throttle cables is routed downward. C Pass the clutch cable through the guide.
CABLE ROUTING F Pass the horn lead by the outside of the throttle cables and clamp it to the forefront of upper face of the under bracket. And then route it under the front brake hose and clamp it to the pawl of the under cover. G Clamp it at the position of 40 X 60 mm (1.57 X 2.36 in) from the upper face of the under bracket with the plastic locking tie. Cut the surplus part of the clamp tip leaving 2 X 4 mm (0.08 X 0.16 in). Point the tip of the clamp to the outside of vehicle.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 Throttle stop screw Coolant reservoir tank hose Crankshaft position sensor lead Rear brake light switch lead Water pump inlet hose Clutch cable Coolant hose protector Hose clamp assembly Hose clamp A Pass the rear brake light switch lead outside of rear engine mount bolt. B Pass the ignition coil lead outside of the radiator hose. C Pass the coolant reservoir tank hose under the frame and right side of the throttle body.
CABLE ROUTING K Put and apply the hose clamp to it. L Pass the crankshaft position sensor lead over the throttle stop screw.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Throttle cable (return side) Throttle cable (pull side) Starter motor lead Canister hose (for CAL) Balance hose (for CAL) Canister (for CAL) Coolant reservoir tank breather hose Oil level switch lead Sidestand switch lead A.C.
CABLE ROUTING F Pass the fuel tank drain hose and fuel tank breather hose through the clamp of the coolant reservoir tank. G Projection allowance from the coolant reservoir tank cover shall be 30 X 50 mm (1.18 X 1.97 in). H 10 X 50 mm (0.39 X 1.97 in). I Fasten the sidestand switch lead and oil level switch lead with a clamp. J Pass the coolant reservoir tank breather hose, oil level switch lead and sidestand switch lead through the clamp. K Pass the sidestand switch lead, oil level switch lead and A.C.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Right handlebar switch lead Sub wire harness Cover 8 Ignition coil lead Throttle position sensor coupler Coolant reservoir tank hose Throttle stop cable Speed sensor lead coupler Crankshaft position sensor lead coupler Fuel tank breather hose (except for CAL) Fuel tank drain hose Fuel hose (return side) Fuel pump 2 coupler Fuel pump 1 coupler 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Starter motor lead Fuel hose (feed side) Canister hose (for CAL) Crankcase
CABLE ROUTING A To the headlight B Make sure not to drop the headlight sub wire harness beneath the projection of the duct. Check it when installing the side cowling. C Clamp the plastic locking tie to the cover 8. Place the coupler at the rear side of the vehicle against the plastic locking tie. Point the tip of the plastic locking tie to the downward in the inner side of the vehicle. D Route the head light and meter leads under the frame’s lower part from the hollow section of the cover 2.
CABLE ROUTING P To the coolant reservoir tank Q To the intake air temperature sensor (air filter case) R To the oil level switch, sidestand switch and A.C. magneto S Install the wire harness wrapping clamp to the stay of the throttle body. T Pass the wire harness over the throttle air vent hose. U Pass the wire harness between frame and coolant hose. V Pass it through the frame hole. W Do not catch the coupler when the air filter case is assembled.
CABLE ROUTING AB To the fuse box and fan motor relay AC Pass the throttle cables over the cover 2. AD Point the tip of the plastic locking tie to the rear side of the vehicle. AE To the main switch lead coupler AF Tip of the plastic locking tie should point to the downward outside of the vehicle. AG Use the plastic locking tie to clamp the starter motor lead at the protector section. AH Branching harness from the wire harness.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 Battery Battery positive lead Starter relay Turn signal relay Pressure sensor Tail/ brake light Tool kit Starting circuit cut-off relay Battery box ECU Wire harness Battery negative lead Battery band SPEC A Push the starter motor lead in the clamping sections (two points) or the battery box assembly and secure it. B Fit the plastic cover in the starter relay after the flange bolts are installed. C Make sure to clamp the wire harness.
CABLE ROUTING H The knob section should be positioned in this area. I Pass the turn signal lead by the outside of the right side attaching boss of the tail / brake light. J Pass the turn signal light and license light leads between the rear side ribs of the battery box assembly and to the rear part of the vehicle. K Connect the turn signal lead couplers. L Connect the license light leads. M Route the branching lead to the license light behind the tail / brake light left side attaching boss.
CABLE ROUTING SPEC For California 1 2 3 4 5 6 Fuel pump assembly Canister hose Canister Breather hose Blance hose Fuel tank drain hose A Install the roll over valve until it contacts with the fuel tank’s nipple. B Install the O-ring with its lip pointed upward. C Install the clip with its tab pointed in the upward direction. D Install the breather hose without projecting canister nipple out of the breather hose. E Install the clip with its tab pointed in the downward direction.
INTRODUCTION/PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM / GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work.
CHK ADJ GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL NO. ITEM REMARKS ODOMETER READINGS 600 mi (1,000 km) or 1 month 4,000mi (7,000 km) or 6 months 8,000 mi (13,000 km) or 12 months 12,000 mi (19,000 km) or 18 months 16,000 mi (25,000 km) or 24 months 20,000 mi (31,000 km) or 30 months Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 7 * Control cables (See page 3-58) S Apply Yamaha chain and cable lube or engine oil 10W-30 thoroughly.
SEATS CHK ADJ EAS00039 SEATS 7 Nm (0.7 mSkg, 5.1 ftSlb) Order 1 2 Job/Part Q’ty Removing the seats Passenger seat Rider seat Remarks Remove the parts in the order listed. 1 1 For installation, reverse the removal procedure.
FUEL TANK CHK ADJ EAS00040 FUEL TANK 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order 1 2 3 4 5 6 7 8 9 Job/Part Q’ty Remarks Remove the parts in the order listed. Refer to “SEATS”. Removing the fuel tank Rider seat Fuel hose connector cover Fuel hose Fuel return hose Fuel sender coupler Fuel pump coupler Fuel tank overflow hose Fuel tank breather hose Fuel tank Fuel pump 1 1 1 1 1 1 1 1 1 Disconnect. Disconnect. For installation, reverse the removal procedure.
FUEL TANK CHK ADJ REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: S fuel return hose S fuel hose CAUTION: Although the fuel has been removed from the fuel tank, be careful when removing the fuel hoses, since there may be fuel remaining in it. NOTE: Before removing the hoses, place a few rags in the area under where it will be removed. 3.
FUEL TANK CHK ADJ INSTALLING THE FUEL PUMP 1. Install: S fuel pump 4 Nm (0.4 mSkg, 2.9 ftSlb) NOTE: S Do not damage the installation surfaces of the fuel tank when installing the fuel pump. S Always use a new fuel pump gasket. S Install the fuel pump as shown in the illustration. S Tighten the fuel pump bolts in stages in a crisscross pattern and to the specified torque. INSTALLING THE FUEL TANK 1.
COWLINGS CHK ADJ COWLINGS Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Q’ty Removing the cowlings Rider and passenger seats Front cowling inner panel (left and right) Front turn signal light lead couplers Side cowlings (left and right) Side cowlings inner panels (left and right) Bottom cowlings (left and right) Bottom cowling front cover Front cowling Rear view mirrors (left and right) Windshield Rear cowling Frame side cover Remarks Remove the parts in the order listed. Refer to “SEATS”.
COWLINGS CHK ADJ REMOVAL 1. Remove: S rear cowling S side cowlings NOTE: To remove the quick fastener, push its center with a screwdriver, then pull the fastener out. INSTALLATION 1. Install: S side cowlings S rear cowling NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cowling and push the pin a in with a screwdriver. Make sure that the pin is flush with the fastener’s head.
AIR FILTER CASE CHK ADJ AIR FILTER CASE 10 Nm (1.0 mSkg, 7.2 ftSlb) Order 1 2 3 4 5 6 7 Job/Part Q’ty Remarks Remove the parts in the order listed. Refer to “SEATS”. Refer to “FUEL TANK”. Removing the air filter case Rider seat Fuel tank Air intake duct Intake temperature sensor coupler Throttle body hose Air induction system hose Clamp Air filter case Crankcase breather hose 2 1 2 1 4 1 1 3-9 Disconnect. Disconnect. Disconnect. Loosen. Disconnect.
ADJUSTING THE VALVE CLEARANCE CHK ADJ EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove S rider seat Refer to “SEATS”. S fuel tank Refer to “FUEL TANK”. S air filter case Refer to “AIR FILTER CASE”.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 4. Measure: S valve clearance Out of specification ! Adjust. Valve clearance (cold) Intake valve 0.13 X 0.20 mm (0.0051 X 0.0079 in) Exhaust valve 0.23 X 0.30 mm (0.0091 X 0.0118 in) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the pickup rotor with the crankcase mating surface b . NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. c.
CHK ADJ ADJUSTING THE VALVE CLEARANCE 5. Remove: S camshafts NOTE: S Refer to “DISASSEMBLING THE ENGINE – CAMSHAFT AND CYLINDER HEAD” in chapter 5. S When removing the timing chain and camshafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase. 6. Adjust: S valve clearance a. Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 .
ADJUSTING THE VALVE CLEARANCE CHK ADJ c. Round off the original valve pad number according to the following table. Last digit Rounded value 0 or 2 0 5 5 8 10 EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm (0.058 in)) Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number.
ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: S Refer to “ASSEMBLING AND ADJUSTING THE ENGINE – CYLINDER HEAD AND CAMSHAFT” in chapter 5. S Lubricate the camshaft bearings, camshaft lobes and camshaft journals. S First, install the exhaust camshaft. S Align the camshaft marks with the camshaft cap marks. S Turn the crankshaft counterclockwise several full turns to seat the parts. g. Measure the valve clearance again. h.
ADJUSTING THE VALVE CLEARANCE CHK ADJ INTAKE INSTALLED PAD NUMBER MEASURED CLEARANCE 0.00 X 0.02 0.03 X 0.07 0.08 X 0.12 0.13 X 0.20 0.21 X 0.25 0.26 X 0.30 0.31 X 0.35 0.36 X 0.40 0.41 X 0.45 0.46 X 0.50 0.51 X 0.55 0.56 X 0.60 0.61 X 0.65 0.66 X 0.70 0.71 X 0.75 0.76 X 0.80 0.81 X 0.85 0.86 X 0.90 0.91 X 0.95 0.96 X 1.00 1.01 X 1.05 1.06 X 1.10 1.11 X 1.15 1.16 X 1.20 1.21 X 1.25 1.26 X 1.30 1.31 X 1.35 1.36 X 1.
ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE THROTTLE BODIES CHK ADJ 7. Install: S all removed parts NOTE: For installation, reverse the removal procedure. SYNCHRONIZING THE THROTTLE BODIES NOTE: Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. 2. Remove: S rider seat Refer to “SEATS”.
SYNCHRONIZING THE THROTTLE BODIES CHK ADJ 5. Install: S air filter case Refer to “AIR FILTER CASE”. S fuel tank Refer to “FUEL TANK”. 6. Start the engine and let it warm up for several minutes. 7. Measure: S engine idling speed Out of specification ! Adjust. Refer to “ADJUSTING THE ENGINE IDLING SPEED”. Engine idling speed 1,250 X 1,350 r/min 8. Adjust: S throttle body synchronization a. With throttle body #3 as standard, adjust throttle bodies #1, #2, and #4 using the air screws 1 .
SYNCHRONIZING THE THROTTLE BODIES/ ADJUSTING THE ENGINE IDLING SPEED CHK ADJ 9. Measure: S engine idling speed Out of specification ! Adjust. Make sure that the vacuum pressure is within specification. 10. Stop the engine and remove the measuring equipment. 11. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 6 X 8 mm (0.24 X 0.31 in) 12. Remove: S digital tachometer S vacuum gauge 13.
ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ 4. Adjust: S engine idling speed a. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained. Direction a Engine idling speed is increased. Direction b Engine idling speed is decreased. 5. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 6 X 8 mm (0.24 X 0.
ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ 3. Adjust: S throttle cable free play NOTE: When the throttle is opened, the accelerator cable 1 is pulled. Throttle body side a. Loosen the locknut 2 on the decelerator cable. b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable. Direction a Throttle cable free play is increased. Direction b Throttle cable free play is decreased. c. Tighten the locknuts.
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS CHK ADJ 4. Install: S left frame side cover Refer to “COWLINGS”. S air filter case Refer to “AIR FILTER CASE”. S fuel tank Refer to “FUEL TANK”. S rider seat Refer to “SEATS”. EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: S rider seat Refer to “SEATS”. S fuel tank Refer to “FUEL TANK”. S air filter case Refer to “AIR FILTER CASE”. 2.
CHECKING THE SPARK PLUGS/ MEASURING THE COMPRESSION PRESSURE CHK ADJ 6. Measure: S spark plug gap a (with a wire Thickness gauge) Out of specification ! Regap. Spark plug gap 0.6 X 0.7 mm (0.0236 X 0.0276 in) 7. Install: S spark plug 13 Nm (1.3 mSkg, 9.4 ftSlb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Install: S air filter case Refer to “AIR FILTER CASE”. S fuel tank Refer to “FUEL TANK”. S rider seat Refer to “SEATS”.
MEASURING THE COMPRESSION PRESSURE CHK ADJ CAUTION: Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinders. 5. Install: S compression gauge 1 S adapter Compression gauge 90890-03081, YU-33223 Adapter 90890-04136 6. Measure: S compression pressure Out of specification ! Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 1,350 kPa (13.50 kg/cm2, 13.50 bar, 191.
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL CHK ADJ d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure again. Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without oil Piston ring(s) wear or damage ! Repair. Same as without oil Piston, valves, cylinder head gasket or piston possibly defective ! Repair. 7.
CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CHK ADJ Recommended oil At 5_C (40_F) or higher A Yamalube 4 (20W40) or SAE 20W40 type SE motor oil At 15_C (60_F) or lower B Yamalube 4 (10W30) or SAE 10W30 type SE motor oil NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again.
CHANGING THE ENGINE OIL CHK ADJ 6. If the oil filter cartridge is also to be replaced, perform the following procedure. a. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench 90890-01426, YU-38411 b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil. CAUTION: Make sure the O-ring 3 is positioned correctly in the groove of the oil filter cartridge. c. Tighten the new oil filter cartridge to specification with an oil filter wrench.
CHANGING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE CHK ADJ 10. Install: S engine oil filler cap S coolant reservoir tank Refer to “CHANGING THE COOLANT”. S bottom cowling Refer to “COWLINGS”. 11. Start the engine, warm it up for several minutes, and then turn it off. EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: S engine oil level Below the minimum level mark ! Add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several minutes, and then turn it off.
CHK ADJ MEASURING THE ENGINE OIL PRESSURE 6. Measure: S engine oil pressure (at the following conditions) Engine oil pressure 240 kPa (2.4 kg/cm2, 2.4 bar, 34.1 psi) Engine speed Approx. 6,600 r/min Engine oil temperature 96_C (205_F) NOTE: Regarding the oil pressure as its own data may fluctuate depending on the oil temperature and viscosity, the oil pressure may fluctuate when measuring. The following data should be used only as a reference when measuring the engine oil pressure.
ADJUSTING THE CLUTCH CABLE FREE PLAY CHK ADJ EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm (0.39 X 0.59 in) 2. Adjust: S clutch cable free play Handlebar side a. Turn the adjusting dial 1 in direction b or c until the specified clutch cable free play is obtained. Direction b Clutch cable free play is increased. Direction c Clutch cable free play is decreased.
CLEANING THE AIR FILTER ELEMENT CHK ADJ EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: S rider seat Refer to “SEATS”. S fuel tank Refer to “FUEL TANK”. 2. Remove: S air filter case cover 1 S air filter element 3. Clean: S air filter element 1 Use solvent to clean the air filter element. After cleaning the air filter element, remove the solvent from the air filter element. 4. Apply the engine oil to the entire surface of the filter and remove the excess oil.
CLEANING THE AIR INTAKE SYSTEM SURGE TANKS/ CHECKING THE THROTTLE BODY JOINTS CHK ADJ EAS00092 CLEANING THE AIR INTAKE SYSTEM SURGE TANKS The following procedure applies to both air intake system surge tanks. 1. Remove: S front cowling Refer to “COWLINGS”. 2. Remove: S air intake system surge tank 1 3. Clean: S air intake system surge tank a. Thoroughly flush out the air intake system surge tank with clean water. b. Hold the air intake system surge tank upside down to allow the water to drain out. c.
CHECKING THE FUEL AND BREATHER HOSES/ CHECKING THE CRANKCASE BREATHER HOSE CHK ADJ EAS00096 CHECKING THE FUEL AND BREATHER HOSES The following procedure applies to all of the fuel and breather hoses. 1. Remove: S rider seat Refer to “SEATS”. S fuel tank Refer to “FUEL TANK”. 2. Check: S breather hoses 1 S fuel hoses 2 Cracks/damage ! Replace. Loose connection ! Connect properly. NOTE: Before removing the fuel hoses, place a few rags in the area under where it will be removed. 3.
CHECKING THE EXHAUST SYSTEM/ CHECKING THE COOLANT LEVEL CHK ADJ EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Remove: S bottom cowling Refer to “COWLINGS”. S radiator Refer to “RADIATOR” in chapter 6. 2. Check: S exhaust pipe 1 S muffler 2 Cracks/damage ! Replace. S gasket 3 Exhaust gas leaks ! Replace. 3. Check: S tightening torque Exhaust pipe nut 4 20 Nm (2.0 mSkg, 15 ftSlb) Exhaust pipe and muffler bolt 5 20 Nm (2.
CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM CHK ADJ 2. Check: S coolant level The coolant level should be between the maximum level mark a and minimum level mark b . Below the minimum level mark ! Add the recommended coolant to the proper level. CAUTION: S 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. S Use only distilled water.
CHECKING THE COOLING SYSTEM/ CHANGING THE COOLANT CHK ADJ 2. Check: S radiator 1 S radiator inlet hose 2 S radiator outlet hose 3 S oil cooler 4 S oil cooler inlet hose 5 S oil cooler outlet hose 6 S water jacket outlet joint 7 S water jacket hose 8 S water pump outlet pipe 9 S water pump outlet hose 10 Cracks/damage ! Replace. Refer to “COOLING SYSTEM” in chapter 6. 3. Install: S side cowlings S bottom cowling Refer to “COWLINGS”. EAS00105 CHANGING THE COOLANT 1.
CHANGING THE COOLANT CHK ADJ 3. Disconnect: S coolant reservoir cap 1 4. Drain: S coolant (from the coolant reservoir tank) 5. Remove: S radiator cap 1 CAUTION: A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury.
CHANGING THE COOLANT CHK ADJ 10. Install: S coolant reservoir tank 11. Connect: S coolant reservoir hose 12. Fill: S cooling system (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 2.15 L (1.89 Imp qt, 2.27 US qt) Coolant reservoir capacity 0.44 L (0.39 Imp qt, 0.
CHANGING THE COOLANT CHK ADJ S Use only distilled water. However, if distilled water is not available, soft water may be used. S If coolant comes into contact with painted surfaces, immediately wash them with water. S Do not mix different types of antifreeze. 13. Install: S radiator cap 14. Fill: S coolant reservoir tank (with the recommended coolant to the maximum level mark a ) 15. Install: S coolant reservoir cap 16. Start the engine, warm it up for several minutes, and then stop it. 17.
ADJUSTING THE FRONT BRAKE CHK ADJ EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) NOTE: S While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position. S Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever holder. Position #1 Position #5 Distance a is the largest. Distance a is the smallest.
ADJUSTING THE REAR BRAKE CHK ADJ EAS00110 ADJUSTING THE REAR BRAKE 1. Check: S brake pedal position (distance a bottom of the footrest bracket) Out of specification ! Adjust. Brake pedal position (below the bottom of the footrest bracket) 7 X 11 mm (0.28 X 0.43 in) 2. Adjust: S brake pedal position a. Loosen the locknut 1 . b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. Direction a Brake pedal is raised. Direction b Brake pedal is lowered.
ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL CHK ADJ 3. Adjust: S rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure the motorcycle is upright. 2. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.
CHECKING THE BRAKE FLUID LEVEL/ ADJUSTING THE REAR BRAKE LIGHT SWITCH CHK ADJ CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal. EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by movement of the brake pedal.
CHECKING THE FRONT AND REAR BRAKE PADSā/ CHECKING THE FRONT AND REAR BRAKE HOSES CHK ADJ EAS00122 CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: S front brake pad S rear brake pad Brake pad wear limit a , b Wear limit reached ! Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” in chapter 7. A Brake pad wear limit a 0.5 mm (0.02 in.) b 1.0 mm (0.04 in.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EAS00135 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system whenever: S the system is disassembled. S a brake hose is loosened, disconnected or replaced. S the brake fluid level is very low. S brake operation is faulty. NOTE: S Be careful not to spill any brake fluid or allow the brake fluid reservoir to overflow. S When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake.
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL CHK ADJ h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 mSkg, 4.3 ftSlb) k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL”.
ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ EAS00140 ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits. 1. Stand the motorcycle on a level surface.
ADJUSTING THE DRIVE CHAIN SLACK/ LUBRICATING THE DRIVE CHAIN CHK ADJ Direction a Drive chain is tightened. Direction b Drive chain is loosened. NOTE: To maintain the proper wheel alignment, adjust both sides evenly. d. Tighten both locknuts to specification. Locknut 16 Nm (1.6 mSkg, 12 ftSlb) e. Tighten the wheel axle nut to specification. Wheel axle nut 110 Nm (11 mSkg, 80 ftSlb) EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts.
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Check: S steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness ! Adjust the steering head. 3.
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ c. Loosen the lower ring nut 4 completely, then tighten it to specification. WARNING Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 14 Nm (1.4 mSkg, 10 ftSlb) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the under bracket and check the upper and lower bearings. Refer to “STEERING HEAD” in chapter 4. e.
CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK CHK ADJ Steering head tension 200 X 500 g e. Repeat the above procedure on the opposite handlebar. f. If the steering head tension is out of specification (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut. g. Reinstall the upper bracket and measure the steering head tension again as described above. h.
ADJUSTING THE FRONT FORK LEGS CHK ADJ EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING S Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. S Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: S Grooves are provided to indicate the adjustment position. S Never go beyond the maximum or minimum adjustment positions. 1.
ADJUSTING THE FRONT FORK LEGS CHK ADJ 1. Adjust: S rebound damping a. Turn the adjusting screw 1 in direction a or b. Direction a Rebound damping is increased (suspension is harder). Direction b Rebound damping is decreased (suspension is softer).
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK ADJ EAS00158 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S spring preload a. Adjust the spring preload with the special wrench and extension bar included in the owner’s tool kit. b. Turn the adjusting ring 1 in direction a or b. c.
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK ADJ 1. Adjust: S rebound damping a. Turn the adjusting screw 1 in direction a or b. Direction a Rebound damping is increased (suspension is harder). Direction b Rebound damping is decreased (suspension is softer).
CHECKING THE TIRES CHK ADJ EAS00162 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: S tire pressure Out of specification ! Regulate. WARNING S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. S The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.
CHECKING THE TIRES CHK ADJ 2. Check: S tire surfaces Damage/wear ! Replace the tire. Minimum tire tread depth 1.6 mm (0.06 in) WARNING S Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. S When using a tube tire, be sure to install the correct tube. S Always replace a new tube tire and a new tube as a set. S To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove.
CHECKING THE TIRES/CHECKING THE WHEELS CHK ADJ Front tire Manufacturer Size Model DUNLOP 120/60ZR 17 M/C (55W) D208FL MICHELIN 120/60ZR 17 M/C (55W) Pilot SPORTS N Manufacturer Size Model DUNLOP 180/55ZR 17 M/C (73W) D208L MICHELIN 180/55ZR 17 M/C (73W) Pilot SPORTS B Rear tire WARNING New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done.
CHECKING AND LUBRICATING THE CABLES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION CHK ADJ EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible. 1. Check: S outer cable Damage ! Replace. 2.
CHECKING AND CHARGING THE BATTERY CHK ADJ EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries. S Charge batteries in a well-ventilated area. S Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: S rider seat Refer to “SEATS”. 2. Disconnect: S battery leads (from the battery terminals) CAUTION: First, disconnect the negative battery lead 1 , and then the positive battery lead 2 . 3.
CHECKING AND CHARGING THE BATTERY CHK ADJ 5. Charge: S battery (refer to the appropriate charging method illustration) Charging Open-circuit voltage (V) Ambient temperature 20_C WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit voltage. CAUTION: S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.
CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Measure the open-circuit voltage prior to charging. Connect a charged and AMP meter to the battery and start charging. YES Make sure that the current is higher than the standard charging current written on the battery. NOTE: Voltage should be measured 30 minutes after the machine is stopped. NOTE: Set the charging voltage at 16 X 17 V. (If the setting is lower, charging will be insufficient.
CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. NOTE: Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging. YES Make sure that the current is higher than the standard charging current written on the battery. Charge the battery until the battery’s charging voltage is 15 V.
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES CHK ADJ 6. Install: S battery 7. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1 , and then the negative battery lead 2 . 8. Check: S battery terminals Dirt ! Clean with a wire brush. Loose connection ! Connect properly. 9. Lubricate: S battery terminals Recommended lubricant Dielectric grease 10. Install: S rider seat Refer to “SEATS”.
CHECKING THE FUSES CHK ADJ Pocket tester 90890-03112, YU-3112 b. If the pocket tester indicates “∞”, replace the fuse. 3. Replace: S blown fuse a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage rating. c. Set on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit.
REPLACING THE HEADLIGHT BULBS CHK ADJ EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Remove: S front cowling inner panels Refer to “COWLINGS”. 2. Disconnect: S headlight bulb cover S headlight coupler 1 3. Remove: S headlight bulb holder 1 4. Remove: S headlight bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 5.
ADJUSTING THE HEADLIGHT BEAMS CHK ADJ EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Remove: S front cowling inner panels Refer to “COWLINGS”. 2. Adjust: S headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b. Direction a Headlight beam is raised. Direction b Headlight beam is lowered. 3. Adjust: S headlight beam (horizontally) a. Turn the adjusting screw 2 in direction a or b.
FRONT WHEEL AND BRAKE DISCS CHAS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 91 Nm (9.1 mSkg, 66 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
FRONT WHEEL AND BRAKE DISCS CHAS EAS00518 4 Order 1 2 3 Job/Part Q’ty Disassembling the front wheel Oil seal (left and right) Wheel bearing (left and right) Spacer Remarks Remove the parts in the order listed. 2 2 1 For assembly, reverse the disassembly procedure.
FRONT WHEEL AND BRAKE DISCS CHAS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remove: S left brake caliper S right brake caliper Refer to “FRONT BRAKE CALIPERS”. NOTE: Do not apply the brake lever when removing the brake calipers. 3.
FRONT WHEEL AND BRAKE DISCS CHAS 3. Measure: S radial wheel runout 1 S lateral wheel runout 2 Over the specified limits ! Replace. Radial wheel runout limit 1 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) 4. Check: S wheel bearings Front wheel turns roughly or is loose ! Replace the wheel bearings. S oil seals Damage/wear ! Replace. 5. Replace: S wheel bearings New S oil seals New a. Clean the outside of the front wheel hub. b. Remove the oil seals 1 with a flat-head screwdriver.
FRONT WHEEL AND BRAKE DISCS CHAS EAS00533 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: S brake discs Damage/galling ! Replace. 2. Measure: S brake disc deflection Out of specification ! Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) Front: 0.1 mm (0.004 in) Rear: 0.15 mm (0.006 in) a. Place the motorcycle on a suitable stand so that the wheel is elevated. b.
FRONT WHEEL AND BRAKE DISCS CHAS Brake disc bolt Front: 18 Nm (1.8 mSkg, 13 ftSlb) Rear: 30 Nm (3.0 mSg, 22 ftSlb) LOCTITE d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc. EAS00545 INSTALLING THE FRONT WHEEL The following procedure applies to both brake discs. 1.
FRONT WHEEL AND BRAKE DISCS CHAS 8. Tighten wheel axle pinch bolt 2 , and then pinch bolt 1 to specified torque. 9. Retighten pinch bolt 2 to the specified torque. Wheel axle pinch bolt: 18 Nm (1.8 mSkg, 13 ftSlb) 10. Tap the outer side of the left fork leg with a rubber mallet to align it with the end of the wheel axle. 11. Tighten wheel axle pinch bolt 4 , and then pinch bolt 3 to specified torque. 12. Retighten pinch bolt 4 to the specified torque. Wheel axle pinch bolt: 18 Nm (1.8 mSkg, 13 ftSlb) 13.
FRONT WHEEL AND BRAKE DISCS CHAS a. Spin the front wheel. b. When the front wheel stops, put an “X1” mark at the bottom of the wheel. c. Turn the front wheel 90_ so that the “X1” mark is positioned as shown. d. Release the front wheel. e. When the wheel stops, put an “X2” mark at the bottom of the wheel. f. Repeat steps (d) through (f) several times until all the marks come to rest at the same spot. g. The spot where all the marks come to rest is the front wheel’s heavy spot “X”. 3.
REAR WHEEL AND BRAKE DISC CHAS EAS00551 REAR WHEEL AND BRAKE DISC REAR WHEEL 23 Nm (2.3 mSkg, 17 ftSlb) 28 Nm (2.8 mSkg, 20 ftSlb) 110 Nm (11 mSkg, 80 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
REAR WHEEL AND BRAKE DISC CHAS EAS00556 REAR BRAKE DISC AND REAR WHEEL SPROCKET 30 Nm (3.0 mSkg, 22 ftSlb) 100 Nm (10 mSkg, 72 ftSlb) Order Job/Part Q’ty 1 2 3 4 5 6 7 8 9 Removing the rear brake disc and rear wheel sprocket Rear brake disc Rear wheel sprocket Collar Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Collar Rear wheel Remarks Remove the parts in the order listed. 1 1 1 1 2 1 6 1 1 For installation, reverse the removal procedure.
REAR WHEEL AND BRAKE DISC CHAS EAS00560 Order 1 2 3 4 5 6 Job/Part Disassembling the rear wheel Collar Bearing Spacer Oil seal Circlip Bearing Q’ty Remarks Disassemble the parts in the order listed. 1 1 1 1 1 1 For installation, reverse the disassembly procedure.
REAR WHEEL AND BRAKE DISC CHAS EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: S brake caliper 1 NOTE: Do not depress the brake pedal when removing the brake caliper. 3. Loosen: S locknuts 1 (left and right) S adjusting bolts 2 (left and right) 4.
REAR WHEEL AND BRAKE DISC CHAS EAS00565 CHECKING THE REAR WHEEL 1. Check: S wheel axle S rear wheel S wheel bearings S oil seals Refer to “CHECKING THE FRONT WHEEL”. 2. Check: S tire S rear wheel Damage/wear ! Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Measure: S radial wheel runout S lateral wheel runout Refer to “CHECKING THE FRONT WHEEL”. EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: S rear wheel drive hub 1 Cracks/damage ! Replace.
CHAS REAR WHEEL AND BRAKE DISC 2. Replace: S rear wheel sprocket a. Remove the self-locking nuts and the rear wheel sprocket. b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. c. Install the new rear wheel sprocket. Rear wheel sprocket self-locking nut 100 Nm (10 mSkg, 72 ftSlb) NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. EAS00572 INSTALLING THE REAR WHEEL 1.
REAR WHEEL AND BRAKE DISC CHAS EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. S Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust: S rear wheel static balance Refer to “ADJUSTING THE FRONT WHEEL STATIC BALANCE”.
FRONT AND REAR BRAKES CHAS EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 6 Nm (0.6 mSkg, 4.3 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. NOTE: The following procedure applies to both of the front brake calipers. Removing the front brake pads 1 2 3 4 5 6 Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw Remarks 1 2 1 1 2 1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS REAR BRAKE PADS 6 Nm (0.6 mSkg, 4.3 ftSlb) 28 Nm (2.8 mSkg, 20 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) 2.5 Nm (0.25 mSkg, 1.8 ftSlb) Order 1 2 3 4 5 6 Job/Part Removing the rear brake pads Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad Bleed screw Q’ty Remarks Remove the parts in the order listed. 1 2 1 4 2 1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00579 CAUTION: Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: WARNING S Never disassemble brake components unless absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. S Never use solvents on internal brake components.
FRONT AND REAR BRAKES CHAS 2. Remove: S brake pad clips 1 S brake pad pin 2 S brake pad spring 3 3. Remove: S brake pads 1 4. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set. Brake pad wear limit 0.5 mm (0.02 in) 5. Install: S brake pads S brake pad spring NOTE: Always install new brake pads, and a brake pad spring as a set.
FRONT AND REAR BRAKES CHAS a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. Bleed screw 6 Nm (0.6 mSkg, 4.3 ftSlb) NOTE: The arrow mark a on the brake pad spring must point in the direction of disc rotation. d. Install new brake pads and a new brake pad spring. 6.
FRONT AND REAR BRAKES CHAS EAS00583 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1. Remove: S screw plug 1 S brake pad pin S brake caliper 2 2. Remove: S brake pad spring 3. Remove: S brake pads 1 (along with the brake pad shims 2 ) 4. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set. Brake pad wear limit 1.0 mm (0.04 in) 5.
CHAS FRONT AND REAR BRAKES a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. Bleed screw 6 Nm (0.6 mSkg, 4.3 ftSlb) d. Install a new brake pad shim 3 onto each new brake pad 4 . 6. Install: S rear brake caliper (front) 28 Nm (2.8 mSkg, 20 ftSlb) rear brake caliper (rear) 23 Nm (2.
FRONT AND REAR BRAKES CHAS EAS00584 FRONT BRAKE MASTER CYLINDER 30 Nm (3.0 mSkg, 22 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Drain. Refer to “CHANGING THE BRAKE FLUID” in chapter 3.
FRONT AND REAR BRAKES CHAS 30 Nm (3.0 mSkg, 22 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) Order 15 16 17 Job/Part Brake master cylinder bracket Brake master cylinder Front brake switch Q’ty Remarks 1 1 1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00585 Order 1 2 3 4 Job/Part Disassembling the front brake master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder body Q’ty Remarks Disassemble the parts in the order listed. 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00586 REAR BRAKE MASTER CYLINDER 18 Nm (1.8 mSkg, 13 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Removing the rear brake master cylinder Brake fluid 1 2 3 4 5 6 7 8 9 10 Remarks Drain. Refer to “CHANGING THE BRAKE FLUID” in chapter 3.
FRONT AND REAR BRAKES CHAS EAS00587 Order Job/Part Q’ty 1 2 Disassembling the rear brake master cylinder Brake master cylinder kit Brake master cylinder body Remarks Disassemble the parts in the order listed. 1 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: brake light switch connector 1 (from the brake light switch) 2. Remove: S union bolt 2 S copper washers 3 S brake hoses 4 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. 3.
FRONT AND REAR BRAKES CHAS EAS00593 A CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders. 1. Check: S brake master cylinder Damage/scratches/wear ! Replace. S brake fluid delivery passages (brake master cylinder body) Obstruction ! Blow out with compressed air. A Front B Rear B 2. Check: S brake master cylinder kit Damage/scratches/wear ! Replace. A Front B Rear A B A 3. Check: S brake fluid reservoir 1 Cracks/damage ! Replace.
FRONT AND REAR BRAKES CHAS EAS00607 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING S Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake components. Recommended brake fluid DOT 4 1. Install: S brake master cylinder kit S circlip New S dust boot 2. Install: S brake master cylinder 1 13 Nm (1.3 mSkg, 9.
FRONT AND REAR BRAKES CHAS NOTE: S While holding the brake hose, tighten the union bolt as shown. S Turn the handlebars to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary. 4. Fill: S brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid.
FRONT AND REAR BRAKES CHAS 6. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. EAS00610 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: S brake master cylinder kit S circlip S dust boot 2.
FRONT AND REAR BRAKES CHAS WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. S When refilling, be careful that water does not enter the brake fluid reservoir.
FRONT AND REAR BRAKES CHAS EAS00613 FRONT BRAKE CALIPERS 7 Nm (0.7 mSkg, 5.1 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. NOTE: The following procedure applies to both of the front brake calipers. Removing the front brake calipers 1 2 3 4 Brake fluid Union bolt Copper washer Brake hose Brake caliper Remarks Drain. 1 2 1 1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00615 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job/Part Q’ty Disassemble the parts in the order listed. NOTE: The following procedure applies to both of the front brake calipers. Disassembling the front brake calipers 1 2 3 4 5 6 7 Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw Remarks 2 1 1 2 4 8 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 mSkg, 22 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 28 Nm (2.8 mSkg, 20 ftSlb) Order 1 2 3 4 Job/Part Removing the rear brake caliper Brake fluid Union bolt Copper washer Brake hose Brake caliper Q’ty Remarks Remove the parts in the order listed. Drain. 1 2 1 1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00617 2.5 Nm (0.25 mSkg, 1.8 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job/Part Q’ty 1 2 3 4 5 6 7 8 Disassembling the rear brake caliper Screw plug Brake pad pin Brake pad Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw 1 1 2 4 1 1 2 1 Remarks Disassemble the parts in the order listed. For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: S brake caliper pistons 1 S brake caliper piston seals 2 a.
FRONT AND REAR BRAKES CHAS EAS00627 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 S brake caliper 4 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: S brake caliper piston 1 S brake caliper piston seals 2 a.
FRONT AND REAR BRAKES CHAS EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is disassembled 1. Check: S brake caliper pistons 1 Rust/scratches/wear ! Replace the brake caliper pistons. S brake caliper cylinders 2 Scratches/wear ! Replace the brake caliper assembly.
FRONT AND REAR BRAKES CHAS EAS00640 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING S Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake components as they will cause the piston seals to swell and distort. S Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 1.
FRONT AND REAR BRAKES CHAS 3. Fill: S brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
CHAS FRONT AND REAR BRAKES ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING S Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake components as they will cause the piston seals to swell and distort. S Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 1. Install: S brake caliper 1 (front) 28 Nm (2.8 mSkg, 20 ftSlb) (rear) 23 Nm (2.
FRONT AND REAR BRAKES CHAS WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. S When refilling, be careful that water does not enter the brake fluid reservoir.
FRONT FORK CHAS EAS00647 FRONT FORK FRONT FORK LEGS 33 Nm (3.3 mSkg, 24 ftSlb) 26 Nm (2.6 mSkg, 19 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) Order 1 2 3 4 5 6 Job/Part Removing the front fork legs Front wheel Front brake calipers Front cowling inner panels Front fender Cap bolt Handlebar pinch bolt Upper bracket pinch bolt Under bracket pinch bolt Front fork leg Q’ty Remarks Remove the parts in the order listed. Refer to “FRONT AND REAR BRAKES”. Refer to “COWLINGS” in chapter 3.
FRONT FORK CHAS EAS00648 23 Nm (2.3 mSkg, 17 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty Disassemble the parts in the order listed. NOTE: The following the procedure applies to both of the front fork legs.
FRONT FORK CHAS 23 Nm (2.3 mSkg, 17 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order 13 14 15 16 17 18 19 Job/Part Damper rod assembly Inner tube Oil seal Washer Outer tube bushing Inner tube bushing Oil lock piece Q’ty Remarks 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT FORK CHAS EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remove S front wheel S front brake caliper Refer to “FRONT WHEEL AND BRAKE DISCS”. 3. Remove: S front cowling inner panels Refer to “COWLINGS” in chapter 3. S handlebar 4.
FRONT FORK CHAS EAS00655 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Loosen: S nut 1 2. Remove: S cap bolt 2 (from the damper rod assembly) 3. Remove: S damper adjusting rod 1 S washer 2 S spacer 3 S fork spring 4. Drain: S fork oil NOTE: Stroke the damper rod 1 several times while draining the fork oil. 5. Remove: S dust seal S oil seal clip 1 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 6.
FRONT FORK CHAS Damper rod holder 90890-01473 7. Remove: S damper rod assembly 8. Remove: S inner tube S oil seal S inner tube bushing a. Hold the front fork leg horizontally. b. Slowly push A the inner tube into the outer tube and just before it bottoms out, pull B the inner tube back quickly. c. Repeat this step until the inner tube separates from the outer tube. EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1.
FRONT FORK CHAS CAUTION: S The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly sensitive to foreign material. S When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. 4. Check: S cap bolt O-ring Damage/wear ! Replace. EAS00661 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
FRONT FORK CHAS WARNING Always use new copper washers. CAUTION: Allow the damper rod assembly to slide slowly down the inner tube 1 until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Lubricate: S inner tube’s outer surface Recommended lubricant Suspension oil “01” or equivalent 3. Tighten: S damper rod assembly bolt 1 40 Nm (4.
FRONT FORK CHAS 5. Install: S washer S oil seal 1 (with the fork seal driver weight and fork seal driver attachment) CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: S Before installing the oil seal, lubricate its lips with lithium-soap-based grease. S Lubricate the outer surface of the inner tube with fork oil. S Before installing the oil seal, cover the top of the front fork leg with a plastic bag 2 to protect the oil seal during installation. 6.
FRONT FORK CHAS 9. Fully compress the front fork leg. 10. Fill: S front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 0.49 L (0.43 Imp qt, 0.52 US qt) Recommended oil Suspension oil “01” CAUTION: S Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. S When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. 11.
FRONT FORK CHAS 14. Measure: S front fork leg oil level a Out of specification ! Correct. Front fork leg oil level (from the top of the inner tube, with the inner tube fully compressed, and without the spring) 106 mm (4.17 in) 15. Install: S nut 1 S fork spring 2 S washer 3 S spacer 4 S washer 5 S damper adjusting rod 6 S cap bolt 7 a. Remove the rod puller and rod puller attachment. b. Install the damper adjusting rod locknut 1 and position it as specified a .
FRONT FORK CHAS e. Install the cap bolt and finger tighten it. WARNING S Before installing the cap bolt, apply grease onto the O-ring. S Always use a new cap bolt O-ring. f. Hold the cap bolt and tighten the nut to specification. Nut 15 Nm (1.5 mSkg, 11 ftSlb) EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: S handlebar (temporarily) 2. Install: S front fork leg Temporarily tighten the upper and under bracket pinch bolts.
CHAS FRONT FORK 5. Install: S handlebar S handlebar pinch bolt 1 33 Nm (3.3 mSkg, 24 ftSlb) S handlebar bolt 2 13 Nm (1.3 mSkg, 9.4 ftSlb) WARNING Make sure the brake hoses are routed properly. 6. Adjust: S spring preload S rebound damping S compression damping Refer to “ADJUSTING THE FRONT FORK LEGS” in chapter 3.
HANDLEBARS CHAS EAS00665 HANDLEBARS 33 Nm (3.3 mSkg, 24 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) 33 Nm (3.3 mSkg, 24 ftSlb) 23 Nm (2.
HANDLEBARS CHAS EAS00667 REMOVING THE HANDLEBARS 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S grip end S handlebar grip NOTE: Blow compressed air between the left handlebar and the handlebar grip, and gradually push the grip off the handlebar. 3. Remove: S left handlebar switch 1 S clutch lever holder 2 4.
CHAS HANDLEBARS EAS00674 INSTALLING THE HANDLEBARS 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Install: S throttle cables S throttle grip 1 S right handlebar switch 2 NOTE: Align the projection a on the right handlebar switch with the hole b in the right handlebar. 3. Install: S right handlebar 1 S right handlebar pinch bolt 2 33 Nm (3.3 mSkg, 24 ftSlb) S right handlebar bolt 3 13 Nm (1.3 mSkg, 9.4 ftSlb) 4.
CHAS HANDLEBARS 5. Install: S clutch lever holder 1 11 Nm (1.1 mSkg, 8.0 ftSlb) NOTE: Align the slit on the clutch lever holder with the punch mark a on the left handlebar. 6. Install: S left handlebar S left handlebar pinch bolt 1 33 Nm (3.3 mSkg, 24 ftSlb) S left handlebar bolt 2 13 Nm (1.3 mSkg, 9.4 ftSlb) 7. Install: S left handlebar switch 1 NOTE: Align the projection a on the left handlebar switch with the hole b on the left handlebar. 8. Install: S handlebar grip a.
HANDLEBARS CHAS 10. Adjust: S clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm (0.39 X 0.59 in) 11. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. Throttle cable free play (at the flange of the throttle grip) 6 X 8 mm (0.24 X 0.
STEERING HEAD CHAS EAS00676 STEERING HEAD UNDER BRACKET 26 Nm (2.6 mSkg, 19 ftSlb) 113 Nm (11.3 mSkg, 82 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 1st 52 Nm (5.2 mSkg, 38 ftSlb) 2nd 14 Nm (1.4 mSkg, 10 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE DISCS”.
STEERING HEAD CHAS 26 Nm (2.6 mSkg, 19 ftSlb) 113 Nm (11.3 mSkg, 82 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 1st 52 Nm (5.2 mSkg, 38 ftSlb) 2nd 14 Nm (1.4 mSkg, 10 ftSlb) Order 8 9 10 11 12 13 14 15 16 Job/Part Rubber washer Lower ring nut Under bracket Bearing cover Bearing inner race Upper bearing Lower bearing Dust seal Bearing outer race Q’ty Remarks 1 1 1 1 2 1 1 1 2 For installation, reverse the removal procedure.
STEERING HEAD CHAS EAS00679 REMOVING THE UNDER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S steering stem nut S washer S upper bracket S lock washer S rubber washer S ring nut 1 (with the steering nut wrench 2 ) NOTE: Hold the lower ring nut with the exhaust and steering nut wrench, and then remove the upper ring nut with the ring nut wrench.
STEERING HEAD CHAS 3. Replace: S bearings S bearing races a. Remove the bearing races 1 from the steering head pipe with a long rod 2 and hammer. b. Remove the bearing race 3 from the under bracket with a floor chisel 4 and hammer. c. Install a new rubber seal and new bearing races. CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: S Always replace the bearings and bearing races as a set.
STEERING HEAD 3. Install: S upper bracket S washer S steering stem nut CHAS 113 Nm (11.3 mSkg, 82 ftSlb) NOTE: Temporarily tighten the steering stem nut. 4. Install: S front fork legs Refer to “INSTALLING THE FRONT FORK LEGS”. NOTE: Temporarily tighten the upper and under bracket pinch bolts. 5. Install: S front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00685 REAR SHOCK ABSORBER ASSEMBLY 52 Nm (5.2 mSkg, 38 ftSlb) 44 Nm (4.4 mSkg, 32 ftSlb) 44 Nm (4.4 mSkg, 32 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed.
REAR SHOCK ABSORBER ASSEMBLY CHAS 52 Nm (5.2 mSkg, 38 ftSlb) 44 Nm (4.4 mSkg, 32 ftSlb) 44 Nm (4.4 mSkg, 32 ftSlb) Order 9 10 11 Job/Part Oil seal/bearing/collar Oil seal/bearing/collar Bracket Q’ty Remarks 6/3/3 2/1/1 1 For installation, reverse the removal procedure.
REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber and gas cylinder.
REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00694 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: S rear wheel Refer to “REAR WHEEL AND BRAKE DISC”. 3.
REAR SHOCK ABSORBER ASSEMBLY CHAS S spring Damage/wear ! Replace the rear shock absorber assembly. S gas cylinder Damage/gas leaks ! Replace. S bushings Damage/wear ! Replace. S dust seals Damage/wear ! Replace. S bolts Bends/damage/wear ! Replace. CHECKING THE CONNECTING ROD AND RELAY ARMS 1. Check: S connecting rod 1 S relay arms 2 Damage/wear ! Replace. 2. Check: S bearings 3 S oil seals 4 Damage/pitting ! Replace. 3. Check: S collars 5 Damage/scratches ! Replace.
SWINGARM AND DRIVE CHAIN CHAS EAS00700 SWINGARM AND DRIVE CHAIN 16 Nm (1.6 mSkg, 12 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 95 Nm (9.5 mSkg, 69 ftSlb) Order 6 Nm (0.6 mSkg, 4.3 ftSlb) Job/Part Q’ty Remove the parts in the order listed. Removing the swingarm and drive chain Rear wheel Refer to “REAR WHEEL AND BRAKE DISC”. Refer to “REAR SHOCK ABSORBER ASSEMBLY”. Refer to “REAR SHOCK ABSORBER ASSEMBLY”. Refer to “ENGINE” in chapter 5.
SWINGARM AND DRIVE CHAIN CHAS 16 Nm (1.6 mSkg, 12 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 95 Nm (9.5 mSkg, 69 ftSlb) Order 10 11 12 13 Job/Part Bearing Spacer Pivot shaft adjust bolt Drive chain case 6 Nm (0.6 mSkg, 4.3 ftSlb) Q’ty Remarks 2 1 1 1 For installation, reverse the removal procedure.
SWINGARM AND DRIVE CHAIN CHAS EAS00703 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: S rear wheel Refer to “REAR WHEEL AND BRAKE DISC”. S rear shock absorber assembly, relay arm and connecting rod Refer to “REAR SHOCK ABSORBER ASSEMBLY”. 3. Measure: S swingarm side play S swingarm vertical movement a.
SWINGARM AND DRIVE CHAIN CHAS EAS00704 REMOVING THE DRIVE CHAIN 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: S drive chain (with the drive chain cutter) EAS00707 CHECKING THE SWINGARM 1. Check: S swingarm Bends/cracks/damage ! Replace. 2. Check: S pivot shaft Roll the pivot shaft on a flat surface. Bends ! Replace.
SWINGARM AND DRIVE CHAIN CHAS 4. Check: S dust covers 1 S spacer 2 Damage/wear ! Replace. S bearings Damage/pitting ! Replace. EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: S ten-link section a of the drive chain Out of specification ! Replace the drive chain. Ten-link drive chain section limit (maximum) 150.1 mm (5.91 in) NOTE: S While measuring the ten-link section, push down on the drive chain to increase its tension. S Measure the length between drive chain roller 1 and 11 as shown.
SWINGARM AND DRIVE CHAIN CHAS CAUTION: This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s internals, and solvents will deteriorate the Orings. A coarse brush can also damage the O-rings. Therefore, use only kerosene to clean the drive chain.
CHAS SWINGARM AND DRIVE CHAIN EAS00711 INSTALLING THE SWINGARM 1. Lubricate: S bearings S spacers S dust covers S pivot shaft Recommended lubricant Lithium-soap-based grease 2. Install: S pivot shaft adjust bolt 1 6 Nm (0.6 mSkg, 4.3 ftSlb) S swingarm S pivot shaft 95 Nm (9.5 mSkg, 69 ftSlb) NOTE: Use the pivot shaft wrench 2 and adapter 3 to tighten the pivot adjust bolt to specification torque. Pivot shaft wrench: 90890-01471, YM-01471 Pivot shaft wrench adapter 90890-01476 3.
ENGINE ENG OVERHAULING THE ENGINE ENGINE DRIVE SPROCKET 10 Nm (1.0 mSkg, 7.2 ftSlb) 6.5 Nm (0.65 mSkg, 4.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 5 90 Nm (9.0 mSkg, 65 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Removing the drive sprocket Bottom cowling Side cowlings Drive chain 1 2 3 4 5 6 7 8 Remarks Refer to “COWLINGS” in chapter 3.
ENGINE ENG EAS00189 EXHAUST PIPE 20 Nm (2.0 mSkg, 15 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) Order 1 2 3 Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the exhaust pipe Bottom cowling Side cowlings Muffler Exhaust pipe assembly Exhaust pipe gasket Refer to “COWLINGS” in chapter 3. 1 1 4 For installation, reverse the removal procedure.
ENGINE ENG EAS00188 LEADS AND HOSES 20 Nm (2.0 mSkg, 15 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Disconnecting the leads and hoses Air filter case Throttle body assembly Disconnect the parts in the order listed. Refer to “AIR FILTER CASE” in chapter 3. Refer to “THROTTLE BODIES” in chapter 7. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Refer to “OIL COOLER” in chapter 6. Refer to “AIR INDUCTION SYSTEM” in chapter 7.
ENGINE ENG 20 Nm (2.0 mSkg, 15 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order 3 4 5 6 7 8 9 10 Job/Part Q’ty 1 1 1 1 1 1 1 1 Clutch cable Ground lead Stator coil assembly coupler Crankshaft position sensor coupler Oil level switch connector Neutral switch connector Speed sensor coupler Cylinder identification sensor coupler 5-4 Remarks Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. For connecting reverse the disconnection procedure.
ENGINE ENG EAS00191 ENGINE 45 Nm (4.5 mSkg, 33 ftSlb) 45 Nm (4.5 mSkg, 33 ftSlb) 45 Nm (4.5 mSkg, 33 ftSlb) 45 Nm (4.5 mSkg, 33 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Removing the parts in the order listed. NOTE: Place a suitable stand under the frame and engine.
ENGINE ENG EAS00192 INSTALLING THE ENGINE 1. Install: S engine bracket 1 (to the engine) 45 Nm (4.5 mSkg, 33 ftSlb) S engine mounting adjust bolts (temporary tighten) 2. Install: S rear engine mounting bolts 1 NOTE: S Lubricate the rear engine mounting bolt threads with lithium-soap-based grease. 3. Install: S right front engine mounting bolts 1 (temporary tighten) S left front engine mounting bolts 2 45 Nm (4.5 mSkg, 33 ftSlb) NOTE: First tighten the rear side engine mounting bolt. 4.
ENGINE ENG Pivot shaft wrench 90890-01471, YM-01471 Pivot shaft wrench adapter 90890-01476 5. Tighten: S nuts 1 (rear engine mounting bolts) 45 Nm (4.5 mSkg, 33 ftSlb) NOTE: First tighten the lower self-locking nut. 6. Tighten: S right front engine mounting bolts 1 45 Nm (4.5 mSkg, 33 ftSlb) NOTE: First tighten the rear side engine mounting bolt. 7. Install: S shift arm 1 10 Nm (1.0 mSkg, 7.2 ftSlb) NOTE: S Align the punch mark a in the shift shaft with the slot in the shift arm.
CAMSHAFTS ENG EAS00194 CAMSHAFTS CYLINDER HEAD COVER 10 Nm (1.0 mSkg, 7.2 ftSlb) 13 Nm (1.3 mSkg, 9.4 ftSlb) Order Job/Part 12 Nm (1.2 mSkg, 8.7 ftSlb) Q’ty Remove the parts in the order listed. Refer to “THROTTLE BODIES” in chapter 7. Refer to “RADIATOR” in chapter 6. Refer to “AIR INDUCTION SYSTEM” in chapter 7.
CAMSHAFTS ENG EAS00196 CAMSHAFTS 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 24 Nm (2.4 mSkg, 17 ftSlb) 10 Nm (1.0 mSkg, 7.
CAMSHAFTS ENG EAS00198 REMOVING THE CAMSHAFTS 1. Remove: S pickup rotor cover Refer to “CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR”. 2. Align: S “T” mark a on the pickup rotor (with the crankcase mating surface b ) a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compression stroke, align the “T” mark a on the pickup rotor with the crankcase mating surface b. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. 3.
CAMSHAFTS ENG 7. Remove: S intake camshaft 1 S exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire a . 8. Remove: S camshaft sprockets EAS00204 CHECKING THE CAMSHAFTS 1. Check: S camshaft lobes Blue discoloration/pitting/scratches ! Replace the camshaft. 2. Measure: S camshaft lobe dimensions a and b Out of specification ! Replace the camshaft. Camshaft lobe dimension limit Intake camshaft a 33.45 X 33.55 mm (1.317 X 1.321 in) : 33.
CAMSHAFTS ENG 3. Measure: S camshaft runout Out of specification ! Replace. Camshaft runout limit 0.06 mm (0.0024 in) 4. Measure: S camshaft-journal-to-camshaft-cap clearance Out of specification ! Measure the camshaft journal diameter. Camshaft-journal-to-camshaftcap clearance 0.028 X 0.062 mm (0.0011 X 0.0024 in) : 0.08 mm (0.0031 in) a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). b. Position strip of Plastigauge 1 onto the camshaft journal as shown.
CAMSHAFTS ENG EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: S timing chain 1 Damage/stiffness ! Replace the timing chain and camshaft sprockets as a set. 2. Check: S camshaft sprocket More than 1/4 tooth wear a ! Replace the camshaft sprockets and the timing chain as a set. a 1 / 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3.
CAMSHAFTS ENG b. Remove the screwdriver and slowly release the timing chain tensioner rod. c. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough movement, replace the timing chain tensioner. 3. Check: S cap bolt S copper washer New S gasket New Damage/wear ! Replace the defective part(s). EAS00215 INSTALLING THE CAMSHAFTS 1. Align: S “T” mark a on the pickup rotor (with the crankcase mating surface b ) a.
ENG CAMSHAFTS 3. Install: S dowel pins S exhaust camshaft caps S intake cmashaft caps NOTE: S Make sure each camshaft cap is installed in its original place. S Make sure the arrow mark a on each camshaft cap points towards the right side of the engine. 4. Install: S camshaft cap bolts 10 Nm (1.0 mSkg, 7.2 ftSlb) NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.
ENG CAMSHAFTS 6. Install: S timing chain tensioner a. While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1 . b. With the timing chain tensioner rod turned all the way into the timing chain tensioner housing (with the thin screwdriver still installed), install the gasket and the timing chain tensioner 2 onto the cylinder block. WARNING Always use a new gasket. c. Tighten the timing chain tensioner bolts 3 to the specified torque.
CAMSHAFTS ENG 10. Measure: S valve clearance Out of specification ! Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3.
CYLINDER HEAD ENG EAS00221 CYLINDER HEAD 1st 19 Nm (1.9 mSkg, 14 ftSlb) 2nd 50 Nm (5.0 mSkg, 36 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order 1 2 3 Job/Part Removing the cylinder head Intake and exhaust camshaft Engine bracket Cylinder head Cylinder head gasket Dowel pin Q’ty Remarks Remove the parts in the order listed. Refer to “CAMSHAFTS”. Refer to “ENGINE”. 1 1 2 For installation, reverse the removal procedure.
CYLINDER HEAD ENG EAS00222 REMOVING THE CYLINDER HEAD 1. Remove: S cylinder head bolts NOTE: S Loosen the bolts in the proper sequence as shown. S Loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. EAS00229 CHECKING THE CYLINDER HEAD 1. Eliminate: S combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: S spark plug bore threads S valve seats 2.
CYLINDER HEAD ENG EAS00233 INSTALLING THE CYLINDER HEAD 1. Install: S gasket New 1 S dowel pins 2 2. Install: S cylinder head NOTE: Pass the timing chain through the timing chain cavity. 3. Tighten: S cylinder head bolts 1st 2nd S cylinder head bolts 1 X 10 19 Nm (1.9 mSkg, 14 ftSlb) 50 Nm (5.0 mSkg, 36 ftSlb) 11 , 12 12 Nm (1.2 mSkg, 8.7 ftSlb) NOTE: S First, tighten the bolts 1 X 10 to approximately 19 Nm (1.9 mSkg, 14 ftSlb) with a torque wrench and then tighten the 50 Nm (5.0 mSkg, 36 ftSlb).
VALVES AND VALVE SPRINGS ENG EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty 1 2 3 4 5 6 7 8 9 10 11 12 13 Remove the valves and valve springs Cylinder head Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring outer Intake valve spring inner Intake valve oil seal Intake valve lower spring seat Intake valve Intake valve guide Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Remarks Remove the parts in the order listed.
VALVES AND VALVE SPRINGS Order 14 15 16 17 18 19 Job/Part Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide Q’ty 8 8 8 8 8 8 ENG Remarks Refer to “REMOVING/INSTALLING THE VALVES”. For installation, reverse the removal procedure.
VALVES AND VALVE SPRINGS ENG EAS00238 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: S valve lifter 1 S valve pad 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. 2.
VALVES AND VALVE SPRINGS ENG Valve spring compressor 90890-04019, YM-04019 Valve spring compressor attachment 90890-04108, YM-01253 4. Remove: S upper spring seat 1 S valve spring outer 2 S valve spring inner (intake only) 3 S valve 4 S oil seal 5 S lower spring seat 6 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1.
VALVES AND VALVE SPRINGS ENG 2. Replace: S valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100_C (212_F) in an oven. a. Remove the valve guide with the valve guide remover 1 . b. Install the new valve guide with the valve guide installer 2 and valve guide remover 1. c. After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valve-guide clearance.
VALVES AND VALVE SPRINGS ENG 5. Measure: S valve margin thickness a Out of specification ! Replace the valve. Valve margin thickness 0.6 X 0.8 mm (0.0236 X 0.0315 in) : 0.5 mm (0.02 in) 6. Measure: S valve stem runout Out of specification ! Replace the valve. NOTE: S When installing a new valve, always replace the valve guide. S If the valve is removed or replaced, always replace the oil seal. Valve stem runout : 0.04 mm (0.
VALVES AND VALVE SPRINGS ENG NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. 4. Lap: S valve face S valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. a. Apply a coarse lapping compound a to the valve face. CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Apply molybdenum disulfide oil onto the valve stem. c.
VALVES AND VALVE SPRINGS ENG j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat. EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: S valve spring free length a Out of specification ! Replace the valve spring. Valve spring free length Intake valve spring (inner) 35.7 mm (1.41 in) : 33.9 mm (1.33 in) Intake valve spring (outer) 40.3 mm (1.59 in) : 38.3 mm (1.
VALVES AND VALVE SPRINGS ENG 3. Measure: S valve spring tilt a Out of specification ! Replace the valve spring. Spring tilt limit Intake valve spring (inner) 2.5_/1.6 mm (0.06 in) (outer) 2.5_/1.8 mm (0.07 in) Exhaust valve spring 2.5_/1.8 mm (0.07 in) EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters. 1. Check: S valve lifter Damage/scratches ! Replace the valve lifters and cylinder head.
VALVES AND VALVE SPRINGS ENG NOTE: S Make sure that each valve is installed in its original place. S Install the valve springs with the larger pitch a facing up. b Smaller pitch 4. Install: S valve cotters 1 NOTE: Install the valve cotters by compressing the valve springs with the valve spring compressor 2 and the valve spring compressor attachment 3. Valve spring compressor 90890-04019, YM-04019 Valve spring compressor attachment 90890-04108, YM-01253 5.
STARTER CLUTCH AND GENERATOR ENG EAS00341 STARTER CLUTCH AND GENERATOR STATOR COIL ASSEMBLY 10 Nm (1.0 mSkg, 7.2 ftSlb) 32 Nm (3.2 mSkg, 23 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Refer to “SEATS” and “FUEL TANK” in chapter 3. Removing the stator coil assembly Rider seat and fuel tank Buttom cowling Left side cowling Coolant Coolant reservoir tank Refer to “COWLINGS” in chapter 3.
STARTER CLUTCH AND GENERATOR ENG 10 Nm (1.0 mSkg, 7.2 ftSlb) 32 Nm (3.2 mSkg, 23 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order 6 7 8 9 10 11 12 13 Job/Part Stator coil assembly Generator rotor bolt Washer Generator rotor Starter clutch assembly Idler gear shaft Idler gear Starter clutch drive gear Q’ty 1 1 1 1 1 1 1 1 Remarks Refer to “REMOVING/INSTALLING THE GENERATOR”. For installation, reverse the removal procedure.
STARTER CLUTCH AND GENERATOR ENG EAS00347 REMOVING THE GENERATOR 1. Remove: S rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. S buttom cowling S left side cowling Refer to “COWLINGS” in chapter 3. 2. Drain: S coolant Refer to “CHANGING THE COOLANT” in chapter 3. S engine oil Refer to “CHANGING THE ENGINE OIL” in chapter 3. 3. Remove: S generator rotor cover NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.
STARTER CLUTCH AND GENERATOR ENG 5. Remove: S generator rotor 1 (with the flywheel puller 2 and flywheel puller attachment) S woodruff key CAUTION: To protect the end of the crankshaft, place an appropriate sized socket between the flywheel puller set’s center bolt and the crankshaft. NOTE: Make sure the flywheel puller is centered over the generator rotor. Flywheel puller 90890-01362, YU-33270 Flywheel puller attachment 90890-04089, YM-33282 REMOVING THE STARTER CLUTCH 1.
STARTER CLUTCH AND GENERATOR ENG EAS00351 CHECKING THE STARTER CLUTCH 1. Check: S starter clutch rollers 1 Damage/wear ! Replace. 2. Check: S starter clutch idle gear 1 S starter clutch drive gear 2 Burrs/chips/roughness/wear ! Replace the defective part(s). 3. Check: S starter clutch gear’s contacting surfaces a Damage/pitting/wear ! Replace the starter clutch gear. 4. Check: S starter clutch operation a. Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch. b.
ENG STARTER CLUTCH AND GENERATOR S Do not allow the sheave holder to touch the projection on the generator rotor. Sheave holder 90890-01701, YS-01880-A EAS00354 INSTALLING THE GENERATOR 1. Install: S generator rotor S washer New S generator rotor bolt NOTE: S Clean the tapered portion of the crankshaft and the generator rotor hub. S Replace the washer with new one. 2. Tighten: S generator rotor bolt 1 75 Nm (7.
STARTER CLUTCH AND GENERATOR ENG NOTE: Tighten the generator rotor cover bolts in stages and in a crisscross pattern. 6. Fill: S engine oil Refer to “CHANGING THE ENGINE OIL” in chapter 3. S coolant Refer to “CHANGING THE COOLANT” in chapter 3. 7. Install: S left side cowling S buttom cowling Refer to “COWLINGS” in chapter 3. S rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3.
SHIFT SHAFT ENG EAS00327 SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER 22 Nm (2.2 mSkg, 16 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Removing the shift shaft and stopper lever Coolant reservoir tank Coolant 1 2 3 4 5 6 7 8 9 10 Drive sprocket cover Shift shaft cover Shift shaft cover gasket Dowel pin Oil seal Shift shaft Shift shaft spring Collar Stopper lever spring Circlip Washer Remarks Drain. Refer to “CHANGING THE COOLANT” in chapter 3.
SHIFT SHAFT ENG 22 Nm (2.2 mSkg, 16 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order 11 12 13 14 Job/Part Stopper lever Collar Washer Shift shaft spring stopper Q’ty Remarks 1 1 1 1 For installation, reverse the removal procedure.
SHIFT SHAFT ENG EAS00328 CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 Bends/damage/wear ! Replace. S shift shaft spring 2 Damage/wear ! Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: S stopper lever 1 Bends/damage ! Replace. Roller turns roughly ! Replace the stopper lever. EAS00332 INSTALLING THE SHIFT SHAFT 1. Install: S shift shaft spring stopper 1 22 Nm (2.2 mSkg, 16 ftSlb) S washers S shift shaft 2 NOTE: S Apply LOCTITE to the threads of the shift shaft spring stopper.
CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR ENG CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Removing the crankshaft position sensor and pickup rotor Rider seat Fuel tank Right side cowling Bottom cowling Engine oil Refer to “SEATS” in chapter 3. Refer to “FUEL TANK” in chapter 3.
CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR ENG 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order 6 7 8 Job/Part Crankshaft position sensor Pickup rotor Plug screw Q’ty Remarks 1 1 1 For installation, reverse the removal procedure.
CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR ENG REMOVING THE PICKUP ROTOR 1. Remove: S clutch cable holder 1 S pickup rotor cover 2 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: S pickup rotor bolt 1 S washer 2 S pickup rotor 3 NOTE: While holding the generator rotor 4 with the rotor holding tool 5 , loosen the pickup rotor bolt. Sheave holder 90890-01701, YS-01880-A INSTALLING THE PICKUP ROTOR 1.
CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR ENG 2. Tighten: S pickup rotor bolt 1 35 Nm (3.5 mSkg, 25 ftSlb) NOTE: While holding the generator rotor 2 with the sheave holder 3 , tighten the pickup rotor bolt. Sheave holder 90890-01701, YS-01880-A 3. Apply: S sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No.1215 90890-85505, ACC-11001-5-01 4.
CLUTCH ENG EAS00273 CLUTCH CLUTCH COVER 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Removing the parts in the order listed. Removing the clutch cover Bottom cowling Right side cowling Engine oil Refer to “COWLINGS” in chapter 3. Coolant 1 2 3 4 5 Coolant hose Clutch cable Clutch cover Clutch cover gasket Dowel pin Remarks 1 1 1 1 2 Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Disconnect.
CLUTCH Order 1 2 3 4 5 6 Job/Part Disassembling the clutch cover Circlip Washer Pull lever Pull lever spring Oil seal Bearing Q’ty ENG Remarks Disassemble the parts in the order listed. 2 2 1 1 1 2 For assembly, reverse the disassembly procedure.
CLUTCH ENG EAS00274 CLUTCH 70 Nm (7.0 mSkg, 51 ftSlb) 8 Nm (0.8 mSkg, 5.8 ftSlb) Order 1 2 3 4 5 6 7 8 9 10 11 12 Job/Part Removing the clutch Compression spring Pressure plate Pull rod Bearing Friction plate (Brown) Clutch plate (t=2.0 mm, 0.08 in) Friction plate (Purple) Clutch plate (t=2.3 mm, 0.09 in) Clutch boss nut Lock plate Clutch boss Thrust plate Q’ty Remarks Remove the parts in the order listed. 6 1 1 1 6 7 2 1 1 1 1 1 For installation, reverse the removal procedure.
CLUTCH ENG EAS00276 REMOVING THE CLUTCH 1. Remove: S clutch cover 1 S 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. 2. Remove: S compression spring bolts 1 S compression springs S pressure plate 2 S pull rod 3 S friction plates S clutch plates 3. Straighten the lock washer tab. 4.
CLUTCH ENG 2. Measure: S friction plate thickness Out of specification ! Replace the friction plates as a set. NOTE: Measure the friction plate at four places. Friction plate thickness 2.9 X 3.1 mm (0.114 X 0.122 in) : 2.8 mm (0.110 in) EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: S clutch plate Damage ! Replace the clutch plates as a set. 2.
CLUTCH ENG 2. Measure: S clutch spring free length a Out of specification ! Replace the clutch springs as a set. Clutch spring free length 50 mm (1.97 in) : 49 mm (1.93 in) EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: S clutch housing dogs Damage/pitting/wear ! Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. 2. Check: S bearing Damage/wear ! Replace the bearing and clutch housing.
CLUTCH ENG EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: S pull lever shaft pinion gear teeth a S pull rod teeth b Damage/wear ! Replace the pull rod and pull lever shaft pinion gear as a set. 2. Check: S pull rod bearing Damage/wear ! Replace. EAS00299 INSTALLING THE CLUTCH 1. Install: S thrust plate 1 S clutch boss 2 S lock washer 3 New S clutch boss nut 4 70 Nm (7.0 mSkg, 51 ftSlb) NOTE: While holding the clutch boss 2 with the clutch holding tool 5 , tighten the clutch boss nut.
CLUTCH ENG 5. Install: S friction plates S clutch plates NOTE: First, install a clutch plate and then alternate between a friction plate and a friction plate. a. Install the clutch plate and friction plate at following the illustrated. Clutch plate 1 : t=2.3 mm (0.09 in) Clutch plate 2 : t=2.0 mm (0.08 in) Friction plate 3 : Color code/Purple Friction plate 4 : Color code/Brown 6. Install: S pressure plate 1 NOTE: Align the punch mark b in the pressure plate with the punch mark a in the clutch boss. 7.
CLUTCH ENG 9. Install: S clutch cover S gasket New NOTE: S Install the pull rod so that the teeth a face towards the rear of the motorcycle. Then, install the clutch cover. S Apply oil onto the bearing. S Apply molybdenum disulfide grease onto the pull rod. S When installing the clutch cover, push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover. Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged.
OIL PAN AND OIL PUMP ENG EAS00356 OIL PAN AND OIL PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Removing the oil pan and oil pump Engine oil Coolant 1 2 3 4 5 6 7 8 Exhaust pipe assembly Water pump Oil level switch coupler Oil level switch Oil level switch lead holder Oil pan Oil pan gasket Dowel pin Oil strainer Oil strainer gasket 1 1 1 1 1 2 1 1 5-54 43 Nm (4.
OIL PAN AND OIL PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) ENG 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order 9 10 11 12 13 Job/Part Oil pipe Oil delivery pipe Oil pump assembly Dowel pin Relief valve assembly Q’ty 43 Nm (4.3 mSkg, 31 ftSlb) Remarks 1 1 1 2 1 For installation, reverse the removal procedure.
OIL PAN AND OIL PUMP ENG 12 Nm (1.2 mSkg, 8.7 ftSlb) Order 1 2 3 4 5 6 7 8 Job/Part Disassembling the oil pump assembly Oil pump cover Pin Oil pump inner rotor Oil pump outer rotor Pin Washer Oil pump rotor housing Oil pump driver sprocket Q’ty Remarks Disassemble the parts in the order listed. 1 2 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
OIL PAN AND OIL PUMP ENG EAS00362 REMOVING THE OIL PAN 1. Remove: S oil level switch 1 S oil pan 2 S oil pan gasket S dowel pins 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. EAS00364 CHECKING THE OIL PUMP 1. Check: S oil pump driven gear 1 S oil pump rotor housing 2 S oil pump cover Cracks/damage/wear ! Replace the defective part(s). 2.
OIL PAN AND OIL PUMP ENG 3. Check: S oil pump operation Rough movement ! Repeat steps (1) and (2) or replace the defective part(s). EAS00365 CHECKING THE RELIEF VALVE 1. Check: S relief valve body 1 S relief valve 2 S spring 3 S O-ring 4 Damage/wear ! Replace the defective part(s). EAS00367 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 1. Check: S oil delivery pipe 1 S oil pipe 2 Damage ! Replace. Obstruction ! Wash and blow out with compressed air. EAS00368 CHECKING THE OIL STRAINER 1.
OIL PAN AND OIL PUMP ENG EAS00374 ASSEMBLING THE OIL PUMP 1. Lubricate: S inner rotor S outer rotor S oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: S oil pump housing 1 S oil pump shaft 2 S washer 3 S pin 4 S inner rotor 5 S outer rotor 6 S dowel pins 7 S oil pump cover 8 12 Nm (1.2 mSkg, 8.7 ftSlb) NOTE: When installing the inner rotor, align the pin 4 in the oil pump shaft with the groove in the inner rotor 5 . 3.
OIL PAN AND OIL PUMP ENG EAS00378 INSTALLING THE OIL STRAINER 1. Install: S oil strainer 1 S relief valve 2 NOTE: Make sure to check the arrow mark a located on the oil strainer housing for the front and rear direction of the engine and then install the oil strainer so that its arrow mark points to the front side of the engine. EAS00380 INSTALLING THE OIL PAN 1. Install: S oil pipe S oil delivery pipe 2. Install: S dowel pins S gasket New 12 Nm (1.2 mSkg, 8.
CRANKCASE ENG CRANKCASE 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Refer to “ENGINE”. Refer to “CYLINDER HEAD”. Refer to “STARTER CLUTCH AND GENERATOR”. Refer to “SHIFT SHAFT”. Refer to “CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR”. Refer to “CLUTCH”. Refer to “WATER PUMP” in chapter 6. Refer to “OIL PAN AND OIL PUMP”.
CRANKCASE ENG 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order 6 7 8 Job/Part Thrust plate Washer Plate Q’ty Remarks 1 1 1 For installation, reverse the removal procedure.
CRANKCASE ENG EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside down. 2. Remove: S crankcase bolts NOTE: S 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. S Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). S The numbers embossed on the crankcase indicate the crankcase tightening sequence. M8 85 mm (3.3 in) bolts: 1 X 7 , 10 M8 115 mm (4.
CRANKCASE ENG EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: S crankcase Cracks/damage ! Replace. S oil delivery passages Obstruction ! Blow out with compressed air. EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1. Check: S bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement ! Replace. 2.
CRANKCASE ENG NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings. 3. Install: S dowel pin 4. Set the shift drum assembly and transmission gears in the neutral position. 5. Install: S lower crankcase 1 (onto the upper crankcase 2 ) CAUTION: Before tightening the crankcase bolts, make sure that the transmission gears shift correctly when the shift drum assembly is turned by hand.
CONNECTING RODS AND PISTONS ENG EAS00252 CONNECTING RODS AND PISTONS 15 Nm (1.5 mSkg, 11 ftSlb) +150_ Order Job/Part Q’ty 1 2 3 4 5 6 7 8 9 10 Removing the connecting rods and pistons Lower crankcase Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring Oil ring Remarks Remove the parts in the order listed. Refer to “CRANKCASE”. 4 4 4 8 4 4 4 4 4 4 For installation, reverse the removal procedure.
CONNECTING RODS AND PISTONS ENG EAS00393 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: S connecting rod cap 1 S big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place. 2. Remove: S piston pin clips 1 S piston pin 2 S piston 3 CAUTION: Do not use a hammer to drive the piston pin out.
CONNECTING RODS AND PISTONS ENG EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: S crankshaft assembly S crankshaft journal upper bearings (from the upper crankcase) Refer to “CRANKSHAFT”. NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. EAS00261 CHECKING THE CYLINDER AND PISTON 1. Check: S piston wall S cylinder wall Vertical scratches ! Replace the cylinder, and the piston and piston rings as a set. 2.
ENG CONNECTING RODS AND PISTONS Cylinder bore “C” 65.50 X 65.51 mm (2.5787 X 2.5791 in) Wear limit 65.56 mm (2.5811 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.002 in) “C” = maximum of D1 X D6 “T” = maximum of D1 or D2 – maximum of D5 or D6 “R” = maximum of D1 D3 or D5 – minimum of D2 D4 or D6 b. If out of specification, replace the cylinder, and the pistons and piston rings as a set. c. Measure piston skirt diameter “P” with the micrometer. a 4 mm (0.
CONNECTING RODS AND PISTONS ENG Piston ring side clearance Top ring 0.030 X 0.065 mm (0.0012 X 0.0026 in) : 0.115 mm (0.0045 in) 2nd ring 0.030 X 0.065 mm (0.0012 X 0.0026 in) : 0.125 mm (0.0049 in) 2. Install: S piston ring (into the cylinder) NOTE: Level the piston ring into the cylinder with the piston crown. a 5 mm (0.20 in) 3. Measure: S piston ring end gap Out of specification ! Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured.
CONNECTING RODS AND PISTONS ENG 2. Measure: S piston pin outside diameter a Out of specification ! Replace the piston pin. Piston pin outside diameter 15.991 X 16.000 mm (0.6296 X 0.6299 in) : 15.971 mm (0.6288 in) 3. Measure: S piston pin bore inside diameter b Out of specification ! Replace the piston. Piston pin bore inside diameter 16.002 X 16.013 mm (0.6300 X 0.6304 in) : 16.043 mm (0.6316 in) 4.
CONNECTING RODS AND PISTONS ENG CAUTION: Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions. a. Clean the big end bearings, crankshaft pins, and the inside of the connecting rods halves. b. Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap.
CONNECTING RODS AND PISTONS ENG e. Tighten the connecting rod nuts. Connecting rod nut 15 Nm (1.5 mSkg, 11 ftSlb) + 150_ f. Replace the connecting rod bolts and nuts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts. g. Clean the connecting rod bolts and nuts. h. Tighten the connecting rod nuts. i. Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod 3 . j.
CONNECTING RODS AND PISTONS ENG 2. Select: S big end bearings (P1 X P4) NOTE: S The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. S “P1” X “P4” refer to the bearings shown in the crankshaft illustration.
CONNECTING RODS AND PISTONS ENG 2. Install: S piston 1 (onto the respective connecting rod 2 ) S piston pin 3 S piston pin clip New 4 NOTE: S Apply engine oil onto the piston pin. S Make sure that the “Y” mark a on the connecting rod faces left when the arrow mark b on the piston is pointing up. Refer to the illustration. S Reinstall each piston into its original cylinder (numbering order starting from the left: #1 to #4). 3.
CONNECTING RODS AND PISTONS ENG 6. Install: S big end bearings S connecting rod assembly (into the cylinder and onto the crankshaft pin) S connecting rod cap (onto the connecting rod) NOTE: S Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. S Be sure to reinstall each big end bearing in its original place. S While compressing the piston rings with one hand, install the connecting rod assembly into the cylinder with the other hand.
CONNECTING RODS AND PISTONS ENG e. Tighten the nut further to reach the specified angle (150_). WARNING When the nut is tightened more than the specified angle, do not loosen the nut and then retighten it. Replace the bolt with a new one and perform the procedure again. CAUTION: S Do not use a torque wrench to tighten the nut to the specified angle. S Tighten the nut until it is at the specified angles. NOTE: When using a hexagonal nut, note that the angle from one corner to another is 60_.
CRANKSHAFT ENG EAS00381 CRANKSHAFT Order Job/Part Q’ty Remove the parts in the order listed. Separate. Refer to “CRANKCASE”. Refer to “CONNECTING RODS AND PISTONS”. Removing the crankshaft Crankcase Connecting rod caps 1 2 3 Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Remarks 1 5 5 For installation, reverse the removal procedure.
CRANKSHAFT ENG EAS00395 CHECKING THE CRANKSHAFT 1. Measure: S crankshaft runout Out of specification ! Replace the crankshaft. Crankshaft runout Less than 0.03 mm (0.0012 in) 2. Check: S crankshaft journal surfaces S crankshaft pin surfaces S bearing surfaces Scratches/wear ! Replace the crankshaft. CHECKING THE CRANKSHAFT JOURNAL BEARINGS 1. Measure: S crankshaft-journal-to-crankshaft-journalbearing clearance Out of specification ! Replace the crankshaft journal bearings.
CRANKSHAFT ENG c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase. NOTE: Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase. d. Put a piece of Plastigauge 2 on each crankshaft journal. NOTE: Do not put the Plastigauge over the oil hole in the crankshaft journal. e. Install the crankshaft journal lower bearings 1 into the lower crankcase and assemble the crankcase halves.
CRANKSHAFT ENG g. Remove the lower crankcase and the crankshaft journal lower bearings. h. Measure the compressed Plastigauge width c on each crankshaft journal. If the crankshaft-journal-to-crankshaft-journal-bearing clearance is out of specification, select replacement crankshaft journal bearings. 2.
CRANKSHAFT ENG EAS00407 INSTALLING THE CRANKSHAFT 1. Install: S crankshaft journal upper bearings 1 (into the upper crankcase) NOTE: S Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase. S Be sure to install each crankshaft journal upper bearing in its original place. 2. Install: S crankshaft 3. Install: S crankcase (lower) Refer to “CRANKCASE”.
TRANSMISSION ENG EAS00419 TRANSMISSION TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Drive axle assembly Circlip Oil seal Bearing Shift drum retainer Shift fork guide bar Spring Shift fork “L” Shift fork “R” Shift drum assembly Shift fork “C” Remarks Remove the part in the order listed.
TRANSMISSION ENG 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order 12 13 14 15 16 Job/Part Main axle assembly Oil pipe Oil baffle plate Thrust plate Washer Q’ty 10 Nm (1.0 mSkg, 7.2 ftSlb) Remarks 1 1 1 1 1 For installation, reverse the removal procedure.
TRANSMISSION Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Job/Part Disassembling the main axle assembly 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 Q’ty ENG Remarks Disassemble the parts in the order listed.
TRANSMISSION Order 15 16 Job/Part Bearing housing Bearing Q’ty ENG Remarks 1 1 For installation, reverse the removal procedure.
TRANSMISSION Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Job/Part Disassembling the drive axle assembly 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 Q’ty ENG Remarks Disassemble the parts in the order listed.
TRANSMISSION Order 15 16 17 18 19 20 21 22 23 24 Job/Part 6th wheel gear Circlip Washer 2nd wheel gear Collar Collar Oil seal Bearing Circlip Drive axle Q’ty ENG Remarks 1 1 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
TRANSMISSION ENG EAS00420 REMOVING THE TRANSMISSION 1. Remove: S main axle assembly 1 (with the Torx wrench T30) a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing. b. Tighten the bolts until they contact the crankcase surface. c. Continue tightening the bolts until the main axle assembly comes free from the upper crankcase. EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1.
TRANSMISSION ENG EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: S shift drum grooves Damage/scratches/wear ! Replace the shift drum assembly. S shift drum segment 1 Damage/wear ! Replace the shift drum assembly. S shift drum bearing 2 Damage/pitting ! Replace the shift drum assembly. EAS00425 CHECKING THE TRANSMISSION 1. Measure: S main axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the main axle. Main axle runout limit 0.02 mm (0.0008 in) 2.
TRANSMISSION ENG 4. Check: S transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect ! Reassemble the transmission axle assemblies. 5. Check: S transmission gear movement Rough movement ! Replace the defective part(s). 6. Check: S circlips Bends/damage/looseness ! Replace. EAS00430 INSTALLING THE TRANSMISSION 1.
TRANSMISSION ENG 3. Install: S shift fork “R” 1 and “L” 2 S drive axle 3 S shift fork guide bar S shift drum retainer 10 Nm (1.0 mSkg, 7.2 ftSlb) NOTE: S Install shift fork “L” into the groove in the 6th wheel gear and shift fork “R” into the groove in the 5th wheel gear on the drive axle. S Make sure that the drive axle bearing circlip a is inserted into the grooves in the upper crankcase. 9. Check: S transmission Rough movement ! Repair. NOTE: Oil each gear, shaft, and bearing thoroughly.
RADIATOR COOL EAS00454 COOLING SYSTEM RADIATOR 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part 7 Nm (0.7 mSkg, 5.1 ftSlb) Q’ty Remove the parts in the order listed. Refer to “SEATS” in chapter 3. Refer to “FUEL TANK” in chapter 3. Refer to “AIR FILTER CASE” in chapter 3. Refer to “COWLINGS” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3.
RADIATOR COOL 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order 9 Job/Part 7 Nm (0.7 mSkg, 5.1 ftSlb) Q’ty Radiator cap Remarks 1 For installation, reverse the removal procedure.
RADIATOR COOL EAS00455 CHECKING THE RADIATOR 1. Check: S 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, flathead screwdriver. 2. Check: S radiator hoses S radiator pipes Cracks/damage ! Replace. 3. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap. Radiator cap opening pressure 110 X 140 kPa (1.1 X 1.4 kg/cm2, 1.1 X 1.4 bar, 16.0 X 20.3 psi) a.
RADIATOR COOL EAS00456 INSTALLING THE RADIATOR 1. Fill: S cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: S cooling system Leaks ! Repair or replace any faulty part. 3. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap. Refer to “CHECKING THE RADIATOR”.
OIL COOLER COOL EAS00457 OIL COOLER 10 Nm (1.0 mSkg, 7.2 ftSlb) 63 Nm (6.3 mSkg, 46 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Refer to “RADIATOR”. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3.
OIL COOLER COOL EAS00458 CHECKING THE OIL COOLER 1. Check: S oil cooler Cracks/damage ! Replace. 2. Check: S oil cooler inlet hose S oil cooler outlet hose Cracks/damage/wear ! Replace. EAS00459 INSTALLING THE OIL COOLER 1. Clean: S mating surfaces of the oil cooler and the crankcase (with a cloth dampened with lacquer thinner) 2. Install: S O-ring New S oil cooler 1 S washer 2 New S bolt 3 63 Nm (6.
THERMOSTAT COOL EAS00461 THERMOSTAT 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Refer to “SEATS” chapter 3. Refer to “AIR FILTER CASE” in chapter 3. Refer to “THROTTLE BODIES” in chapter 7. Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Removing the thermostat Rider seat Air filter case Throttle body assembly Coolant 1 2 3 Remarks Radiator inlet hose Thermostat cover Thermostat 1 1 1 For installation, reverse the removal procedure.
THERMOSTAT COOL EAS00462 CHECKING THE THERMOSTAT 1. Check: S thermostat 1 Does not open at 71 X 85_C (160 X 185_F) ! Replace. 1 a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermostat and thermometer’s indicated temperature. 1 2 3 4 A B Thermostat Thermometer Water Container Fully closed Fully open NOTE: If the accuracy of the thermostat is in doubt, replace it.
THERMOSTAT COOL 3. Fill: S cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 4. Check: S cooling system Leaks ! Repair or replace any faulty part. 5. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap. Refer to “CHECKING THE RADIATOR”.
WATER PUMP COOL EAS00408 WATER PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Removing the water pump Bottom cowling Coolant 1 2 3 4 5 Water pump inlet hose Water pump outlet hose Water pump hose Clutch cable/holder Water pump Remarks Remove the parts in the order listed. Refer to “COWLINGS” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3.
WATER PUMP COOL 10 Nm (1.0 mSkg, 7.2 ftSlb) Order 1 2 3 4 5 6 7 8 Job/Part Disassembling the water pump Water pump cover O-ring Impeller shaft Circlip Water pump seal Oil seal Bearing Water pump housing Q’ty Remarks Disassemble the parts in the order listed. 1 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
WATER PUMP COOL EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: S circlip S impeller shaft 2. Remove: S water pump seal 1 NOTE: Remove the water pump seal from the outside of the water pump housing. 2 Water pump housing 3. Remove: S oil seal 1 (with a thin, flat-head screwdriver) NOTE: Remove the oil seal from the outside of the water pump housing. 4. Remove: S bearing 1 NOTE: Remove the bearing from inside of the water pump housing. 5.
WATER PUMP COOL EAS00473 CHECKING THE WATER PUMP 1. Check: S water pump housing 1 S water pump cover 2 S impeller 3 S rubber damper 4 S rubber damper holder 5 S water pump seals S oil seal Cracks/damage/wear ! Replace. 2. Check: S bearing Rough movement ! Replace. 3. Check: S water pump outlet pipe S radiator outlet hose Cracks/damage/wear ! Replace. EAS00475 ASSEMBLING THE WATER PUMP 1.
WATER PUMP COOL Mechanical seal installer 90890-04078, YM-33221 4 Middle driven shaft bearing driver 90890-04058, YM-04058 5 Quick Gasket ACC-11001-05-01 Yamaha bond #1215 90890-85505 A Push down. 3. Install: S rubber damper New 1 S rubber damper holder New 2 NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. 4. Measure: S impeller shaft tilt Out of specification ! Repeat steps (3) and (4).
WATER PUMP COOL INSTALLING THE WATER PUMP 1. Install: S water pump assembly 12 Nm (1.2 mSkg, 8.7 ftSlb) NOTE: Align the projection a at the oil pump shaft and water pump shaft groove b . 2. Install: S water pump outlet hose 1 S water pump inlet hose 2 NOTE: S Install the inlet hose with yellow a mark positioned outside. S Install the hose clamp with its screw head pointed to the inner side not to contact with the cowling. 3. Fill: S coolant Refer to “CHANGING THE COOLANT” in chapter 3.
FI FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Ignition coil 2 Air filter case 3 Intake temperature 4 5 6 7 sensor Fuel delivery hose Fuel tank Fuel pump Fuel return hose 8 Intake 13 Coolant 19 Atmospheric pressure 9 14 15 20 Fuel injection system 10 11 12 air pressure sensor Throttle position sensor Fuel injector Catalytic converter Crankshaft position sensor 16 17 18 7-1 temperature sensor Spark plug Cylinder identification sensor Pressure regulator Battery ECU senso
FUEL INJECTION SYSTEM FI WIRING DIAGRAM 1 Main switch 5 Battery 6 Fuse (main) 9 Fuse (fuel injection) 10 Fuse (ignition) 11 Starting circuit cut-off relay 12 Sidestand switch 13 Fuel pump 14 ECU 15 Ignition coil 16 Spark plug 17 Fuel injector 19 Neutral switch 20 Crankshaft position sensor 21 Intake air temperature sensor 22 Coolant temperature sensor 23 Throttle position sensor 24 Intake air pressure sensor 25 Atmospheric pressure sensor 26 Cylinder identification sensor 27 Speed sensor 28 Lean angle cu
FI FUEL INJECTION SYSTEM EAS00899 ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control 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.
FUEL INJECTION SYSTEM FI EAS00902 ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
FI FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. * Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light does not come on. The engine trouble warning light comes on. Check the fault code number displayed on the meter. Check the operation of following sensors and actuators in the Diagnostic mode (Refer to “Diagnostic mode table” in chapter 7.
FUEL INJECTION SYSTEM FI EAS00905 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ON”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more. NOTE: S All displays on the meter disappear except the clock and tripmeter displays. S “dIAG” appears on the clock LCD. 4.
FUEL INJECTION SYSTEM FI Fault code table Fault code No. Symptom 11 No normal signals are received from the cylinder identification sensor when the engine is started or while the motor cycle travels. NOTE: This code appears if no normal signals from the start switch is turned ON. S S S S S Open or short circuit in wiring sub lead. Open or short circuit in wiring harness. Defective cylinder identification sensor. Malfunction in ECU. Improperly installed sensor.
FUEL INJECTION SYSTEM Fault code No. Symptom FI Probable cause of malfunction Diagnostic code Open circuit is detected in the primary lead of the ignition coil (#1). S S S S Open circuit in wiring harness. Malfunction in ignition coil. Malfunction in ECU. Malfunction in a component of ignition cut-off circuit system. 30 Open circuit is detected in the primary lead of the ignition coil (#2). S S S S Open circuit in wiring harness. Malfunction in ignition coil. Malfunction in ECU.
FUEL INJECTION SYSTEM FI EAS00907 Diagnostic mode table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “DIAGNOSTIC MODE”. NOTE: S Check the intake temperature and coolant temperature as close as possible to the intake temperature sensor and the coolant temperature sensor respectively. S If it is not possible to check the atmospheric pressure with an atmospheric pressure gauge, determine the atmospheric pressure by using 760 mmHg as the standard.
FUEL INJECTION SYSTEM Diagnostic code Item Data displayed on meter (reference value) Ignition coil #3 After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates ignition coil #3 for five times every second and illuminates the engine trouble warning light. * Connect an ignition checker. * If the engine stop switch is ON, turn it OFF once, and then turn it back ON. Check that spark is generated, 5 times with the engine stop switch ON.
FI FUEL INJECTION SYSTEM Diagnostic code Item Data displayed on meter (reference value) Headlight relay 1 After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates the headlight relay five times every 5 seconds and illuminates the engine trouble warning light. (ON 2 seconds, OFF 3 seconds) * If the engine stop switch is ON, turn it OFF once, and then turn it back ON. Check the headlight relay operating sound 5 times with the engine stop switch ON.
FUEL INJECTION SYSTEM FI EAS00908 TROUBLESHOOTING DETAILS This section describes the countermeasures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order in the “TROUBLESHOOTING CHART”. After the check and service of the malfunctioned part has been completed, reset the meter display according to the “Reinstatement method”. Fault code No.
FI FUEL INJECTION SYSTEM Fault code No. 12 Symptom No normal signals are received from the crankshaft position sensor. Used diagnostic code No. – – Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Installed condition of sensor Check the installed area for looseness or pinching. Defective crankshaft position sensor. Replace if defective. 1. Disconnect the crankshaft position sensor coupler from the wire harness. 2.
FUEL INJECTION SYSTEM Fault code No. 13 Symptom FI Intake air pressure sensor - open or short circuit detected. Used diagnostic code No. 03 (intake air pressure sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective intake air pressure sensor Replace if defective. 1. Connect the pocket tester (DC 20 V) to the intake air pressure sensor coupler terminal as shown. Reinstated by turning the main switch ON.
FUEL INJECTION SYSTEM Fault code No. 14 Used diagnostic code Symptom FI Intake air pressure sensor - hose system malfunction (clogged or detached hose). No. 03 (intake air pressure sensor) Inspection operation item and probable cause Operation item and countermeasuer Reinstatement method Intake air pressure sensor hose detached, clogged, kinked, or pinched. Intake air pressure sensor malfunction at intermediate electrical potential.
FUEL INJECTION SYSTEM Fault code No. 19 Symptom FI Open circuit is detected in the input line from the sidestand switch to the ECU. Used diagnostic code No. 20 (sidestand switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective sidestand switch Replace if defective. Refer to “CHECKING THE SWITCHES” in chapter 8. If the transmission is in gear, it is reinstated by retracting the sidestand.
FUEL INJECTION SYSTEM FI Fault code No. 22 Symptom Open or short circuit detected from the intake temperature sensor. Used diagnostic code No. 05 (intake temperature sensor) Inspection operation item and probable cause Installed condition of sensor Defective intake temperature sensor. Operation item and countermeasure Check the installed area for looseness or pinching. Replace if defective. 1. Remove the intake air temperature sensor from the air filter case. 2.
FUEL INJECTION SYSTEM Fault code No. 23 Symptom FI Open or short circuit detected from the atmospheric pressure sensor. Used diagnostic code No. 02 (atmospheric pressure sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective atmospheric pressure sensor. Replace if defective. 1. Connect the pocket tester (DC 20 V) to the atmospheric pressure sensor coupler terminal as shown. Reinstated by turning the main switch ON.
FUEL INJECTION SYSTEM Fault code No. 30 Symptom FI The motorcycle has overturned. Used diagnostic code No. 08 (lean angle cut-off switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective lean angle cut-off switch Replace if defective. 1. Remove the lean angle cut-off switch from the motorcycle. 2. Connect the lean angle cut-off switch coupler to the wireharness. 3.
FUEL INJECTION SYSTEM Fault code No. 33 Symptom FI Malfunction detected in the primary lead of the ignition coil (#1). Used diagnostic code No. 30 (ignition coil #1) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective ignition coil (test the primary and secondary coils for continuity). Replace if defective. Refer to “IGNITION SYSTEM” in chapter 8. Open or short circuit in lead. Repair or replace if there is an open or short circuit.
FUEL INJECTION SYSTEM Fault code No. 36 Symptom FI Malfunction detected in the primary lead of the ignition coil (#4). Used diagnostic code No. 33 (ignition coil #4) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective ignition coil (test the primary and secondary coils for continuity). Replace if defective. Refer to “IGNITION SYSTEM” in chapter 8. Open or short circuit in lead wire. Repair or replace if there is an open or short circuit.
FUEL INJECTION SYSTEM Fault code No. 42 1 No normal signals are received from the speed sensor. 2 Open or short circuit is detected in the neutral switch. Used diagnostic code No. 07 (speed sensor) No. 21 (neutral switch) Inspection operation item and probable Operation item and countermeasure cause Defective speed sensor Replace if defective. 1. Measure the speed sensor output voltage. 2. Connect the pocket tester (DC 20 V) to the speed sensor coupler terminal as shown.
FUEL INJECTION SYSTEM Fault code No. 43 Symptom FI The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09 (fuel system voltage) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Malfunction in ECU Fuel injection system relay is on. Open or short circuit in the wiring harness. Repair or replace if there is an open or short circuit.
FUEL INJECTION SYSTEM Fault code No. 44 Symptom FI Error is detected while reading or writing on EEP-ROM (CO adjustment value). Used diagnostic No. 60 (EEP-ROM improper cylinder indication) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Malfunction in ECU Execute diagnostic code 60 * Check the faulty cylinder. (If there are multiple cylinders, the number of the faulty cylinders appear alternately at 2-second intervals.
FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom FI No signal are received from the ECU. Used diagnostic code No. – – Inspection operation item and probable cause Operation item and countermeasure Open or short circuit in wiring harness and / or Repair or replace if there is an open or short sub lead. circuit. Between sensor coupler and ECU coupler Yellow / Blue - Yellow / Blue Black / White - Black / White Connected condition of connector Inspect the coupler for any pins that may have pulled out.
FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom FI Non-registered data has been received from the meter. Used diagnostic code No. – – Inspection operation item and probable cause Operation item and countermeasure Open or short circuit in wiring harness and / or Repair or replace if there is an open or short sub lead. circuit.
THROTTLE BODIES FI THROTTLE BODIES Order Job/Part Q’ty Removing the throttle bodies Seats/fuel tank/rubber sheet Air filter case Coolant 1 2 3 4 5 Sub-wire harness coupler Coolant temp sensor coupler Throttle stop screw Throttle body joint clamp screw Throttle bodies 2 1 1 4 1 7-27 Remarks Remove the parts in the order listed. Refer to “SEATS” and “FUEL TANK” in chapter 3. Refer to “AIR FILTER CASE” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Disconnect. Loosen.
THROTTLE BODIES Order 6 7 8 9 Job/Part Throttle cable Plunger control unit hose Throttle body joint Heat protector Q’ty 2 2 4 1 FI Remarks Disconnect. Disconnect. For installation, reverse the removal procedure.
THROTTLE BODIES Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the injector Throttle position sensor coupler Intake air pressure sensor Cylinder #1-injector coupler Cylinder #2-injector coupler Cylinder #3-injector coupler Cylinder #4-injector coupler Sub wire harness 2 Negative pressure hose Pressure regulator Q’ty 1 1 1 1 1 1 1 1 1 7-29 FI Remarks Remove the parts in the order listed. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.
THROTTLE BODIES Order 10 11 12 13 14 Job/Part Intake air pressure sensor Fuel distributor Injector Throttle position sensor Throttle body assembly Q’ty FI Remarks 1 1 4 1 1 For installation, reverse the removal procedure.
THROTTLE BODIES FI EAS00911 CAUTION: The throttle bodies should not be disassembled. EAS00912 CHECKING THE INJECTOR 1. Check: S injector Damage ! Replace. EAS00913 CHECKING THE THROTTLE BODY 1. Check: S throttle body Cracks/damage ! Replace the throttle bodies. 2. Check: S fuel passages Obstruction ! Clean. a. Wash the throttle body in a petroleumbased solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of passages with compressed air.
THROTTLE BODIES FI CHECKING THE PRESSURE REGULATOR 1. Check: S pressure regulator Damage ! Replace. CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: S pressure regulator operation a. Remove the fuel tank. Refer to “FUEL TANK” in chapter 3. b. Disconnect the negative pressure hose 1 from the pressure regulator at the joint. c. Connect the vacuum/pressure pump gauge set 2 onto the negative pressure hose from the pressure regulator. d.
THROTTLE BODIES FI Increase the vacuum pressure ! Fuel pressure is decreased Decrease the vacuum pressure ! Fuel pressure is increased Faulty ! Replace the pressure regulator. EAS00916 CHECKING AND ADJUSTING THROTTLE POSITION SENSOR THE NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: S throttle position sensor a. Disconnect the throttle position sensor coupler. b. Remove the throttle position sensor from the throttle body. c.
THROTTLE BODIES FI f. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range. The resistance does not change or it changes abruptly ! Replace the throttle position sensor. The slot is worn or broken ! Replace the throttle position sensor. NOTE: Check mainly that the resistance changes gradually when turning the throttle, since the readings (from closed to wide-open throttle) may differ slightly from those specified.
AIR INDUCTION SYSTEM FI EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approximately 600 to 700_C (1112 to 1292_F).
AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 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 7-36 FI
AIR INDUCTION SYSTEM FI EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: S hoses Loose connection ! Connect properly. Cracks/damage ! Replace. S pipes Cracks/damage ! Replace. 2. Check: S reed valve 1 S reed valve stopper S reed valve seat Cracks/damage ! Replace the reed valve. 3. Measure: S reed valve bending limit a Out of specification ! Replace the reed valve. Reed valve bending limit 0.4 mm (0.016 in) 1 Surface plate 4. Check: S air cut-off valve Cracks/damage ! Replace.
AIR INDUCTION SYSTEM FI 5. Check S air induction system solenoid a. Remove the air induction system solenoid coupler from the wire harness. b. Connect the pocket tester (Ω 1) to the air induction system solenoid terminal as shown. Tester positive probe ! orange 1 Tester negative probe ! green 2 c. Measure the air induction system solenoid resistance. Air induction system solenoid resistance 18 X 22 Ω at 20_C (68_F) d. Out of specification ! Replace.
ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 Main switch Front brake light switch Clutch switch Battery Starter relay Fuse (main) Neutral switch Rear brake light switch 9 10 11 12 13 14 8-1 Sidestand switch Oil level switch Radiator fan motor Horn Ignition coil Fuse box ELEC
ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 Coolant temperature sensor Intake air temperature sensor Intake air pressure sensor Lean angle cut-off switch Atmospheric pressure sensor ECU Starting circuit cut-off relay Turn signal relay 9 10 11 12 13 14 ELEC Speed sensor Crankshaft position sensor Cylinder identification sensor Radiator fan motor relay Headlight relay (on / off) Headlight relay (dimmer) 8 8-2
CHECKING SWITCH CONTINUITY ELEC EAS00730 CHECKING SWITCH CONTINUITY 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. CAUTION: Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler 1 taking care not to loosen or damage the leads.
CHECKING THE SWITCHES ELEC EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.
CHECKING THE BULBS AND BULB SOCKETS ELEC EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear ! Repair or replace the bulb, bulb socket or both. Improperly connected ! Properly connect. No continuity ! Repair or replace the bulb, bulb socket or both. TYPES OF BULBS The bulbs used on this motorcycle are shown in the illustration on the left.
CHECKING THE BULBS AND BULB SOCKETS ELEC CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: S bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: S Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.
CHECKING THE BULBS AND BULB SOCKETS ELEC CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: S bulb socket (for continuity) (with the pocket tester) No continuity ! Replace. Pocket tester 90890-03112, YU-3112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. a. Install a good bulb into the bulb socket. b.
IGNITION SYSTEM ELEC EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM 1 5 6 10 11 12 14 15 16 19 20 28 44 55 8-8 Main switch Battery Fuse (main) Fuse (ignition) Starting circuit cut-off relay Sidestand switch ECU Ignition coil Spark plug Neutral switch Crankshaft position sensor Lean angle cut-off switch Engine stop switch Clutch switch
IGNITION SYSTEM EAS00737 ELEC EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The ignition system fails to operate (no spark or intermittent spark). Check: 1. main and ignition fuses 2. battery 3. spark plugs 4. ignition spark gap 5. ignition coil resistance 6. crankshaft position sensor 7. main switch 8. engine stop switch 9. neutral switch 10. sidestand switch 11. clutch switch 12. starting circuit cut-off relay 13.
ELEC IGNITION SYSTEM EAS00743 EAS00747 4. Ignition spark gap 5. Ignition coil resistance The following procedure applies to all of the spark plugs. S Disconnect the ignition coil from the spark plug. S Connect the dynamic spark tester 1 and ignition coil 2 as shown. S Turn the main switch to “ON”. S Measure the ignition spark gap a . S Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs.
IGNITION SYSTEM EAS00748 ELEC EAS00750 6. Crankshaft position sensor resistance 8. Engine stop switch S Disconnect the crankshaft position sensor coupler from the wire harness. S Connect the pocket tester (Ω 100) to the crankshaft position sensor coupler as shown. S Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the engine stop switch OK? YES Positive tester probe ! gray 1 Negative tester probe ! black 2 NO Replace the right handlebar switch. EAS00751 9.
IGNITION SYSTEM ELEC EAS00753 12. Starting circuit cut-off relay NOTE: When you switch the positive and negative tester probes, the readings in the above chart will be reversed. S Disconnect the starting circuit cut-off relay coupler from the wire harness. S Connect the pocket tester (Ω 1) to the starting circuit cut-off relay coupler as shown. S Check the starting circuit cut-off relay for continuity.
IGNITION SYSTEM YES NO Replace the lean angle cut-off switch. EAS00754 14. Wiring S Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the ignition system’s wiring properly connected and without defects? YES Replace the ignitor unit. NO Properly connect or repair the ignition system’s wiring.
ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 1 5 6 7 8 10 11 12 19 44 45 55 8-14 Main switch Battery Fuse (main) Starter relay Starter motor Fuse (ignition) Starting circuit cut-off relay Sidestand switch Neutral switch Engine stop switch Start switch Clutch switch
ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: S The transmission is in neutral (the neutral switch is closed). S The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
ELECTRIC STARTING SYSTEM EAS00757 ELEC EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The starter motor fails to turn. Check: 1. main and ignition fuses 2. Battery 3. starter motor 4. starting circuit cut-off relay 5. starter relay 6. main switch 7. engine stop switch 8. neutral switch 9. sidestand switch 10. clutch switch 11. start switch 12.
ELECTRIC STARTING SYSTEM ELEC EAS00759 4. Starting circuit cut-off relay S Disconnect the starting circuit cut-off relay coupler from the wire harness. S Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay coupler as shown.
ELECTRIC STARTING SYSTEM EAS00752 ELEC EAS00766 9. Sidestand switch 12. Wiring S Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the sidestand switch OK? S Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the starting system’s wiring properly connected and without defects? YES NO YES Replace the sidestand switch. The starting system circuit is OK. EAS00763 10. Clutch switch S Check the clutch switch for continuity.
STARTER MOTOR ELEC EAS00767 STARTER MOTOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 5 Nm (0.5 mSkg, 3.6 ftSlb) Order 1 2 Job/Part Removing the starter motor Rider seat Fuel tank Left side cowling Starter motor lead Starter motor Q’ty Remarks Remove the parts in the order listed. Refer to “SEATS” in chapter 3. Refer to “FUEL TANK” in chapter 3. Refer to “COWLINGS” in chapter 3. 1 1 For installation, reverse the removal procedure.
STARTER MOTOR ELEC EAS00768 7 Nm (0.7 mSkg, 5.1 ftSlb) 3.4 Nm (0.34 mSkg, 2.5 ftSlb) Order 1 2 3 4 5 6 7 8 9 10 11 12 Job/Part Disassembling the starter motor O-ring Front cover Lock washer Oil seal Bearing Washer set Rear cover Washer set O-ring Brush holder Armature assembly Starter motor yoke Q’ty Remarks Disassembly the parts in the order listed. 1 1 1 1 1 1 1 1 2 1 1 1 For assembly, reverse the disassembly procedure.
STARTER MOTOR ELEC EAS00770 CHECKING THE STARTER MOTOR 1. Check: S commutator Dirt ! Clean with 600 grit sandpaper. 2. Measure: S commutator diameter a Out of specification ! Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3. Measure: S mica undercut a Out of specification ! Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut 0.7 mm (0.
STARTER MOTOR ELEC 5. Measure: S brush length a . Out of specification ! Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: S brush spring force Out of specification ! Replace the brush springs as a set. Brush spring force 7.16 X 9.52 N (730 X 971 gf, 25.77 X 34.27 oz) 7. Check: S gear teeth Damage/wear ! Replace the gear. 8. Check: S bearing S oil seal Damage/wear ! Replace the defective part(s). EAS00772 ASSEMBLING THE STARTER MOTOR 1.
ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM 2 3 5 6 8-23 A.C.
CHARGING SYSTEM ELEC EAS00774 Minimum open-circuit voltage 12.8 V or more at 20_C (68_F) TROUBLESHOOTING The battery is not being charged. S Is the battery OK? Check: 1. main fuse 2. battery 3. charging voltage 4. stator coil resistance 1 5. stator coil resistance 2 6. wiring connections (of the entire charging system) YES NO S Clean the battery terminals. S Recharge or replace the battery. EAS00775 NOTE: S Before troubleshooting, remove the following part(s): 1. seat 2. fuel tank 3.
ELEC CHARGING SYSTEM EAS00776 4. Stator coil resistance 1 5. Stator coil resistance 2 S Disconnect stator coil lead coupler. S Connect the pocket tester (Ω 1) to the stator coil lead coupler as shown. S Remove the generator cover. S Connect the pocket tester (Ω 1) to the stator coils as shown.
LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 8-26 ELEC
LIGHTING SYSTEM 1 5 6 10 14 38 40 47 51 52 56 63 64 65 66 67 Main switch Battery Fuse (main) Fuse (ignition) ECU High beam indicator light Meter light Fuse (headlight) Headlight relay (on / off) Headlight relay (dimmer) Dimmer switch Front turn signal/position light (right) Front turn signal/position light (left) Headlight License light Tail/ brake light 8-27 ELEC
LIGHTING SYSTEM ELEC EAS00781 Minimum open-circuit voltage 12.8 V or more at 20_C (68_F) TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, licence light or meter light. S Is the battery OK? YES Check: 1. main, ignition and headlight fuses 2. battery 3. main switch 4. dimmer switch 5. headlight relay (on/off) 6. headlight relay (dimmer) 7. wiring connections (of the entire lighting system) NO S Clean the battery terminals.
LIGHTING SYSTEM ELEC 5. Headlight relay (on/off) S Disconnect the headlight relay (on/off) from the coupler. S Connect the pocket tester (Ω 1) and battery (12 V) to the headlight relay (on/off) coupler as shown. Positive battery lead ! blue/black 1 Negative battery lead ! yellow/white 2 S Does the headlight relay (dimmer) have continuity? Positive tester probe ! red/yellow 3 Negative tester probe ! black/blue 4 YES NO Replace the headlight relay (dimmer). EAS00787 7.
LIGHTING SYSTEM ELEC EAS00788 Headlight Positive tester probe ! black/yellow 3 Negative tester probe ! black 4 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. B High beam 1. Headlight bulb and socket S Check the headlight bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” S Are the headlight bulb and socket OK? YES NO Replace the headlight bulb, socket or both.
ELEC LIGHTING SYSTEM EAS00789 EAS00790 2. The meter light fails to come on. 3. The tail/brake light fails to come on. 1. Meter light (LEDs) 1. Tail/brake light (LEDs) S Check the meter light for continuity. Refer to “CHECKING THE LEDs” S Are the meter light OK? S Check the tail/brake light for continuity. Refer to “CHECKING THE LEDs” S Are the tail/brake light OK? YES NO YES Replace the meter assembly. NO Replace the tail/brake light assembly. 2. Voltage 2.
LIGHTING SYSTEM ELEC EAS00792 5. The turn signal/position light fails to come on. 4. The license light fails to come on. 1. License light bulb and socket 1. Turn signal/position light bulb and socket S Check the license light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” S Are the license light bulb and socket OK? YES S Check the turn signal/position light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 8-33 ELEC
SIGNALING SYSTEM 1 5 6 10 11 13 14 19 27 30 31 32 33 34 35 37 39 41 43 46 53 57 58 59 60 61 62 63 64 67 Main switch Battery Fuse (main) Fuse (ignition) Starting circuit cut-off relay Fuel pump ECU Neutral switch Speed sensor Fuel level warning light Oil level warning light Neutral indicator light Tachometer Shift timing indicator light Multi-function meter Coolant temperature indicator light Turn signal indicator light Oil level switch Front brake light switch Fuse (signal) Rear brake light switch Horn swi
SIGNALING SYSTEM ELEC EAS00794 TROUBLESHOOTING YES S Any of the following fail to light: turn signal light, brake light or an indicator light. S The horn fails to sound. S Clean the battery terminals. S Recharge or replace the battery. Check: 1. main, ignition and signaling fuses 2. battery 3. main switch 4. wiring connections (of the entire signaling system) EAS00749 3. Main switch S Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”.
ELEC SIGNALING SYSTEM EAS00797 2. Voltage 2. The tail/brake light fails to come on. S Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown. 1. Tail/brake light (LEDs) S Check the tail/brake light for continuity. Refer to “CHECKING THE LEDs” S Are the tail/brake light OK? Positive tester probe ! black/white 1 Negative tester probe ! ground YES NO Replace the tail/brake light assembly. 2. Brake light switches S Turn the main switch to “ON”. S Push the horn switch.
SIGNALING SYSTEM YES This circuit is OK. S Turn the main switch to “ON”. S Measure the voltage (DC 12 V) on brown 1 at the turn signal relay coupler (wire harness side). S Is the voltage within specification? NO The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired. YES NO The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be repaired. EAS00799 3.
SIGNALING SYSTEM ELEC YES Left turn signal light Positive tester probe ! chocolate 1 Negative tester probe ! ground Right turn signal light Positive tester probe ! dark green 2 Negative tester probe ! ground A B NO Replace the meter assembly. 2. Neutral switch S Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the neutral switch OK? YES NO Replace the neutral switch. C 3.
SIGNALING SYSTEM ELEC EAS00802 3. Voltage 5. The oil level warning light fails to come on. S Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. 1. Oil level warning light (LEDs) S Check the oil level warning light for continuity. Refer to “CHECKING THE LEDs” S Are the oil level warning light OK? YES Positive tester probe ! black/red 1 Negative tester probe ! black/white 2 NO Replace the meter assembly. 2. Oil level switch S Turn the main switch to “ON”.
SIGNALING SYSTEM ELEC 2. Fuel sender 3. Voltage S Drain the fuel from the fuel tank and remove the fuel pump from the fuel tank. S Disconnect the fuel sender coupler from the wire harness. S Connect the pocket tester (Ω 1) to the fuel sender as shown. S Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown.
SIGNALING SYSTEM ELEC 2. Speed sensor 3. Voltage S Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness side) as shown. S Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Positive tester probe ! white/yellow 1 Negative tester probe ! blue 2 Positive tester probe ! yellow/blue 1 Negative tester probe ! black/white 2 S Turn the main switch to “ON”. S Elevate the rear wheel and slowly rotate it.
COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM 1 5 6 10 14 Main switch Battery Fuse (main) Fuse (ignition) ECU 22 48 49 50 Coolant temperature sensor Fuse (radiator fan motor) Radiator fan motor relay Radiator fan motor 8-42 ELEC
COOLING SYSTEM EAS00808 ELEC EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. S The radiator fan motor fails to turn. S The coolant temperature indicator light fails to light when the engine is warm. Minimum open-circuit voltage 12.8 V or more at 20_C (68_F) Check: 1. main, ignition, and radiator fan motor fuses 2. battery 3. main switch 4. radiator fan motor 5. radiator fan motor relay 6.
COOLING SYSTEM ELEC EAS00809 4. Radiator fan motor 5. Radiator fan motor relay S Disconnect the radiator fan motor coupler from the wire harness. S Connect the battery (DC 12 V) as shown. S Disconnect the radiator fan motor relay form the wire harness. S Connect the pocket tester (Ω 1) and battery (12 V) to the radiator fan motor terminal as shown. S Check the radiator fan motor of continuity.
COOLING SYSTEM ELEC EAS00812 6. Coolant temperature sensor S Remove the coolant temperature sensor. S Connect the pocket tester (Ω 1k) to the 1 coolant temperature sensor as shown. S Immerse the coolant temperature sensor in a container filled with coolant 2 . NOTE: Make sure the coolant temperature sensor terminals do not get wet. S Place a thermometer 3 in the coolant. S Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table.
FUEL PUMP SYSTEM ELEC EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 1 5 6 9 10 11 13 14 44 8-46 Main switch Battery Fuse (main) Fuse (fuel injection) Fuse (ignition) Starting circuit cut-off relay Fuel pump ECU Engine stop switch
FUEL PUMP SYSTEM ELEC EAS00815 FUEL PUMP SYSTEM The ECU includes the control unit for the fuel pump.
FUEL PUMP SYSTEM EAS00816 ELEC EAS00739 TROUBLESHOOTING 2. Battery If the fuel pump fails to operate. S Check the condition of the battery Refer to “CHECKING THE BATTERY” in chapter 3. Check: 1. Main, ignition and fuel injection fuses 2. Battery 3. Main switch 4. Engine stop switch 5. Starting circuit cut-off relay (the fuel pump injection system relay) 6. Fuel pump 7. Wiring connections (the entire fuel system) Minimum open-circuit voltage 12.
ELEC FUEL PUMP SYSTEM EAS00759 EAS00817 5. Starting circuit cut-off relay 6. Fuel pump resistance S Disconnect the starting circuit cut-off relay coupler from the wire harness. S Connect the pocket tester (Ω 1) and battery (12V) to the starting circuit cut-off relay coupler as shown. S Disconnect the fuel pump coupler from the wire harness. S Connect the pocket tester (Ω 1) to the fuel pump coupler as shown.
FUEL PUMP SYSTEM ELEC EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: S Stop the engine before refueling. S Do not smoke, and keep away from open flames, sparks, or any other source of fire. S If you do accidentally spill gasoline, wipe it up immediately with dry rags. S If gasoline touches the engine when it is hot, a fire may occur.
SELF-DIAGNOSIS ELEC SELF-DIAGNOSIS The YZF-R6 features a self-diagnosing system for the following circuit(-s): S Fuel sender S Oil level switch If any of these circuits are defective, their respective condition codes will be displayed on the warning light when the main switch is turn to “ON” (irrespective of whether the engine is running or not) Circuit Defect(-s) System response Condition code Fuel sender S Open-circuit S Short-circuit S The fuel warning light indicate the condition code.
SELF-DIAGNOSIS TROUBLESHOOTING ELEC 1. Wire harness The warning light starts to indicate the self-diagnosis sequence. S Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? Check: 1. Fuel sender 2. Oil level switch YES NOTE: S Before troubleshooting, remove the following part(-s): 1) Seats 2) Fuel tank 3) Lower cowling S Troubleshoot with the following special tool(-s). NO Repair or replace the wire harness. 2.
SELF-DIAGNOSIS 2. Oil level switch CIRCUIT DIAGRAM 2. Oil level switch S Check the oil level switch for continuity. Refer to “The oil level warning light fails to come on”. S Is the oil level switch OK? YES Replace the multifunction meter. 35 Multi-function meter 41 Oil level switch 1. Wire harness S Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? YES ELEC NO Repair or replace the wire harness. 8-53 NO Replace the oil level switch.
STARTING FAILURES TRBL SHTG EAS00844 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
STARTING FAILURES/INCORRECT ENGINE IDLING SPEED/ POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Switches and wiring S Faulty main switch S Faulty engine stop switch S Broken or shorted wiring S Faulty neutral switch S Faulty start switch S Faulty sidestand switch S Faulty clutch switch S Improperly grounded circuit S Loose connections TRBL SHTG Starting system S Faulty starter motor S Faulty starter relay S Faulty starting circuit cut-off relay S Faulty starter clutch EAS00846 INCORRECT ENGINE IDLING SPEED ENGI
FAULTY GEAR SHIFTING/FAULTY CLUTCH TRBL SHTG EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to “CLUTCH DRAGS”. SHIFT PEDAL DOES NOT MOVE Shift shaft S Improperly adjusted shift rod S Bent shift shaft.
OVERHEATING/OVERCOOLING/ POOR BRAKING PERFORMANCE TRBL SHTG EAS00855 OVERHEATING ENGINE Cylinder head(s) and piston(s) S Heavy carbon buildup Engine oil S Incorrect oil level S Incorrect oil viscosity S Inferior oil quality COOLING SYSTEM Coolant S Low coolant level Radiator S Damaged or leaking radiator S Faulty radiator cap S Bent or damaged radiator fin Water pump S Damaged or faulty water pump S Thermostat S Thermostat stays closed S Oil cooler S Clogged or damaged oil cooler S Hose(s) and pipe(s) S
FAULTY FRONT FORK LEGS/UNSTABLE HANDLING TRBL SHTG EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL S Bent, damaged or rusty inner tube S Cracked or damaged outer tube S Improperly installed oil seal S Damaged oil seal lip S Incorrect oil level (high) S Loose damper rod assembly bolt S Damaged damper rod assembly bolt copper washer S Cracked or damaged cap bolt O-ring MALFUNCTION S Bent or damaged inner tube S Bent or damaged outer tube S Damaged fork spring S Worn or damaged outer tube bushing S Bent or dam
FAULTY LIGHTING OR SIGNALING SYSTEM TRBL SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON S Wrong headlight bulb S Too many electrical accessories S Hard charging S Incorrect connection S Improperly grounded circuit S Poor contacts (main switch) S Burnt-out headlight bulb S Faulty headlight relay (on/off) HEADLIGHT BULB BURNT OUT S Wrong headlight bulb S Faulty battery S Faulty rectifier/regulator S Improperly grounded circuit S Faulty main switch S Headlight bulb life expired
YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Main switch A.C.
YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Main switch A.C.
PRINTED IN U.S.A.
YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC WIRING DIAGRAM
