2005 MT-01(T) SERVICE MANUAL 5YU1-AE1
EAS20040 MT-01(T) 2005 SERVICE MANUAL ©2004 by Yamaha Motor Co., Ltd. First edition, December 2004 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one 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.
EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title “1” is shown at the top of each page. • Sub-section titles “2” appear in smaller print than the section title.
EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 1 2 3 4 5 6 15.Apply locking agent (LOCTITE®). 16.Replace the part with a new one. T. R. 7 8 9 10 E 12 11 B 15 M G 13 14 M LS 16 LT 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6. Wear limit, clearance 7. Engine speed 8. Electrical data 9. Engine oil 10.Gear oil 11.
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 FUEL SYSTEM 6 ELECTRICAL SYSTEM 7 TROUBLESHOOTING 8
GEN INFO 1
GENERAL INFORMATION IDENTIFICATION ............................................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1 MODEL LABEL.......................................................................................... 1-1 FEATURES...................................................................................................... 1-2 OUTLINE OF THE FI SYSTEM...............................................
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped on the right side of the steering head pipe. 1 EAS20150 MODEL LABEL The model label “1” is affixed to the lead holder under the seat. This information will be needed to order spare parts.
FEATURES EAS20170 FEATURES ET5YU1009 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
FEATURES ET5YU1010 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 392 kPa (3.92 kg/cm², 55.7 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
FEATURES Tachometer ET5YU1011 INSTRUMENT FUNCTIONS Multifunction display 1 EW5YU1005 WARNING Be sure to stop the vehicle before making any setting changes to the multifunction display. 2 3 2 1. Tachometer 2. Tachometer red zone 4 The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range.
FEATURES If the multifunction display indicates an error code, note the code number, and then check the vehicle. Refer to “FUEL INJECTION SYSTEM” on page 7-25. 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.
FEATURES 3. Tachometer needle The brightness can be adjusted for the following: • the tachometer panel (item number “1”) • the LCD (item number “2”) • the tachometer needle (item number “3”) Select the brightness control mode as follows. 1. Turn the key to “OFF”. 2. Push and hold the “SELECT” button. 3. Turn the key to “ON”, and then release the “SELECT” button after five seconds. Item number “1” is displayed. 1 2 3 1. Tachometer needle 2. Item number 3. Brightness level 1 7.
IMPORTANT INFORMATION EAS20180 IMPORTANT INFORMATION EAS20190 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. EAS20210 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease. 2.
IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” 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. Oil bearings liberally when installing, if appropriate. ECA13300 CAUTION: Do not spin the bearing with compressed air because this will damage the bearing surfaces.
CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Analog pocket tester YU-03112-C Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • Lead • Coupler • Connector 2. Check: • Lead • Coupler • Connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect several times. NOTE: • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (3).
SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. NOTE: • For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
SPECIAL TOOLS Tool name/Tool No.
SPECIAL TOOLS Tool name/Tool No.
SPECIAL TOOLS Tool name/Tool No. Illustration Reference pages Valve guide reamer (ø6) 90890-04066 Valve guide reamer (6.0 mm) YM-04066 5-36 Piston pin puller set 90890-01304 Piston pin puller YU-01304 5-42 YU-01304 Universal clutch holder 90890-04086 YM-91042 5-55, 5-58 Sheave holder 90890-01701 Primary clutch holder YS-01880-A 5-55, 5-57, 5-68, 5-69, 5-77, 5-79 Yamaha bond No.
SPECIAL TOOLS Tool name/Tool No.
SPEC 2
SPECIFICATIONS GENERAL SPECIFICATIONS ........................................................................ 2-1 ENGINE SPECIFICATIONS ............................................................................ 2-2 CHASSIS SPECIFICATIONS ........................................................................ 2-10 ELECTRICAL SPECIFICATIONS ................................................................. 2-14 TIGHTENING TORQUES .............................................................................
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 5YU1 (Europe) 5YU2 (AUS) Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius 2185 mm (86.0 in) 790 mm (31.1 in) 1160 mm (45.7 in) 825 mm (32.5 in) 1525 mm (60.0 in) 143 mm (5.63 in) 3200 mm (126.0 in) Weight With oil and fuel Maximum load 259.
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Displacement Cylinder arrangement Bore × stroke Compression ratio Standard compression pressure (at sea level) Air cooled 4-stroke, OHV 1670.0 cm³ (101.90 cu.in) V-type 2 cylinders 97.0 × 113.0 mm (3.82 × 4.45 in) 8.40 :1 1200 kPa/200 r/min (170.7 psi/200 r/min) (12.0 kgf/cm²/200 r/min) 1000–1400 kPa (142.2–199.1 psi) (10.0–14.
ENGINE SPECIFICATIONS Spark plug (s) Manufacturer/model Manufacturer/model Spark plug gap NGK/DPR7EA-9 DENSO/X22EPR-U9 0.8–0.9 mm (0.031–0.035 in) Cylinder head Volume Warpage limit* 98.60–103.60 cm³ (6.02–6.32 cu.in) 0.03 mm (0.0012 in) * Camshaft Drive system Camshaft to crankcase clearance Camshaft lobe dimensions Intake A Gear drive 0.050–0.084 mm (0.0020–0.0033 in) 38.241–38.341 mm (1.5055–1.5095 in) (cylinder #1) 38.243–38.343 mm (1.5056–1.5096 in) (cylinder #2) 38.141 mm (1.
ENGINE SPECIFICATIONS Valve, valve seat, valve guide Valve clearance (cold) Intake Exhaust Valve dimensions Valve head diameter A (intake) Valve head diameter A (exhaust) 0.00–0.04 mm (0.0000–0.0016 in) 0.00–0.04 mm (0.0000–0.0016 in) 33.90–34.10 mm (1.3346–1.3425 in) 27.90–28.10 mm (1.0984–1.1063 in) A Valve face width B (intake) Valve face width B (exhaust) 1.300–2.300 mm (0.0512–0.0906 in) 1.200–2.400 mm (0.0472–0.0945 in) B Valve seat width C (intake) Limit Valve seat width C (exhaust) Limit 0.
ENGINE SPECIFICATIONS Valve-stem-to-valve-guide clearance (intake) Limit Valve-stem-to-valve-guide clearance (exhaust) Limit Valve stem runout Valve spring Inner spring Free length (intake) Limit Free length (exhaust) Limit Installed length (intake) Installed length (exhaust) Spring rate K1 (intake) Spring rate K2 (intake) Spring rate K1 (exhaust) Spring rate K2 (exhaust) Installed compression spring force (intake) Installed compression spring force (exhaust) Spring tilt (intake)* Spring tilt (exhaust)* 0
ENGINE SPECIFICATIONS Installed compression spring force (exhaust) Spring tilt (intake) Spring tilt (exhaust) Winding direction (intake) Winding direction (exhaust) 139.00–161.00 N (31.25–36.19 lb) (14.17– 16.42 kgf) 2.5°/1.9 mm (2.5°/0.075 in) 2.5°/1.9 mm (2.5°/0.
ENGINE SPECIFICATIONS Piston ring Top ring Ring type Dimensions (B × T) Barrel 1.20 × 3.80 mm (0.05 × 0.15 in) B T End gap (installed) Limit Ring side clearance Limit 2nd ring Ring type Dimensions (B × T) 0.30–0.50 mm (0.01–0.02 in) 0.70 mm (0.0276 in) 0.030–0.080 mm (0.0012–0.0032 in) 0.120 mm (0.0047 in) Taper 1.20 × 3.80 mm (0.05 × 0.15 in) B T End gap (installed) Limit Ring side clearance Limit Oil ring Dimensions (B × T) 0.30–0.45 mm (0.01–0.02 in) 0.80 mm (0.0315 in) 0.030–0.070 mm (0.0012–0.
ENGINE SPECIFICATIONS Crankshaft Width A Runout limit C Big end side clearance D Big end radial clearance E Limit C 132.80–133.20 mm (5.23–5.24 in) 0.040 mm (0.0016 in) 0.320–0.474 mm (0.0126–0.0187 in) 0.037–0.074 mm (0.0015–0.0029 in) 0.09 mm (0.0035 in) C E D A Journal oil clearance (using plastigauge®) Limit 0.030–0.062 mm (0.0012–0.0024 in) 0.09 mm (0.
ENGINE SPECIFICATIONS Shifting mechanism Shift mechanism type Shift fork guide bar bending limit Shift fork thickness Guide bar 0.025 mm (0.0010 in) 6.26–6.39 mm (0.2465–0.2516 in) Air filter Air filter element Oil-coated paper element Fuel pump Pump type Model/manufacturer Maximum consumption amperage Output pressure Electrical 5YU/DENSO 4.6 A 392.0 kPa (56.8 psi) (3.
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Caster angle Trail Double cradle 25.00° 103.0 mm (4.06 in) Front wheel Wheel type Rim size Rim material Wheel travel Radial wheel runout limit Lateral wheel runout limit Cast wheel 17M/C × MT3.50 Aluminum 120.0 mm (4.72 in) 1.0 mm (0.04 in) 0.5 mm (0.02 in) Rear wheel Wheel type Rim size Rim material Wheel travel Radial wheel runout limit Lateral wheel runout limit Cast wheel 17M/C × MT6.00 Aluminum 117.0 mm (4.61 in) 1.0 mm (0.
CHASSIS SPECIFICATIONS Front brake Type Operation Front brake lever free play Front disc brake Disc outside diameter × thickness Brake disc thickness limit Brake disc deflection limit Brake pad lining thickness (inner) Limit Brake pad lining thickness (outer) Limit Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Dual disc brake Right hand operation 7.0–19.0 mm (0.28–0.75 in) 320.0 × 4.5 mm (12.60 × 0.18 in) 4.0 mm (0.16 in) 0.10 mm (0.
CHASSIS SPECIFICATIONS Front suspension Type Spring/shock absorber type Front fork travel Fork spring free length Limit Collar length Installed length Spring rate K1 Spring stroke K1 Inner tube outer diameter Inner tube bending limit Optional spring available Recommended oil Quantity Level Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions *With the adjusting screw fully turned in Minimum Standard Maximum Compression damping adjusting positions *With the adjusti
CHASSIS SPECIFICATIONS Rear suspension Type Spring/shock absorber type Rear shock absorber assembly travel Spring free length Limit Installed length Spring rate K1 Spring stroke K1 Optional spring available Enclosed gas/air pressure (STD) Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions *With the adjusting knob fully turned in Minimum Standard Maximum Compression damping adjusting positions *With the adjusting screw fully turned in Minimum Standard Maximum Sw
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Ignition timing (B.T.D.C.) Transistorized coil ignition (digital) Electric 10.0°/900 r/min Engine control unit Model/manufacturer F8T83071/MITSUBISHI Ignition coil Model/manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance 2JN/MORIC 6.0 mm (0.24 in) 2.16–2.64 Ω 8.64–12.96 kΩ Spark plug cap Material Resistance Resin 10.
ELECTRICAL SPECIFICATIONS Bulb voltage, wattage × quantity Low beam headlight High beam headlight Auxiliary light Tail/brake light Front turn signal light Rear turn signal light License plate light Meter lighting 12 V, 51.0 W × 1 12 V, 55.0 W × 1 12 V, 5.0 W × 3 LED 12 V, 10.0 W × 2 12 V, 10.0 W × 2 12 V, 5.
ELECTRICAL SPECIFICATIONS Starting circuit cut-off relay Model/manufacturer Coil resistance G8R-30Y-U3/OMRON 162–198 Ω Headlight relay Model/manufacturer Coil resistance ACM33211M05/MATSUSHITA 86.40–105.60 Ω Fuel pump relay Model/manufacturer Coil resistance G8R-30Y-U3/OMRON 162–198 Ω Thermo unit Model/manufacturer Resistance at 100 °C 5PX/DENSO 898.38–1098.
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Item Thread Q’ty size Tightening torque Remarks Oil tank: Oil pipe bolt M6 11 13 Nm (1.3 m·kg, 9.4 ft·lb) Oil tank and oil tank bracket nut M6 1 13 Nm (1.3 m·kg, 9.4 ft·lb) Oil tank bolt M6 2 13 Nm (1.3 m·kg, 9.4 ft·lb) Oil tank and down tube bolt M6 16 10 Nm (1.0 m·kg, 7.2 ft·lb) Engine oil drain bolt (oil tank) M14 1 35 Nm (3.5 m·kg, 25 ft·lb) Oil strainer cover bolt (oil tank) M6 2 10 Nm (1.0 m·kg, 7.
TIGHTENING TORQUES Item Thread Q’ty size Tightening torque Remarks Cylinder head cover bolt M6 24 10 Nm (1.0 m·kg, 7.2 ft·lb) Rocker arm base bolt M6 8 10 Nm (1.0 m·kg, 7.2 ft·lb) Rocker arm base bolt M8 4 24 Nm (2.4 m·kg, 17 ft·lb) Locknut (rocker arm adjusting screw) M7 4 20 Nm (2.0 m·kg, 14 ft·lb) Valve lifter case bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) Camshaft cover bolt M6 7 10 Nm (1.0 m·kg, 7.2 ft·lb) Front cylinder camshaft end cover bolt M5 2 7 Nm (0.7 m·kg, 5.
TIGHTENING TORQUES Item Stopper lever bolt Thread Q’ty size Tightening torque Remarks M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil pipe 2 bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) Generator cover bolt M6 11 10 Nm (1.0 m·kg, 7.2 ft·lb) Stator coil assembly lead holder screw M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT Stator coil assembly screw M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) LT Generator rotor bolt M12 1 80 Nm (8.0 m·kg, 58 ft·lb) Starter clutch bolt M8 6 24 Nm (2.
TIGHTENING TORQUES Item Thread Q’ty size Tightening torque Remarks 15 Nm (1.5 m·kg, 11 ft·lb) See NOTE. Crankshaft: Connecting rod bolt (1st) M8 4 M Connecting rod bolt (final) M8 4 Specified angle 120°–150° See NOTE. M Chain drive: Drive sprocket cover bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) Drive chain guide bolt (drive sprocket side) M8 3 24 Nm (2.4 m·kg, 17 ft·lb) Drive sprocket nut M22 1 95 Nm (9.5 m·kg, 68 ft·lb) Throttle body joint clamp screw M4 2 4 Nm (0.4 m·kg, 2.
TIGHTENING TORQUES Oil tank tightening sequence: 8 6 10 2 4 16 15 12 13 14 11 1 9 5 7 3 Cylinder head tightening sequence: A. Front cylinder B.
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Item Thread Q’ty size Tightening torque Remarks Engine mounting: Engine mounting bolt (left upper side) M10 2 53 Nm (5.3 m·kg, 38 ft·lb) Engine mounting bolt (right upper side) M10 1 53 Nm (5.3 m·kg, 38 ft·lb) L=80 mm (3.15 in) Engine mounting bolt (right upper side) M10 1 53 Nm (5.3 m·kg, 38 ft·lb) L=65 mm (2.56 in) Engine bracket bolt (left upper side) M10 2 53 Nm (5.
TIGHTENING TORQUES Item Thread Q’ty size Tightening torque Remarks Cylinder-#2 right ignition coil bracket bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder-#2 left ignition coil bracket bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Engine bracket (right upper side) and holder bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel tank bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) Air filter case bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Air filter case bracket bolt M6 1 10 Nm (1.0 m·kg, 7.
TIGHTENING TORQUES Item Thread Q’ty size Tightening torque Remarks Shift arm bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Left rider footrest assembly bolt M8 2 30 Nm (3.0 m·kg, 22 ft·lb) Right rider footrest assembly bolt M8 2 30 Nm (3.0 m·kg, 22 ft·lb) Footrest cover bracket M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb) Passenger footrest nut M10 2 28 Nm (2.8 m·kg, 20 ft·lb) Front wheel axle M18 1 72 Nm (7.2 m·kg, 52 ft·lb) Front wheel axle pinch bolt M8 1 23 Nm (2.
TIGHTENING TORQUES Item Thread Q’ty size Tightening torque Remarks Grip end M16 2 29 Nm (2.9 m·kg, 21 ft·lb) Clutch master cylinder holder bolt M6 2 13 Nm (1.3 m·kg, 9.4 ft·lb) Rearview mirror M10 2 14 Nm (1.4 m·kg, 10 ft·lb) Upper bracket pinch bolt M8 2 26 Nm (2.6 m·kg, 19 ft·lb) Steering stem nut M22 1 110 Nm (11.0 m·kg, 80 ft·lb) Lower ring nut (initial tightening torque) M25 1 52 Nm (5.2m·kg, 37 ft·lb) See NOTE. Lower ring nut (final tightening torque) M25 1 23 Nm (2.
TIGHTENING TORQUES Item Thread Q’ty size Tightening torque Drive chain guard bolt (swingarm side) M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) Drive chain guide bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) Locknut (drive chain adjusting bolt) M8 2 16 Nm (1.6 m·kg, 11 ft·lb) Remarks NOTE: 1. First, tighten the lower ring nut to approximately 52 Nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 23 Nm (2.
LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips LS O-rings LS Bearings E Cylinder head nuts and washers E Connecting rod small end and big end E Crankshaft journals E Piston surfaces E Piston pins E Connecting rod bolts M Camshaft cam lobes and camshaft journals M Valve push rods E Valve push rod end balls E Valve stems (intake and exhaust) M Valve stem ends (intake and exhaust) E
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Shift forks and shift fork guide bars E Shift drum E Shift shaft and shift shaft oil seal lip LS Crankcase mating surface Yamaha bond No.1215 Stator coil lead grommet Yamaha bond No.1215 Crankshaft position sensor lead grommet Yamaha bond No.
LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Down tube bolt (front and rear) E Steering bearings and upper bearing dust cover lip LS Lower bearing dust seal lip LS Steering ring nut thread (upper and lower) LS Main switch bracket spacer outer surfaces LS Front wheel oil seal lips (left and right) LS Rear wheel oil seal lips (left and right) LS Rear wheel drive hub oil seal lip LS Rear wheel drive hub mating surface LS Tube guide (throttle grip) inn
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART A 40 39 37 30 29 28 36 35 34 33 32 38 27 35 34 33 32 31 28 29 30 26 25 23 24 21 22 20 17 14 16 18 15 19 13 12 4 7 9 8 6 5 3 2 1 2-31 10 11
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pan 2. Engine oil drain bolt (crankcase) 3. Oil strainer (crankcase) 4. Oil pump 5. Oil pump rotor 1 6. Oil pump rotor 2 7. Check ball 8. Relief valve 9. Oil tank 10. Oil strainer (oil tank) 11. Engine oil drain bolt (oil tank) 12. Drive axle 13. Drive axle gears 14. Main axle 15. Oil pump drive gear 16. Main axle gears 17. Clutch 18. Bypass valve 19. Oil filter cartridge 20. Generator shaft journal (left) 21. Generator shaft journal (right) 22.
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS A 2 1 4 A B 2 B E D 3 E C D 1 D-D B-B 5 C E-E 3 2-33
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. 2. 3. 4. 5.
LUBRICATION SYSTEM CHART AND DIAGRAMS 1 4 3 2 2-35
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. 2. 3. 4.
LUBRICATION SYSTEM CHART AND DIAGRAMS 3 A 1 B B A 2 A-A 1 2-37 B-B
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Oil strainer (crankcase) 3.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2 1 A 4 2-39 3
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. 2. 3. 4. A.
CABLE ROUTING EAS20430 CABLE ROUTING A 2 3 4 1 5 6 17 J 7 8 16 15 I B 14 6 C H 6 G 13 9 F 12 D E 10 11 2-41
CABLE ROUTING 1. Air temperature sensor coupler 2. Sub-wire harness 3 coupler 3. Front turn signal light coupler 4. Headlight assembly coupler 5. Headlight coupler (low beam) 6. Wire harness 7. Clutch fluid reservoir hose 8. Left handlebar switch lead 9. Starter motor lead 10. Rectifier/regulator 11. Stator coil assembly lead 12. Horn 13. Horn lead 14. Front brake hose 15. Throttle cable (accelerator cable) 16. Throttle cable (decelerator cable) 17. Front brake fluid reservoir hose A.
CABLE ROUTING 3 2 F A 1 H 6 C 4 5 B D 7 G E I J K 8 M 9 O P A L Q R M 10 S T S U 11 N AD F 18 17 17 V E AC 16 D W AB 12 D Y C X B C B 15 AA 13 Z 14 19 AH AL 15 A 15 15 AE 13 14 12 15 20 AM 21 16 AG C-C AK AF AI AN 15 20 AG B-B AJ D-D 2-43 E F
CABLE ROUTING Q. Route the cylinder-#1 left spark plug lead under the frame boss and to the outside of the wire harness and clutch hose. R. Route the clutch hose to the outside of the wire harness. S. Fasten the clutch hose and EXUP servo motor lead with the plastic locking ties. Face the buckle of the plastic locking tie forward, with the end facing outward, and then cut off the excess end of the tie. T.
CABLE ROUTING 10 11 O 9 L J 6 H 5 12 8 M 7 13 14 K N I 4 15 G 3 2 F B D E P 1 D C D Q B A C A 16 W 25 24 17 R B 29 S 23 18 V T 22 21 U 20 1 AD 19 AE E 19 26 22 27 X Y A B AA Z C AF 14 AB 28 AC 30 AB 15 13 31 D-D 2-45 3 E
CABLE ROUTING K. Fasten the wire harness and sub-wire harness 2 with the plastic band at the section just before the split in the wire harness. Face the end of the plastic band outward. L. Wrap the protective covering around the right handlebar switch coupler, headlight coupler, immobilizer unit coupler and main switch coupler, making sure to cover the sections of the leads that are not covered by the protective sleeves. M.
CABLE ROUTING R Q A S 24 21 22 20 B 1 2 T U 3 W 23 19 4 V X Y 25 AE 26 23 29 C 24 D AD AC 5 6 D 6 A 27 U AB Z 7 P E 28 F 18 AA O 8 N 17 G M 9 L 16 15 A 10 14 AF H I K 13 J 12 11 2-47
CABLE ROUTING H. Route the tail/brake light lead and rear turn signal light leads along the side of the rear brake fluid reservoir, making sure that “UPPER” on the reservoir is visible. There should be no slack in the tail/brake light lead and the rear turn signal light lead between the wire harness and the plastic locking tie next to the hole in the frame. I.
CABLE ROUTING R Q A S 24 21 22 20 B 1 2 T U 3 W 23 19 4 V X Y 25 AE 26 23 29 C 24 D AD AC 5 6 D 6 A 27 U AB Z 7 P E 28 F 18 AA O 8 N 17 G M 9 L 16 15 A 10 14 AF H I K 13 J 12 11 2-49
CABLE ROUTING AB.Route the starter motor lead and sub-wire harness 1 under the battery box, making sure that they are routed between the bolt holes in the battery box. AC.Route the seat lock cable under the wire harness to the left of the battery box. Be sure not to pinch the seat lock cable when installing the battery box. AD.Fasten the sub-wire harness 1 at the white tape with the plastic locking tie. Face the end of the plastic locking tie rearward, and then cut off the excess end of the tie. AE.
CABLE ROUTING 1 4 C B 3 D E D 5 3 6 A A 2 9 F G 7 4 8 2-51
CABLE ROUTING 1. 2. 3. 4. 5. 6. 7. 8. 9. A. B. C. D. E. F. G. Fuel tank Pressure regulator Fuel return hose Fuel hose Fuel return pipe Fuel return hose (fuel return pipe to fuel pump) Fuel pump Fuel pipe Fuel hose (intake manifold assembly to pressure regulator) Face the ends of the hose clamps downward. Install the fuel return hose onto the fuel return pipe until the hose contacts the paint mark on the pipe. Connect the end of the fuel hose that has a black connector to the fuel pipe.
CABLE ROUTING A 1 C B 1 2 2 E D 3 D A A 4 A A 5 A 8 7 F 6 G I H 9 10 11 10 9 9 J A K 2-53 A
CABLE ROUTING 1. Fuel tank overflow hose 2. Fuel tank breather hose 3. Rollover valve hose 1 4. Rollover valve hose 2 5. Rollover valve 1 6. Rollover valve 2 7. Rollover valve hose 3 8. Rollover valve hose 4 9. Fuel tank breather/overflow hose 10. Oil tank 11. Bottom cover A. Face the ends of the hose clamps in the directions shown in the illustration. B. Install the fuel tank overflow hose onto the front pipe of the fuel tank with its yellow paint mark facing outward. C.
CABLE ROUTING 2 B A 3 4 5 C A 6 1 I 13 7 H D G E 12 11 8 F A 10 9 B C 15 14 8 17 J 3 E K 10 L A M C N 2-55 16 B
CABLE ROUTING 1. Cylinder-#2 intake air pressure sensor 2. Cylinder-#2 ISC (idle speed control) unit outlet hose 3. ISC (idle speed control) unit 4. Intake solenoid vacuum hose (one-way valve to throttle body) 5. Cylinder-#1 ISC (idle speed control) unit outlet hose 6. Throttle position sensor 7. Throttle body 8. Cylinder-#1 intake air pressure sensor hose 9. Fuel return hose 10. Pressure regulator 11. Cylinder-#1 intake air pressure sensor 12. Clutch hose 13. Cylinder-#2 intake air pressure sensor hose 14.
CHK ADJ 3
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ............................................................................ 3-1 INTRODUCTION ....................................................................................... 3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART....................... 3-1 ENGINE ........................................................................................................... 3-3 ADJUSTING THE VALVE CLEARANCE ..................................................
ELECTRICAL SYSTEM................................................................................. 3-33 CHECKING AND CHARGING THE BATTERY....................................... 3-33 CHECKING THE FUSES ........................................................................ 3-33 REPLACING THE HEADLIGHT BULBS ................................................. 3-33 ADJUSTING THE HEADLIGHT BEAM ...................................................
PERIODIC MAINTENANCE EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform the 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. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
PERIODIC MAINTENANCE NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING (× 1000 km) 1 ANNUAL CHECK 10 20 30 40 • Check operation and shock absorber for oil leakage. √ √ √ √ • Check operation. √ √ √ √ 21 * Fuel injection system • Adjust synchronization. √ √ √ √ √ 22 Engine oil • Change. • Check oil level and vehicle for oil leakage. √ √ √ √ √ √ 23 Engine oil filter cartridge • Replace. √ • Check operation.
ENGINE • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. 2. Disconnect: • Spark plug caps 3. Remove: • Spark plugs 4. Remove: • Oil catch tank “1” • Tappet covers “2” • Front cylinder head cover “3” EAS20470 ENGINE EAS20530 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • The valve clearance is automatically adjusted by the hydraulic valve lifter. However, there are times that the valve clearance needs to be adjusted manually.
ENGINE d. Measure the valve clearance with a thickness gauge. Valve clearance (cold) Intake 0.00–0.04 mm (0.0000–0.0016 in) Exhaust 0.00–0.04 mm (0.0000–0.0016 in) Thickness gauge 90890-03079 Narrow gauge set YM-34483 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Piston #1 TDC (rear cylinder) a. Turn the crankshaft counterclockwise. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Piston #2 TDC (front cylinder) a. Turn the crankshaft counterclockwise from the piston #1 TDC by 408 degrees. b.
ENGINE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ d. Hold the adjusting screw to prevent it from moving and tighten the locknut to specification with the locknut wrench “6”. a. Loosen the locknut “1” with the locknut wrench “2”. NOTE: Locknut wrench 90890-04150 2 Set the torque wrench at a right angle to the locknut wrench. 1 T. Locknut (rocker arm adjusting screw) 20 Nm (2.0 m·kg, 14 ft·lb) R. Locknut wrench 90890-04150 b.
ENGINE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Remove: • Seat Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. 3. Disconnect: • Intake solenoid vacuum hose (one-way valve to throttle body) “1” • Cylinder-#1 intake air pressure sensor hose “2” a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed 850–950 r/min b.
ENGINE 9. Install: • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. • Seat Refer to “GENERAL CHASSIS” on page 4-1. NOTE: Apply locking agent (LOCTITE®) to the threads of the adjusting nut “3”. c. Loosen the locknut “4” on the accelerator cable. d. Turn the adjusting nut “5” in direction “a” or “b” until the specified throttle cable free play is obtained. EAS20630 ADJUSTING THE THROTTLE CABLE FREE PLAY 1.
ENGINE 5. Check: • Electrode “1” Damage/wear → Replace the spark plug. • Insulator “2” Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • Spark plug (with a spark plug cleaner or wire brush) 7. Measure: • Spark plug gap “a” (with a wire thickness gauge) Out of specification → Regap. c. Tighten the locknut “1”.
ENGINE 1. Stand the vehicle on a level surface. 2. Remove: • Air duct “1” • Timing mark accessing screw “2” a b NOTE: 1 The ignition timing is not adjustable. 2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Connect: • Timing light “1” • Digital tachometer 5. Install: • Timing mark accessing screw T. Timing light 90890-03141 Inductive clamp timing light YU-03141 R. Timing mark accessing screw 8 Nm (0.8 m·kg, 5.8 ft·lb) • Air duct T. R. Air duct bolt 10 Nm (1.0 m·kg, 7.
ENGINE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. 1 EWA12940 WARNING To prevent sparking, ground all spark plug leads before cranking the engine. NOTE: 5. Disconnect: • Spark plug cap 6. Remove: • Spark plug The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm², 14 psi). c.
ENGINE EAS20730 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. NOTE: • Place the vehicle on a suitable stand. • Make sure the vehicle is upright. 2. Start the engine, warm it up for approximately 15 minutes until the oil temperature rises to 60 °C (140 °F), and then turn it off. 3. Remove: • Dipstick “1” 4. Check: • Engine oil level The engine oil level should be between the minimum level mark “a” and maximum level mark “b”.
ENGINE 6. Remove: • Engine oil drain bolt (crankcase) “1” d. Tighten the new oil filter cartridge to specification with an oil filter wrench. T. 1 7. Drain: • Engine oil (completely from the oil tank and crankcase) 8. If the oil filter cartridge is also to be replaced, perform the following procedure. R. Oil filter cartridge 17 Nm (1.7 m·kg, 12 ft·lb) e. Install the rectifier/regulator. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ T. a. Remove the rectifier/regulator “1”. R. Rectifier/regulator bolt 7 Nm (0.
ENGINE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: a. Slightly loosen the oil gallery bolts “1”. Pour the engine oil in two stages. First, pour in 2.5 L of oil, then start the engine and rev it 3 to 5 times. Stop the engine, and then pour in the remainder of the specified amount. EC5YU1004 CAUTION: When starting the engine make sure the dipstick is securely fitted into the oil tank. 1 12.
ENGINE ECA13420 CAUTION: 1 Clutch fluid may damage painted surfaces or plastic parts. Therefore, always clean up any spilt clutch fluid immediately. a NOTE: In order to ensure a correct reading of the clutch fluid level, make sure the top of the reservoir is horizontal. 2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS20910 BLEEDING THE HYDRAULIC CLUTCH SYSTEM EAS20890 CHECKING THE CLUTCH FLUID LEVEL 1. Stand the vehicle on a level surface.
ENGINE d. Place the other end of the hose into a container. e. Slowly squeeze the clutch lever several times. f. Fully squeeze the clutch lever without releasing it. g. Loosen the bleed screw. This will release the tension and cause the clutch lever to contact the handlebar grip. h. Tighten the bleed screw and then release the clutch lever. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the clutch fluid in the plastic hose. j. Tighten the bleed screw to specification. 1 4.
ENGINE EAS21010 CHECKING THE THROTTLE BODY JOINTS 1. Remove: • Seat Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. 2. Check: • Throttle body joints “1” Cracks/damage → Replace. 1 2 1 3. Install: • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. • Seat Refer to “GENERAL CHASSIS” on page 4-1. EAS21050 1 3.
ENGINE • Muffler bolts “13” Front exhaust pipe and front exhaust pipe joint bolt 20 Nm (2.0 m·kg, 14 ft·lb) Front exhaust pipe and rear exhaust pipe bolt 20 Nm (2.0 m·kg, 14 ft·lb) Rear exhaust pipe and rear exhaust pipe joint bolt 20 Nm (2.0 m·kg, 14 ft·lb) Rear exhaust pipe bolt 20 Nm (2.0 m·kg, 14 ft·lb) Rear exhaust pipe and catalyst pipe bolt 20 Nm (2.0 m·kg, 14 ft·lb) Catalyst pipe nut 20 Nm (2.0 m·kg, 14 ft·lb) Catalyst pipe and muffler bolt 20 Nm (2.0 m·kg, 14 ft·lb) Muffler bolt 24 Nm (2.
ENGINE EXUP cable free play (at the EXUP valve pulley) a: 3 mm (0.12 in) or less b: 0 mm 14 15 a b 4. Install: • Seat Refer to “GENERAL CHASSIS” on page 4-1. ab EAS21100 ADJUSTING THE EXUP CABLES 1. Remove: • EXUP valve pulley cover “1” 4. Adjust: • EXUP cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slide back the rubber cover. b. Loosen both locknuts “1”. 1 1 1 2. Check: • EXUP system operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ c. Insert a 3.5 mm (0.
ENGINE 3 d c c d 3 e. Tighten both locknuts and then slide the rubber cover to its original position. f. Remove the pin. g. Turn the main switch to “ON”, check that the EXUP valve pulley contacts the stoppers (fully-open and fully-closed positions), and then check that the notch in the EXUP valve pulley is aligned with the hole in the EXUP valve cover. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • EXUP valve pulley cover T. R. EXUP valve pulley cover bolt 10 Nm (1.0 m·kg, 7.
CHASSIS EAS21140 CHASSIS Installed rear brake master cylinder length 145.3–145.7 mm (5.72–5.74 in) EAS21160 ADJUSTING THE FRONT DISC BRAKE 1. Adjust: • Brake lever position (distance “a” from the throttle grip to the brake lever) a NOTE: • While pushing the brake lever forward, turn the adjusting knob “1” until the brake lever is in the desired position. • Be sure to align the setting on the adjusting knob with the arrow mark “2” on the brake lever. 2.
CHASSIS EW5YU1001 WARNING B A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident. Therefore, check and, if necessary, bleed the brake system. a A. Front brake B.
CHASSIS 3. Hold the vehicle upright and apply the brake several times. 4. Check: • Brake hoses Brake fluid leakage → Replace the damaged hoses. Refer to “FRONT BRAKE” on page 4-18. 1 EAS21290 CHECKING THE REAR BRAKE HOSE 1. Remove: • Seat Refer to “GENERAL CHASSIS” on page 4-1. 2. Check: • Brake hoses “1” Cracks/damage/wear → Replace. 3. Check: • Brake hose guide “2” Loose → Tighten the clamp bolt. EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. 1.
CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the main body “1” of the rear brake light switch so that it does not rotate and turn the adjusting nut “2” in direction “a” or “b” until the rear brake light comes on at the proper time. a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the brake fluid reservoir diaphragm. c. Connect a clear plastic hose “1” tightly to the bleed screw “2”.
CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. a. Loosen both locknuts “1”. b. Turn the shift rod “2” in direction “a” or “b” until the specified installed shift rod length is obtained. h. Tighten the bleed screw and then release the brake lever or brake pedal. i.
CHASSIS NOTE: T. Measure the drive chain slack 85 mm (3.35 in) “b” from the end of the drive chain guide. R. Rear wheel axle nut 150 Nm (15.0 m·kg, 110 ft·lb) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21440 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 vehicle is used in dusty areas.
CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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” on page 4-57. e. Install the rubber washer “3”. f. Install the upper ring nut “2”. g. Finger tighten the upper ring nut “2”, then align the slots of both ring nuts.
CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting bolt “1” in direction “a” or “b”. 2 Direction “a” Spring preload is increased (suspension is harder). Direction “b” Spring preload is decreased (suspension is softer). 1 3. Hold the vehicle upright and apply the front brake. 4. Check: • Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to “FRONT FORK” on page 4-47.
CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Compression damping adjusting positions Minimum 16 click(s) out* Standard 7 click(s) out* Maximum 1 click(s) out* * With the adjusting screw fully turned in a. Turn the adjusting screw “1” in direction “a” or “b”. Direction “a” (turn in) Rebound damping is increased (suspension is harder). Direction “b” (turn out) Rebound damping is decreased (suspension is softer).
CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Spring preload adjusting positions Installed spring length Minimum 155.0 mm (6.10 in) Standard 150.0 mm (5.91 in) Maximum 145.0 mm (5.71 in) a. Turn the adjusting knob “1” in direction “a” or “b”. Direction “a” (turn in) Rebound damping is increased (suspension is harder). Direction “b” (turn out) Rebound damping is decreased (suspension is softer).
CHASSIS Compression damping adjusting positions Minimum 12 click(s) out* Standard 10 click(s) out* Maximum 1 click(s) out* * With the adjusting screw fully turned in Tire air pressure (measured on cold tires) Loading condition 0–90 kg (0–198 lb) Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar) Loading condition 90–202 kg (198–445 lb) Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.
CHASSIS 2. Side wall 3. Wear indicator Front tire Size 120/70 ZR17 M/C (58W) Manufacturer/model METZELER/MEZ4J FRONT (Europe) MICHELIN/PILOT ROAD S (AUS) EWA14080 WARNING • Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. • When using a tube tire, be sure to install the correct tube. • Always replace a new tube tire and a new tube as a set.
CHASSIS EAS21740 NOTE: LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. After a tire or wheel has been changed or replaced, always balance the wheel. Recommended lubricant Lithium-soap-based grease EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. EWA13270 WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement.
ELECTRICAL SYSTEM EAS21750 ECA13690 ELECTRICAL SYSTEM CAUTION: 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. EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” on page 7-85.
ELECTRICAL SYSTEM ECA13690 CAUTION: Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. 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. f. Attach: • Headlight bulb holder g. Connect: • Headlight coupler h.
CHAS 4
CHASSIS GENERAL CHASSIS....................................................................................... 4-1 CHECKING THE AIR FILTER CASE VALVE............................................ 4-5 FRONT WHEEL............................................................................................... 4-6 REMOVING THE FRONT WHEEL............................................................ 4-8 DISASSEMBLING THE FRONT WHEEL.................................................. 4-8 CHECKING THE FRONT WHEEL .....
HANDLEBAR ................................................................................................ 4-42 REMOVING THE HANDLEBAR.............................................................. 4-44 CHECKING THE HANDLEBAR .............................................................. 4-44 INSTALLING THE HANDLEBAR ............................................................ 4-44 FRONT FORK................................................................................................
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery T. 5 R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 4 8 1 9 3 7 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 (4) LT Order Job/Parts to remove Q’ty Remarks 1 Seat 1 2 Lead holder 1 3 Negative battery lead 1 Disconnect. 4 Positive battery lead 1 Disconnect.
GENERAL CHASSIS Removing the side covers and headlight assembly T. R. 9 Nm (0.9 m • kg, 6.5 ft • Ib) LT 9 Nm (0.9 m • kg, 6.5 ft • Ib) T. 2 R. 4 LT LT 8 79 3 1 LT T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. 10 5 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 6 T. R. 7 Nm (0.7 m • kg, 5.
GENERAL CHASSIS Removing the tail/brake light assembly T. T. R. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 2 1 345 LT 7 Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page 4-1. Seat 1 Muffler cooling fan motor coupler 1 Disconnect. 2 Tail/brake light coupler 1 Disconnect. 3 Rear right turn signal light coupler 1 Disconnect. 4 Rear left turn signal light coupler 1 Disconnect. 5 License plate light coupler 1 Disconnect.
GENERAL CHASSIS Removing the air filter case and oil catch tank T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) (5) 10 1 6 2 9 8 5 5 7 4 12 3 LT Job/Parts to remove R. Order T. 11 Q’ty Fuel tank 9 Nm (0.9 m • kg, 6.5 ft • Ib) Remarks Refer to “FUEL TANK” on page 6-1.
GENERAL CHASSIS ET5YU1013 CHECKING THE AIR FILTER CASE VALVE 1. Check: • Air filter case valve operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the air filter case (with the air filter case valve). b. Connect the vacuum/pressure pump gauge set “1” to the air filter case valve “2”. Vacuum/pressure pump gauge set 90890-06756 c. Check that the air filter case valve operates when vacuum pressure is applied to the valve using the vacuum/pressure pump gauge set. Faulty → Replace the air filter case valve.
FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs T. R. 35 Nm (3.5 m • kg, 25 ft • Ib) T. R. 35 Nm (3.5 m • kg, 25 ft • Ib) 2 T. 6 Nm (0.6 m • kg, 4.3 ft • Ib) R. 1 4 T. R. 72 Nm (7.2 m • kg, 52 ft • lb) 6 T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) 3 6 Nm (0.6 m • kg, 4.3 ft • Ib) T. 5 R. LS 8 9 (6) LS 9 LT 8 10 (6) 10 T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) Job/Parts to remove Q’ty R. Order T. LT 7 18 Nm (1.
FRONT WHEEL Disassembling the front wheel New 1 2 LS 3 2 1 New LS Order Job/Parts to remove Q’ty 1 Oil seal 2 Wheel bearing 2 3 Spacer 1 Remarks 2 For assembly, reverse the disassembly procedure.
FRONT WHEEL EAS21900 EAS21920 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. CHECKING THE FRONT WHEEL 1. Check: • Front wheel axle Roll the wheel axle on a flat surface. Bends → Replace. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. EWA13460 WARNING NOTE: Do not attempt to straighten a bent wheel axle. Place the vehicle on a suitable stand so that the front wheel is elevated. 2.
FRONT WHEEL NOTE: Place the front wheel on a suitable balancing stand. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Spin the front wheel. b. When the front wheel stops, put an “X1” mark at the bottom of the wheel. • Oil seals Damage/wear → Replace. EAS21960 ASSEMBLING THE FRONT WHEEL 1. Install: • Wheel bearings New • Oil seals New ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ c. Turn the front wheel 90° so that the “X1” mark is positioned as shown. d. Release the front wheel. e.
FRONT WHEEL EAS22000 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) The following procedure applies to both of the front brake discs. 1. Install: • Front brake disc T. R. b. Turn the front wheel 90° so that the heavy spot is positioned as shown. Front brake disc bolt 18 Nm (1.8 m·kg, 13 ft·lb) LOCTITE® NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. c. If the heavy spot does not stay in that position, install a heavier weight. d.
FRONT WHEEL T. R. Front wheel axle 72 Nm (7.2 m·kg, 52 ft·lb) • Front wheel axle pinch bolt T. R. Front wheel axle pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) EC5YU1002 CAUTION: Before tightening the wheel axle, push down hard on the handlebar several times and check if the front fork rebounds smoothly. 6. Install: • Front brake calipers T. R. Front brake caliper bolt 35 Nm (3.5 m·kg, 25 ft·lb) EWA13500 WARNING Make sure the brake hose is routed properly.
REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel 10 6 8 1 LS 7 5 4 9 LT T. R. 27 Nm (2.7 m • kg, 19 ft • Ib) T. R. 2 22 Nm (2.2 m • kg, 16 ft • Ib) T. R. 150 Nm (15.0 m • kg, 110 ft • lb) T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) 3 Order Job/Parts to remove Q’ty Remarks NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 1 Rear brake caliper 1 2 Drive chain adjusting locknut 2 Loosen. 3 Drive chain adjusting bolt 2 Loosen.
REAR WHEEL Removing the rear brake disc and rear wheel sprocket T. R. 4 5 100 Nm (10.0 m • kg, 72 ft • lb) 6 7 2 (6) 8 New 9 LS LT LS 1 5 3 (6) LT T. R. Order Job/Parts to remove Q’ty 1 Rear brake disc 2 Rear wheel sprocket 1 3 Collar (brake disc side) 1 4 Collar (wheel sprocket side) 1 5 Dust cover 2 6 Oil seal 1 7 Bearing 1 8 Rear wheel drive hub 1 9 Rear wheel drive hub damper 6 18 Nm (1.
REAR WHEEL Disassembling the rear wheel LS 1 2 3 6 5 4 New LS Order Job/Parts to remove Q’ty 1 Collar 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 Remarks 1 For assembly, reverse the disassembly procedure.
REAR WHEEL EAS22040 EAS22090 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. CHECKING THE REAR WHEEL 1. Check: • Rear wheel axle • Rear wheel • Wheel bearings • Oil seals Refer to “CHECKING THE FRONT WHEEL” on page 4-8. 2. Check: • Tire • Rear wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” on page 3-30 and “CHECKING THE WHEELS” on page 3-31. 3. Measure: • Radial wheel runout • Lateral wheel runout Refer to “CHECKING THE FRONT WHEEL” on page 4-8.
REAR WHEEL EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust: • Rear wheel static balance Refer to “ADJUSTING THE FRONT WHEEL STATIC BALANCE” on page 4-9. b. Correct 1. Drive chain roller 2. Rear wheel sprocket ET5YU1026 CHECKING THE REAR BRAKE DISC Refer to “CHECKING THE REAR BRAKE DISC” on page 4-36.
REAR WHEEL • Collar (brake disc side) “2” NOTE: The collar (brake disc side) has marks “a” to distinguish it from the collar (wheel sprocket side). a 1 2 5. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-24. Drive chain slack 40.0–50.0 mm (1.57–1.97 in) 6. Install: • Rear brake caliper T. R. Rear brake caliper bolt (M12) 27 Nm (2.7 m·kg, 19 ft·lb) Rear brake caliper bolt (M8) 22 Nm (2.
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) T. R. 35 Nm (3.5 m • kg, 25 ft • Ib) 1 3 3 2 4 5 6 Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad spring 1 6 Front brake pad 2 For installation, reverse the removal procedure.
FRONT BRAKE Removing the front brake master cylinder T. 2 R. 3 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) 4 1 7 5 15 8 6 16 9 New 13 11 12 10 14 T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-23.
FRONT BRAKE Removing the front brake master cylinder T. 2 R. 3 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) 4 1 7 5 15 8 6 16 9 New 13 11 12 10 14 T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) Order 16 Job/Parts to remove Q’ty Front brake master cylinder Remarks 1 For installation, reverse the removal procedure.
FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Brake master cylinder body 1 Remarks For assembly, reverse the disassembly procedure.
FRONT BRAKE Removing the front brake calipers T. 3 R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) T. R. 2 New 30 Nm (3.0 m • kg, 22 ft • Ib) 1 T. R. 35 Nm (3.5 m • kg, 25 ft • Ib) 4 Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-23.
FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Front brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston seal 8 7 Bleed screw 1 For assembly, reverse the disassembly procedure.
FRONT BRAKE c. Remove the brake caliper. d. Hold the dial gauge at a right angle against the brake disc surface. EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
FRONT BRAKE a d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc. 2. Install: • Brake pads • Brake pad spring NOTE: Always install new brake pads and a brake pad spring as a set. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 6. Install: • Front wheel Refer to “FRONT WHEEL” on page 4-6. a.
FRONT BRAKE NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 3 2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Brake pad pin • Brake pad clips • Front brake caliper 1 EAS22350 T. R. Front brake caliper bolt 35 Nm (3.5 m·kg, 25 ft·lb) 4. Check: • 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” on page 3-21.
FRONT BRAKE EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS EWA13620 WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston seals. a b. Remove the brake caliper piston seals.
FRONT BRAKE 3. Install: • Front brake pads • Brake pad spring • Brake pad pin • Brake pad clips • Front brake caliper a T. R. Front brake caliper bolt 35 Nm (3.5 m·kg, 25 ft·lb) Refer to “REPLACING THE FRONT BRAKE PADS” on page 4-25. 4. Fill: • Brake fluid reservoir (with the specified amount of the recommended brake fluid) 7. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-23.
FRONT BRAKE • Front brake hose union bolt “2” T. 2. Check: • Brake master cylinder kit Damage/scratches/wear → Replace. 3. Check: • Brake fluid reservoir Cracks/damage → Replace. • Brake fluid reservoir diaphragm Cracks/damage → Replace. 4. Check: • Brake hoses Cracks/damage/wear → Replace. R. Front brake hose union bolt 30 Nm (3.0 m·kg, 22 ft·lb) EWA13530 WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” on page 2-41.
FRONT BRAKE ECA13540 CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-23. 5. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-21. a 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake system.
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads T. R. 17 Nm (1.7 m • kg, 12 ft • Ib) T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) 3 2 1 LS 7 4 5 LT T. R. 27 Nm (2.7 m • kg, 19 ft • Ib) 7 T. R. 22 Nm (2.2 m • kg, 16 ft • Ib) 6 T. 5 R. 3 Nm (0.3 m • kg, 2.
REAR BRAKE Removing the rear brake master cylinder 2 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 3 1 4 5 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) New 10 9 7 Job/Parts to remove R. Order T. 8 New 30 Nm (3.0 m • kg, 22 ft • Ib) Q’ty Remarks Brake fluid Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-23. Seat/Battery box/Lead holder Refer to “GENERAL CHASSIS” on page 4-1. Drive sprocket cover Refer to “CHAIN DRIVE” on page 4-69.
REAR BRAKE Disassembling the rear brake master cylinder Order 1 Job/Parts to remove Q’ty Brake master cylinder kit Remarks 1 2 Brake hose joint 1 3 Bush 1 4 Brake master cylinder body 1 For assembly, reverse the disassembly procedure.
REAR BRAKE Removing the rear brake caliper T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 1 2 New T. R. 22 Nm (2.2 m • kg, 16 ft • Ib) 4 3 LT LS T. R. Order 27 Nm (2.7 m • kg, 19 ft • Ib) Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-23. Brake fluid 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper 1 For installation, reverse the removal procedure.
REAR BRAKE Disassembling the rear brake caliper T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) 9 T. 2 R. 17 Nm (1.7 m • kg, 12 ft • Ib) 1 LS 6 T. R. 3 3 Nm (0.3 m • kg, 2.
REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit 5.5 mm (0.22 in) EWA14100 WARNING 5. Adjust: • Brake disc deflection Refer to “CHECKING THE FRONT BRAKE DISCS” on page 4-24. T. R. Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary.
REAR BRAKE 4. Check: • 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” on page 3-21. NOTE: Always install new brake pads, brake pad shims, and a brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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.
REAR BRAKE • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. 2 2 1 EWA13610 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston seals. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the pistons from the brake caliper. 3 EWA13550 WARNING 2 • Cover the brake caliper piston with a rag.
REAR BRAKE EAS22670 INSTALLING THE REAR BRAKE CALIPER 1. Install: • Rear brake caliper “1” (temporarily) • Copper washers New • Rear brake hose “2” • Rear brake hose union bolt “3” Recommended fluid DOT 4 EWA13090 WARNING T. R. • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system.
REAR BRAKE EAS22700 EAS22730 REMOVING THE REAR BRAKE MASTER CYLINDER ASSEMBLING THE REAR BRAKE MASTER CYLINDER EWA13520 NOTE: WARNING Before removing the rear brake master cylinder, drain the brake fluid from the entire brake system. • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components. 1.
REAR BRAKE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. • When refilling, be careful that water does not enter the brake fluid reservoir.
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 4 1 R. R. T. T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. R. 5 1 29 Nm (2.9 m • kg, 21 ft • Ib) T. T. 14 Nm (1.4 m • kg, 10 ft • Ib) 14 LS 14 7 8 15 12 9 14 Nm (1.4 m • kg, 10 ft • Ib) 2 11 5 10 LS 3 6 LS 16 13 T. 12 R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 16 7 T. R. 29 Nm (2.9 m • kg, 21 ft • Ib) T. 13 Nm (1.3 m • kg, 9.4 ft • Ib) R. R. R. Order T. T. 40 Nm (4.0 m • kg, 29 ft • Ib) Job/Parts to remove 40 Nm (4.
HANDLEBAR Removing the handlebar 4 1 R. R. T. T. 20 Nm (2.0 m • kg, 14 ft • Ib) T. R. T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) 5 1 14 14 29 Nm (2.9 m • kg, 21 ft • Ib) LS 7 8 15 12 9 14 Nm (1.4 m • kg, 10 ft • Ib) 2 11 5 10 LS 3 6 LS 16 12 T. 13 R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 16 7 T. R. 29 Nm (2.9 m • kg, 21 ft • Ib) T. 13 Nm (1.3 m • kg, 9.4 ft • Ib) R. R. R. 16 T. T. Order 40 Nm (4.
HANDLEBAR EAS22860 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. 1 EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” 2 NOTE: Blow compressed air between the handlebar and the left handlebar grip, and gradually push the grip off the handlebar. 3. Install: • Handlebar “1” • Upper handlebar holders “2” T. R. Upper handlebar holder bolt 20 Nm (2.
HANDLEBAR T. R. Grip end 29 Nm (2.9 m·kg, 21 ft·lb) NOTE: • Align the mating surfaces of the clutch master cylinder holder with the punch mark “a” on the handlebar. • First, tighten the upper bolt, then the lower bolt. • The clutch master cylinder holder has a punch mark “b” to distinguish it from the front brake master cylinder holder. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b.
HANDLEBAR 9. Install: • Front brake master cylinder assembly • Front brake master cylinder holder “1” T. R. Front brake master cylinder holder bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: • Align the end of the brake master cylinder holder with the punch mark “a” on the handlebar. • First, tighten the upper bolt, then the lower bolt. 1 a 10.Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-7. Throttle cable free play 3.0–5.0 mm (0.12–0.
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs T. R. 26 Nm (2.6 m • kg, 19 ft • Ib) 4 T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) 3 T. R. 28 Nm (2.8 m • kg, 20 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 5 2 Job/Parts to remove R. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) T. T. Order 6 1 7 Nm (0.7 m • kg, 5.1 ft • Ib) Q’ty Remarks The following procedure applies to both of the front fork legs. Front wheel Refer to “FRONT WHEEL” on page 4-6.
FRONT FORK Disassembling the front fork legs T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) LS 1 T. R. 25 Nm (2.5 m • kg, 18 ft • Ib) New 2 3 6 5 16 7 15 10 4 8 9 14 13 New 12 New 11 New T. R. Order Job/Parts to remove Q’ty 35 Nm (3.5 m • kg, 25 ft • Ib) Remarks The following procedure applies to both of the front fork legs.
FRONT FORK Disassembling the front fork legs T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) LS 1 T. R. 25 Nm (2.5 m • kg, 18 ft • Ib) New 2 3 6 5 16 7 15 10 4 8 9 14 13 New 12 New 11 New T. R. Order 16 Job/Parts to remove Q’ty Inner tube 35 Nm (3.5 m • kg, 25 ft • Ib) Remarks 1 For assembly, reverse the disassembly procedure.
FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. 2 EWA13120 1 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: • Cap bolt “1” (from the damper adjusting rod) • Spacer “2” • Nut “3” 2.
FRONT FORK 6 1 7 a 3 d. Remove the cap bolt. e. Remove the rod holder and fork spring compressor. f. Remove the spacer and nut. EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • Inner tube • Outer tube Bends/damage/scratches → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Drain: • Fork oil NOTE: EWA13650 Stroke the damper rod “1” several times while draining the fork oil.
FRONT FORK ECA14200 CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. 2 1 4. Check: • Cap bolt O-ring “1” Damage/wear → Replace. • Cap bolt collar projections “2” Cracks/damage → Replace. 2. Lubricate: • Inner tube’s outer surface Recommended oil Suspension oil 01 3.
FRONT FORK • Lubricate the outer surface of the inner tube with fork oil. • Before installing the oil seal, cover the top of the front fork leg with a plastic bag to protect the oil seal during installation. 4 3 2 NOTE: Adjust the oil seal clip so that it fits into the outer tube’s groove. 1 8. Install: • Dust seal “1” (with the fork seal driver weight “2”) Fork seal driver 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 5. Install: • Outer tube (to the inner tube) 6.
FRONT FORK 14.Measure: • Front fork leg oil level “a” (from the top of the inner tube, with the outer tube fully compressed and without the fork spring) Out of specification → Correct. Level 65.0 mm (2.56 in) 10.Fully compress the front fork leg. 11.Fill: • Front fork leg (with the specified amount of the recommended fork oil) a Quantity 583.0 cm³ (19.71 US oz) (20.56 Imp.oz) Recommended oil Suspension oil 01 15.
FRONT FORK j. Install the nut “4” all the way onto the damper rod assembly. d. e. f. g. Install the upper spring seat and nut. Reinstall the rod puller attachment. Install the spacer. Press down on the spacer with the fork spring compressor “9”. h. Pull up the rod puller and install the rod holder “10” between the nut “4” and the spacer “5”. k. Install the damper adjusting rod. l. Install the washer and cap bolt, and then finger tighten the cap bolt. m.
FRONT FORK EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure the outer tube is flush with the top of the handlebar holder. 2. Tighten: • Lower bracket pinch bolts “1” T. R. Lower bracket pinch bolt 28 Nm (2.8 m·kg, 20 ft·lb) • Cap bolt “2” T. R. Cap bolt 20 Nm (2.0 m·kg, 14 ft·lb) • Upper bracket pinch bolt “3” T. R.
STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 4 2 T. R. 110 Nm (11.0 m • kg, 80 ft • lb) 3 1 R. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 T. T. 9 10 11 12 18 19 20 21 1st 52 Nm (5.2 m • kg, 37 ft • lb) 2nd 23 Nm (2.3 m • kg, 17 ft • lb) LS 14 T. R. 21 15 17 16 7 Nm (0.7 m • kg, 5.1 ft • Ib) 8 LS 7 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 13 T. R. 7 Nm (0.7 m • kg, 5.
STEERING HEAD Removing the lower bracket 4 2 T. R. 110 Nm (11.0 m • kg, 80 ft • lb) 3 1 R. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 T. T. 9 10 11 12 18 19 20 21 1st 52 Nm (5.2 m • kg, 37 ft • lb) 2nd 23 Nm (2.3 m • kg, 17 ft • lb) LS 14 T. R. 21 15 17 16 7 Nm (0.7 m • kg, 5.1 ft • Ib) 8 LS 7 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 13 T. R. 7 Nm (0.7 m • kg, 5.
STEERING HEAD 3. Replace: • Bearings • Bearing races EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a. Remove the bearing races from the steering head pipe with a long rod “1” and hammer. b. Remove the bearing race from the lower bracket with a floor chisel “2” and hammer. c. Install new bearing races. Securely support the vehicle so that there is no danger of it falling over. 2.
STEERING HEAD 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-25. 3. Install: • Front brake hose joint bracket “1” • Front brake hose joint “2” NOTE: Make sure that the tab “a” on the front brake hose joint bracket “1” contacts the side “b” of the front brake hose joint “2”. 1 a 2 b 4. Install: • Upper bracket • Steering stem nut NOTE: Temporarily tighten the steering stem nut. 5.
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 5 12 5 LS 12 LS 2 4 3 8 9 T. R. LS 8 6 2 40 Nm (4.0 m • kg, 29 ft • Ib) 3 1 10 LS 1 R. 10 T. 10 40 Nm (4.0 m • kg, 29 ft • Ib) 11 LS 7 6 LS T. R. 49 Nm (4.
REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the rear wheel is elevated. EWA13740 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.
REAR SHOCK ABSORBER ASSEMBLY • Oil seals Damage/pitting → Replace. 3. Check: • Collars • Spacers Damage/scratches → Replace. 4 24 4 2 6 4 d c d b EAS23270 A INSTALLING THE CONNECTING ARM AND RELAY ARM 1. Lubricate: • Spacers • Bearings B 7 b d 2. Install: • Bearing “1” (to the relay arm) • Bearings “2” (to the connecting arm) • Oil seals “3” (to the relay arm) • Oil seals “4” (to the connecting arm) Installed depth “a” 8.0 mm (0.31 in) Installed depth “b” 4.0 mm (0.16 in) Installed depth “c” 7.
REAR SHOCK ABSORBER ASSEMBLY T. R. Relay arm nut (relay arm and connecting arm) 49 Nm (4.9 m·kg, 35 ft·lb) EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: • Spacers • Bearings Recommended lubricant Lithium-soap-based grease 2. Install: • Relay arm (to the swingarm) NOTE: When installing the relay arm, lift up the swingarm. 3. Tighten: • Rear shock absorber assembly nut (front side) T. R. Rear shock absorber assembly nut (front side) 49 Nm (4.
SWINGARM EAS23330 SWINGARM Removing the swingarm T. R. T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 13 LT T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 2 LT LT 5 4 T. R. 25 Nm (2.5 m • kg, 18 ft • Ib) 8 14 LT 3 12 6 LS 23 15 5 22 21 16 20 New 1710 7 19 19 LS 6 11 9 9 24 25 18 24 LS LS T. R. 1 25 Nm (2.5 m • kg, 18 ft • Ib) T. R. T. R. Order Job/Parts to remove 125 Nm (12.5 m • kg, 90 ft • lb) 7 Nm (0.7 m • kg, 5.
SWINGARM Removing the swingarm T. R. T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 13 LT T. R. 7 Nm (0.7 m kg, 5.1 ft Ib) • • 2 LT LT 5 4 T. R. 25 Nm (2.5 m • kg, 18 ft • Ib) 8 14 LT 3 12 6 LS 23 15 5 22 21 16 20 New 1710 7 19 19 LS 6 11 9 9 24 25 18 24 LS LS T. R. 1 25 Nm (2.5 m • kg, 18 ft • Ib) T. R. T. R. Order Job/Parts to remove 125 Nm (12.5 m • kg, 90 ft • lb) 7 Nm (0.7 m • kg, 5.
SWINGARM EAS23350 EAS23360 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. CHECKING THE SWINGARM 1. Check: • Swingarm Bends/cracks/damage → Replace. 2. Check: • Pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. EWA13770 WARNING Do not attempt to straighten a bent pivot shaft. 2.
SWINGARM • Bearing “3” • Oil seal “4” Installed depth of bearing “a” 6.3 mm (0.25 in) Installed depth of bearing “b” 5.7 mm (0.22 in) Installed depth of oil seal “c” 0.5–1.0 mm (0.02–0.04 in) Installed depth of oil seal “d” 0.5 mm (0.02 in) Installed depth of bearing “e” 4.0 mm (0.16 in) Installed depth of oil seal “f” 1.0 mm (0.04 in) 1 5 1 2 6 A B 2 d d c b a e f 7 5 8 A B 4 5. 6. 7. 8. A. B. 3 Swingarm Swingarm pivot shaft Relay arm Bolt Left side Right side 3.
CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain T. R. T. R. 26 Nm (2.6 m • kg, 19 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 2 5 3 6 4 New 7 LT 8 LT T. 24 Nm (2.4 m • kg, 17 ft • Ib) R. 12 10 11 9 New E T. R. 95 Nm (9.5 m • kg, 68 ft • Ib) 1 T. R. Order Job/Parts to remove Q’ty 10 Nm (1.0 m • kg, 7.2 ft • Ib) Remarks Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-23.
CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 3. Clean: • Drive chain 2. Remove: • Drive chain (with the drive chain cutter) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosene and remove any remaining dirt. c.
CHAIN DRIVE b. Correct 1. Drive chain roller 2. Drive chain sprocket ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • O-rings “1” Damage → Replace the drive chain. • Drive chain rollers “2” Damage/wear → Replace the drive chain. • Drive chain side plates “3” 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.
CHAIN DRIVE 1 2 a b New 3 3. Install: • Clutch release cylinder Refer to “INSTALLING THE CLUTCH RELEASE CYLINDER” on page 5-62.
ENG 5
ENGINE ENGINE REMOVAL ........................................................................................ 5-1 CHECKING THE OIL PIPES ..................................................................... 5-2 CHECKING THE OIL STRAINER ............................................................. 5-2 INSTALLING THE OIL TANK .................................................................... 5-2 REMOVING THE MUFFLER END COVERS ............................................
CLUTCH ........................................................................................................ 5-46 REMOVING THE CLUTCH ..................................................................... 5-55 REMOVING THE PRIMARY DRIVE GEAR ............................................ 5-55 CHECKING THE FRICTION PLATES..................................................... 5-55 CHECKING THE CLUTCH PLATES ....................................................... 5-56 CHECKING THE CLUTCH SPRING PLATE...........
OIL PUMP...................................................................................................... 5-81 CHECKING THE OIL PUMP ................................................................... 5-84 CHECKING THE RELIEF VALVE ........................................................... 5-84 CHECKING THE OIL STRAINER ........................................................... 5-84 ASSEMBLING THE OIL PUMP............................................................... 5-84 INSTALLING THE OIL PUMP ...
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the oil tank T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) 1 2 T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) LS New LS 3 LS New 7 4 LS T. R. 13 Nm (1.3 m • kg, 9.4 ft • Ib) LS 5 New 9 6 T. R. 35 Nm (3.5 m • kg, 25 ft • Ib) 8 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) (16) New T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. Order Job/Parts to remove 10 Nm (1.0 m • kg, 7.
ENGINE REMOVAL ET5YU1027 CHECKING THE OIL PIPES 1. Check: • Oil pipes Damage → Replace. Obstruction → Wash and blow out with compressed air. ET5YU1028 CHECKING THE OIL STRAINER 1. Check: • Oil strainer (oil tank) Damage → Replace. Contaminants → Clean with engine oil. ET5YU1019 INSTALLING THE OIL TANK 1. Install: • Oil tank T. Oil tank bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) R. NOTE: Tighten the oil tank bolts in the proper tightening sequence as shown.
ENGINE REMOVAL Removing the exhaust pipe T. R. T. R. 24 Nm (2.4 m • kg, 17 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 LT 6 8 7 LT LT 5 6 8 New 9 . T 20 Nm (2.0 m • kg, 14 ft • Ib) R. New 11 New 9 7 New 11 10 13 . R 7 Nm (0.7 m • kg, 5.1 ft • Ib) 13 New New T. R. 14 20 Nm (2.0 m • kg, 14 ft • Ib) 4 12 T. 45 Nm (4.5 m • kg, 32 ft • Ib) R. T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 3 T. (3) R. . R. 20 Nm (2.0 m • kg, 14 ft • Ib) 2 T. R.
ENGINE REMOVAL ET5YU1029 REMOVING THE MUFFLER END COVERS 1. Remove: • Muffler end covers “1” 1 a NOTE: Before removing a muffler end cover, turn it in the direction of the arrow shown in the illustration. b 1 1 1 ET5YU1030 INSTALLING THE MUFFLER END COVERS 1.
ENGINE REMOVAL Removing the EXUP servo motor and rear exhaust pipe joint T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 10 12 9 11 15 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. 19 R. 22 T. 16 20 24 17 Nm (1.7 m • kg, 12 ft • Ib) 17 New LS 18 4 New 23 T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. LS 13 14 2 LT 1 LS 6 21 5 New LS 7 T. R. 8 R. R. R. R. T. T. Order T. T. New 24 Nm (2.4 m • kg, 17 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 3 7 Nm (0.
ENGINE REMOVAL Removing the EXUP servo motor and rear exhaust pipe joint T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 10 12 9 11 15 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. 19 R. 22 T. 16 20 24 17 Nm (1.7 m • kg, 12 ft • Ib) 17 New LS 18 4 New 23 T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. LS 13 14 2 LT 1 LS 6 21 5 New LS 7 T. R. 8 R. R. R. R. T. T. Order T. T. New 24 Nm (2.4 m • kg, 17 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 7 Nm (0.
ENGINE REMOVAL Removing the EXUP servo motor and rear exhaust pipe joint T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 10 12 9 11 15 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. 19 R. 22 T. 16 20 24 17 Nm (1.7 m • kg, 12 ft • Ib) 17 New LS 18 4 New 23 T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. LS 13 14 2 LT 1 LS 6 21 5 New LS 7 T. R. 8 R. R. R. R. T. T. Order T. T. New 24 Nm (2.4 m • kg, 17 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib) 3 7 Nm (0.
ENGINE REMOVAL Removing the leads T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 9 11 8 4 5 11 10 6 3 1 2 7 Order Job/Parts to remove Q’ty Remarks 1 Stator coil assembly lead 1 2 Horn lead 1 3 Wire harness 1 4 Decompression solenoid coupler 2 Disconnect. 5 Speed sensor coupler 1 Disconnect. 6 Starter motor connector 1 7 Starter motor lead 1 8 Crankshaft position sensor coupler 1 Disconnect. 9 Negative battery lead 1 Disconnect.
ENGINE REMOVAL Removing the down tube R. R. E 2 T. T. 53 Nm (5.3 m • kg, 38 ft • Ib) 17 7 3 T. 4 3 53 Nm (5.3 m • kg, 38 ft • Ib) R. 53 Nm (5.3 m • kg, 38 ft • Ib) 1 15 6 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. . 74 Nm (7.4 m • kg, 53 ft • lb) 5 15 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) LT LT 16 T. 94 Nm (9.4 m • kg, 68 ft • Ib) R. 13 18 11 14 E T. 12 8 11 10 55 Nm (5.5 m • kg, 40 ft • Ib) 19 12 9 T. R. 94 Nm (9.
ENGINE REMOVAL Removing the down tube R. R. E 2 T. T. 53 Nm (5.3 m • kg, 38 ft • Ib) 17 7 3 T. 4 3 53 Nm (5.3 m • kg, 38 ft • Ib) R. 53 Nm (5.3 m • kg, 38 ft • Ib) 1 15 6 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. . 74 Nm (7.4 m • kg, 53 ft • lb) 5 15 T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) LT LT 16 T. 94 Nm (9.4 m • kg, 68 ft • Ib) R. 13 18 11 14 E T. 12 8 11 10 55 Nm (5.5 m • kg, 40 ft • Ib) 19 12 9 T. R. 94 Nm (9.
ENGINE REMOVAL Removing the engine T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 74 Nm (7.4 m • kg, 53 ft • lb) 53 Nm (5.3 m • kg, 38 ft • Ib) T. R. 4 11 13 1 12 10 14 3 E 2 6 5 E 7 T. R. 74 Nm (7.4 m • kg, 53 ft • lb) T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) T. R. 9 8 Nm (0.8 m • kg, 5.8 ft • Ib) Order 8 Job/Parts to remove Q’ty Remarks NOTE: Place a suitable stand under the frame and engine.
ENGINE REMOVAL Removing the engine T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 74 Nm (7.4 m • kg, 53 ft • lb) 53 Nm (5.3 m • kg, 38 ft • Ib) T. R. 4 11 13 1 12 10 14 3 E 2 6 5 E 7 T. R. T. R. T. R. Order 14 8 Nm (0.8 m • kg, 5.8 ft • Ib) 8 74 Nm (7.4 m • kg, 53 ft • lb) 8 Nm (0.8 m • kg, 5.8 ft • Ib) 9 Job/Parts to remove Q’ty Engine bracket (rear upper side) Remarks 1 For installation, reverse the removal procedure.
ENGINE REMOVAL 3. Position the engine “6” under the vehicle for installation. 4.
ENGINE REMOVAL NOTE: Engine mounting nut (front lower side) 94 Nm (9.4 m·kg, 68 ft·lb) Engine bracket nut (front upper side) 53 Nm (5.3 m·kg, 38 ft·lb) Engine mounting nut (front upper side) 94 Nm (9.4 m·kg, 68 ft·lb) Engine bracket bolt (left upper side) 53 Nm (5.3 m·kg, 38 ft·lb) Engine mounting bolt (left upper side) 53 Nm (5.3 m·kg, 38 ft·lb) Engine bracket bolt (right upper side) 53 Nm (5.3 m·kg, 38 ft·lb) Engine mounting bolt (right upper side) 53 Nm (5.
ENGINE REMOVAL 26 24 26 28 30 10 14 29 27 25 2 19 21 12 11 18 9 22 23 18 20 19 13 5-15
CAMSHAFTS EAS23750 CAMSHAFTS Removing the camshaft sprocket cover T. 1 R. 18 Nm (1.8 m • kg, 13 ft • Ib) T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 3 New 2 4 LS New T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) 7 (6) 6 New 5 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Parts to remove Q’ty Engine Remarks Refer to “ENGINE REMOVAL” on page 5-1.
CAMSHAFTS Removing cylinder head covers T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 LS 7 7 10 Nm (1.0 m • kg, 7.2 ft • Ib) 3 New 5 2 New 3 R. 4 1 T. 1 2 4 7 7 6 LS 7 6 6 6 7 5 6 6 LT LT LT 6 6 4 7 4 7 7 6 9 8 11 10 New 6 New 10 11 11 7 11 T. R. Order 1 Job/Parts to remove Q’ty Tappet cover bolt 10 Nm (1.0 m • kg, 7.2 ft • Ib) Remarks 4 2 Tappet cover 2 3 O-ring 2 4 Cylinder head cover bolt 4 l = 60 mm (2.
CAMSHAFTS Removing the push rods and rocker arms T 10 Nm (1.0 m • kg, 7.2 ft • Ib) . R. T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) T. R. 24 Nm (2.4 m • kg, 17 ft • Ib) 10 12 13 1 11 12 13 12 13 10 E 2 12 13 11 E 9 E 9 9 8 E 7 4 4 E New 3 E 4 5 3 New E 5 6 E E Order E Job/Parts to remove Q’ty Remarks 1 Rear rocker arm base assembly 1 2 Front rocker arm base assembly 1 3 Rocker arm base gasket 2 4 Dowel pin 4 5 Push rod 1 3 l = 288.5 mm (11.
CAMSHAFTS Removing the valve lifters T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) LT LT E 2 New 4 E 5 LT LT New New New 1 New E 6 2 E 1 New 3 6 New 2 3 New E New E 2 New Order Job/Parts to remove Q’ty E Remarks Refer to “CYLINDERS AND PISTONS” on page 5-41. Front cylinder 1 Push rod cover 2 2 O-ring 4 3 Seal 2 4 Rear valve lifter case 1 5 Front valve lifter case 1 6 Valve lifter 4 For installation, reverse the removal procedure.
CAMSHAFTS Removing the camshafts LS 12 13 9 M New 11 New 10 T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) R. (6) T. 14 R. 12 7 Nm (0.7 m • kg, 5.1 ft • Ib) LT LT 8 M 3 LT LT 2 6 7 5 4 T. 1 R. 30 Nm (3.0 m • kg, 22 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. Order Job/Parts to remove 52 Nm (5.2 m • kg, 37 ft • Ib) Q’ty Remarks 1 Decompression solenoid 1 2 Long decompression push rod 1 92 mm (3.6 in) 3 Short decompression push rod 1 78 mm (3.
CAMSHAFTS EAS23790 REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Align: • TDC mark “a” on the crankshaft position sensor rotor (with the pointer “b” on the clutch cover) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compression stroke, align the TDC mark “a” on the crankshaft position sensor rotor with the pointer “b” on the clutch cover. b a EAS23830 c.
CAMSHAFTS EAS23860 CHECKING THE CAMSHAFTS 1. Check: • Cam Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • Cam dimensions “a” and “b” Out of specification → Replace the camshaft. Camshaft lobe dimensions Intake A 38.241–38.341 mm (1.5055– 1.5095 in) (cylinder #1) 38.243–38.343 mm (1.5056– 1.5096 in) (cylinder #2) Limit 38.141 mm (1.5016 in) (cylinder #1) 38.143 mm (1.5017 in) (cylinder #2) Intake B 31.950–32.050 mm (1.2579– 1.2618 in) Limit 31.850 mm (1.2539 in) Exhaust A 38.
CAMSHAFTS Crankcase hole inside diameter 25.000–25.021 mm (0.9843– 0.9851 in) 3. Measure: • Camshaft journal diameter (crankcase side) “a” Out of specification → Replace the camshaft. 6. Measure: • Camshaft cover hole inside diameter “a” Out of specification → Replace the camshaft cover. Camshaft journal diameter (crankcase side) 24.942–24.965 mm (0.9820– 0.9829 in) Camshaft cover hole inside diameter 28.000–28.021 mm (1.1024– 1.1032 in) 4.
CAMSHAFTS NOTE: Rocker arm shaft outside diameter 17.976–17.991 mm (0.7077– 0.7083 in) Calculate the clearance by subtracting the camshaft journal diameter (camshaft cover side) from the camshaft cover hole inside diameter. Camshaft to camshaft cover clearance 0.020–0.054 mm (0.0008–0.0021 in) 9. Check: • Camshaft drive gears • Camshaft driven gears Chips/pitting/roughness/wear → Replace the defective part(s). 5.
CAMSHAFTS 4. Measure: • Valve lifter case inside diameter “a” Out of specification → Replace. EAS23920 CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES 1. Check: • Valve lifter Blue discoloration/excessive wear/pitting/ scratches → Replace and check the lubrication system. 2. Check: • Valve lifter case “1” Damage/wear → Replace the valve lifter case. • Seal “2” • O-ring “3” Damage/wear → Replace the O-ring. Valve lifter hole inside diameter (intake) 23.000–23.021 mm (0.9055– 0.
CAMSHAFTS • O-ring Damage/wear → Replace the oil seal and Oring as a set. EAS23980 CHECKING THE DECOMPRESSION SYSTEM 1. Check: • Decompression system NOTE: • Check the decompression system while the decompression push rod is installed in the camshaft. • Check that the decompression pin “1” projects from the camshaft. • Check that the decompression push rod “2” moves smoothly. 2.
CAMSHAFTS • Align the punch mark “a” on the camshaft drive gear “1” with the punch mark “b” on the camshaft driven gear “2”. • Insert a cross-headed screwdriver into one of the holes in the outer camshaft driven gear and rotate the gear until the teeth of both driven gears are aligned. The teeth of both camshaft driven gears must be aligned for installation. 6. Tighten: • Camshaft drive gear bolt “1” • Front cylinder camshaft end cover bolts “2” T. R. Camshaft drive gear bolt 30 Nm (3.
CAMSHAFTS ECA14630 CAUTION: • Do not pump the valve lifter excessively. • Kerosene is highly flammable. 1. Kerosene 2. Valve lifter b. Install the valve lifter into the engine. ECA14650 CAUTION: Be sure to install the valve lifter in its appropriate position. c. d. e. f. 1. 2. 3. 4. 5. Start the engine and warm it up. Stop the engine. Remove the camshaft sprocket cover.
CAMSHAFTS EAS24070 INSTALLING THE ROCKER ARMS AND PUSH RODS The following procedure applies to both cylinders. 1. Install: • Rocker arms “1” • Rocker arm shafts “2” (onto rocker arm base) NOTE: The thread hole “a” of the rocker arm shaft must face to the outside. 1. Piston #1 TDC punch mark 2. Cylinder-#2 intake valve at its highest point 2. Install: • Rocker arm base (with rocker arms) • Push rods i. Leave the camshaft drive and driven gears aligned for five minutes to allow the valve lifter to bleed.
CAMSHAFTS NOTE: Apply locking agent (LOCTITE®) to the threads of the bolt “3”. T. Cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) R. A. B. 1. 2. 3. 4. 5. 6. Bolts “3”, “4”: l = 40 mm (1.57 in) Bolts “5”: l = 50 mm (1.97 in) Bolt with washer “6”: l = 50 mm (1.97 in) Bolts “7”: l = 60 mm (2.36 in) Rear cylinder Front cylinder Intake side rocker arm Exhaust side rocker arm Intake valve lifter Exhaust valve lifter 5 7 4 LT 3 Push rod 1 l = 288.5 mm (11.358 in) Push rod 2 l = 290.5 mm (11.
CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads E T. R. 45 Nm (4.5 m • kg, 32 ft • Ib) T. R. 39 Nm (3.9 m • kg, 28 ft • Ib) E T. 7 R. 21 Nm (2.1 m • kg, 15 ft • Ib) 4 New E E New 4 New 9 3 10 6 5 New 8 New 9 2 New 1 T. R. T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) Order 10 18 Nm (1.8 m • kg, 13 ft • Ib) 10 Job/Parts to remove Q’ty Cylinder head covers/Rocker arms Remarks Refer to “CAMSHAFTS” on page 5-16.
CYLINDER HEADS EAS24140 REMOVING THE CYLINDER HEADS 1. Remove: • Cylinder head nuts NOTE: • Loosen the nuts in the proper sequence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. 2. Check: • Cylinder head Damage/scratches → Replace. 3. Measure: • Cylinder head warpage Out of specification → Resurface the cylinder head. Warpage limit 0.03 mm (0.0012 in) B ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 3 6 a.
CYLINDER HEADS EAS24250 INSTALLING THE CYLINDER HEADS 1. Tighten: • Cylinder head nuts (M12) “1”–“4” T. R. Cylinder head nut (M12) 45 Nm (4.5 m·kg, 32 ft·lb) • Cylinder head nuts (M10) “5”, “6” T. R. Cylinder head nut (M10) 39 Nm (3.9 m·kg, 28 ft·lb) NOTE: • Lubricate the cylinder head nuts with engine oil. • Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages. B 4 1 6 5 3 2 A. Front cylinder B.
VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs 2 1 1 New 7 1 2 4 2 7 New 4 M 3 3 M 8 8 1 7 New 4 9 9 3 8 2 New 7 9 4 3 8 E 9 5 6 E M M Order Job/Parts to remove Q’ty Remarks The following procedure applies to both cylinders. Cylinder heads Refer to “CYLINDER HEADS” on page 5-31.
VALVES AND VALVE SPRINGS 3. Remove: • Upper spring seat “1” • Outer valve spring “2” • Inner valve spring “3” • Valve “4” • Valve stem seal “5” • Lower spring seat “6” EAS24280 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. NOTE: 1.
VALVES AND VALVE SPRINGS 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. NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover (ø6) 90890-04064 Valve guide remover (6.0 mm) YM-04064-A Valve guide installer (ø6) 90890-04065 Valve guide installer (6.0 mm) YM-04065-A Valve guide reamer (ø6) 90890-04066 Valve guide reamer (6.0 mm) YM-04066 2.
VALVES AND VALVE SPRINGS Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 2.0 mm (0.08 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Limit 2.0 mm (0.08 in) 6. Measure: • Valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the oil seal. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Valve stem runout 0.010 mm (0.0004 in) a.
VALVES AND VALVE SPRINGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. ECA13790 CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • Valve spring free length “a” Out of specification → Replace the valve spring. b. Apply molybdenum disulfide oil onto the valve stem. c.
VALVES AND VALVE SPRINGS Inner spring Installed compression spring force (intake) 63.00–73.00 N (14.16–16.41 lb) (6.42–7.44 kgf) Installed compression spring force (exhaust) 63.00–73.00 N (14.16–16.41 lb) (6.42–7.44 kgf) Installed length (intake) 29.00 mm (1.14 in) Installed length (exhaust) 29.00 mm (1.14 in) Outer spring Installed compression spring force (intake) 139.00–161.00 N (31.25–36.19 lb) (14.17–16.42 kgf) Installed compression spring force (exhaust) 139.00–161.00 N (31.25–36.19 lb) (14.17–16.
VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. • Upper spring seat “7” (into the cylinder head) NOTE: ECA13800 Install the valve springs with the larger pitch “a” facing up. CAUTION: Hitting the valve tip with excessive force could damage the valve. b. Smaller pitch 4. Install: • Valve cotters NOTE: Install the valve cotters by compressing the valve springs with the valve spring compressor set “1”.
CYLINDERS AND PISTONS EAS24360 CYLINDERS AND PISTONS Removing the cylinders and pistons 2 8 New 3 8 9 9 10 10 E 4 E E 5 New 5 New 7 6 1 5 New 6 7 5 New New 3 4 Order Job/Parts to remove Q’ty Cylinder head Remarks Refer to “CYLINDER HEADS” on page 5-31. 1 Front cylinder 1 2 Rear cylinder 1 3 Cylinder gasket 2 4 Dowel pin 4 5 Piston pin clip 4 6 Piston pin 2 7 Piston 2 8 Top ring 2 9 2nd ring 2 10 Oil ring 2 For installation, reverse the removal procedure.
CYLINDERS AND PISTONS • Oil ring EAS24380 REMOVING THE PISTONS The following procedure applies to all of the pistons. 1. Remove: • Piston pin clips “1” • Piston pin “2” • Piston “3” NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. ECA13810 CAUTION: Do not use a hammer to drive the piston pin out.
CYLINDERS AND PISTONS EAS24430 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. c. Measure piston skirt diameter D “a” with the micrometer.
CYLINDERS AND PISTONS 3. Measure: • Piston pin bore diameter “b” Out of specification → Replace the piston. 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. Piston pin bore inside diameter 22.004–22.015 mm (0.8663– 0.8667 in) Limit 22.045 mm (0.8679 in) NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings. Piston ring Top ring End gap (installed) 0.30–0.50 mm (0.01–0.02 in) Limit 0.
CYLINDERS AND PISTONS A 90 ˚ d.e b 90 ˚ 45 ˚ 2. Install: • Piston “1” • Piston pin “2” • Piston pin clips “3” New a. b. c. d. e. A. NOTE: • Apply engine oil onto the piston pin. • Make sure the arrow mark “a” on the piston faces towards the front of the vehicle. • Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase.
CLUTCH EAS25060 CLUTCH Removing the clutch cover 1 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 6 2 3 6 (5) New 5 (10) T. 4 R. Order Job/Parts to remove Q’ty 10 Nm (1.0 m • kg, 7.2 ft • Ib) Remarks Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” on page 3-11. Battery box/Air duct Refer to “GENERAL CHASSIS” on page 4-1. Oil tank/Shift rod Refer to “ENGINE REMOVAL” on page 5-1.
CLUTCH Removing the crankshaft position sensor T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) LT LT LT LT 3 3 3 LT LT LT 4 2 New 1 LS Order Job/Parts to remove Q’ty 1 Oil seal 2 Bearing 1 3 Crankshaft position sensor lead holder 3 4 Crankshaft position sensor 1 Remarks 1 For installation, reverse the removal procedure.
CLUTCH Removing the clutch LS 25 24 23 22 19 New 18 21 17 E 16 15 R. 14 T. 20 125 Nm (12.5 m • kg, 90 ft • lb) 13 29 12 11 10 9 New New 8 28 27 26 6 5 LT E T. R. 100 Nm (10.0 m • kg, 72 ft • lb) 7 New (6) LS 4 E T. R.
CLUTCH Removing the clutch LS 25 24 23 22 19 New 18 21 17 E 16 15 R. 14 T. 20 125 Nm (12.5 m • kg, 90 ft • lb) 13 29 12 11 10 9 New New 8 28 27 26 6 5 LT E T. R. 100 Nm (10.0 m • kg, 72 ft • lb) 7 New (6) LS 4 E T. R.
CLUTCH Removing the clutch master cylinder T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) T. R. 7 3 LS 13 1 2 30 Nm (3.0 m • kg, 22 ft • Ib) 6 14 New 8 4 5 16 15 T. R. 10 13 Nm (1.3 m • kg, 9.4 ft • Ib) 11 17 LS 12 9 Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-14.
CLUTCH Removing the clutch master cylinder T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) T. R. 7 3 LS 13 1 2 30 Nm (3.0 m • kg, 22 ft • Ib) 6 14 New 8 4 5 16 15 T. R. 10 13 Nm (1.3 m • kg, 9.4 ft • Ib) 11 17 LS 12 9 Order Job/Parts to remove Q’ty 16 Clutch master cylinder holder 1 17 Clutch master cylinder 1 Remarks For installation, reverse the removal procedure.
CLUTCH Disassembling the clutch master cylinder 3 4 New 5 6 New 7 LS 2 New 1 Order 1 Job/Parts to remove Q’ty Clutch master cylinder push rod 1 2 Clutch master cylinder kit 1 3 Dust seal 1 4 Circlip 1 5 Clutch fluid reservoir hose joint 1 6 O-ring 1 7 Clutch master cylinder body 1 Remarks For assembly, reverse the disassembly procedure.
CLUTCH Removing the clutch release cylinder 6 6 4 5 2 Job/Parts to remove R. R. Order New 3 T. T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 Q’ty 26 Nm (2.6 m • kg, 19 ft • Ib) Remarks Drain. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-14. Clutch fluid 1 Clutch pipe union bolt cap 1 2 Clutch pipe union bolt 1 3 Copper washer 2 4 Clutch pipe 1 5 Clutch release cylinder 1 6 Dowel pin 2 For installation, reverse the removal procedure.
CLUTCH Disassembling the clutch release cylinder 5 T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) LS 3 New 4 2 LS 1 Order 1 Job/Parts to remove Q’ty Boots 1 2 Clutch release cylinder piston 1 3 Clutch release cylinder spring 1 4 Clutch release cylinder piston seal 1 5 Bleed screw 1 Remarks For assembly, reverse the disassembly procedure.
CLUTCH EAS25080 REMOVING THE CLUTCH 1. Loosen: • Clutch boss nut “1” Sheave holder 90890-01701 Primary clutch holder YS-01880-A NOTE: While holding the clutch boss “2” with the universal clutch holder “3”, loosen the clutch boss nut. Universal clutch holder 90890-04086 YM-91042 2 1 3 3 2. Remove: • Clutch boss nut “1” • Washer “2” • Clutch boss assembly “3” 2 NOTE: EAS25100 There is a built-in damper between the clutch boss and the clutch plate.
CLUTCH EAS25150 CHECKING THE CLUTCH HOUSING 1. Check: • 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. EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: • Clutch plate Damage → Replace the clutch plates as a set. 2.
CLUTCH EAS25190 CHECKING THE CLUTCH PUSH RODS 1. Check: • O-ring • Short clutch push rod • Long clutch push rod • Ball Cracks/damage/wear → Replace the defective part(s). 2. Measure: • Long clutch push rod bending limit Out of specification → Replace the defective part(s). Yamaha bond No. 1215 90890-85505 Long clutch push rod bending limit 0.15 mm (0.0059 in) EAS25230 INSTALLING THE PRIMARY DRIVE GEAR 1.
CLUTCH 3. Install: • Clutch boss “1” • Conical spring washer “2” • Clutch boss nut “3” New T. R. Clutch boss nut 125 Nm (12.5 m·kg, 90 ft·lb) NOTE: • Lubricate the clutch boss nut threads and conical spring washer mating surfaces with engine oil. • Install the washer “2” with the “OUT” mark “a” facing out. • While holding the clutch boss with the universal clutch holder “4”, tighten the clutch boss nut. • Stake the clutch boss nut “3” at a cutout “b” in the main axle.
CLUTCH EAS25280 DISASSEMBLING THE CLUTCH MASTER CYLINDER a ECA13840 2 CAUTION: 1 • Clutch components rarely require disassembly. • Therefore, always follow these preventive measures: • Never disassemble clutch components unless absolutely necessary. • If any connection on the hydraulic clutch system is disconnected, the entire clutch system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. • Never use solvents on internal clutch components.
CLUTCH EAS25290 EAS25310 CHECKING THE CLUTCH MASTER CYLINDER INSTALLING THE CLUTCH MASTER CYLINDER 1. Install: • Clutch master cylinder “1” • Clutch master cylinder holder “2” Recommended clutch component replacement schedule Every two years Clutch hose Every four years Clutch fluid Every two years and whenever the clutch is disassembled T. Piston seals R. Clutch master cylinder holder bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) NOTE: 1.
CLUTCH 2 3 a a New 1 b 3. Fill: • Clutch fluid reservoir (with the specified amount of the recommended clutch fluid) 6. Check: • Clutch lever operation Soft or spongy feeling → Bleed the clutch system. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-14. Recommended clutch fluid Brake fluid DOT4 ET5YU1020 REMOVING THE CLUTCH RELEASE CYLINDER 1. Remove: • Clutch pipe union bolt “1” • Copper washers “2” • Clutch pipe “3” EWA13370 WARNING • Use only the designated clutch fluid.
CLUTCH 1. Check: • Clutch release cylinder body Cracks/damage → Replace the clutch release cylinder. 2. Check: • Clutch release cylinder • Clutch release cylinder piston Rust/scratches/wear → Replace the clutch release cylinder and clutch release cylinder piston as a set. a 2 b 3 1 New 2.
CLUTCH a 5. Check: • Clutch lever operation Soft or spongy feeling → Bleed the clutch system. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-14.
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever LS 1 3 New 2 6 5 7 4 LT LT T. R. 22 Nm (2.2 m • kg, 16 ft • Ib) T. R. Order Job/Parts to remove Q’ty Clutch housing 10 Nm (1.0 m • kg, 7.2 ft • Ib) Remarks Refer to “CLUTCH” on page 5-46. 1 Shift shaft 1 2 Circlip 2 3 Shift shaft spring 1 4 Shift shaft spring stopper 1 5 Washer 1 6 Stopper lever 1 7 Stopper lever spring 1 For installation, reverse the removal procedure.
SHIFT SHAFT • Hook the end of the shift shaft spring onto the shift shaft spring stopper “3”. EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever. • Stopper lever spring Damage/wear → Replace. EAS25450 INSTALLING THE SHIFT SHAFT 1.
GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil assembly T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) LT LS New 7 3 6 New 6 8 LS LT LT 1 2 5 New T. R. 4 New R. Order T. (9) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) Job/Parts to remove Q’ty Remarks Engine oil Drain.
GENERATOR AND STARTER CLUTCH Removing the generator rotor 6 7 5 3 1 4 E 2 E . T R. Order 80 Nm (8.0 m • kg, 58 ft • Ib) E Job/Parts to remove Q’ty 1 Starter clutch idle gear shaft #2 2 Starter clutch idle gear shaft #1 1 3 Starter clutch idle gear #2 1 4 Starter clutch idle gear #1 1 5 Generator rotor 1 6 Woodruff key 1 7 Starter clutch gear 1 Remarks 1 For installation, reverse the removal procedure.
GENERATOR AND STARTER CLUTCH 2. Check: • Starter clutch gear’s contacting surfaces Damage/pitting/wear → Replace the starter clutch gear. 3. Check: • Starter clutch operation EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer NOTE: While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the starter clutch gear “1” onto the generator rotor “2” and hold the generator rotor. b.
GENERATOR AND STARTER CLUTCH 2. Tighten: • Generator rotor bolt “1” T. R. Generator rotor bolt 80 Nm (8.0 m·kg, 58 ft·lb) NOTE: Tighten the generator rotor bolt “1” while holding the generator rotor “2” with a sheave holder “3”. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 3 1 2 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No.
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 1 2 Order Job/Parts to remove Q’ty Oil tank Remarks Refer to “ENGINE REMOVAL” on page 5-1. 1 Starter motor lead 1 2 Starter motor assembly 1 Disconnect. For installation, reverse the removal procedure.
ELECTRIC STARTER Disassembling the starter motor LS LS New 1 2 New 3 New 5 4 New 6 12 New New 13 14 9 8 10 New 12 11 7 Order 1 Job/Parts to remove Q’ty Circlip Remarks 1 2 Starter motor gear 1 3 Starter motor rear cover 1 4 Bearing 1 5 Oil seal 1 6 Circlip 1 7 Starter motor front cover 1 8 Brush 2 9 Brush holder (along with the brushes) 1 10 Brush seat (along with the brushes) 1 11 Bearing 1 12 Gasket 2 13 Armature assembly 1 14 Starter motor yoke 1 For
ELECTRIC STARTER ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Commutator diameter “a” Out of specification → Replace the starter motor. a. Measure the armature assembly resistances with the pocket tester. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Armature coil Commutator resistance “1” 0.0081–0.0099 Ω at 20°C (68°F) Insulation resistance “2” Above 1 MΩ at 20°C (68°F) Limit 27.5 mm (1.
ELECTRIC STARTER 3. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” NOTE: Align the match mark “a” on the starter motor yoke with the match mark “b” on the starter motor rear cover. a 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing • Oil seal Damage/wear → Replace the defective part(s). 3 2 EAS24800 ASSEMBLING THE STARTER MOTOR 1.
CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Camshafts Refer to “CAMSHAFTS” on page 5-16. Pistons Refer to “CYLINDERS AND PISTONS” on page 5-41. Shift shaft Refer to “SHIFT SHAFT” on page 5-64. Generator rotor Refer to “GENERATOR AND STARTER CLUTCH” on page 5-66.
CRANKCASE Separating the crankcase Order 10 Job/Parts to remove Q’ty Right crankcase Remarks 1 For installation, reverse the removal procedure.
CRANKCASE Removing the oil baffle plate and bearings Order Job/Parts to remove Q’ty Remarks Oil pump Refer to “OIL PUMP” on page 5-81. Crankshaft Refer to “CRANKSHAFT” on page 5-86. Transmission Refer to “TRANSMISSION” on page 5-92. 1 Oil baffle plate 1 2 Bearing retainer 1 3 Bearing retainer 1 4 Oil seal 1 5 Bearing 4 For installation, reverse the removal procedure.
CRANKCASE • M6 × 75 mm bolts: “14”, “15” • M6 × 60 mm bolts: “4”–“7” • M6 × 40 mm bolts: “8”, “10”–“12”, “16”–“20” EAS25570 DISASSEMBLING THE CRANKCASE NOTE: Loosen the generator shaft bolt before removing the generator rotor. 1. Loosen: • Generator shaft bolt “1” NOTE: While the holding the generator rotor “2” with the primary sheave holder “3”, loosen the generator shaft bolt. Sheave holder 90890-01701 Primary clutch holder YS-01880-A A. Right crankcase B. Left crankcase 3.
CRANKCASE • Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly. ET5YU1023 INSTALLING THE BEARING RETAINER 1. Install: • Bearing retainer “1” NOTE: • Install the bearing retainer “1” with its “OUT” mark “a” facing outward. • Apply locking agent (LOCTITE®) to the threads of the bearing retainer bolt.
CRANKCASE • Tap lightly on the left crankcase with a softface hammer. 4. Install: • Crankcase bolts (M8) • Crankcase bolts (M6) T. R. Crankcase bolt (M8) 24 Nm (2.4 m·kg, 17 ft·lb) Crankcase bolt (M6) 10 Nm (1.0 m·kg, 7.2 ft·lb) A. Right crankcase B. Left crankcase NOTE: • Lubricate the bolt threads with engine oil. • Tighten each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. • Tighten the bolts in numerical order (refer to the numbers in the illustration). 5.
CRANKCASE 5-80
OIL PUMP EAS24910 OIL PUMP Removing the oil pump Order Job/Parts to remove Q’ty Remarks Separate. Refer to “CRANKCASE” on page 5-74. Crankcase 1 Oil strainer (crankcase) 1 2 Oil pump assembly 1 For installation, reverse the removal procedure.
OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty 1 Spring retainer 1 2 Spring 1 3 Relief valve 1 4 Oil pump housing cover 1 1 5 Pin 2 6 Spring 1 7 Collar 1 8 Ball 1 9 Oil pump outer rotor 1 1 10 Oil pump inner rotor 1 1 11 Pin 1 12 Oil pump housing cover 2 1 13 Pin 2 14 Oil pump shaft 1 15 Pin 1 16 Oil pump inner rotor 2 1 17 Oil pump outer rotor 2 1 5-82 Remarks
OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty 18 Oil seal 2 19 Oil pump housing 1 Remarks For assembly, reverse the disassembly procedure.
OIL PUMP 3. Check: • Oil pump operation Rough movement → Repeat steps (1) and (2) or replace the defective part(s). EAS24960 CHECKING THE OIL PUMP 1. Check: • Oil pump housing • Oil pump housing cover Cracks/damage/wear → Replace the defective part(s). 2. Measure: • Inner-rotor-to-outer-rotor-tip clearance “a” • Outer-rotor-to-oil-pump-housing clearance “b” • Oil-pump-housing-to-inner-rotor-and-outerrotor clearance “c” Out of specification → Replace the oil pump.
OIL PUMP 3. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-84. • Oil pump shaft “6” • Pins “7” • Oil pump housing cover 2 “8” T. R. Oil pump housing cover 2 screw 2 Nm (0.2 m·kg, 1.4 ft·lb) EAS25020 INSTALLING THE OIL PUMP 1. Install: • Oil pump “1” T. • Pin “9” • Oil pump inner rotor 1 “10” • Oil pump outer rotor 1 “11” • Ball “12” • Collar “13” • Spring “14” • Pins “15” • Oil pump housing cover 1 “16” R. Oil pump bolt 10 Nm (1.0 m·kg, 7.
CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Separate. Refer to “CRANKCASE” on page 5-74. Crankcase 1 Remarks Crankshaft 1 2 Generator shaft 1 3 Connecting rod cap 2 4 Big end lower bearing 2 5 Connecting rod 2 6 Big end upper bearing 2 For installation, reverse the removal procedure.
CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS The following procedure applies to all of the connecting rods. 1. Remove: • Connecting rod caps “1” • Connecting rod • Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place. 3. Measure: • Crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace the big end bearings. Journal oil clearance (using plastigauge®) 0.030–0.062 mm (0.0012–0.
CRANKSHAFT c. Put a piece of Plastigauge® “1” on the crankshaft pin. g. Put a mark “1” on the connecting rod bolts “2” and the connecting rod cap “3”. d. Assemble the connecting rod halves. h. Tighten the connecting rod bolts further to reach the specified angle 120°–150°. NOTE: T. • Do not move the connecting rod or crankshaft until the clearance measurement has been completed. • Lubricate the bolts threads and nut seats with molybdenum disulfide grease.
CRANKSHAFT For example, if the connecting rod “P1” and the crankshaft web “P” numbers are “5” and “2” respectively, then the bearing size for “P1” is: “P1” (connecting rod) - “P” (crankshaft) = 5 - 2 = 3 (brown) Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Select: • Big end bearings (“P1”–“P2”) 5. Measure: • Crankshaft journal diameter “a” Out of specification → Replace the crankshaft.
CRANKSHAFT • Be sure to reinstall each big end bearing in its original place. • Make sure the projections “c” on the connecting rods face towards the left side of the crankshaft. • Make sure the characters “d” on both the connecting rod and connecting rod cap are aligned. 7. Calculate: • Crankshaft journal-to-crankshaft journal bearing clearance Out of specification → Replace the crankshaft and crankshaft journal bearings as a set.
CRANKSHAFT a. Tighten the connecting rod bolts to the specified torque. ECA13970 CAUTION: T. R. To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. Connecting rod bolt (1st) 15 Nm (1.5 m·kg, 11 ft·lb) b. Put a mark “1” on the connecting rod bolts “2” and the connecting rod cap “3”.
TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Refer to “CRANKCASE” on page 5-74. Crankcase 1 Shift fork guide bar 2 2 Shift drum assembly 1 3 Shift fork-L 1 4 Shift fork-R 1 5 Shift fork-C 1 6 Drive axle assembly 1 7 Main axle assembly 1 8 Spacer 1 For installation, reverse the removal procedure.
TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty 1 Circlip 1 2 Washer 1 3 5th pinion gear 1 4 Collar 1 5 Washer 1 6 2nd/3rd pinion gear 1 7 Circlip 1 8 Washer 1 9 4th pinion gear 1 10 Collar 1 11 Main axle/1st pinion gear 1 Remarks For assembly, reverse the disassembly procedure.
TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty 1 5th wheel gear 1 2 Circlip 1 3 Washer 1 4 2nd wheel gear 1 5 Collar 1 6 Circlip 1 7 Washer 1 8 1st wheel gear 1 9 Collar 1 10 Washer 1 11 4th wheel gear 1 12 Circlip 1 13 Washer 1 14 3rd wheel gear 1 15 Collar 1 16 Drive axle 1 Remarks For assembly, reverse the disassembly procedure.
TRANSMISSION EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • Shift fork cam follower “1” • Shift fork pawl “2” Bends/damage/scoring/wear → Replace the shift fork. EAS26300 CHECKING THE TRANSMISSION 1. Measure: • Main axle runout (with a centering device and dial gauge “1”) Out of specification → Replace the main axle. Main axle runout limit 0.08 mm (0.0032 in) 2. Check: • Shift fork guide bar Roll the shift fork guide bar on a flat surface.
TRANSMISSION • Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). 4. Check: • Transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 5. Check: • Transmission gear movement Rough movement → Replace the defective part(s). 6. Check: • Circlips Bends/damage/looseness → Replace. EAS26320 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1.
FUEL 6
FUEL SYSTEM FUEL TANK..................................................................................................... 6-1 REMOVING THE FUEL TANK .................................................................. 6-2 REMOVING THE FUEL PUMP ................................................................. 6-2 CHECKING THE FUEL PUMP BODY....................................................... 6-2 CHECKING THE FUEL PUMP OPERATION............................................ 6-2 INSTALLING THE FUEL PUMP......
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank and fuel pump T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 8 9 4 5 New 6 3 (6) 2 7 T. R. Order Job/Parts to remove Q’ty 4 Nm (0.4 m • kg, 2.9 ft • Ib) Remarks Refer to “GENERAL CHASSIS” on page 4-1. Seat 1 Fuel tank cover 1 2 Fuel pump coupler 1 Disconnect. 3 Fuel sender coupler 1 Disconnect. 4 Fuel tank overflow hose 1 Disconnect. 5 Fuel tank breather hose 1 Disconnect. 6 Fuel hose 1 Disconnect.
FUEL TANK EAS26630 EAS26670 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Disconnect: • Fuel hose • Fuel return hose CHECKING THE FUEL PUMP BODY 1. Check: • Fuel pump body Obstruction → Clean. Cracks/damage → Replace fuel pump assembly. 2. Check: • Diaphragms and gaskets Tears/fatigue/cracks → Replace fuel pump assembly.
FUEL TANK EC5YU1017 CAUTION: When installing the fuel hose and the fuel return hose, make sure that they are securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position, otherwise the fuel hose will not be properly installed. NOTE: • Install the fuel hose securely onto the fuel pump until a distinct “click” is heard. • To install the fuel hose onto the fuel pump, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown.
THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the pressure regulator and rollover valves T. 5 R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 3 7 4 2 5 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 15 8 1 12 9 12 10 14 13 11 T. 12 R. 9 Nm (0.9 m • kg, 6.5 ft • Ib) 12 Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 6-1. Air duct Refer to “GENERAL CHASSIS” on page 4-1.
THROTTLE BODIES Removing the pressure regulator and rollover valves T. 5 R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 3 7 4 2 5 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 15 8 1 12 9 12 10 14 13 11 T. 12 R. 9 Nm (0.9 m • kg, 6.5 ft • Ib) 12 Order Job/Parts to remove Q’ty 14 Rollover valve 2 1 15 Rollover valve bracket 1 Remarks For installation, reverse the removal procedure.
THROTTLE BODIES Removing the throttle bodies 5 T. 7 R. LS 4 Nm (0.4 m • kg, 2.9 ft • Ib) T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) 8 6 6 T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) 2 3 1 4 Order Job/Parts to remove Q’ty Remarks Seat/Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 6-1. 1 Throttle position sensor coupler 1 Disconnect. 2 Cylinder-#1 intake air pressure sensor hose 1 Disconnect.
THROTTLE BODIES Removing the intake manifolds T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 3 2 (2) (2) 4 8 New New 8 5 7 1 6 Order Job/Parts to remove Q’ty Remarks 1 Fuel hose 1 2 Fuel hose (intake manifold assembly to pressure regulator) 1 3 Cylinder-#2 ISC (idle speed control) unit outlet hose 1 4 Cylinder-#1 ISC (idle speed control) unit outlet hose 1 5 Intake manifold assembly 1 6 Cylinder-#2 injector coupler 1 Disconnect. 7 Cylinder-#1 injector coupler 1 Disconnect.
THROTTLE BODIES Removing the injectors T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) New New T. R. 5 Nm (0.5 m • kg, 3.6 ft • Ib) 1 2 New 5 4 New New New 5 New New 4 3 T. R. Order 5 Nm (0.5 m • kg, 3.6 ft • Ib) Job/Parts to remove Q’ty 1 Fuel pipe 1 2 Injector joint 1 1 3 Injector joint 2 1 4 Injector 2 5 Intake manifold 2 Remarks For installation, reverse the removal procedure.
THROTTLE BODIES EAS26980 EAS27010 CHECKING THE INJECTORS 1. Check: • Injectors Damage → Replace. CHECKING THE PRESSURE REGULATOR OPERATION 1. Check: • Pressure regulator operation EAS26990 a. Remove the pressure regulator cover. Refer to “THROTTLE BODIES” on page 6-4. b. Disconnect the fuel hose “1” from the pressure regulator “2”. c. Connect the fuel pressure adapter “3” between the fuel hose “1” and pressure regulator “2”. d. Connect the pressure gauge “4” to the fuel pressure adapter “3”. e.
THROTTLE BODIES h. Use the vacuum/pressure pump gauge set to adjust the fuel pressure in relation to the vacuum pressure as described below. 3 NOTE: The vacuum pressure should not exceed 100 kPa (760 mm Hg). 3 2 • Increase the vacuum pressure → Fuel pressure is decreased • Decrease the vacuum pressure → Fuel pressure is increased 1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Faulty → Replace the pressure regulator. ET5YU1016 INSTALLING THE FUEL PIPE 1.
ISC (IDLE SPEED CONTROL) UNIT ET5YU1012 ISC (IDLE SPEED CONTROL) UNIT Removing the ISC (idle speed control) unit and intake solenoid T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 13 12 7 4 8 5 15 11 14 6 3 9 2 10 16 1 R. R. Job/Parts to remove T. T. Order 9 Nm (0.9 m • kg, 6.5 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 6-1. Air filter case Refer to “GENERAL CHASSIS” on page 4-1.
ISC (IDLE SPEED CONTROL) UNIT Removing the ISC (idle speed control) unit and intake solenoid T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 13 12 7 4 8 5 15 11 14 6 3 9 2 10 16 1 R. R. Job/Parts to remove T. T. Order 9 Nm (0.9 m • kg, 6.5 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Q’ty Remarks 12 ISC (idle speed control) unit coupler 1 Disconnect. 13 Cylinder-#1 ISC (idle speed control) unit outlet hose 1 Disconnect.
ISC (IDLE SPEED CONTROL) UNIT ET5YU1015 CHECKING THE ISC (IDLE SPEED CONTROL) SYSTEM 1. Check: • Hoses Loose connections → Connect properly. Cracks/damage → Replace. 2. Check: • Surge tank Cracks/damage → Replace. 3. Check: • One-way valve Cracks/damage/faulty → Replace. NOTE: Check that air flows smoothly only in the direction of the arrow shown in the illustration. 4. Check: • Intake solenoid Damage → Replace.
– ELEC + 7
ELECTRICAL SYSTEM IGNITION SYSTEM ......................................................................................... 7-1 CIRCUIT DIAGRAM .................................................................................. 7-1 TROUBLESHOOTING .............................................................................. 7-3 ELECTRIC STARTING SYSTEM .................................................................... 7-5 CIRCUIT DIAGRAM ....................................................................
ELECTRICAL COMPONENTS...................................................................... 7-85 CHECKING THE SWITCHES ................................................................. 7-89 CHECKING THE BULBS AND BULB SOCKETS ................................... 7-92 CHECKING THE FUSES ........................................................................ 7-93 CHECKING AND CHARGING THE BATTERY....................................... 7-94 CHECKING THE RELAYS ..................................................
7-1 BB3 BB2 BB4 BB1 B B B B B2 B1 B1 B2 BB2 BB1 B2 B1 BB4 BB3 ON OFF Br/W L Br/R B L R/Y Br/L B L L (BLACK) (BLACK) B L R/W Br/L G/Y Br Br/W R/B Br/G Br/L R Br/L Br/L R Br/R B Br/R G/Y Br/L Br/R R/B R B B B (BLACK) B B B B R B B Y (GRAY) (BROWN) Br Y Br B B L B R R R B (BROWN) B (BLACK) R B L B R R/B Br/W R R R B B (GRAY) B G/R (BLUE) L R/G B B2 (BLUE) Lg B L Y Y R R/W L/W B B B/Y R/B R/W R R/W L R R/G B2 B R/W Lg Y/L Y L/W
IGNITION SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 19.Sidestand switch 20.Crankshaft position sensor 24.Lean angle cut-off switch 29.ECU (electronic control unit) 32.Spark plug 33.Cylinder-#2 right ignition coil 34.Cylinder-#2 left ignition coil 35.Cylinder-#1 left ignition coil 36.Cylinder-#1 right ignition coil 56.Clutch switch 73.Engine stop switch 81.
IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case 4. Battery box 5. Engine 1. Check the fuses. (Main, ignition, and ECU) Refer to “CHECKING THE FUSES” on page 7-93. NG → Replace the fuse(s). OK ↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-94. NG → • Clean the battery terminals.
IGNITION SYSTEM 8. Check the main switch. Refer to “CHECKING THE SWITCHES” on page 7-89. NG → Replace the main switch/immobilizer unit. OK ↓ 9. Check the engine stop switch. Refer to “CHECKING THE SWITCHES” on page 7-89. NG → Replace the right handlebar switch. OK ↓ 10.Check the neutral switch. Refer to “CHECKING THE SWITCHES” on page 7-89. NG → Replace the neutral switch. OK ↓ 11.Check the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 7-89. NG → Replace the sidestand switch. OK ↓ 12.
7-5 BB3 BB2 BB4 BB1 B B B B B2 B1 B1 B2 BB2 BB1 B2 B1 BB4 BB3 ON OFF Br/W L Br/R B L R/Y Br/L B L L (BLACK) (BLACK) B L R/W Br/L G/Y Br Br/W R/B Br/G Br/L R Br/L Br/L R Br/R B Br/R G/Y Br/L Br/R R/B R B B B (BLACK) B B B B R B B Y (GRAY) (BROWN) Br Y Br B B L B R R R B (BROWN) B (BLACK) R B L B R R/B Br/W R R R B B (GRAY) B G/R (BLUE) L R/G B B2 (BLUE) Lg B L Y Y R R/W L/W B B B/Y R/B R/W R R/W L R R/G B2 B R/W Lg Y/L Y L/
ELECTRIC STARTING SYSTEM 3. Main switch 4. Battery 6. Starter relay 7. Starter motor 8. Main fuse 10.ECU fuse 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 19.Sidestand switch 29.ECU (electronic control unit) 38.Decompression solenoid 56.Clutch switch 70.Auto decompression fuse 73.Engine stop switch 74.Start switch 81.
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is turned “ON” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral switch circuit is closed). • The clutch lever is pulled to the handlebar (the clutch switch circuit is closed) and the sidestand is up (the sidestand switch circuit is closed).
ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Relay unit (starting circuit cut-off relay) 7. Relay unit (diode) 8. Clutch switch 9. Sidestand switch 10.Neutral switch 11.Start switch 12.Starter relay 13.Starter motor 14.ECU fuse 15.Auto decompression fuse 16.Decompression solenoid 17.
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case 4. Oil tank 1. Check the fuses. (Main, ignition, auto decompression, and ECU) Refer to “CHECKING THE FUSES” on page 7-93. NG → Replace the fuse(s). OK ↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-94. NG → • Clean the battery terminals. • Recharge or replace the battery. OK ↓ 3.
ELECTRIC STARTING SYSTEM 8. Check the engine stop switch. Refer to “CHECKING THE SWITCHES” on page 7-89. NG → Replace the right handlebar switch. OK ↓ 9. Check the neutral switch. Refer to “CHECKING THE SWITCHES” on page 7-89. NG → Replace the neutral switch. OK ↓ 10.Check the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 7-89. NG → Replace the sidestand switch. OK ↓ 11.Check the clutch switch. Refer to “CHECKING THE SWITCHES” on page 7-89. NG → Replace the clutch switch. OK ↓ 12.
7-11 BB3 BB2 BB4 BB1 B B B B B2 B1 B1 B2 BB2 BB1 B2 B1 BB4 BB3 ON OFF R Br/L Br/R Br/G Br Br/L R Br/L Br/L R Br/R Br/R B Br/R (BLACK) B B B B B B B R B (BLACK) R R R R B B B B R R R B B2 R/G Y/L Lg R/W R/B Br/W R R R B B L R/G B B2 R/W R R/W L R R/G B2 B R/W Lg Y/L R Lg R/W Y/L R/G Gy/R B B Sb Sb Sb/W L Y/G B/L (BLACK) B/L P/Y L (BLACK) B/L P/W L (BLACK) L Y B B/Y L/W1 L Sb Y L D Y D L B R/L B/L P/Y L B/L P/W L Y L Gy1 B/L B B
CHARGING SYSTEM 1. 2. 4. 8.
CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 1. Check the fuse. (Main) Refer to “CHECKING THE FUSES” on page 7-93. NG → Replace the fuse. OK ↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-94. NG → • Clean the battery terminals. • Recharge or replace the battery. OK ↓ 3. Check the stator coil. Refer to “CHECKING THE STATOR COIL” on page 7-101.
CHARGING SYSTEM 7-14
7-15 BB3 BB2 BB4 BB1 B B B B B2 B1 B1 B2 BB2 BB1 B2 B1 BB4 BB3 ON OFF Br/W L Br/R B L R/Y Br/L B L L (BLACK) (BLACK) B L R/W Br/L G/Y Br Br/W R/B Br/G Br/L R Br/L Br/L R Br/R B Br/R G/Y Br/L Br/R R/B R B B B (BLACK) B B B B R B B Y (GRAY) (BROWN) Br Y Br B B L B R R R B (BROWN) B (BLACK) R B L B R R/B Br/W R R R B B (GRAY) B G/R (BLUE) L R/G B B2 (BLUE) Lg B L Y Y R R/W L/W B B B/Y R/B R/W R R/W L R R/G B2 B R/W Lg Y/L Y L
LIGHTING SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 29.ECU (electronic control unit) 47.High beam indicator light 50.Meter light 54.Headlight relay 57.Pass switch 58.Dimmer switch 67.Auxiliary light 68.Headlight (high beam) 69.Headlight (low beam) 75.Tail/brake light 76.License plate light 80.Headlight fuse 82.Signaling system fuse 83.
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light, taillight, license plate light, auxiliary light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case 4. Headlight assembly 1. Check the condition of each bulb and bulb socket. Refer to “CHECKING THE BULBS AND BULB SOCKETS” on page 7-92. NG → Replace the bulb(s) and bulb socket(s). OK ↓ 2.
LIGHTING SYSTEM 8. Check the entire lighting system wiring. Refer to “CIRCUIT DIAGRAM” on page 7-15. NG → Properly connect or repair the lighting system wiring. OK ↓ This circuit is OK.
7-19 BB3 BB2 BB4 BB1 B B B B B2 B1 B1 B2 BB2 BB1 B2 B1 BB4 BB3 ON OFF Br/W L Br/R B L R/Y Br/L B L L (BLACK) (BLACK) B L R/W Br/L G/Y Br Br/W R/B Br/G Br/L R Br/L Br/L R Br/R B Br/R G/Y Br/L Br/R R/B R B B B (BLACK) B B B B R B B Y (GRAY) (BROWN) Br Y Br B B L B R R R B (BROWN) B (BLACK) R B L B R R/B Br/W R R R B B (GRAY) B G/R (BLUE) L R/G B B2 (BLUE) Lg B L Y Y R R/W L/W B B B/Y R/B R/W R R/W L R R/G B2 B R/W Lg Y/L Y L
SIGNALING SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 12.Backup fuse (odometer, clock and immobilizer system) 13.Relay unit 16.Neutral switch 18.Fuel sender 25.Speed sensor 29.ECU (electronic control unit) 42.Fuel level warning light 43.Neutral indicator light 44.Multi-function meter 45.Engine trouble warning light 48.Left turn signal indicator light 49.Right turn signal indicator light 52.Horn 53.Turn signal/hazard relay 59.Hazard switch 60.Turn signal switch 61.Horn switch 62.
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or indicator light. • The horn fails to sound. • The speedometer fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case 4. Headlight assembly 1. Check the fuses. (Main, ignition, signaling system, parking lighting, and ECU) Refer to “CHECKING THE FUSES” on page 7-93. NG → Replace the fuse(s). OK ↓ 2. Check the battery.
SIGNALING SYSTEM 3. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM” on page 7-19. NG → Properly connect or repair the signaling system wiring. OK ↓ This circuit is OK. The tail/brake light fails to come on. 1. Check the front brake light switch. Refer to “CHECKING THE SWITCHES” on page 7-89. NG → Replace the front brake light switch. OK ↓ 2. Check the rear brake light switch. Refer to “CHECKING THE SWITCHES” on page 7-89. NG → Replace the rear brake light switch. OK ↓ 3.
SIGNALING SYSTEM 5. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM” on page 7-19. NG → Properly connect or repair the signaling system wiring. OK ↓ This circuit is OK. The neutral indicator light fails to come on. 1. Check the neutral switch. Refer to “CHECKING THE SWITCHES” on page 7-89. NG → Replace the neutral switch. OK ↓ 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM” on page 7-19. NG → Properly connect or repair the signaling system wiring.
SIGNALING SYSTEM 7-24
7-25 BB3 BB2 BB4 BB1 B B B B B2 B1 B1 B2 BB2 BB1 B2 B1 BB4 BB3 ON OFF Br/W L Br/R B L R/Y Br/L B L L (BLACK) (BLACK) B L R/W Br/L G/Y Br Br/W R/B Br/G Br/L R Br/L Br/L R Br/R B Br/R G/Y Br/L Br/R R/B R B B B (BLACK) B B B B R B B Y (GRAY) (BROWN) Br Y Br B B L B R R R B (BROWN) B (BLACK) R B L B R R/B Br/W R R R B B (GRAY) B G/R (BLUE) L R/G B B2 (BLUE) Lg B L Y Y R R/W L/W B B B/Y R/B R/W R R/W L R R/G B2 B R/W Lg Y/L Y L
FUEL INJECTION SYSTEM 3. Main switch 4. Battery 5. Fuel injection system fuse 8. Main fuse 10.ECU fuse 15.Fuel pump relay 16.Neutral switch 17.Fuel pump 19.Sidestand switch 20.Crankshaft position sensor 21.Throttle position sensor 22.Cylinder-#1 intake air pressure sensor 23.Cylinder-#2 intake air pressure sensor 24.Lean angle cut-off switch 25.Speed sensor 26.Muffler cooling fan temperature sensor 27.Air temperature sensor 28.Engine temperature sensor 29.ECU (electronic control unit) 30.
FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is stored in the memory of the ECU.
FUEL INJECTION SYSTEM a b c c d a. Main switch “OFF” b. Main switch “ON” c. Engine trouble warning light off d. Engine trouble warning light on for 1.4 seconds EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE 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 Fault code No. Item Symptom Able / unable to start Able / unable to drive 24 O2 sensor No normal signal is received from the O2 sensor. Able Able 25 Cylinder-#2 intake air pressure sensor (open or short circuit) Cylinder-#2 intake air pressure sensor: open or short circuit detected. Able Able 26 Cylinder-#2 intake air pressure sensor (hose system) Cylinder-#2 intake air pressure sensor: hose system malfunction (clogged or detached hose).
FUEL INJECTION SYSTEM Fault code No. Item Symptom Speed sensor No normal signals are received from the speed sensor. 42 Able / unable to start Able / unable to drive Able Able Neutral switch Open or short circuit is detected in the neutral switch. 43 Fuel system voltage (monitoring voltage) The ECU is unable to monitor the battery voltage Able (an open or short circuit in the line to the ECU).
FUEL INJECTION SYSTEM 4. Turn the main switch to “OFF” and back to “ON”, then check that no fault code number is displayed. EAS27400 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on. 1. Check: • Fault code number NOTE: If fault codes are displayed, repeat steps (1) to (4) until no fault code number is displayed. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the fault code number displayed on the meter. b.
FUEL INJECTION SYSTEM NOTE: • All displays on the meter disappear except the clock and odometer/trip meter/fuel reserve trip meter displays. • “dIAG” appears on the odometer/trip meter/fuel reserve trip meter LCD. 4. Press the “SELECT” button to select the diagnostic mode “dIAG”. 5. After selecting “dIAG”, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or more to activate the diagnostic mode. The diagnostic code number “d01” appears on the clock LCD. 6.
FUEL INJECTION SYSTEM Fault code No. Symptom Probable cause of malfunction Diagnostic code No. 14 Cylinder-#1 intake air pressure sensor: hose system malfunction (clogged or detached hose). • Cylinder-#1 intake air pressure sensor hose is detached, clogged, kinked, or pinched. 03 • Malfunction in ECU. 15 Throttle position sensor: open or short circuit detected. • Open or short circuit in wire sub lead. • Open or short circuit in wire harness. • Defective throttle position sensor.
FUEL INJECTION SYSTEM Fault code No. Symptom Probable cause of malfunction Diagnostic code No. 33 • Open or short circuit in wire sub lead. • Open or short circuit in wire harness. Malfunction detected in the • Malfunction in cylinder-#1 left or right primary wire of the ignition coil. cylinder-#1 left or right • Malfunction in ECU. ignition coil. • Malfunction in a component of ignition cutoff circuit system. 30 32 34 • Open or short circuit in wire harness.
FUEL INJECTION SYSTEM Fault code No. Symptom Probable cause of malfunction Diagnostic code No. 42 No normal signals are received from the speed sensor. Open circuit is detected in the neutral switch. • Open circuit in wire harness. • Defective speed sensor. • Malfunction in vehicle speed sensor detected. 07 • Defective neutral switch. 21 • Malfunction in the engine side of the neutral switch. • Malfunction in ECU.
FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Probable cause of malfunction • Improper connection in wire harness. • Malfunction in meter. • Malfunction in ECU. Diagnostic code No. — Sensor operation table Diagnostic code No. 01 Item Meter display Checking method Throttle angle • Fully closed position 15–20 Check with throttle fully closed. • Fully opened position 95–100 Check with throttle fully open.
FUEL INJECTION SYSTEM Diagnostic code No. Item Meter display Checking method 11 Engine temperature Displays the engine temperature. Compare the actually measured engine temperature with the meter display value. 12 Muffler cooling fan temperature Displays the muffler cooling fan temperature. Compare the actually measured muffler cooling fan temperature with the meter display value. 20 Sidestand switch 21 • Stand retracted ON • Stand extended OFF Set ON/OFF the Sidestand switch.
FUEL INJECTION SYSTEM Diagnostic code No. Item Meter display Checking method 63 Stopping the flashing of the 00 engine trouble warning light (erasing the muffler cooling fan temperature sensor fault code) To stop the flashing of the engine trouble warning light, set the engine stop switch to “ ”. 70 Control number — 0–255 Actuator operation table Diagnostic code No.
FUEL INJECTION SYSTEM Diagnostic code No. 50 51 52 54 55 Item Actuation Checking method Fuel pump relay Actuates the fuel pump relay for five times every second. Illuminates the engine trouble warning light. Check the operating sound (The engine trouble warning of the fuel pump relay five light is OFF when the relay is times. ON, and the engine trouble warning light is ON when the relay is OFF).
FUEL INJECTION SYSTEM Code number displayed on the meter when the engine failed to work normally. Refer to “Self-Diagnostic Function table”. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC MODE” on page 7-31. Fault code No. 12 Diagnostic code No. Symptom No normal signals are received from the crankshaft position sensor.
FUEL INJECTION SYSTEM Fault code No. 13 Diagnostic code No. Symptom Cylinder-#1 intake air pressure sensor: open or short circuit detected. 03 Cylinder-#1 intake air pressure sensor Order Item/components and probable cause Check or maintenance job 1 Connections • Cylinder-#1 intake air pressure sensor coupler • Main wire harness ECU coupler • Check the coupler for any pins Turning the that may be pulled out. main switch to • Check the locking condition of “ON”. the coupler.
FUEL INJECTION SYSTEM Fault code No. 14 Diagnostic code No. Symptom Cylinder-#1 intake air pressure sensor: hose system malfunction (clogged or detached hose). 03 Cylinder-#1 intake air pressure sensor Order Item/components and probable cause Check or maintenance job 1 Cylinder-#1 intake air pressure sensor • Check the cylinder-#1 intake air hose pressure sensor hose condition. • Repair or replace the sensor hose.
FUEL INJECTION SYSTEM Fault code No. 15 Diagnostic code No. Symptom Throttle position sensor: open or short circuit detected. 01 Throttle position sensor Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of throttle position sensor. • Check for looseness or pinching. • Check that the sensor is installed in the specified position. Turning the main switch to “ON”.
FUEL INJECTION SYSTEM Fault code No. 17 Diagnostic code No. Symptom EXUP servo motor circuit: open or short circuit detected. 53 EXUP servo motor Order Item/components and probable cause Check or maintenance job 1 Connections • EXUP servo motor coupler • Main wire harness ECU coupler • Check the coupler for any pins Turning the that may be pulled out. main switch to • Check the locking condition of “ON”. the coupler. • If there is a malfunction, repair it and connect the coupler securely.
FUEL INJECTION SYSTEM Fault code No. 19 Diagnostic code No. Symptom A break or disconnection of the blue/yellow lead of the ECU is detected. 20 Sidestand switch Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections • Main wire harness ECU coupler • Execute the diagnostic mode. (Code No.20) • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler.
FUEL INJECTION SYSTEM Fault code No. 24 Diagnostic code No. Symptom No normal signal is received from the O2 sensor. — — Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Installed state of O2 sensor. Check for looseness or pinching. 2 Connections • O2 sensor coupler • Main wire harness ECU coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler.
FUEL INJECTION SYSTEM Fault code No. 25 Diagnostic code No. Symptom Cylinder-#2 intake air pressure sensor: open or short circuit detected. 04 Cylinder-#2 intake air pressure sensor Order Item/components and probable cause Check or maintenance job 1 Connections • Cylinder-#2 intake air pressure sensor coupler • Main wire harness ECU coupler • Check the coupler for any pins Turning the that may be pulled out. main switch to • Check the locking condition of “ON”. the coupler.
FUEL INJECTION SYSTEM Fault code No. 26 Diagnostic code No. Symptom Cylinder-#2 intake air pressure sensor: hose system malfunction (clogged or detached hose). 04 Cylinder-#2 intake air pressure sensor Order Item/components and probable cause Check or maintenance job 1 Cylinder-#2 intake air pressure sensor • Check the cylinder-#2 intake air hose pressure sensor hose condition. • Repair or replace the sensor hose.
FUEL INJECTION SYSTEM Fault code No. 28 Diagnostic code No. Symptom Engine temperature sensor: open or short circuit detected. 11 Engine temperature sensor Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Installed state of engine temperature sensor. Check for looseness or pinching. 2 Connections • Engine temperature sensor coupler • Main wire harness ECU coupler • Sub-wire harness 2 coupler • Check the coupler for any pins that may be pulled out.
FUEL INJECTION SYSTEM Fault code No. 29 Diagnostic code No. Symptom Decompression solenoid (thermistor): open or short circuit detected. 55 Decompression solenoid Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Installed state of decompression solenoid. Check for looseness or pinching. 2 Connections • Decompression solenoid (thermistor) coupler • Main wire harness ECU coupler • Check the coupler for any pins that may be pulled out.
FUEL INJECTION SYSTEM Fault code No. 33 Diagnostic code No. Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil.
FUEL INJECTION SYSTEM Fault code No. 34 Diagnostic code No. Symptom Malfunction detected in the primary wire of the cylinder-#2 left ignition coil. 31 Cylinder-#2 left ignition coil Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections • Cylinder-#2 left ignition coil connector (primary coil side) • Main wire harness ECU coupler • Check the connector and coupler for any pins that may be pulled out.
FUEL INJECTION SYSTEM Fault code No. 35 Diagnostic code No. Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil.
FUEL INJECTION SYSTEM Fault code No. 36 Diagnostic code No. Symptom Malfunction detected in the primary wire of the cylinder-#2 right ignition coil. 33 Cylinder-#2 right ignition coil Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections • Cylinder-#2 right ignition coil connector (primary coil side) • Main wire harness ECU coupler • Check the connector and coupler for any pins that may be pulled out.
FUEL INJECTION SYSTEM Fault code No. 37 Diagnostic code No. Symptom Engine speed is high when the engine is idling. 54 ISC valve Order Item/components and probable cause Check or maintenance job Reinstatement method 1 ECU fuse is blown. • Check the ECU fuse. Refer to “CHECKING THE FUSES” on page 7-93. 2 Throttle valve does not fully close. • Check the throttle body. Refer to “THROTTLE BODIES” on page 6-4. • Check the throttle cables.
FUEL INJECTION SYSTEM Fault code No. 38 Diagnostic code No. Symptom Decompression solenoid: open or short circuit detected. 55 Decompression solenoid Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Installed state of decompression solenoid. Check for looseness or pinching. 2 Connections • Decompression solenoid coupler • Main wire harness ECU coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler.
FUEL INJECTION SYSTEM Fault code No. 41 Diagnostic code No. Symptom Lean angle cut-off switch: open or short circuit detected. 08 Lean angle cut-off switch Order Item/components and probable cause Check or maintenance job 1 Connections • Lean angle cut-off switch coupler • Main wire harness ECU coupler • Check the coupler for any pins Turning the that may be pulled out. main switch to • Check the locking condition of “ON”. the coupler.
FUEL INJECTION SYSTEM Fault code No. 42 Diagnostic code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. A 07 Speed sensor B 21 Neutral switch Order Item/components and probable cause Check or maintenance job Reinstatement method A-1 Connections • Speed sensor coupler • Main wire harness ECU coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler.
FUEL INJECTION SYSTEM Fault code No. 42 Diagnostic code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. A 07 Speed sensor B 21 Neutral switch Order Item/components and probable cause Check or maintenance job Reinstatement method B-1 Connections • Neutral switch coupler • Main wire harness ECU coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler.
FUEL INJECTION SYSTEM Fault code No. 43 Diagnostic code No. Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). 09 Fuel system voltage Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections • Relay unit coupler (fuel pump relay) • Main wire harness ECU coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler.
FUEL INJECTION SYSTEM Fault code No. 46 Diagnostic code No. Symptom Power supply to the fuel injection system is not normal. — — Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections • Main wire harness ECU coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. • If there is a malfunction, repair it and connect the coupler securely. Starting the engine and operating it at idle.
FUEL INJECTION SYSTEM Fault code No. 62 Diagnostic code No. Symptom Muffler cooling fan temperature sensor: open or short circuit detected. 12 Muffler cooling fan temperature sensor Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of muffler cooling fan temperature sensor. Check for looseness or pinching.
FUEL INJECTION SYSTEM Fault code No. 63 Diagnostic code No. Symptom Engine trouble warning light is flashing. (Abnormally high temperature is detected by muffler cooling fan temperature sensor.
FUEL INJECTION SYSTEM Fault code No. Er-2 Symptom No signals are received from the ECU within the specified duration. Diagnostic code No. — — Order Item/components and probable cause Check or maintenance job 1 Connections • Main wire harness ECU coupler • Main wire harness meter assembly coupler • Check the coupler for any pins Turning the that may be pulled out. main switch to • Check the locking condition of “ON”. the coupler.
FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Diagnostic code No. — — Order Item/components and probable cause Check or maintenance job 1 Connections • Main wire harness ECU coupler • Main wire harness meter assembly coupler • Check the coupler for any pins Turning the that may be pulled out. main switch to • Check the locking condition of “ON”. the coupler. • If there is a malfunction, repair it and connect the coupler securely.
FUEL INJECTION SYSTEM 7-66
7-67 BB3 BB2 BB4 BB1 B B B B B2 B1 B1 B2 BB2 BB1 B2 B1 BB4 BB3 ON OFF Br/W L B L R/Y Br/L B L L (BLACK) (BLACK) B L R/W Br/L G/Y Br Br/L Br/W R/B Br/G R Br/L Br/L R Br/R Br/R B Br/R G/Y Br/L Br/R R/B R (BLACK) B B B B B B B R B B R R R B Y (BROWN) Br (BROWN) B (BLACK) R Y Br B B L B R R/B Br/W R R R B B (BLUE) L R/G B B2 (BLUE) Lg L Y Y R R/W L/W B B B/Y R/B R/W R R/W L R R/G B2 B R/W Lg Y/L Y L/W1 R/W B/R W/B Br R R B B2 R/G
FUEL PUMP SYSTEM 3. Main switch 4. Battery 5. Fuel injection system fuse 8. Main fuse 10.ECU fuse 15.Fuel pump relay 17.Fuel pump 29.ECU (electronic control unit) 73.Engine stop switch 81.
FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case 1. Check the fuses. (Main, ignition, fuel injection system, and ECU) Refer to “CHECKING THE FUSES” on page 7-93. NG → Replace the fuse(s). OK ↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-94. NG → • Clean the battery terminals. • Recharge or replace the battery. OK ↓ 3. Check the main switch.
FUEL PUMP SYSTEM 7-70
7-71 BB3 BB2 BB4 BB1 B B B B B2 B1 B1 B2 BB2 BB1 B2 B1 BB4 BB3 ON OFF Br/W L B L R/Y Br/L B L L (BLACK) (BLACK) B L R/W Br/L G/Y Br Br/L Br/W R/B Br/G R Br/L Br/L R Br/R Br/R B Br/R G/Y Br/L Br/R R/B R (BLACK) B B B B B B B R B B R R R B Y (BROWN) Br (BROWN) B (BLACK) R Y Br B B B R R/B Br/W R R R B B (BLUE) L R/G B B2 (BLUE) Lg Y R R/W L/W B B B/Y R/B R/W R R/W L R R/G B2 B R/W Lg Y/L Y L/W1 R/W B/R W/B Br R R B B2 R/G Y/L Lg
MUFFLER COOLING SYSTEM 4. Battery 8. Main fuse 9. Muffler cover fan fuse 10.ECU fuse 26.Muffler cooling fan temperature sensor 29.ECU (electronic control unit) 78.Muffler cooling fan motor 79.
MUFFLER COOLING SYSTEM ET5YU1004 TROUBLESHOOTING The muffler cooling fan motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 1. Check the fuses. (Main, muffler cover fan, and ECU) Refer to “CHECKING THE FUSES” on page 7-93. NG → Replace the fuse(s). OK ↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-94. NG → • Clean the battery terminals. • Recharge or replace the battery. OK ↓ 3. Check the muffler cooling fan motor.
MUFFLER COOLING SYSTEM 7-74
7-75 BB3 BB2 BB4 BB1 B B B B B2 B1 B1 B2 BB2 BB1 B2 B1 BB4 BB3 ON OFF Br/W L Br/R B L R/Y Br/L B L L (BLACK) (BLACK) B L R/W Br/L G/Y Br Br/W R/B Br/G Br/L R Br/L Br/L R Br/R B Br/R G/Y Br/L Br/R R/B R B B B (BLACK) B B B B R B B Y (GRAY) (BROWN) Br Y Br B B L B R R R B (BROWN) B (BLACK) R B L B R R R/B Br/W R R B B (GRAY) B G/R (BLUE) L R/G B B2 (BLUE) Lg B L Y Y R R/W L/W B B B/Y R/B R/W R R/W L R R/G B2 B R/W Lg Y/L Y L
IMMOBILIZER SYSTEM 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 11.Immobilizer unit 12.Backup fuse (odometer, clock and immobilizer system) 29.ECU (electronic control unit) 44.Multi-function meter 46.Immobilizer system indicator light 81.
IMMOBILIZER SYSTEM EAS27670 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys.
IMMOBILIZER SYSTEM Parts to be replaced Main switch/immobilizer unit Standard key Main Immobilizswitch er unit √ Standard key is lost All keys have been lost (including code re-registering key) √ √ New standard key √ √ Immobilizer unit is defective Code re-registering key and standard keys √ √ Code re-registering key and standard keys Code re-registering key and standard keys √ ECU is defective Main switch is defective ECU Accesso- Key registration requirement ry lock* and key √ Accessory l
IMMOBILIZER SYSTEM Standby mode a. Main switch “ON” b. Main switch “OFF” c. LED on d. LED off e. Standby mode on f. Standby mode off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. NOTE: Do not start the engine with a standard key that has not been registered.
IMMOBILIZER SYSTEM Standard key registration a. b. c. d. e. f. g. First standard key h. Second standard key i. Registration mode Main switch “ON” Main switch “OFF” LED on LED off Less than 5.0 s Code re-registering key A. Registration of the second standard key is complete. B. Immobilizer system indicator light stops flashing when the registration of the second standard key is complete.
IMMOBILIZER SYSTEM EAS27700 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. 1. Check the fuses. (Main, ignition, backup, and ECU) Refer to “CHECKING THE FUSES” on page 7-93. NG → Replace the fuse(s). OK ↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-94. NG → • Clean the battery terminals. • Recharge or replace the battery. OK ↓ NG → 3. Check the main switch.
IMMOBILIZER SYSTEM Fault code Part Symptom Cause 52 IMMOBILIZER UNIT Codes between the key and immobilizer unit do not match. 1. Signal received from other transponder (failed to recognize code after ten consecutive attempts). 2. Signal received from unregistered standard key. 1. Place the immobilizer unit at least 50 mm away from the transponder of other vehicles. 2. Register the standard key. 53 IMMOBILIZER UNIT Codes cannot be transmitted between the ECU and the immobilizer unit.
IMMOBILIZER SYSTEM Example: fault code 52 a b a. Light on b.
IMMOBILIZER SYSTEM 7-84
ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 5 4 3 2 6 7 1 8 15 9 14 10 12 13 11 7-85
ELECTRICAL COMPONENTS 1. Air temperature sensor 2. Cylinder-#2 left ignition coil 3. Cylinder-#2 right ignition coil 4. ISC (idle speed control) unit 5. Intake solenoid 6. Cylinder-#1 right ignition coil 7. Cylinder-#1 left ignition coil 8. Muffler cooling fan temperature sensor 9. Muffler cooling fan motor 10.Speed sensor 11.Rear brake light switch 12.Neutral switch 13.Decompression solenoid 14.Rectifier/regulator 15.
ELECTRICAL COMPONENTS 6 4 5 3 7 8 9 2 10 11 1 18 12 13 17 14 16 15 7-87
ELECTRICAL COMPONENTS 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#2 intake air pressure sensor 3. Immobilizer unit 4. Throttle position sensor 5. Main fuse 6. Fuse box 7. Muffler cooling fan motor relay 8. ECU (electronic control unit) 9. Headlight relay 10.Relay unit 11.Turn signal/hazard relay 12.Fuel injection system fuse 13.Starter relay 14.Lean angle cut-off switch 15.Battery 16.EXUP servo motor 17.Crankshaft position sensor 18.
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 1 R/W L/W B 5 B B B/Y R/B (BLUE) B 2 R/W R/B 4 B Br/R R Br/L Br/R B ON 3 B L/W B/Y R OFF Br/L 11 B R/Y Br/W L/B P B B/Y B G Y Dg B Ch B B B R/Y Y 13 Y L/B G 8 Dg Br/W Ch 9 Dg Br/W Ch 10 B (BROWN) (BLACK) 12 6 7 P B/Y 7-89 B B (BLUE)
ELECTRICAL COMPONENTS 1. Front brake light switch 2. Engine stop switch 3. Start switch 4. Main switch 5. Neutral switch 6. Sidestand switch 7. Rear brake light switch 8. Hazard switch 9. Turn signal switch 10.Horn switch 11.Clutch switch 12.Pass switch 13.
ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
ELECTRICAL COMPONENTS 1. Remove: • Bulb EAS27990 CHECKING THE BULBS AND BULB SOCKETS EW5YU1009 NOTE: WARNING Do not check any of the lights that use LEDs. Since headlight bulbs get extremely hot, keep flammable products and your hands away from them until they have cooled down. 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.
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 Analog pocket tester YU-03112-C Checking the condition of the bulb sockets The following procedure applies to all of the bulb sockets. 1. Check: • Bulb socket (for continuity) (with the pocket tester) No continuity → Replace. b. If the pocket tester indicates “∞”, replace the fuse.
ELECTRICAL COMPONENTS electrolyte level will drop considerably. Therefore, take special care when charging the battery. cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTE: 4. Install: • Lead holder • Seat Refer to “GENERAL CHASSIS” on page 4-1. 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.
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b. Check the charge of the battery, as shown in the charts and the following example. Example Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge of the battery = 20–30% NOTE: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Voltage should be measured 30 minutes after the engine is stopped. 5. Charge: • Battery (refer to the appropriate charging method) b. Connect a charger and ammeter to the battery and start charging.
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 8. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. Lubricate: • Battery terminals Charging method using a constant voltage charger a. Measure the open-circuit voltage prior to charging. NOTE: Voltage should be measured 30 minutes after the engine is stopped. Recommended lubricant Dielectric grease b. Connect a charger and ammeter to the battery and start charging. c.
ELECTRICAL COMPONENTS Relay unit (starting circuit cut-off relay) 1 3 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe 2 4 + Sb/W B/R L Result Continuity (between “3” and “4”) R/L L/R L/G L/Y Sb B/Y L/W Muffler cooling fan motor relay R 3 1. 2. 3. 4. Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe 4 + 2 1 G/Y Result Continuity (between “3” and “4”) Br/W 1. 2. 3. 4.
ELECTRICAL COMPONENTS EAS28050 CHECKING THE RELAY UNIT (DIODE) 1. Check: • Relay unit (diode) Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Turn the main switch to “ON”. c. Measure the turn signal/hazard relay input voltage. NOTE: The pocket tester and the analog pocket tester readings are shown in the following table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • Turn signal/hazard relay output voltage Out of specification → Replace.
ELECTRICAL COMPONENTS EAS28100 3 CHECKING THE IGNITION COILS The following procedure applies to all of the ignition coils. 1. Check: • Primary coil resistance Out of specification → Replace. 1 5 4 2 Sb/W B/R L R/L L/R Primary coil resistance 2.16–2.64 Ω L/G L/Y Sb B/Y L/W R ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the wire harness. b. Connect the pocket tester (Ω × 1) to the relay unit terminal as shown. c.
ELECTRICAL COMPONENTS c. Turn the main switch to “ON” and engine stop switch to “ ”. d. Measure the ignition spark gap “a”. e. Crank the engine by pushing the start switch “ ” and gradually increase the spark gap until a misfire occurs. • Positive tester probe → black/red “1” • Negative tester probe → spark plug lead “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28120 c. Measure the secondary coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE CRANKSHAFT POSITION SENSOR 1.
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Check: • Lean angle cut-off switch output voltage Out of specification → Replace. a. Connect the pocket tester (Ω × 1) to the stator coil coupler as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Lean angle cut-off switch output voltage Less than 65°: 0.4–1.4 V More than 65°: 3.7–4.4 V • Positive tester probe → black “1” • Negative tester probe → black “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachometer to the cylinder-#1 left spark plug lead or right spark plug lead. b. Connect the pocket tester (DC 20 V) to the rectifier/regulator coupler as shown. 1 Pocket tester 90890-03112 Analog pocket tester YU-03112-C 2 c. Measure the horn resistance. • Positive tester probe → red “1” • Negative tester probe → black “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • Horn sound Faulty sound → Adjust or replace.
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1k) to the engine temperature sensor terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Fuel sender resistance 1.35–1.65 kΩ at 25 °C (77 °F) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1k) to the fuel sender terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C 3 1 • Positive tester probe → green “1” • Negative tester probe → black “2” 2 b.
ELECTRICAL COMPONENTS 2 1 1 W L L W/Y B B/ L B Y L 2 b. Turn the main switch to “ON”. c. Elevate the rear wheel and slowly rotate it. d. Measure the voltage of white/yellow and black/blue. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28300 CHECKING THE THROTTLE POSITION SENSOR 1. Remove: • Throttle position sensor (from the throttle body) 2.
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ For counterclockwise rotation “a” • Positive battery lead → black/green “1” • Negative battery lead → black/red “2” For clockwise rotation “b” • Positive battery lead → black/red “2” • Negative battery lead → black/green “1” a. Insert a plug “1” into the fuel return hose end. b. Fill the fuel tank. c. Put the end of the fuel hose “2” into an open container. d. Connect the battery (DC 12 V) to the fuel pump terminal as shown.
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the decompression solenoid couplers from the wire harness. b. Connect the pocket tester (Ω × 10) to the decompression solenoid coupler as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Measure the decompression solenoid resistance.
ELECTRICAL COMPONENTS ET5YU1007 ET5YU1008 CHECKING THE AIR TEMPERATURE SENSOR 1. Remove: • Air temperature sensor CHECKING THE INTAKE SOLENOID 1. Check: • Intake solenoid resistance Out of specification → Replace. EW5YU1002 WARNING • Handle the air temperature sensor with special care. • Never subject the air temperature sensor to strong shocks. If the air temperature sensor is dropped, replace it. 2. Check: • Air temperature sensor resistance Out of specification → Replace.
ELECTRICAL COMPONENTS 5 B 1 B 2 3 4 c. Check the muffler cooling fan motor movement. b. Immerse the muffler cooling fan temperature sensor “3” in a container filled with water “4”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTE: Make sure that the muffler cooling fan temperature sensor terminals do not get wet. ET5YU1006 CHECKING THE MUFFLER COOLING FAN TEMPERATURE SENSOR 1.
TRBL SHTG 8
TROUBLESHOOTING TROUBLESHOOTING..................................................................................... 8-1 GENERAL INFORMATION ....................................................................... 8-1 STARTING FAILURES.............................................................................. 8-1 INCORRECT ENGINE IDLING SPEED .................................................... 8-1 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ........................... 8-2 FAULTY GEAR SHIFTING.................
TROUBLESHOOTING Electrical system 1. Battery • Discharged battery • Faulty battery 2. Fuse(s) • Blown, damaged or incorrect fuse • Improperly installed fuse 3. Spark plug(s) • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or damaged insulator • Faulty spark plug cap 4. Ignition coil(s) • Cracked or broken ignition coil body • Broken or shorted primary or secondary coils • Faulty spark plug lead 5.
TROUBLESHOOTING Electrical system 1. Battery • Discharged battery • Faulty battery 2. Spark plug(s) • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or damaged insulator • Faulty spark plug cap 3. Ignition coil(s) • Broken or shorted primary or secondary coils • Faulty spark plug lead • Cracked or broken ignition coil 4.
TROUBLESHOOTING Malfunction • Bent or damaged inner tube • Bent or damaged outer tube • Damaged fork spring • Worn or damaged outer tube bushing • Bent or damaged damper rod • Incorrect oil viscosity • Incorrect oil level EAS28590 OVERHEATING Engine 1. Cylinder head(s) and piston(s) • Heavy carbon buildup 2. Engine oil • Incorrect oil level • Incorrect oil viscosity • Inferior oil quality EAS28670 UNSTABLE HANDLING 1. Handlebar • Bent or improperly installed handlebar 2.
TROUBLESHOOTING • Faulty main switch • Faulty horn switch • Faulty battery • Blown, damaged or incorrect fuse • Faulty wire harness • Incorrect connection • Improperly grounded circuit • Poor contacts (main or light switch) • Burnt-out headlight bulb Headlight bulb burnt out • Wrong headlight bulb • Faulty battery • Faulty rectifier/regulator • Improperly grounded circuit • Faulty main switch • Faulty light switch • Headlight bulb life expired Tail/brake light does not come on • Wrong tail/brake light LED
EAS28740 WIRING DIAGRAM MT-01(T) 2005 1. AC magneto 2. Rectifier/regulator 3. Main switch 4. Battery 5. Fuel injection system fuse 6. Starter relay 7. Starter motor 8. Main fuse 9. Muffler cover fan fuse 10. ECU fuse 11. Immobilizer unit 12. Backup fuse (odometer, clock and immobilizer system) 13. Relay unit 14. Starting circuit cut-off relay 15. Fuel pump relay 16. Neutral switch 17. Fuel pump 18. Fuel sender 19. Sidestand switch 20. Crankshaft position sensor 21. Throttle position sensor 22.
L/B L/G L/R L/W L/Y P/L P/W P/Y R/B R/G R/L R/W R/Y Sb/W W/B W/G W/R W/Y Y/B Y/G Y/L Blue/Black Blue/Green Blue/Red Blue/White Blue/Yellow Pink/Blue Pink/White Pink/Yellow Red/Black Red/Green Red/Blue Red/White Red/Yellow Sky blue/White White/Black White/Green White/Red White/Yellow Yellow/Black Yellow/Green Yellow/Blue
YAMAHA MOTOR CO., LTD.
MT-01(T) 2005 WIRING DIAGRAM L B/R Sb/W R Sb/W B/R L/G L/Y L Sb R/L L/R B/Y L/W1 R A L/G L/W1 O B/R O L/R L/Y R/L Sb O B/R O B/Y Br/B R/W Sb B B B2 R/G R/W Lg R/L R R B B (BLUE) B G B B R/L B B (DARK GREEN) B R/W B/R Gy/B Gy/B Gy/R Gy/R R/W L/Y Gy1 Gy1 G Gy W W B (BLACK) (BLACK) WIRE HARNESS SUB-WIRE-HARNESS2 Dg Ch B B Ch Dg B B A B/R Gy1 B/L B Gy B L Y B Br/R R L R B/L L W/Y W L B L W/Y B/L B/R Y L (BLACK) B B B Y L B/L Y L D Y D L B/L Br/L B
