EAS00010 FZ6-SS/FZ6-SSC SERVICE MANUAL 2003 by Yamaha Motor Corporation, U.S.A. First edition, November 2003 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 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 . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE PADS . . . . . . . . . . . ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . .
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . .
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT SHAFT AND STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 5-39 5-41 5-41 5-41 CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR . . . . . . .
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CONNECTING RODS AND PISTONS . . . . . . . . REMOVING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . CHECKING THE CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BIG END BEARINGS . . . . . . . . . . . . . . . . . . . .
CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECU’S SELF-DIAGNOSTIC FUNCTION . . . . . . . . . . . . . . . . . . . . . . ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAIL-SAFE ACTIONS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT CUT-OFF SYSTEM OPERATION . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 8-14 8-15 8-16 STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19 CHECKING THE STARTER MOTOR . . . . . . . . . .
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE . . . . . . . . . . . . 9-2 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFTING IS DIFFICULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT PEDAL DOES NOT MOVE . . . . . . . . .
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 carburetor.
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 250 kPa (2.5 kg/cm2). 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 bottom segment of the fuel meter started flashing) S a tachometer (which shows the engine speed) S a fuel meter S a water
FEATURES GEN INFO Clock mode To set the clock: 1. Push the “SELECT” button and “RESET” button together for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button to set the hours. 3. Push the “SELECT” button, and the minute digits will start flashing. 4. Push the “RESET” button to set the minutes. 5. Push the “SELECT” button and then release it to start the clock.
IMPORTANT INFORMATION GEN INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, eliminate 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 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. Middle driven shaft bearing driver 90890-04058 YM-4058 Mechanical seal installer 90890-04078 YM-33221 Tool name/Function Middle driven shaft bearing driver Mechanical seal installer These tools are used to install the water pump seal. Clutch holding tool 90890-04086 YM-91042 This tool is used to hold the clutch boss when removing or installing the clutch boss nut. Valve lapper 90890-04101 This tool is needed to remove and install the valve lifter.
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 5VX3 (USA except for CAL) 5VX4 (CAL) SSS 2,095 mm (82.5 in) 750 mm (29.5 in) 1,215 mm (47.8 in) 795 mm (31.3 in) 1,440 mm (56.7 in) 145 mm (5.71 in) 2,800 mm (110.
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 Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure Engine oil temperature Reli
ENGINE SPECIFICATIONS Item 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 Starting system type Spark plugs Model (manufacturer) Spark plug gap Cylinder head Volume Max.
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 (0.0032 in) Measurement A 32.45 X 32.55 mm (1.278 X 1.282 in) Measurement B 24.95 X 25.05 mm (0.982 X 0.986 in) 32.40 mm (1,276 in) 24.90 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 92RH2015 /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 37.0 mm (1.46 in) 38.4 mm (1.51 in) 41.8 mm (1.65 in) 35.2 mm (1.39 in) 36.5 mm (1.44 in) 39.7 mm (1.56 in) 30 mm (1.18 in) 32.5 mm (1.28 in) 36.1 mm (1.42 in) SSS SSS SSS 69.0 X 79.0 N (7.03 X 8.05 kg, 15.50 X 17.75 lb) 114.0 X 132.0 N (11.62 X 13.46 kg, 25.63 X 29.
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) 0.08 mm (0.0032 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 4th 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 46/16 (2.875) 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.
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. lateral wheel runout Front tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 X 90 kg (0 X 198 lb) 90 X 190 kg (198 X 419 lb) 90 X 189 kg (198 X 417 lb) High-speed riding Min.
CHASSIS SPECIFICATIONS Item Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 X 90 kg (0 X 198 lb) 90 X 190 kg (198 X 419 lb) 90 X 189 kg (198 X 417 lb) High-speed riding Min. tire tread depth Front brakes Brake type Operation Recommended fluid 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) (except for CAL) 290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi) (CAL) 250 kPa (2.5 kgf/cm2, 2.
CHASSIS SPECIFICATIONS Item Front suspension Suspension type Front fork type Front fork travel Spring Free length SPEC Standard Limit Telescopic fork Coil spring/oil damper 130 mm (5.12 in) SSS SSS SSS 354.0 mm (13.94 in) Spacer length Installed length Spring rate (K1) Spring rate (K2) Spring stroke (K1) Spring stroke (K2) Inner tube outer diameter Inner tube bending limit 131.5 mm (5.18 in) 347.0 mm (13.66 in) 7.4 N/mm (0.75 kg/mm, 42.25 lb/in) 11.8 N/mm (1,20 kg/mm, 67.38 lb/in) 0 X 70 mm (0 X 2.
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 Swingarm Free play (at the end of the swingarm) Radial Axial Drive chain Model (manufacturer) Link quantity Drive chain slack Maximum ten-link section
ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit 12 V SSS DC. T.C.I. 5_ BTDC at 1,300 r/min Digital 248 X 372 Ω at 20_C (68_F)/Gy-B SSS SSS SSS SSS F8T811 (MITSUBISHI) SSS Ignition coils Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance JO383 (DENSO) 6 mm (0.24 in) 1.53 X 2.07 Ω at 20_C (68_F) 12.0 X 18.0 kΩ at 20_C (68_F) SSS SSS SSS SSS Spark plug cap Material Resistance Resin 10.
ELECTRICAL SPECIFICATIONS Item SPEC Standard Indicator light (voltage /wattage quantity) Neutral indicator light High beam indicator light Oil level warning light Turn signal indicator light Engine trouble warning light Electric starting system System type Starter motor Model (manufacturer) Power output Brushes Overall length LED LED LED LED LED 1 1 1 2 1 Limit SSS SSS SSS SSS SSS Constant mesh SSS SM-14 (MITSUBA) 0.6 kW SSS SSS 10 mm (0.39 in) 3.5 mm (0.
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) Taillight fuse Reserve fuse 30 A 1 10 A 1 20 A 1 10 A 1 10 A 1 20 A 1 10 A 1 10 A 1 30 A, 20 A, 10 A SSS SSS SSS SSS SSS SSS SSS SSS SSS Fuel level sender Model (manufacture) Sender unit resistance-full Sender unit resistance-empty 5VX (DENSO) 20 X 26 Ω 134 X 140 Ω SSS SSS SSS St
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 Air indication system reed valve cover Air-cut valve stay Camshaft sprockets Connecting rod caps (except for CAL) Connecting rod caps (for CAL) Generator rotor Timing chain tensioner Timing chain tensioner cap bolt Thermostat cover Coolant hose joint Water pump cover Water pump Thermo sensor Coolant hose drain bolt (water pump) Radiator and fram
TIGHTENING TORQUES Item Crankcase (main journal) Crankcase Crankcase Crankcase 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 Starter motor cover bolt Clutch pressure plate Clutch boss Drive sprocket Transmissio
TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence.
TIGHTENING TORQUES SPEC CHASSIS TIGHTENING TORQUES Item Upper bracket pinch bolt Steering stem nut Upper bracket and upper handlebar holder Under bracket pinch bolt Lower ring nut Front fork cap bolt Damper rod assembly bolt Pinch bolt (front wheel axle) Front brake master cylinder and master cylinder bracket Front brake master cylinder cap screw Front brake hose union bolt Front brake hose holder and front fork Front cowling stay and frame Front cowling bracket and frame Front fender and front fork Clutc
TIGHTENING TORQUES Item Side cover and rear frame Rear mud guard and rear frame Engine stop switch and frame Coolant reserver tank bracket and stay 1, 2 Stay 1, 2 and frame Coolant reserver tank bracket and coolant reserver tank Canister and canister bracket (for CAL) Canister bracket and coolant reserver tank bracket (forCAL) Front wheel axle shaft and bolt Front wheel axle pinch bolt Front brake caliper and front fork Front brake disc and front wheel Brake caliper bleed screw Rear wheel axle nut Rear brak
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings and bushes Crankshaft pins Piston surfaces Piston pins Connecting rod bolts 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
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 Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Sidestand pivoting point and metal-to-metal moving parts Link and sidestand switch contact point Throttle grip inner surface Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and m
COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 1 Radiator 2 Oil cooler 2-25 SPEC
COOLING SYSTEM DIAGRAMS 1 Water pump 2 Oil cooler 3 Radiator 2-26 SPEC
COOLING SYSTEM DIAGRAMS 1 Oil cooler 2 Water pump 2-27 SPEC
COOLING SYSTEM DIAGRAMS 1 Radiator 2 Thermostat 2-28 SPEC
ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART 2-29 SPEC
LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil level switch 2 Oil cooler 3 Relief valve 2-30 SPEC
LUBRICATION DIAGRAMS 1 2 3 4 Oil pump Exhaust camshaft Intake camshaft Oil strainer 2-31 SPEC
LUBRICATION DIAGRAMS 1 Oil cooler 2 Oil strainer 3 Oil level switch 4 Oil pump 2-32 SPEC
LUBRICATION DIAGRAMS 1 Main axle 2 Oil pump 3 Relief valve 2-33 SPEC
LUBRICATION DIAGRAMS 1 2 3 4 Cylinder head Intake camshaft Exhaust camshaft Crankshaft 2-34 SPEC
LUBRICATION DIAGRAMS 1 Main axle 2 Drive axle 2-35 SPEC
CABLE ROUTING SPEC CABLE ROUTING 1 2 3 4 5 Left handlebar switch lead Main switch lead Clutch cable Throttle cables Right handlebar switch lead A Clamp the right and left handlebar switch leads and handlebars. Point the tip of the clamp downward in front of the handlebars. B Clamp the horn lead and main switch lead to the inner tube. Point the binding section to the outside of the vehicle body and cut the tip down to the length of 1 to 5 mm (0.04 to 0.20 in). C Route the horn lead by the headmost side.
CABLE ROUTING F Clamp the brake hose to the inner tube. Point the binding section to the outside of the vehicle body and cut the tip down to the length of 1 to 5 mm (0.04 to 0.20 in). G Pass the throttle cables through the wire guide. Route the right handlebar switch lead by the outside of the wire guide.
CABLE ROUTING 1 2 3 4 5 Right handlebar switch lead Rear brake light switch lead Neutral switch lead Fuel tank breather hose Crankshaft position sensor lead A Pass the right handlebar switch lead through the hole located on the right side of the frame. B Route the right handlebar switch lead under the bracket 2. C Route the coolant reservoir tank hose under the cover 2. Route the radiator hose (outside) inner side. SPEC D Route the radiator hoses (2 pieces) under the cover 2.
CABLE ROUTING I Pass the neutral switch lead between the engine and coolant reservoir tank bracket. J To the starter motor. K Install the right handlebar switch lead coupler through the hole of the bracket 2 from the downside. L Route the starter motor lead by the inner side of the air cut-off valve hose. M Pass the ignition coil leads #1 and #4 through inner side of the air cut-off valve hose, and then between the frame and bracket 2.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Main switch lead Stay assembly Left handlebar switch lead Clutch cable Throttle cables Battery negative lead coupler Starter relay lead Battery negative lead Fuel tank drain hose Rectifier/regulator Turn signal relay Radiator fan motor relay Dimmer relay Starting circuit cut-off relay Clamp 16 17 18 19 20 21 22 23 24 25 26 27 28 29 2-40 SPEC License plate light lead Rear turn signal light lead (right) Rear turn signal light lead (left) Speed sensor lead
CABLE ROUTING A Route the throttle cables above the stay assy 1. B Route the main switch lead above the clutch cable. C Line up the left handlebar switch lead coupler and fan motor lead coupler behind the head pipe. D To the main switch. E Place three couplers on the flange of the cover. F To the fuel pump. G Clamp four wire leads. There should be no excessive slack on the wire leads. H To the engine. I To the fuel tank.
CABLE ROUTING R To the rear turn signal light (left) S Pass the fuel tank drain hose through the clamp located under the coolant reservoir tank. T Route it behind the starter motor lead. U Point the bend-R section of the throttle cable (pull side) to the inner side horizontally. It is also possible to visually check the bend-R section. V To the headlight lead. W Point the tip of the clamp to the inner side of the vehicle body. SPEC X Make sure to pass the neutral switch lead through the hole of the flap.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 Right handlebar switch lead Throttle cables Battery positive lead Coolant reservoir tank hose Battery cover Connecter cover Fuel tank breather hose Brake fluid reservoir hose Lean angle cut-off switch Fuse box Rear turn signal light lead (right) Rear turn signal light lead (left) License plate light lead 14 15 16 17 18 19 20 21 22 23 24 25 2-43 SPEC Seat lock cable Rectifier/regulator E.C.
CABLE ROUTING A Either right or left side arrangement for the left handlebar switch lead coupler and radiator fan motor coupler can be accepted. B Point the L-shape terminal to the front side of the vehicle. C Hook the starter motor lead to the alternate pawls on the battery cover. D Route the crank shaft position sensor lead above the starter motor leads. E To the crankshaft position sensor. F Clamp the starter motor lead and crank shaft position sensor lead.
CABLE ROUTING S To the license plate light. T To the tail/brake light. U Insert the enwinding clamp of the wire harness into the hole of the rear frame. V Attach the rectifier regulator lead to the clamp of the rectifier bracket. W To the engine ground. X To the fuel injection. Y To the fuel pump. Z Route the clutch cable under the fuel injection lead. AA Pass the clutch cables through the clamp, and then install the clamp to the cover. Position of the clamp is forward of the cable stopper.
CABLE ROUTING AL Route the spark plug lead #4 by the front side of the spark plug leads #2 and #3. AM Route the spark plug leads #2 and #3 behind the air cut-off valve hose.
CABLE ROUTING 1 2 3 4 5 6 7 8 Fuel pump assembly Fuel tank breather hose (except for CAL) Fuel tank drain hose Fuel hose Clip Clamp Charge hose (for CAL) Roll over valve (for CAL) A B C D Air opening. Install the O-ring with its lip pointed upward. Fuel tank breather hose has a white point mark. Point the knob of clip front side. SPEC a Fuel piping connector attachment directions. (fuel pump side) 1.
CABLE ROUTING except for CAL 1 Coolant breather hose 2 Coolant reservoir tank 3 Coolant reservoir tank hose 4 Clamp 5 Fuel tank drain hose SPEC A Front side. B Pass the coolant reservoir tank hose hangs down downward from back of the bolt. C Insert this portion securely. D Spittle is turned back. E Insert the clamp certainly. F It may open and close to direction of which. All notches gear at the time of attachment. G Pass the coolant reservoir tank hose inside of the clamp. H Insert in certainly.
CABLE ROUTING for CAL 1 Clip 2 Roll over valve 3 Canister hoes 4 Balance hose 5 Coolant reservoir tank 6 Coolant reservoir tank hose 7 Coolant breather hose 8 Roll over valve hose 9 Canister 10 Hose 11 Fuel tank drain hose 12 Clamp SPEC A Front side. B Point the paint marking upward. C Pass the canister hose and balance hose behind the bolt. D Pass the canister hose outside, pass the balance hose inside. E Pass the coolant reservoir tank hose hangs dowm downward from back of the bolt.
CABLE ROUTING K Insert the clamp certainly. L It may open and close to direction of which. All notches gear at the time of attachment. M Pass the coolant reservoir tank hose and the fuel tank drain hose inside of the clamp. N Point the knob of clamp downward. O Point the knob of clamp upward. P Insert in certainly. Q To the fuel tank drain tube. R Point the paint marking (both white) front side. The application of water is possible at the time of attachment.
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. 9 ITEM * Swingarm pivot bearings (See page 4-70) Drive chain (See page 3-49, 50) 10 600 mi (1,000 km) or 1 month REMARKS S Check bearing assemblies for looseness. S Moderately repack with lithium-soap-based 12,000 mi (19,000 km) or 18 months Ǹ S Check chain slack/alignment and condition. S Adjust and lubricate chain with a special O- 16,000 mi (25,000 km) or 24 months 20,000 mi (31,000 km) or 30 months Repack.
SEAT CHK ADJ EAS00038 SEAT Order 1 Job/Part Q’ty Removing the seat Seat Remarks Remove the parts in the order listed. 1 For installation, reverse the removal procedure.
FUEL TANK CHK ADJ EAS00040 FUEL TANK 7 Nm (0.7 mSkg, 5.1 ftSlb) Order 7 Nm (0.7 mSkg, 5.1 ftSlb) Job/Part Q’ty Removing the fuel tank 1 2 3 4 5 6 7 Seat Front cowling inner panel (left and right) Fuel hose Fuel sender coupler Fuel pump coupler Fuel tank drain hose Fuel tank breather hose (except for CAL) Canister hose (for CAL) Remove the parts in the order listed. Disconnect. Refer to “SEAT”. Refer to “COWLINGS”.
FUEL TANK 7 Nm (0.7 mSkg, 5.1 ftSlb) Order 8 Job/Part CHK ADJ 7 Nm (0.7 mSkg, 5.1 ftSlb) Q’ty Roll over valve (for CAL) Remarks 1 For installation, reverse the removal procedure. Refer to the CABLE ROUTING for how to attach a hose.
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 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 33 Nm (3.3 mSkg, 24 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 5 Nm (0.5 mSkg, 3.6 ftSlb) Order Job/Part Q’ty 1 2 3 4 5 6 7 Removing the cowlings Seat Front cowling inner panel (left and right) Front turn signal light lead couplers Front cowling Rear view mirrors (left and right) Windshield Rear cowling Frame side cover Remarks Remove the parts in the order listed. Refer to “SEAT”. 2 2 1 2 1 1 2 Disconnect.
AIR FILTER CASE CHK ADJ EAS00043 AIR FILTER CASE 7 Nm (0.7 mSkg, 5.1 ftSlb) Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Q’ty Remarks Remove the parts in the order listed. Refer to “SEAT”. Refer to “COWLINGS”.
BATTERY BOX AND BATTERY BOX BRACKET CHK ADJ BATTERY BOX AND BATTERY BOX BRACKET 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty 1 Battery box 1 2 3 Battery box bracket Ignition coil assembly 3 2 Remarks Remove the parts in the order listed. NOTE: This part has to be set properly. For installation, reverse the removal procedure.
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 seat Refer to “SEAT”. S front cowling inner panel (left and right) Refer to “COWLINGS”. S fuel tank Refer to “FUEL TANK”.
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 “CAMSHAFTS” 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 . Valve lapper 90890-04101 NOTE: S Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.
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 “CAMSHAFTS” 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 seat Refer to “SEAT”.
SYNCHRONIZING THE THROTTLE BODIES CHK ADJ 6. 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 7. Adjust: S throttle body synchronization a. With throttle body #1 as standard, adjust throttle bodies #2, #3, and #4 using the air screws 1 . #1 2 , #2 3 , #3 4 , #4 5 NOTE: S After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.
ADJUSTING THE ENGINE IDLING SPEED CHK ADJ EAS00052 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the throttle bodies synchronization should be adjusted properly, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Check: S engine idling speed Out of specification ! Adjust. Engine idling speed 1250 X 1350 r/min 3. Adjust: S engine idling speed a.
ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ EAS00055 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and throttle bodies synchronization should be adjusted properly. 1. Check: S throttle cable free play a Out of specification ! Adjust. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm (0.12 X 0.20 in) 2. Remove: S seat Refer to “SEAT”. S front cowling inner panel (left and right) Refer to “COWLINGS”.
ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ Handlebar side a. Loosen the locknut 1 . b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. Direction a Throttle cable free play is increased. Direction b Throttle cable free play is decreased. c. Tighten the locknut. 4. Install: S battery assembly Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. S air filter case Refer to “AIR FILTER CASE”. S fuel tank Refer to “FUEL TANK”.
ADJUSTING THE EXHAUST GAS VOLUME CHK ADJ 3. Using the “SELECT” button, select either the Co adjustment mode (which appears as “Co”) or the diagnosis mode (which appears as “dIAG”) 4. After “Co” appears as a result of pressing the “SELECT” button, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or more to excute the selection. 5. Press the “SELECT” or “RESET” buttons to select the “C1” or “C2”.
CHECKING THE SPARK PLUGS CHK ADJ EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: S radiator lower bolt 1 S radiator lower hose bracket bolt 2 2. Remove: S spark plug caps S spark plugs A Right side #1 and #2 and #3 B Left side #4 A CAUTION: Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 3. Check: S spark plug type Incorrect ! Change.
CHECKING THE SPARK PLUGS/ MEASURING THE COMPRESSION PRESSURE 7. Install: S spark plug S spark plug caps CHK ADJ 18 Nm (1.8 mSkg, 13 ftSlb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Install: S radiator lower hose bracket bolt S radiator lower bolt EAS00065 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1.
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 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. Install: S spark plug 18 Nm (1.
CHECKING THE ENGINE OIL LEVEL CHK ADJ EAS00069 CHECKING THE ENGINE OIL 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. Start the engine, warm it up for several minutes, and then turn it off. 3. Check: S engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b . Below the minimum level mark ! Add the recommended engine oil to the proper level.
CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CHK ADJ 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. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. EAS00074 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2.
CHANGING THE ENGINE OIL CHK ADJ 5. 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 9. Install: S engine oil filler cap 10. Start the engine, warm it up for several minutes, and then turn it off. 11. Check: S engine (for engine oil leaks) 12. Check: S engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. 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.
MEASURING THE ENGINE OIL PRESSURE CHK ADJ 5. 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.
ADJUSTING THE CLUTCH CABLE FREE PLAY/ CLEANING THE AIR FILTER ELEMENT CHK ADJ 4. Install: S air filter case Refer to “AIR FILTER CASE”. S fuel tank Refer to “FUEL TANK”. S front cowling inner panel (left and right) Refer to “COWLINGS”. S seat Refer to “SEAT”. EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: S rider seat Refer to “SEAT”. S front cowling inner panel (left and right) Refer to “COWLINGS”. S fuel tank Refer to “FUEL TANK”. 2. Remove: S air filter case cover 1 S air filter element 2 3.
CLEANING THE AIR FILTER ELEMENT/ CHECKING THE THROTTLE BODY JOINTS CHK ADJ NOTE: When installing the air filter element into the air filter case cover, make sure their sealing surfaces are aligned to prevent any air leaks. 6. Install: S fuel tank Refer to “FUEL TANK”. S front cowling inner panel (left and right) Refer to “COWLINGS”. S rider seat Refer to “SEAT”. EAS00095 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds. 1.
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 “SEAT”. S front cowling inner panel (left and right) Refer to “COWLINGS” S fuel tank Refer to “FUEL TANK”. 2. Check: S breather hose 1 S fuel hose 2 Cracks/damage ! Replace. Loose connection ! Connect properly.
CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM CHK ADJ 3. Install: S fuel tank Refer to “FUEL TANK”. S front cowling inner panel (left and right) Refer to “COWLINGS”. S rider seat Refer to “SEAT”. EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Remove: S radiator Refer to “RADIATOR” in chapter 6. 2. Check: S exhaust pipe 1 S catalyst pipe 2 S muffler 3 Cracks/damage ! Replace. S gasket 4 Exhaust gas leaks ! Replace. 3.
CHECKING THE COOLANT LEVEL CHK ADJ EAS00102 CHECKING THE COOLANT 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 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.
CHECKING THE COOLING SYSTEM/ CHANGING THE COOLANT CHK ADJ EAS00104 CHECKING THE COOLING SYSTEM 1. 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. EAS00105 CHANGING THE COOLANT 1. Remove: S seat Refer to “SEAT”.
CHK ADJ CHANGING THE COOLANT 3. Disconnect: S coolant reservoir cap 1 4. Drain: S coolant (from the coolant reservoir tank) 5. Remove: S radiator cap lock bolt 1 S radiator cap 2 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 2.0 L (1.76 Imp qt, 2.11 US qt) Coolant reservoir capacity 0.27 L (0.24 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 from the top of the rider footrest to the top of the brake pedal) Out of specification ! Adjust. Brake pedal position (below the top of the rider footrest) 25.8 mm (1.02 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.
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/ CHECKING THE FRONT AND REAR BRAKE PADS 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. EAS00118 CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2.
ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT AND REAR BRAKE HOSES CHK ADJ EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by movement of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1. Check: S rear brake light operation timing Incorrect ! Adjust. 2. Adjust: S rear brake light operation timing a.
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 f. Tighten both locknuts to specification. Locknut 16 Nm (1.6 mSkg, 12 ftSlb) g. Tighten the wheel axle nut to specification. Wheel axle nut 120 Nm (12 mSkg, 87 ftSlb) EAS00143 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas.
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 6 completely, then tighten it to specification. WARNING Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 18 Nm (1.8 mSkg, 13 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 lower 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 REAR SHOCK ABSORBER ASSEMBLY CHK ADJ EAS00156 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 a ring nut wrench. Ring nut wrench 90890-01268, YU-01268 b. Turn the adjusting ring 1 in direction a or b. c.
CHECKING THE TIRES CHK ADJ 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. S Operation of an overloaded motorcycle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE MOTORCYCLE.
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) 1 Tire tread depth 2 Sidewall 3 Wear indicator 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.
CHECKING THE TIRES/CHECKING THE WHEELS CHK ADJ Front tire Manufacturer Size Model BRIDGESTONE 120/70ZR 17 M/C (58W) BT020F GG DUNLOP 120/70ZR 17 M/C (58W) D252F Manufacturer Size Model BRIDGESTONE 180/55ZR 17 M/C (73W) BT020R GG DUNLOP 180/55ZR 17 M/C (73W) D252 Rear tire WARNING New tires and wheels 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 CENTERSTAND 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. Check: S cable operation Rough movement ! Lubricate.
LUBRICATING THE REAR SUSPENSION CHK ADJ EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension.
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 “SEAT”. S front cowling inner panel (left and right) Refer to “COWLINGS”. S fuel tank Refer to “FUEL TANK”. 2.
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 CHK ADJ Charging method using a variable-current (voltage) charger Charging method using a constant voltage charger 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.
CHK ADJ CHECKING THE FUSES EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Remove: S right side cover Refer to “COWLINGS”. 2. Check: fuse a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω 1”. Pocket tester 90890-03112, YU-3112 b. If the pocket tester indicates “∞”, replace the fuse. 3.
CHECKING THE FUSES CHK ADJ WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. 4. Install: S right side cover Refer to “COWLINGS”.
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 2 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. 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. 2. Adjust: S headlight beam (horizontally) a. Turn the adjusting knob 2 in direction a or b. Left headlight Direction a Headlight beam moves to the right.
FRONT WHEEL AND BRAKE DISCS CHAS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 6 Nm (0.6 mSkg, 4.3 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 4 Nm (0.4 mSkg, 2.9 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) 72 Nm (7.2 mSkg, 52 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 Order 1 2 3 Job/Part Q’ty Disassembling the front wheel Oil seal (left and right) Wheel bearing (left and right) Spacer Remarks Disassemble 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 NOTE: Do not apply the brake lever when removing the brake calipers. 3.
FRONT WHEEL AND BRAKE DISCS CHAS 2. Check: S tire S front wheel Damage/wear ! Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 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.
FRONT WHEEL AND BRAKE DISCS CHAS c. Remove the wheel bearings 3 with a general bearing puller. d. Install the new wheel bearings and oil seals in the reverse order of disassembly. CAUTION: Do not contact the wheel bearing inner race 1 or balls 2 . Contact should be made only with the outer race 3 . Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal. EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1.
FRONT WHEEL AND BRAKE DISCS CHAS 3. Measure: S brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification ! Replace. Brake disc thickness limit (minimum) Front: 4.5 mm (0.18 in) Rear: 4.5 mm (0.18 in) 4. Adjust: S brake disc deflection a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 18 Nm (1.8 mSkg, 13 ftSlb) LOCTITE d.
CHAS FRONT WHEEL AND BRAKE DISCS 3. Insert the wheel axle. NOTE: Install the tire and wheel with the mark 1 pointing in the direction of wheel rotation. 4. Lower the front wheel so that it is on the ground. 5. Tighten: S wheel axle 72 Nm (7.2 mSkg, 52 ftSlb) S wheel axle pinch bolt 23 Nm (2.3 mSkg, 17 ftSlb) CAUTION: Before tightening the wheel axle pinch bolt, push down hard in the handlebar several times and check if the front fork rebounds smoothly. 6.
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 22 Nm (2.2 mSkg, 16 ftSlb) 27 Nm (2.7 mSkg, 20 ftSlb) 120 Nm (12 mSkg, 87 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 1 2 3 4 5 6 7 8 Job/Part 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 Rear wheel Q’ty Remarks Remove the parts in the order listed. 1 1 2 2 2 1 6 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 assembly, 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 locknut 1 S adjusting nut 2 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.
REAR WHEEL AND BRAKE DISC CHAS 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 10 Nm (1.0 mSkg, 7.2 ftSlb) 6 Nm (0.6 mSkg, 4.3 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 Front brake caliper Brake pad Brake pad spring Bleed screw Remarks 1 2 2 1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS REAR BRAKE PADS 3 Nm (0.3 mSkg, 2.2 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 27 Nm (2.7 mSkg, 20 ftSlb) 22 Nm (2.2 mSkg, 16 ftSlb) Order 1 2 3 4 5 6 7 Job/Part Removing the rear brake pads. Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad Brake screw Brake pad spring Q’ty Remarks Remove the parts in the order listed 1 1 1 4 2 1 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 EAS00582 REPLACING THE FRONT BRAKE PADS The following procedure applies to both brake calipers. NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1. Remove: S side reflector 1 S side reflector bracket (left side only) 2 S brake hose holder 3 S brake caliper 4 2. Remove: S brake pads 1 (along with the brake pad shims) S brake pad shims (onto the brake pads) S brake pad spring 3.
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) d. Install a new brake pad shim onto each new brake pad. 5. Install: S brake caliper 40 Nm (4.0 mSkg, 29 ftSlb) 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 2 S brake caliper 3 S brake pad spring 4 2. Remove: S brake pads 1 (along with the brake pad shims) 3. 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) 4.
FRONT AND REAR BRAKES CHAS 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 . 5. Install: S brake pad cover S brake caliper (front) (rear) S brake pad pin S screw plug 27 Nm (2.7 mSkg, 20 ftSlb) 22 Nm (2.2 mSkg, 16 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 3 Nm (0.3 mSkg, 2.2 ftSlb) 6.
FRONT AND REAR BRAKES CHAS EAS00584 FRONT BRAKE MASTER CYLINDER 2 Nm (0.2 mSkg, 1.4 ftSlb) 10 Nm (1.0 mSkg, 72 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed.
FRONT AND REAR BRAKES CHAS 2 Nm (0.2 mSkg, 1.4 ftSlb) 10 Nm (1.0 mSkg, 72 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order 10 Job/Part Master cylinder assembly Q’ty Remarks 1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00585 Order 1 2 3 4 5 6 Job/Part Disassembling the front brake master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder Push rod Q’ty Remarks Disassemble the parts in the order listed. 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00586 REAR BRAKE MASTER CYLINDER 30 Nm (3.0 mSkg, 22 ftSlb) 23 Nm (2.3 mSkg, 17 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 Remarks Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
FRONT AND REAR BRAKES CHAS EAS00587 Order Job/Part Q’ty 1 2 3 4 5 Disassembling the rear brake master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder body Remarks Disassemble the parts in the order listed. 1 1 1 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: S brake light switch coupler 1 (from the brake light switch) 2. Remove: S union bolt 1 S copper washers 2 S brake hoses 3 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 3. Check: S rear brake fluid reservoir 1 Cracks/damage ! Replace. S rear brake fluid reservoir diaphragm 2 Cracks/damage ! Replace. 4. Check: S front brake master cylinder reservoir 1 Cracks/damage ! Replace. S front brake master cylinder reservoir diaphragm 2 Damage/wear ! Replace. 5. Check: S brake hoses Cracks/damage/wear ! Replace. Refer to “CHECKING THE FRONT AND REAR BRAKE HOSES” in chapter 3. EAS00589 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1.
FRONT AND REAR BRAKES CHAS EAS00598 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 master cylinder kit S circlip New S brake master cylinder 1 NOTE: S Install the brake master cylinder holder with the “UP” mark facing up.
FRONT AND REAR BRAKES CHAS NOTE: S While holding the brake hose, tighten the union bolt as shown. S Turn the handlebar 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. 3. Fill: S brake master cylinder 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 EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: S brake master cylinder kit S circlip S dust boot 2. Install: S copper washers New S brake hoses S union bolt 30 Nm (3.0 mSkg, 22 ftSlb) WARNING Proper brake hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING” in chapter 2. CAUTION: When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a as shown. 3.
FRONT AND REAR BRAKES CHAS CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. 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. 6. Adjust: S brake pedal position a Refer to “ADJUSTING THE REAR BRAKE” in chapter 3.
FRONT AND REAR BRAKES CHAS EAS00613 FRONT BRAKE CALIPERS 4 Nm (0.4 mSkg, 2.9 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 10 Nm (1.0 mSkg, 72 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order 1 2 3 4 5 6 Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. NOTE: The following procedure applies to both of the front brake calipers. Brake fluid Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
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 Brake pad Brake caliper piston Brake caliper piston seal Brake pad spring Bleed screw Remarks 2 2 4 1 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00616 REAR BRAKE CALIPER 22 Nm (2.2 mSkg, 16 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 27 Nm (2.7 mSkg, 20 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. Removing the rear brake caliper Brake fluid 1 2 3 4 Union bolt Copper washer Brake hose Brake caliper Remarks 1 2 1 1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00617 6 Nm (0.6 mSkg, 4.3 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 3 Nm (0.3 mSkg, 2.2 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 p 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.
CHAS FRONT AND REAR BRAKES EAS00638 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 2. Fill: S brake master cylinder 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.
FRONT AND REAR BRAKES CHAS EAS00642 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 27 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 30 Nm (3.0 mSkg, 22 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE DISCS”. Refer to “FRONT AND REAR BRAKES”. Removing the front fork legs Front wheel 1 2 3 4 5 Front brake calipers Front fender Cap bolt Upper bracket pinch bolt Under bracket pinch bolt Front fork leg Remarks 1 1 1 1 1 Loosen. Loosen. Loosen.
FRONT FORK CHAS EAS00648 24 Nm (2.4 mSkg, 17 ftSlb) 23 Nm (2.3 mSkg, 17 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 24 Nm (2.4 mSkg, 17 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order 13 14 15 16 17 Job/Part Inner tube Outer tube bushing Inner tube bushing Oil flow stopper Outer tube Q’ty Remarks 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. Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Loosen: S upper bracket pinch bolt 1 S cap bolt 2 S under bracket pinch bolt 3 WARNING Before loosening the upper and under bracket pinch bolts, support the front fork leg. 3.
FRONT FORK CHAS 3. Remove: S dust seal 1 S oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 4. Remove: S damper rod assembly bolt NOTE: While holding the damper rod assembly with the damper rod holder 1 and T-handle 2 , loosen the damper rod assembly bolt. Damper rod holder 90890-01294 T-handle 90890-01326 5. Remove: S inner tube a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c.
FRONT FORK CHAS EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: S inner tube 1 S outer tube 2 Bends/damage/scratches ! Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: S spring free length a Out of specification ! Replace. Spring free length 354 mm (13.94 in) : 347 mm (13.66 in) 3. Check: S damper rod 1 Damage/wear ! Replace.
FRONT FORK CHAS EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING S Make sure the oil levels in both front fork legs are equal. S Uneven oil levels can result in poor handling and a loss of stability. NOTE: S When assembling the front fork leg, be sure to replace the following parts: – inner tube bushing – outer tube bushing – oil seal – dust seal – before assembling the front fork leg, make sure all of the components are clean. 1.
FRONT FORK CHAS Damper rod holder 90890-01294 T-handle 90890-01326 4. Install: S outer tube bushing 1 (with the fork seal driver weight 2 and fork seal driver attachment 3 ) Fork seal driver weight 90890-01367 Fork seal driver attachment 90890-01374 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.
FRONT FORK CHAS 7. Install: S dust seal 1 (with the fork seal driver weight) Fork seal driver weight 90890-01367 8. Fill: S front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 0.467 L (0.41 Imp qt, 0.49 US qt) Recommended oil Suspension oil “01” or equivalent CAUTION: S Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.
FRONT FORK CHAS 10. Install: S spring 1 S spring seat 2 S spacer 3 S cap bolt NOTE: S Install the spring with the smaller pitch a facing up. S Before installing the cap bolt, lubricate its Oring with grease. b Larger pitch EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: S front fork leg Temporarily tighten the upper and under bracket pinch bolts. NOTE: Make sure the inner fork tube is flush with the top of the upper bracket. 2.
HANDLEBAR CHAS EAS00664 HANDLEBAR 26 Nm (2.6 mSkg, 19 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) 23 Nm (2.
HANDLEBAR CHAS EAS00666 REMOVING THE HANDLEBAR 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 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar. 3. Disconnect: S clutch switch connector 4. Remove: S left handlebar switch 1 S clutch cable 2 S clutch lever holder 3 5.
HANDLEBAR CHAS EAS00672 INSTALLING THE HANDLEBAR 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 handlebar 1 S upper handlebar holders 2 23 Nm (2.3 mSkg, 17 ftSlb) S upper handlebar holder caps 3 CAUTION: S First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. S Turn the handlebar all the way to the left and right.
CHAS HANDLEBAR 5. Install: S grip end 26 Nm (2.6 mSkg, 19 ftSlb) 6. 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) 3 X 5 mm (0.12 X 0.20 in) 7. Install: S clutch lever holder 1 S clutch cable NOTE: Align the slit on the clutch lever holder with the punch mark a on the handlebar. 8. Adjust: S clutch cable free play Refer to “ADJUST THE CLUTCH CABLE FREE PLAY” in chapter 3.
STEERING HEAD CHAS EAS00676 STEERING HEAD UNDER BRACKET 110 Nm (11 mSkg, 80 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE DISCS”. Removing the under bracket Front wheel 1 2 3 4 5 6 Remarks Front fender Front fork Handlebar Front cowling inner panel (left and right) Fuel tank Main switch coupler Steering stem nut Washer Upper bracket Horn stay Lock washer Refer to “FRONT FORK”.
STEERING HEAD CHAS 110 Nm (11 mSkg, 80 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order 7 8 9 10 11 12 13 14 15 16 Job/Part Upper ring nut 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 1 2 1 1 1 2 For installation, reverse the removal procedure.
STEERING HEAD CHAS EAS00677 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 rung nut with the ring nut wrench.
STEERING HEAD CHAS 3. Replace: S bearing balls 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 lower bracket with a floor chisel 4 and hammer. c. Install a new dust 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 bearing balls and bearing races as a set.
STEERING HEAD CHAS 3. Install: S upper bracket S washer S steering stem nut 110 Nm (11 mSkg, 80 ftSlb) 4. Install: S front fork legs Refer to “INSTALLING THE FRONT FORK LEGS”.
REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00685 REAR SHOCK ABSORBER ASSEMBLY 40 Nm (4.0 mSkg, 29 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Removing the rear shock absorber assembly Rear wheel 1 2 3 4 Self-locking nut/collar/bolt (Swingarm-rear shock absorber) Self-locking nut/washer/bolt (Frame-rear shock absorber) Rear shock absorber Oil seal/bearing Remarks Refer to “REAR WHEEL AND BRAKE DISC”.
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 EAS00686 HANDLING THE REAR SHOCK ABSORBER WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, 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. S Do not tamper or attempt to open the rear shock absorber.
REAR SHOCK ABSORBER ASSEMBLY CHAS S spring Damage/wear ! Replace the rear shock absorber assembly. S bushings Damage/wear ! Replace. S dust seals Damage/wear ! Replace. S bolts Bends/damage/wear ! Replace. EAS00697 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: S collar S bearings S oil seals Recommended lubricant Lithium-soap-based grease 2. Install: S collar S rear shock absorber assembly NOTE: When installing the rear shock absorber assembly, lift up the swingarm. 3.
SWINGARM AND DRIVE CHAIN CHAS SWINGARM AND DRIVE CHAIN 7 Nm (0.7 mSkg, 5.1 ftSlb) 16 Nm (1.6 mSkg, 12 ftSlb) 120 Nm (12 mSkg, 87 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Removing the swingarm and drive chain Muffler assembly Catalyst assembly Exhaust pipe assembly Rear wheel Refer to “EXHAUST PIPE” in chapter 5.
SWINGARM AND DRIVE CHAIN 7 Nm (0.7 mSkg, 5.1 ftSlb) CHAS 16 Nm (1.6 mSkg, 12 ftSlb) 120 Nm (12 mSkg, 87 ftSlb) Order 8 9 10 11 Job/Part Drive chain guide Dust cover Bearing Spacer Q’ty Remarks 1 2 2 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 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. AS00711 INSTALLING THE SWINGARM 1. Lubricate: S bearings S spacer S dust covers S pivot shaft Recommended lubricant Lithium-soap-based grease 2. Install: S swingarm 1 S pivot shaft nut 2 120 Nm (12 mSkg, 87 ftSlb) 3. Install: S rear shock absorber assembly S rear wheel Refer to “INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY” and “INSTALLING THE REAR WHEEL”. 4.
SWINGARM AND DRIVE CHAIN CHAS 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. S Perform this measurement at two or three different places. 2.
SWINGARM AND DRIVE CHAIN CHAS 4. Check: S drive chain rollers 1 Damage/wear ! Replace the drive chain. S drive chain side plates 2 Damage/wear ! Replace the drive chain. Cracks ! Replace the drive chain and make sure the battery breather hose is properly routed away from the drive chain and below the swingarm. 5. Lubricate: S drive chain Recommended lubricant Engine oil or chain lubricant suitable for non-O-ring chains 6.
ENGINE ENG EAS00188 ENGINE ENGINE DRIVE SPROCKET 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 5 90 Nm (9.0 mSkg, 65 ftSlb) Order Job/Part Q’ty Removing the drive sprocket Drive chain 1 2 3 4 5 6 7 2 1 1 1 1 1 1 Lock nut Shift rod Shift arm Drive sprocket cover Nut Lock washer Drive sprocket Remarks Loosen. Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. Loosen. For installation, reverse the removal procedure.
ENGINE ENG EAS00189 EXHAUST PIPE 20 Nm (2.0 mSkg, 15 ftSlb) 9 Nm (0.9 mSkg, 6.5 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 34 Nm (3.4 mSkg, 26 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 16 Nm (1.6 mSkg, 11.6 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) Order 1 2 3 4 5 Job/Part Q’ty Remarks Remove the parts in the order listed.
ENGINE ENG EAS00191 LEADS AND HOSES Order Job/Part Q’ty Disconnecting the leads and hoses Seat Front cowling inner panel (left and right) Fuel tank Battery Air filter case Battery box and battery box bracket Throttle body assembly Engine oil Oil filter cartridge Oil cooler Air cut-off valve 5-3 Remarks Disconnect the parts in the order listed. Refer to “SEAT” in chapter 3. Refer to “COWLINGS” in chapter 3. Refer to “FUEL TANK” in chapter 3. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3.
ENGINE Order Job/Part Q’ty Remarks Refer to “COOLING SYSTEM” in chapter 6. Refer to “STARTER MOTOR” in chapter 8. Radiator Starter motor 1 2 3 4 5 6 7 8 9 ENG 1 1 1 1 1 1 1 1 1 Battery negative lead Battery positive lead Clutch cable Ground lead Stator coil assembly coupler Crankshaft position sensor coupler Oil level switch connector Neutral switch connector Speed sensor coupler 5-4 Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. For installation, reverse the removal procedure.
ENGINE ENG EAS00191 ENGINE 55 Nm (5.5 mSkg, 40 ftSlb) 55 Nm (5.5 mSkg, 40 ftSlb) 55 Nm (5.5 mSkg, 40 ftSlb) 55 Nm (5.5 mSkg, 40 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine. Removing the engine 1 2 3 4 5 Remarks 1 2 2 2 1 Right front engine mounting bolt Left front engine mounting bolt Self locking nut Rear engine mounting bolt Engine Refer to “INSTALLING THE ENGINE”. For installation, reverse the removal procedure.
ENGINE ENG EAS00192 INSTALLING THE ENGINE 1. Install: S rear engine mounting bolts 1 NOTE: Lubricate the rear engine mounting bolt threads with lithium-soap-based grease. 2. Install: S right front engine mounting bolt 2 S left front engine mounting bolts 3 NOTE: Do not fully tighten the bolts. 3. Tighten: S self-locking nut 4 55 Nm (5.5 mSkg, 40 ftSlb) NOTE: First tighten the lower self-locking nut. 4. Tighten S left front engine mounting bolts 5 55 Nm (5.
ENGINE ENG 5. Tighten S right front engine mounting bolts 6 55 Nm (5.5 mSkg, 40 ftSlb) 6. Install: S shift arm 7 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. S Align the bottom edge of the shift pedal with the mark on the frame-to-swingarm bracket.
CAMSHAFTS ENG EAS00194 CAMSHAFTS CYLINDER HEAD COVER 12 Nm (1.2 mSkg, 8.7 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) Order Job/Part Q’ty Removing the cylinder head cover Battery Remove the parts in the order listed. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Refer to “AIR FILTER CASE” in chapter 3. Refer to “BATTERY BOX AND BATTERY BOX BRACKET” in chapter 3. Refer to “THROTTLE BODIES” in chapter 7. Refer to “COOLING SYSTEM” in chapter 6. Refer to “AIR INDUCTION SYSTEM” in chapter 7.
CAMSHAFTS ENG EAS00196 CAMSHAFTS 10 Nm (1.0 mSkg, 7.2 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 10 Nm (1.0 mSkg, 7.
CAMSHAFTS ENG 10 Nm (1.0 mSkg, 7.2 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order 10 11 12 13 Job/Part Exhaust camshaft Pin Timing chain guide (intake side) Cam sprocket Q’ty Remarks 1 1 1 2 For installation, reverse the removal procedure.
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 32.45 X 32.55 mm (1.278 X 1.282 in) : 32.
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 (0.0032 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 aluminum 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 camshaft 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 NOTE: NOTE: 5-20 ENG
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 Lubricate the cylinder head bolts with engine oil.
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 stem 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 stem 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 valve stem 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) 37.0 mm (1.46 in) : 35.2 mm (1.39 in) Intake valve spring (outer) 38.4 mm (1.51 in) : 36.5 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_/1.7 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.
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 seat Refer to “SEAT” in chapter 3. S front cowling inner panel (left and right) Refer to “COWLINGS” in chapter 3. S fuel tank Refer to “FUEL TANK” 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 a 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 fuel tank Refer to “FUEL TANK” in chapter 3. S front cowling inner panel (left and right) Refer to “COWLINGS” in chapter 3. S seat Refer to “SEAT” 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 Coolant reservoir tank 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) Order Job/Part Q’ty Remove the parts in the order listed.
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) Order 5 6 7 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 pickup rotor cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 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 : YAMAHA BOND No. 1215 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Removing the clutch cover Engine oil Coolant 1 2 3 4 5 6 Coolant hose Clutch cable Clutch cable holder Clutch cover Clutch cover gasket Dowel pin 1 1 1 1 1 2 Remarks Remove the parts in the order listed. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Disconnect. Disconnect.
CLUTCH Order 1 2 3 4 5 6 7 8 9 Job/Part Disassembling the clutch cover Circlip Washer Pull lever Pull lever spring Washer Oil seal Bearing Pull lever shaft Washer Q’ty ENG Remarks Disassemble the parts in the order listed. 2 1 1 1 1 1 2 1 1 For assembly, reverse the disassembly procedure.
CLUTCH ENG EAS00274 CLUTCH 90 Nm (9.0 mSkg, 65 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 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 cable holder 1 S clutch cover 2 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 55 mm (2.17 in) : 52.3 mm (2.06 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 90 Nm (9.0 mSkg, 65 ftSlb) NOTE: While holding the clutch boss 2 with the clutch holding tool 5 , tighten the clutch boss nut.
CLUTCH ENG 4. 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 as shown in the illustration. Clutch plate 1 : t=2.3 mm (0.09 in) Clutch plate 2 : t=2.0 mm (0.08 in) Friction plate 3 Friction plate 4 : Color/Brown 5. Install: S pressure plate 1 NOTE: Align the punch mark b in the pressure plate with the punch mark a in the clutch boss. 6.
CLUTCH ENG 8. Install: S clutch cover S gasket New S clutch cable holder 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) 12 Nm (1.2 mSkg, 8.7 ftSlb) 43 Nm (4.3 mSkg, 31 ftSlb) 10 Nm (1.0 mSkg, 7.
OIL PAN AND OIL PUMP 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) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 43 Nm (4.3 mSkg, 31 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 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) +120_ 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”.
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 rod 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 (except for CAL) or bolts (for CAL). Connecting rod nut (except for CAL) 15 Nm (1.5 mSkg, 11 ftSlb) + 150_ Connecting rod bolt (for CAL) 15 Nm (1.5 mSkg, 11 ftSlb) + 120_ f. Replace the connecting rod bolts 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. (except for CAL) Clean the connecting rod bolts.
CONNECTING RODS AND PISTONS ENG k. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS AND PISTONS”. l. Measure the compressed Plastigauge width on the crankshaft pin. If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings. 2.
CONNECTING RODS AND PISTONS ENG INSTALLING THE CONNECTING ROD AND PISTON (except for CAL) The following procedure applies to all of the connecting rods and pistons. 1. Install: S top ring 1 S 2nd ring 2 S upper oil ring rail 3 S oil ring expander 4 S lower oil ring rail 5 NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers a face up. 2.
CONNECTING RODS AND PISTONS ENG 4. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring e Oil ring expander 5. Lubricate: S crankshaft pins S big end bearings S connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil 6.
CONNECTING RODS AND PISTONS ENG b. Clean the connecting rod bolts and nuts. c. Tighten the connecting rod nuts. d. Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod 3 . 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 bolt and then retighten it. Replace the bolt with a new one and perform the procedure again.
CONNECTING RODS AND PISTONS ENG INSTALLING THE CONNECTING ROD AND PISTON (for CAL) The following procedure applies to all of the connecting rods and pistons. 1. Install: S top ring 1 S 2nd ring 2 S upper oil ring rail 3 S oil ring expander 4 S lower oil ring rail 5 NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers a face up. 2.
CONNECTING RODS AND PISTONS ENG 4. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring e Oil ring expander 5. Lubricate: S crankshaft pins S big end bearings S connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil 6. Install: S big end bearings 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.
CONNECTING RODS AND PISTONS ENG 7. Tighten: NOTE: Install by carrying out the following procedures in order to assemble in the most suitable condition. S connecting rod bolts. 24.5 Nm (2.5 mSkg, 17.7 ftSlb) a. Replace the connecting rod bolts with new oncs. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts. b. Clean the connecting rod bolts. c.
CONNECTING RODS AND PISTONS ENG 9. Tighten: S connecting rod bolts 15 Nm (1.5 mSkg, 11 ftSlb) + 120_ a. Clean the connecting rod bolts. b. Tighten the connecting rod bolts. c. Put a mark 1 on the corner of the connecting rod bolt 2 and the connecting rod 3 . d. Tighten the bolt further to reach the specified angle (120_). e. After the installation, check that the section shown a is flush with each other by touching the surface.
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. 4. Check: S transmission Rough movement ! Repair. NOTE: Oil each gear, shaft, and bearing thoroughly.
RADIATOR COOL EAS00454 COOLING SYSTEM RADIATOR 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Removing the radiator Seat Front cowling inner panel (left and right) Fuel tank Air filter case Coolant 1 2 3 4 5 6 7 8 1 1 1 1 1 1 1 1 Coolant reservoir hose Throttle body hose Water pump breather hose Radiator outlet hose Radiator inlet hose Oil cooler outlet hose Radiator Radiator cap 6-1 10 Nm (1.0 mSkg, 7.2 ftSlb) Remarks Remove the parts in the order listed.
RADIATOR COOL 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order 9 Job/Part Q’ty Radiator fan 10 Nm (1.0 mSkg, 7.2 ftSlb) 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 93 X 123 kPa (0.93 X 1.23 kg/cm2, 13.2 X 17.5 psi) a.
RADIATOR COOL EAS00456 INSTALLING THE RADIATOR 1. Install: S radiator S coolant hoses 2. Fill: S cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 3. Check: S cooling system Leaks ! Repair or replace any faulty part. 4. 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 10 Nm (1.0 mSkg, 7.2 ftSlb) 63 Nm (6.3 mSkg, 46 ftSlb) Order 10 11 12 Job/Part Q’ty O-ring Water pump outlet hose Radiator outlet hose Remarks 1 1 1 For installation, reverse the removal procedure.
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 union bolt 3 63 Nm (6.
THERMOSTAT COOL EAS00460 THERMOSTAT 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remove the parts in the order listed. Refer to “SEAT” in chapter 3. Refer to “COWLINGS” Refer to “FUEL TANK” Refer to “AIR FILTER CASE” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Refer to “THROTTLE BODIES” in chapter 7.
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 Thermometer Water Thermostat Container Fully closed Fully open NOTE: If the accuracy of the thermostat is in doubt, replace it.
THERMOSTAT COOL EAS00466 INSTALLING THE THERMOSTAT 1. Install: S thermostat NOTE: Install the thermostat with its breather hole a facing up. 2. Install: S thermostat cover 12 Nm (1.2 mSkg, 8.7 ftSlb) NOTE: Before installing the thermostat cover to the cylinder head, lubricate the O-ring with a thin coat of lithium soap based grease. 3. Fill: S cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 4.
WATER PUMP COOL EAS00468 WATER PUMP 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order 1 2 3 4 Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. NOTE: It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Coolant Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Disconnect. Radiator outlet hose Water pump outlet hose Water pump breather hose Water pump 1 1 1 1 Disconnect.
WATER PUMP COOL 10 Nm (1.0 mSkg, 7.2 ftSlb) Order 1 2 3 4 5 6 7 8 9 10 Job/Part Disassembling the water pump Water pump cover O-ring Impeller shaft Circlip Water pump seal Oil seal Bearing Water pump housing O-ring Copper washer Q’ty Remarks Disassemble the parts in the order listed. 1 1 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 water pump cover S O-ring 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 hose 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 O-ring New S copper washer New S water pump assembly 10 Nm (1.0 mSkg, 7.2 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 radiator outlet hose 2 NOTE: S Install the radiator outlet hose with white a mark positioned outside. S Install the hose clamp with its screw head pointed to the inner side. 3.
FUEL INJECTION SYSTEM FI FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 2 3 4 5 6 7 Ignition coil Air filter case Intake air temperature sensor Fuel delivery hose Fuel tank Fuel pump Intake air pressure sensor 8 9 10 11 12 13 14 Throttle position sensor Fuel injector Catalytic converter Crankshaft position sensor Coolant temperature sensor Spark plug Pressure regulator 7-1 15 16 17 18 19 Battery ECU Fuel injection system relay Engine trouble warning light Lean angle cut-off switch
FUEL INJECTION SYSTEM FI WIRING DIAGRAM 1 Main switch 5 Fuse (fuel injection) 6 Fuse (main) 9 Battery 10 Starting circuit cut-off relay 11 Sidestand switch 12 Neutral switch 13 Fuel pump 14 Throttle position sensor 15 Intake air pressure sensor 16 Lean angle cut-off switch 17 Crankshaft position sensor 18 Intake air temperature sensor 19 Coolant temperature sensor 20 ECU 21 Cylinder #1-injector 22 Cylinder #2-injector 23 Cylinder #3-injector 24 Cylinder #4-injector 32 Engine trouble warning light 26 Spe
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.
FUEL INJECTION SYSTEM FI Communication error with the meter Er-1 ECU internal malfunction (output signal error) No signals are received from the ECU. – Unable Unable Er-2 ECU internal malfunction (output signal error) No signals are received from the ECU within the specified duration. – Unable Unable Er-3 ECU internal malfunction (output signal error) Data from the ECU cannot be received correctly.
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 It is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “OFF”. 2. Disconnect the wire harness coupler from the fuel pump. 3.
FUEL INJECTION SYSTEM FI 7. Verify the operation of the sensor or actuator. S Sensor operation The data representing the operating conditions of the sensor appears on the trip LCD. S Actuator operation Set the engine stop switch to “ON” to operate the actuator. * If the engine stop switch is set to “ON”, set it to “OFF”, and then set it to “ON” again. 8. Turn the main switch to “OFF” to cancel the the diagnostic mode.
FUEL INJECTION SYSTEM FI Fault code table Fault code No. Symptom Open or short circuit in wiring harness. Defective crankshaft position sensor. Malfunction in pickup rotor. Malfunction in ECU. Improperly installed sensor. — Intake air pressure sensor-open or short circuit detected. S S S S Open or short circuit in wiring sub lead. Open or short circuit in wiring harness. Defective intake air pressure sensor. Malfunction in ECU.
FUEL INJECTION SYSTEM Fault code No. 50 Symptom Probable cause of malfunction FI Diagnostic code Faulty ECU memory. When this malfunction is detected, the code number might not appear on the meter. S Malfunction in ECU. (The program and data are not properly written on or read from the internal memory.) No signals are received from the ECU. S Open or short circuit in wiring sub lead. S Malfunction in meter. S 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 air temperature and coolant temperature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively. S If it is not possible to check the intake air temperature, use the ambient temperature as reference.
FI FUEL INJECTION SYSTEM Diagnostic code Item Data displayed on meter (reference value) AI system solenoid After 1 second has elapsed from the time the engine stop switch has been turned from OFF to ON, it actuates the AI system solenoid five times every second and illuminates the engine trouble warning light. * If the engine stop switch is ON, turn it OFF once, and then turn it back ON. Check the operating sound of the AI system solenoid 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. After the check and service of the malfunctioned part has been completed, reset the meter display according to the “Reinstatement method”. Fault code No.: Fault code number displayed on the meter when the engine failed to work normally.
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) Order Inspection operation item and probable cause 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. Operation item and countermeasure Reinstatement method If there is a malfunction, repair it and connect it securely.
FUEL INJECTION SYSTEM Fault code No. 14 Symptom FI Intake air pressure sensor - hose system malfunction (clogged or detached hose). Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstated by starting the engine and operating it at idle. 1 Intake air pressure sensor hose detached, clogged, kinked, or pinched.
FUEL INJECTION SYSTEM Fault code No. 16 Symptom FI Stuck throttle position sensor detected. Used diagnostic code No. 01 (throttle position sensor) Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstated by starting the engine, ti it operating at idle, and then racing it. 1 Installed condition of throttle position sensor. Check the installed area for looseness or pinching. Check that it is installed in the specified position.
FUEL INJECTION SYSTEM FI Fault code No. 22 Symptom Open or short circuit detected from the intake air temperature sensor. Used diagnostic code No. 05 (intake air temperature sensor) Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstated by turning the mainswitch ON. 1 Installed condition of sensor Check the installed area for looseness or pinching.
FUEL INJECTION SYSTEM Fault code No. 30 Symptom FI The motorcycle has overturned. Used diagnostic code No. 08 (lean angle cut-off switch) Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstated by turning the main switch ON (however (however, the engine cannot be restarted unless the main switch is first turned OFF). 1 The motorcycle has overturned. Raise the motorcycle upright.
FUEL INJECTION SYSTEM Fault code No. 33 Symptom FI Malfunction detected in the primary lead of the ignition coil (#1, #4). Used diagnostic code No. 30 (ignition coil #1, #4) Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstated by starting the engine and operating it at idle. In case of multi l cylinder tiple li d open or short circuit in lead, make sure to turn ON and OFF the main switch after each time of cranking.
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) ! A1 X A4 No. 21 (neutral switch) ! B1 X B4 Order Inspection operation item and probable Operation item and countermeasure cause A1 Connected condition of speed sensor If there is a malfunction, repair it and connect it connector securely.
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) Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstated by starting the engine and operating it at idle. 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler.
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) Order Inspection operation item and probable cause 1 Malfunction in ECU Fault code No. 46 Symptom Operation item and countermeasure Reinstatement method Execute diagnostic code 60 1.Check the faulty cylinder.
FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom FI No signals are received from the ECU. Used diagnostic code No. – – Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstated by turning the main switch ON and receives a normal signal. 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect it securely.
FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom FI Non-registered data has been received from the meter. Used diagnostic code No. – – Order Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Reinstated by turning the main switch ON and receives a normal signal. 1 Connected condition of connector Inspect the coupler for any pins that may have pulled out. Check the locking condition of the coupler.
THROTTLE BODIES FI EAS00909 THROTTLE BODIES Order Job/Part Q’ty Removing the throttle bodies Seat Front cowling inner panel (left and right) Fuel tank Battery Air filter case Battery box and battery box bracket 1 2 3 4 5 6 7 8 Sub-wire harness coupler Coolant temperature sensor coupler Balance hose (for CAL) Throttle body joint clamp screw Throttle bodies Throttle cable Throttle body joint Heat protector 2 1 1 4 1 2 4 1 7-25 Remarks Remove the parts in the order listed.
THROTTLE BODIES Order 9 Job/Part Plunger control unit hose Q’ty 1 7-26 FI Remarks Disconnect For installation, reverse the removal procedure.
THROTTLE BODIES FI EAS00910 INJECTORS Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Job/Part Removing the injectors Throttle position sensor coupler Intake air pressure sensor coupler Cylinder #1-injector coupler Cylinder #2-injector coupler Cylinder #3-injector coupler Cylinder #4-injector coupler Sub wire harness Negative pressure hose Intake air pressure sensor Fuel distributor Injector Throttle position sensor Fuel pulsation damper Throttle body assembly Q’ty 1 1 1 1 1 1 1 1 1 1 4 1 1 1 Remarks Remove t
THROTTLE BODIES FI EAS00911 CAUTION: The throttle bodies should not be disassembled. EAS00912 CHECKING THE INJECTORS 1. Check: S injectors Damage ! Replace. EAS00913 CHECKING THE THROTTLE BODIES 1. Check: S throttle bodies Cracks/damage ! Replace the throttle bodies as a set. 2. Check: S fuel passages Obstructions ! Clean. a. Wash the throttle bodies in a petroleumbased solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages with compressed air.
THROTTLE BODIES FI CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: S fuel pump operation Refer to “FUEL TANK” in chapter 3. a. Remove the seat fuel tank. Refer to “SEAT AND FUEL TANK” in chapter 3. b. Connect the pressure gauge 1 and adapter 2 onto the fuel injection pipe. Pressure gauge 90890-03153, YU-03153 Adapter 90890-03176, YM-03176 c. Install the fuel tank. Refer to “FUEL TANK” in chapter 3. d. Start the engine. e. Measure the fuel pressure. Fuel pressure 250 kPa (2.5 kg/cm2, 36.
THROTTLE BODIES FI EAS00916 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 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. Connect the pocket tester (Ω 1k) to the throttle position sensor. Positive tester probe ! blue terminal 1 Negative tester probe ! black/blue terminal 2 d.
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 7-33 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 AI system solenoid a. Remove the AI system solenoid coupler from the wire harness. b. Connect the pocket tester (Ω 1) to the AI system solenoid terminal as shown. Tester positive probe ! brown/red 1 Tester negative probe ! red/white 2 c. Measure the AI system solenoid resistance. AI system solenoid resistance 18 X 22 Ω at 20_C (68_F) d. Out of specification ! Replace.
ELECTRICAL COMPONENTS ELEC EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 Main switch Front brake light switch Starter relay Battery Fuse box Rear brake light switch Neutral switch Sidestand switch 9 10 11 12 Oil level switch Radiator fan motor Horn Ignition coil 8 8-1
ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 Coolant temperature sensor Intake air temperature sensor Intake air pressure sensor Fuel pump ECU Lean angle cut-off switch Starting circuit cut-off relay Dimmer relay 9 10 11 12 8-2 Radiator fan motor relay Turn signal relay Rectifier/ regulator Throttle position sensor ELEC
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 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. S Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 2.
CHECKING THE BULBS AND BULB SOCKETS ELEC 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. Connect the pocket tester probes to the respective leads of the bulb socket. c. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket.
IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM 1 6 9 10 11 12 16 17 Main switch Fuse (main) Battery Starting circuit cut-off relay Sidestand switch Neutral switch Lean angle cut-off switch Crankshaft position sensor 20 27 28 29 40 47 54 ECU Ignition coil #1 and #4 ignition coil #2 and #3 Spark plug Engine stop switch Fuse (ignition) Clutch switch 8-8 ELEC
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. spark plug cap resistance 6. ignition coil resistance 7. crankshaft position sensor 8. main switch 9. engine stop switch 10. neutral switch 11. sidestand switch 12. clutch switch 13.
ELEC IGNITION SYSTEM EAS00743 4. Ignition spark gap The following procedure applies to all of the spark plugs. S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker 1 and spark plug cap 2 as shown. S Set 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 Negative tester probe ! spark plug lead 1 Positive tester probe ! spark lug lead 2 ELEC Crankshaft position sensor resistance 248 X 372 Ω at 20_C (68_F) (between gray and black) S Is the crankshaft position sensor OK? YES NO Replace the crankshaft position sensor. S Measure the secondary coil resistance. EAS00749 8. Main switch Secondary coil resistance 12 X 18 kΩ at 20_C (68_F) S Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”.
IGNITION SYSTEM EAS00752 Positive tester probe ! sky blue 2 Negative tester probe ! black/red 1 11. Sidestand switch S Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the sidestand switch OK? YES ELEC Positive tester probe ! blue/green 3 Negative tester probe ! black/red 1 NO No continuity Replace the sidestand switch. EAS00763 12. Clutch switch S Check the clutch switch for continuity. Refer to “CHECKING THE SWITCHES”.
IGNITION SYSTEM EAS00754 15. 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 ECU. NO Properly connect or repair the ignition system’s wiring.
ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 1 6 7 8 9 10 Main switch Fuse (main) Starter relay Starter motor Battery Starting circuit cut-off relay 11 12 40 41 47 54 Sidestand switch Neutral switch Engine stop switch Start switch Fuse (ignition) Clutch switch 8-14 ELEC
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 ELEC EAS00766 EAS00752 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 Job/Part Q’ty Remove the parts in the order listed. Refer to “SEAT” in chapter 3. Refer to “COWLINGS” in chapter 3. Refer to “FUEL TANK” in chapter 3. Refer to “THROTTLE BODIES” in chapter 7. Removing the starter motor Seat Front cowling inner panel (left and right) Fuel tank Throttle bodies 1 2 Starter motor lead Starter motor Remarks 1 1 For installation, reverse the removal procedure.
STARTER MOTOR ELEC EAS00768 7.8 Nm (0.78 mSkg, 5.6 ftSlb) 3.4 Nm (0.34 mSkg, 2.5 ftSlb) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 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 O-ring Q’ty Remarks Disassembly the parts in the order listed. 1 1 1 1 1 1 1 1 2 1 1 1 2 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. Install: S brush seat 1 2.
STARTER MOTOR ELEC 3. Install: S starter motor yoke 1 S O-ring 2 New S front cover 3 Srear cover 4 S bolts 5 3.4 Nm (0.34 mSkg, 2.5 ftSlb) NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers.
CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM 2 3 6 9 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 lead 5. stator coil resistance 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.
CHARGING SYSTEM ELEC EAS00776 4. Stator coil lead 5. Stator coil resistance 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 8-27 ELEC
LIGHTING SYSTEM 1 6 9 20 35 46 47 48 51 52 55 60 61 62 65 66 Main switch Fuse (main) Battery ECU High beam indicator light Fuse (headlight) Fuse (ignition) Fuse (tail) License plate light Tail/ brake light Dimmer switch Dimmer relay Headlight (high beam) Headlight (low beam) Front turn signal/position light (right) Front turn signal/position light (left) 8-28 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, tail, ignition and headlight fuses 2. battery 3. main switch 4. dimmer switch 5. dimmer relay 6. wiring connections (of the entire lighting system) NO S Clean the battery terminals. S Recharge or replace the battery. EAS00749 3.
LIGHTING SYSTEM 5. Dimmer relay S Disconnect the dimmer relay from the coupler. S Connect the pocket tester (Ω 1) and battery (12 V) to the dimmer relay as shown. Positive battery lead ! red/yellow 1 Negative battery lead ! yellow/black 2 Positive tester probe ! red/yellow 3 Negative tester probe ! green 4 S Does the dimmer relay have continuity between red/yellow and green? YES NO Replace the dimmer relay. EAS00787 6. Wiring S Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”.
LIGHTING SYSTEM ELEC EAS00788 Headlight Positive tester probe ! black 3 Negative tester probe ! black/yellow 4 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. Headlight coupler (wire harness side) 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.
LIGHTING SYSTEM EAS00792 2. The license plate light fails to come on. 1. License plate light bulb and socket S Check the license plate light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. S Are the license plate light bulb and socket OK? YES NO Replace the license plate light bulb, socket or both. 2. Voltage S Connect the pocket tester (DC 20 V) to the license plate light coupler (wire harness light side) as shown.
LIGHTING SYSTEM ELEC EAS00790 EAS00791 3. The tail/brake light fails to come on. 4. The turn signal/position light fails to come on. 1. Tail/brake light bulb and socket 1. Turn signal/position light and socket S Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. S Are the tail/brake light bulb and socket OK? 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 8-34 ELEC
SIGNALING SYSTEM 1 4 6 9 10 12 13 20 31 33 34 36 37 39 45 47 48 49 50 52 56 57 58 59 63 64 65 66 Main switch Fuse (backup) Fuse (main) Battery Starting circuit cut-off relay Neutral switch Fuel pump ECU Oil level waning light Neutral indicator light Multi-function meter Turn signal indicator light Oil level switch Front brake light switch Fuse (signal) Fuse (ignition) Fuse (tail) Turn signal relay Rear brake light switch Tail/ brake light Hazard switch Turn signal switch Horn switch Horn Rear turn signal l
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. NO S Clean the battery terminals. S Recharge or replace the battery. Check: 1. backup, main, ignition, signal, and tail 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”.
SIGNALING SYSTEM ELEC 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 bulb and socket S Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. S Are the tail/brake light bulb and socket OK? Negative tester probe ! ground Positive tester probe ! black/white 1 YES NO Replace the tail/ brake light bulb, socket or both.
SIGNALING SYSTEM YES This circuit is OK. S Turn the main switch to “ON”. S Measure the voltage (DC 12 V) on brown/ green 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/position light Positive tester probe ! ground Negative tester probe ! chocolate 1 Right turn signal/position light Positive tester probe ! ground Negative tester probe ! dark green 2 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 EAS00753 3.
SIGNALING SYSTEM EAS00802 S Are the tester readings correct? YES ELEC 5. The oil level warning light fails to come on. NO 1. Oil level warning light (LEDs) S Check the oil level warning light for continuity. When the main switch is turn to “ON”, the oil level warning light is come on. S Are the oil level warning light OK? Replace the starting circuit cut-off relay. 4. Voltage YES S Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown.
ELEC SIGNALING SYSTEM EAS00803 3. Voltage 6. The fuel 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. Fuel sender 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 10) to the fuel sender terminals as shown.
SIGNALING SYSTEM 2. Voltage S Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Positive tester probe ! green/white 1 Negative tester probe ! black/white 2 S Turn the main switch to “ON”. S Measure the voltage (DC 12 V) of green/white 1 and black/white 2 at the meter assembly coupler. S Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the meter assembly coupler is faulty and must be repaired.
COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM 1 6 9 19 20 42 43 44 47 Main switch Fuse (main) Battery Coolant temperature sensor ECU Fuse (radiator fan motor) Radiator fan motor relay Radiator fan motor Fuse (ignition) 8-43 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 for continuity.
COOLING SYSTEM ELEC EAS00812 6. Coolant temperature sensor S Remove the coolant temperature sensor. S Connect the pocket tester (Ω 1k) to the coolant temperature sensor 1 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 EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 1 5 6 9 10 13 20 40 47 Main switch Fuse (fuel injection) Fuse (main) Battery Starting circuit cut-off relay Fuel pump ECU Engine stop switch Fuse (ignition) 8-47 ELEC
FUEL PUMP SYSTEM ELEC EAS00815 FUEL PUMP SYSTEM The ECU includes the control unit for the fuel pump.
ELEC FUEL PUMP SYSTEM EAS00816 EAS00739 TROUBLESHOOTING 2. Battery If the fuel pump fails to operate. S Check the condition of the battery Refer to “CHECKING AND CHARGING 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 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 (fuel injection system relay) 6. Fuel pump resistance S Disconnect the fuel pump coupler from the wire harness. S Connect the pocket tester (Ω 1) to the fuel pump coupler as shown. 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.
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 FZ6-SS/FZ6-SSC features a self-diagnosing system for the following circuit(-s): S Fuel pump thermistor 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 turned “ON” (irrespective of whether the engine is running or not).
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 pump thermistor 2. oil level switch YES NOTE: S Before troubleshooting, remove the following part(-s): 1. seat 2. front cowling inner panel (left and right) 3. fuel tank 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. 34 Multi-function meter 37 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. 8-54 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 FAILURE/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 ENGIN
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 Clogged coolant passages S 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 cool
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 dama
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 or light switch) S Burnt-out headlight bulb HEADLIGHT BULB BURNT OUT S Wrong headlight bulb S Faulty battery S Faulty rectifier/regulator S Improperly grounded circuit S Faulty main switch S Faulty light switch S Headlight bulb life expired TA
FZ6-SS/FZ6-SSC 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 Main switch A.C.
FZ6-SS/FZ6-SSC WIRING DIAGRAM D C Y Br/W G/W G/W Br/W Y B/L P/W Y/R R/L R/B P/W B/L WIRE HARNESS SUB-WIRE HARNESS 2 L G/B WIRE HARNESS B R/B R/L R/W L/R Y A B G B/G B B/Y L/R R/W G/W W Ch Dg G/B L SUB-WIRE HARNESS 1 Y/L R/G Dg Ch W G/W WIRE HARNESS Lg B/W HEADLIGHT SUB WIRE HARNESS 2 WIRE HARNESS R/G Y/L B/W Lg HEADLIGHT SUB WIRE HARNESS 1 R Lg L/W L/W R/G R/B 4 R 5 R R R L/W L/W R/B W/L R/L B/W B/R L/W L/Y R/W L/G B/R Sb Lg L/Y R/L L/G B Sb 3 W B/Y 10 B/R
FZ6-SS/FZ6-SSC WIRING DIAGRAM
