yamaha fz6-s 2004 (europe) service manual

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FZ6-S (S)SERVICE MANUAL

2003 by Yamaha Motor Co., Ltd.First edition, August 2003

All rights reserved.Any reproduction or unauthorized use

without the written permission ofYamaha Motor Co., Ltd.is expressly prohibited.

NOTE:

WARNING

CAUTION:

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NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealersand their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehiclesshould have a basic understanding of mechanics and the techniques to repair these types of vehicles.Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-hicle unsafe and unfit for use.Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealersand will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

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IMPORTANT MANUAL INFORMATIONParticularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person checking or repairing the mo-torcycle.

A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures are laidout with the individual steps in sequential order.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of eachpage indicate the current chapter.Refer to “SYMBOLS”.

2 Each chapter is divided into sections. The current section title is shown at the top of each page,except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) ap-pears.

3 Sub-section titles appear in smaller print than the section title.

4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of eachremoval and disassembly section.

5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates adisassembly step.

6 Symbols indicate parts to be lubricated or replaced.Refer to “SYMBOLS”.

7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.

8 Jobs requiring more information (such as special tools and technical data) are described sequen-tially.

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24 25

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19 2018

16 1715

1413

11 12

10

GENINFO SPEC

ENG

FI ELEC

COOL

CHKADJ

TRBLSHTG

CHAS

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SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols 1 to 9 indicate the subject of eachchapter.1 General information2 Specifications3 Periodic checks and adjustments4 Chassis5 Engine6 Cooling system7 Fuel injection system8 Electrical system9 Troubleshooting

Symbols 10 to 17 indicate the following.10 Serviceable with engine mounted11 Filling fluid12 Lubricant13 Special tool14 Tightening torque15 Wear limit, clearance16 Engine speed17 Electrical data

Symbols 18 to 23 in the exploded diagrams indi-cate the types of lubricants and lubricationpoints.18 Engine oil19 Gear oil20 Molybdenum-disulfide oil21 Wheel-bearing grease22 Lithium-soap-based grease23 Molybdenum-disulfide grease

Symbols 24 to 25 in the exploded diagrams indi-cate the following.24 Apply locking agent (LOCTITE)25 Replace the part

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS ANDADJUSTMENTS

CHASSIS

ENGINE

COOLING SYSTEM

FUEL INJECTION SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

GENINFO 1SPEC 2

3

ENG

4

COOL

5

FI

6

CHAS

7ELEC 8TRBLSHTG 9

CHKADJ

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TABLE OF CONTENTS

GENINFO

CHAPTER 1GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FEATURES 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTLINE OF FI SYSTEM 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FI SYSTEM 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT FUNCTION 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL AND DISASSEMBLY 1-6. . . . . . . . . REPLACEMENT PARTS 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS 1-6. . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS 1-7. . . . . . . . . . . . . . BEARINGS AND OIL SEALS 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE CONNECTIONS 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENINFO

1-1

MOTORCYCLE IDENTIFICATIONGENINFO

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GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONEAS00017

VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the right side of the steering head pipe.

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MODEL LABELThe model label 1 is affixed to the frame. Thisinformation will be needed to order spare parts.

1-2

FEATURESGENINFO

7 Intake air pressuresensor

8 Throttle position sen-sor

9 Fuel injector10 Catalytic converter11 Crankshaft position

sensor

12 Coolant temperaturesensor

13 Spark plug14 Pressure regulator15 Battery16 ECU17 Fuel injection system

relay

18 Engine trouble warn-ing light

19 Lean angle cut-offswitch

1 Ignition coil2 Air filter case3 Intake air temperature

sensor4 Fuel delivery hose5 Fuel tank6 Fuel pump

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FEATURESOUTLINE OF FI SYSTEMThe main function of a fuel supply system is to provide fuel to the combustion chamber at the optimumair-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 combustionchamber is created by the volume of the intake air and the fuel that is metered by the jet used in therespective carburetor.Despite the same volume of intake air, the fuel volume requirement varies by the engine operatingconditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that me-ter the fuel through the use of jets have been provided with various auxiliary devices, so that an opti-mum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditionsof the engine.As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, itbecomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-modate this need, this model has adopted an electronically controlled fuel injection (FI) system, inplace of the conventional carburetor system. This system can achieve an optimum air-fuel ratio re-quired by the engine at all times by using a microprocessor that regulates the fuel injection volumeaccording to the engine operating conditions detected by various sensors.The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,better fuel economy, and reduced exhaust emissions. Furthermore, the air induction system (AI sys-tem) has been placed under computer control together with the FI system in order to realize cleanerexhaust gases.

1-3

FEATURESGENINFO

Illustration is for reference only.

6 Throttle position sen-sor

7 Intake air pressuresensor

8 ECU


10 Crankshaft positionsensor

A Fuel systemB Control system

1 Fuel pump2 Pressure regulator3 Fuel injector4 Throttle body5 Intake air temperature

sensor

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FI SYSTEMThe fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuelpressure that is applied to the injector at only 250 kPa (2.5 kg/cm2). Accordingly, when the energizingsignal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected intothe intake manifold only during the time the passage remains open. Therefore, the longer the length oftime the injector is energized (injection duration), the greater the volume of fuel that is supplied. Con-versely, the shorter the length of time the injector is energized (injection duration), the lesser the vol-ume of fuel that is supplied.

The injection duration and the injection timing are controlled by the ECU. Signals that are input from thethrottle position sensor, crankshaft position sensor, intake air pressure sensor, intake temperaturesensor and coolant temperature sensor enable the ECU to determine the injection duration. The injec-tion timing is determined through the signals from the crankshaft position sensor. As a result, the vol-ume of fuel that is required by the engine can be supplied at all times in accordance with the drivingconditions.

1-4

FEATURESGENINFO

1 Multi-function display2 “SELECT” button3 “RESET” button4 Engine trouble warning light

NOTE:

INSTRUMENT FUNCTIONMulti-function displayThe multi-function display is equipped with thefollowing:a speedometer (which shows the ridingspeed)

an odometer (which shows the total distancetraveled)

two tripmeters (which show the distancetraveled since they were last set to zero)

a fuel reserve tripmeter (which shows thedistance traveled since the bottom segmentof the fuel meter started flashing)

a tachometer (which shows the enginespeed)

a fuel metera water temperaturea clocka intake air temperaturea self-diagnosis device

Be sure to turn the key to “ON” before using the “SELECT” and ”RESET” buttons.For the U.K. only: To switch the speedometer and odometer/tripmeter display between kilometersand miles, press the “SELECT” button for at least two seconds.

Odometer, tripmeter and tachometer modesPushing the “SELECT” button switches the display between the odometer mode “ODO” and the trip-meter modes “TRIP 1” and “TRIP 2” and the tachometer mode “E” is the following order:ODO TRIP 1 TRIP 2 (TRIP F) E ODOWhen approximately 3.6 L of fuel remain in the fuel tank, the bottom segment of the fuel meter will startflashing, and the odometer display will automatically change to the fuel reserve tripmeter mode “TRIPF” and start counting the distance traveled from that point. In that case, pushing the “SELECT” buttonswitches the display between the various tripmeter and odometer modes in the following order: TRIP-F E ODO TRIP 1 TRIP 2 TRIP FTo reset a tripmeter, select it by pushing the “SELECT” button, and then push the “RESET” button for atleast one second. If you do not reset the fuel reserve tripmeter manually, it will reset itself automaticallyand the display will return to the prior mode after refueling and traveling 5 km (3.1 mi).Tachometer modeDisplays the digital indication of the engine speed on the odometer section.Air intake temperature indicator.When “ODO” is displayed, pressing the “RESET” for a long time allows the indicator to switch displaysbetween Clock and Air intake temperature. (It activates the clock indication when the main switch isturned OFF.)In the Co adjustment mode, the indication automatically changes from clock (Air intake temperature) tothe engine speed.

1-5

FEATURESGENINFO

Clock modeTo set the clock:1. Push the “SELECT” button and “RESET” button together for at least two seconds.2. When the hour digits start flashing, push the “RESET” button to set the hours.3. Push the “SELECT” button, and the minute digits will start flashing.4. Push the “RESET” button to set the minutes.5. Push the “SELECT” button and then release it to start the clock.

1-6

IMPORTANT INFORMATIONGENINFO

springlip

oilgrease

lip

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IMPORTANT INFORMATIONPREPARATION FOR REMOVAL AND DISASSEMBLY1. Before removal and disassembly, eliminate

all dirt, mud, dust and foreign material.2. Use only the proper tools and cleaning

equipment.Refer to the “SPECIAL TOOLS”.

3. When disassembling, always keep matedparts together. This includes gears, cylin-ders, pistons and other parts that have been“mated” through normal wear. Mated partsmust always be reused or replaced as an as-sembly.

4. During disassembly, clean all of the partsand place them in trays in the order of disas-sembly. This will speed up assembly and al-low for the correct installation of all parts.

5. Keep all parts away from any source of fire.

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REPLACEMENT PARTSUse only genuine Yamaha parts for all replace-ments. Use oil and grease recommended byYamaha for all lubrication jobs. Other brandsmay be similar in function and appearance, butinferior in quality.

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GASKETS, OIL SEALS AND O-RINGS1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket sur-faces, oil seal lips and O-rings must becleaned.

2. During reassembly, properly oil all matingparts and bearings and lubricate the oil seallips with grease.

1-7

IMPORTANT INFORMATIONGENINFO

CAUTION:

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LOCK WASHERS/PLATES AND COTTERPINSAfter removal, replace all lock washers/plates1 and cotter pins. After the bolt or nut has beentightened to specification, bend the lock tabsalong a flat of the bolt or nut.

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BEARINGS AND OIL SEALSInstall bearings and oil seals so that themanufacturer’s marks or numbers are visible.When installing oil seals, lubricate the oil seallips with a light coat of lithium-soap-basedgrease. Oil bearings liberally when installing, ifappropriate.1 Oil seal

Do not spin the bearing with compressed airbecause this will damage the bearing sur-faces.

1 Bearing

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CIRCLIPSBefore reassembly, check all circlips carefullyand replace damaged or distorted circlips. Al-ways replace piston pin clips after one use.When installing a circlip 1 , make sure thesharp-edged corner 2 is positioned oppositethe thrust 3 that the circlip receives.4 Shaft

1-8

CHECKING THE CONNECTIONSGENINFO

NOTE:

NOTE:

NOTE:

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CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnect: leadcouplerconnector

2. Check: leadcouplerconnectorMoisture Dry with an air blower.Rust/stains Connect and disconnect sev-eral times.

3. Check:all connectionsLoose connection Connect properly.

If the pin 1 on the terminal is flattened, bend itup.

4. Connect: leadcouplerconnector

Make sure all connections are tight.

5. Check:continuity(with the pocket tester)

Pocket tester90890-03112, YU-3112

If there is no continuity, clean the terminals.When checking the wire harness, performsteps (1) to (3).

As a quick remedy, use a contact revitalizeravailable at most part stores.

1-9

SPECIAL TOOLSGENINFO

NOTE:

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SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Use onlythe appropriate special tools as this will help prevent damage caused by the use of inappropriate toolsor 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.

For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.For others, use part number starting with “90890-”.

Tool No. Tool name/Function Illustration

Flywheel puller90890-01362YU-33270-BAdapter90890-04089YM-33282

Flywheel pullerAdapter

This tool is used to remove the generator ro-tor.

90890-01701YS-01880-A

Sheave holder

This tool is used to hold the generator rotorwhen removing or installing the generator ro-tor bolt or pickup coil rotor bolt.

90890-01304YU-01304

Piston pin puller

This tool is used to remove the piston pins.Radiator cap tester90890-01325YU-24460-01Adapter90890-01352YU-33984

Radiator cap testerAdapter

These tools are used to check the coolingsystem.

90890-01403YU-33975

Steering nut wrench

This tool is used to loosen or tighten the steer-ing stem ring nuts.

90890-01460-01326

Damper rod holderT-handleThese tool are used for holding the damperrod when removing or installing the damperrod.

Pivot shaft wrench90890-01471YM-01471Pivot shaft wrenchadapter90890-01476

Pivot shaft wrenchPivot shaft wrench adapter

This tool is used to loosen or tighten the pivotadjust bolt and engine mount adjust bolt.

1-10


Tool No. Tool name/Function Illustration

90890-01426YU-38411

Oil filter wrench

This tool is needed to loosen or tighten the oilfilter cartridge.

Fork seal driver90890-01367YM-33963Fork seal driverattachment90890-01374YM-8020-A

Fork seal driver weightFork seal driver attachment

This tool is used to install the front fork’s oilseal and dust seal.

Vacuum gauge90890-03094YU-08030

Vacuum gauge

This gauge is used to synchronize the carbu-retors.

Compressiongauge90890-03081YU-33223Adapter90890-04136

Compression gaugeAdapter

These tools are used to measure enginecompression.

90890-03112YU-3112

Pocket tester

This tool is used to check the electrical sys-tem.

Oil pressure gauge90890-03153YU-03153Adapter90890-03139

Oil pressure gaugeAdapter

These tools are used to measure engine oilpressure.

90890-03176YM-03176

Fuel pressure adapter

This tool is needed to measure fuel pressure.

90890-03153YU-03153

Pressure gauge

This tool used is to measure fuel pressure.

90890-04044YM-04044

Piston ring compressor

This tool is used to compress piston ringswhen installing the cylinder.

Valve springcompressor90890-04019YM-04019Attachment90890-04108YM-01253

Valve spring compressorAttachment

These tools are used to remove or install thevalve assemblies.

1-11


Tool No. Tool name/Function IllustrationMiddle driven shaftbearing driver90890-04058YM-4058Mechanical seal installer90890-04078YM-33221

Middle driven shaft bearing driverMechanical seal installer

These tools are used to install the water pumpseal.

90890-04086YM-91042

Clutch holding tool

This tool is used to hold the clutch bosswhen removing or installing the clutch bossnut.

90890-04101

Valve lapper

This tool is needed to remove and installthe valve lifter.

90890-04111

Valve guide remover (φ4)

This tool is used to remove or install the valveguides.

90890-04112

Valve guide installer (φ4)

This tool is used to install the valve guides.

90890-04113YM-04113

Valve guide reamer (φ4)

This tool is used to rebore the new valveguides.

90890-06754YM-34487

Ignition checker

This tool is used to check the ignition systemcomponents.

90890-06756YB-35956

Vacuum/pressure pump gauge set

This tool used to measure the vacuum pres-sure.

90890-85505ACC-11001-05-01

Yamaha bond No. 1215

This bond is used to seal two mating surfaces(e.g., crankcase mating surfaces).

SPEC

CHAPTER 2SPECIFICATIONS

GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS SPECIFICATIONS 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONVERSION TABLE 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL TIGHTENING TORQUE SPECIFICATIONS 2-17. . . . . . . . . . . .

TIGHTENING TORQUES 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE TIGHTENING TORQUES 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS TIGHTENING TORQUES 2-21. . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 2-23. . . . . . . . . . . . . . . ENGINE 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM DIAGRAMS 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OIL LUBRICATION CHART 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION DIAGRAMS 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 2-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code 5VX1 (EUR), 5VX2 (AUS)

DimensionsOverall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

2,095 mm (82.5 in)750 mm (29.5 in)1,215 mm (47.8 in)795 mm (31.3 in)1,440 mm (56.7 in)145 mm (5.71 in)2,800 mm (110.2 in)

WeightWet (with oil and a full fuel tank)Maximum load (except motorcycle)

207 kg (456 lb)190 kg (419 lb)

2-2

ENGINE SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

EngineEngine typeDisplacementCylinder arrangementBore strokeCompression ratioEngine idling speedVacuum pressure at engine idlingspeedStandard compression pressure(at sea level)

Liquid-cooled, 4-stroke, DOHC600 cm3 (36.61 cu.in)Forward-inclined parallel 4-cylinder65.5 44.5 mm (2.58 1.75 in)12.2 : 11,250 1,350 r/min29 kPa (218 mmHg, 8.6 inHg)

1,550 kPa (15.50 kg/cm2,15.50 bar,220.46 psi) at 400 r/min

FuelRecommended fuelFuel tank capacityTotal (including reserve)Reserve only

Regular unleaded gasoline only

19.4 L (4.25 lmp gal, 5.1 US gal)3.6 L (0.79 lmp gal, 0.9 US gal)

Engine oilLubrication systemRecommended oil

QuantityTotal amountWithout oil filter cartridgereplacementWith oil filter cartridge replacement

Oil pressure

Engine oil temperatureRelief valve opening pressure

Wet sump

Refer to the chart for the engine oil grade

3.4 L (2.99 Imp qt, 3.59 US qt)2.5 L (2.20 lmp qt, 2.64 US qt)

2.8 L (2.47 lmp qt, 2.96 US qt)240 kPa at 6,600 r/min(2.4 kg/cm2 at 6,600 r/min)(2.4 bar at 6,600 r/min)(34.1 psi at 6,600 r/min)96C (205F)450 550 kPa (4.5 5.5 kg/cm2, 4.5 5.5 bar, 65.3 79.8 psi)

2-3


Item Standard Limit

Oil filterOil filter typeBypass valve opening pressure

Formed80 120 kPa (0.8 1.2 kg/cm2,0.8 1.2 bar, 11.6 17.4 psi)

Oil pumpOil pump typeInner-rotor-to-outer-rotor-tipclearanceOuter-rotor-to-oil-pump-housingclearance

Trochoid0.03 0.09 mm(0.0012 0.0035 in)0.03 0.08 mm(0.0012 0.0032 in)

0.15 mm(0.0059 in)0.15 mm(0.0059 in)

Cooling systemRadiator capacityRadiator cap opening pressure

Radiator coreWidthHeightDepth

Coolant reservoirCapacity

Water pumpWater pump typeReduction ratioMax. impeller shaft tilt

2.0 L (1.76 lmp pt, 2.11 US qt)93.3 122.7 kPa (0.93 1.23 kg/cm2,0.93 1.23 bar, 13.5 17.8 psi)

300 mm (11.81 in)188 mm (7.4 in)24 mm (0.94 in)

0.27 L (0.24 lmp qt, 0.29 US qt)

Single suction centrifugal pump86/44 31/31 (1.955)

0.15 mm(0.006 in)

Starting system type Electric starter

Spark plugsModel (manufacturer) quantitySpark plug gap

CR9EK (NGK) 40.6 0.7 mm (0.0236 0.0276 in)

Cylinder headVolumeMax. warpage

10.3 10.9 cm3 (0.63 0.67 cu.in)

0.05 mm(0.002 in)

2-4


Item Standard Limit

CamshaftsDrive systemCamshaft cap inside diameterCamshaft journal diameterCamshaft-journal-to-camshaft-cap clearanceIntake camshaft lobe dimensions

Measurement A

Measurement B

Exhaust camshaft lobe dimensions

Measurement A

Measurement B

Max. camshaft runout

Chain drive (right)23.008 23.029 mm (0.9058 0.9067 in)22.967 22.980 mm (0.9042 0.9047 in)0.028 0.062 mm (0.0011 0.0024 in)

32.45 32.55 mm (1.278 1.282 in)

24.95 25.05 mm (0.982 0.986 in)

32.45 32.55 mm (1.278 1.282 in)

24.95 25.05 mm (0.982 0.986 in)

0.08 mm(0.0032 in)

32.40 mm(1,276 in)24.90 mm(0.980 in)

32.40 mm(1.276 in)24.90 mm(0.980 in)0.06 mm(0.0024 in)

2-5


Head Diameter Face Width Seat Width Margin Thickness

Item Standard Limit

Timing chainModel/number of linksTensioning system

92RH2015/120Automatic

Valves, valve seats, valve guidesValve clearance (cold)

IntakeExhaust

Valve dimensions

0.13 0.20 mm (0.0051 0.0079 in)0.23 0.30 mm (0.0091 0.0118 in)

Valve head diameter AIntakeExhaust

Valve face width BIntakeExhaust

Valve seat width CIntakeExhaust

Valve margin thickness DIntakeExhaust

Valve stem diameterIntake

Exhaust

Valve guide inside diameterIntake

Exhaust

Valve-stem-to-valve-guide clearanceIntake

Exhaust

Valve stem runout

Valve seat widthIntakeExhaust

24.9 25.1 mm (0.9803 0.9882 in)21.9 22.1 mm (0.8622 0.8701 in)

1.14 1.98 mm (0.0449 0.0780 in)1.14 1.98 mm (0.0449 0.0780 in)

0.9 1.1 mm (0.0354 0.0433 in)0.9 1.1 mm (0.0354 0.0433 in)

0.6 0.8 mm (0.0236 0.0315 in)0.6 0.8 mm (0.0236 0.0315 in)

3.975 3.990 mm (0.1565 0.1571 in)

3.960 3.975 mm (0.1559 0.1565 in)

4.000 4.012 mm (0.1575 0.1580 in)

4.000 4.012 mm (0.1575 0.1580 in)

0.010 0.037 mm (0.0004 0.0015 in)

0.025 0.052 mm (0.0010 0.0020 in)

0.9 1.1 mm (0.0354 0.0433 in)0.9 1.1 mm (0.0354 0.0433 in)

1.6 mm (0.06 in)1.6 mm (0.06 in)

0.5 mm (0.02 in)0.5 mm (0.02 in)

3.95 mm(0.1555 in)3.935 mm(0.1549 in)

4.042 mm(0.1591 in)4.042 mm(0.1591 in)

0.08 mm(0.0031 in)0.10 mm(0.0039 in)0.04 mm(0.0016 in)

1.6 mm (0.06 in)1.6 mm (0.06 in)

2-6


Item Standard Limit

Valve springsFree lengthIntake (inner)Intake (outer)Exhaust

Installed length (valve closed)Intake (inner)Intake (outer)Exhaust

Compressed spring force(installed)Intake (inner)

(outer)

Exhaust

Spring tilt

Intake (inner)

Intake (outer)

Exhaust

Winding direction (top view)Intake (inner)Intake (outer)Exhaust

37.0 mm (1.46 in)38.4 mm (1.51 in)41.8 mm (1.65 in)

30 mm (1.18 in)32.5 mm (1.28 in)36.1 mm (1.42 in)

69.0 79.0 N (7.03 8.05 kg,15.50 17.75 lb)114.0 132.0 N (11.62 13.46 kg,25.63 29.67 lb)160 184 N (16.32 18.76 kg, 35.97 41.36 lb)

Counter clockwiseClockwiseClockwise

35.2 mm (1.39 in)36.5 mm (1.44 in)39.7 mm (1.56 in)

2.5/1.6 mm(0.06 in)2.5 /1.7 mm(0.07 in)2.5/1.8 mm(0.07 in)

CylindersCylinder arrangementBore strokeCompression ratioBoreMax. out-of-round

Forward-inclined, parallel 4-cylinder65.5 mm 44.5 mm (2.58 1.75 in)12.2 : 165.50 65.51 mm (2.5787 2.5791 in)

0.05 mm (0.002 in)

2-7


Item Standard Limit

PistonPiston-to-cylinder clearance

Diameter D

Height HPiston pin bore (in the piston)Diameter

OffsetOffset direction

Piston pinsOutside diameter

Piston-pin-to-piston-pin-boreclearance

Piston ringsTop ring

Ring typeDimensions (B T)End gap (installed)

Ring side clearance

2nd ring

Ring typeDimensions (B T)End gap (installed)

Ring side clearance

Oil ring

Dimensions (B T)End gap (installed)

0.010 0.035 mm (0.0004 0.0014 in)

65.475 65.490 mm (2.5778 2.5783 in)

4 mm (0.16 in)

16.002 16.013 mm (0.6300 0.6304 in)0.5 mm (0.0197 in)Intake side

15.991 16.000 mm (0.6296 0.6299 in)0.002 0.022 mm (0.0001 0.0009 in)

Barrel0.90 2.45 mm (0.04 0.10 in)0.25 0.35 mm (0.0098 0.0138 in)

0.030 0.065 mm (0.0012 0.0026 in)

Taper0.8 2.5 mm (0.03 0.10 in)0.7 0.8 mm (0.0276 0.0315 in)

0.030 0.065 mm (0.0012 0.0026 in)

1.5 2.0 mm (0.06 0.08 in)0.10 0.35 mm (0.0039 0.0138 in)

0.055 mm(0.0022 in)

16.043 mm(0.6316 in)

15.971 mm(0.6288 in)0.072 mm(0.0028 in)

0.60 mm(0.0236 in)0.115 mm(0.0045 in)

1.15 mm(0.0453 in)0.125 mm(0.0049 in)

2-8


Item Standard Limit

Connecting rodsCrankshaft-pin-to-big-end-bearingclearanceBearing color code

0.028 0.052 mm (0.0011 0.0020 in)

1 = Blue 2 = Black 3 = Brown 4 = Green

0.08 mm(0.0032 in)

Crankshaft

Width AWidth BMax. runout C

Big end side clearance DBig end radial clearanceSmall end free playCrankshaft-journal-to-crankshaft-journal-bearing clearanceBearing color code

51.85 52.55 mm (2.04 2.06 in)268.8 270.0 mm (10.58 10.63 in)

0.160 0.262 mm (0.0063 0.0103 in)0.038 0.062 mm (0.0015 0.0024 in)0.32 0.50 mm (0.01 0.02 in)0.028 0.052 mm (0.0011 0.0020 in)

0 = White 1 = Blue 2 = Black3 = Brown 4 = Green

0.03 mm(0.0012 in)

0.10 mm(0.0039 in)

ClutchClutch typeClutch release methodClutch release method operationOperationClutch cable free play (at the endof the clutch lever)Friction platesColor codeThickness

Plate quantityColor codeThickness

Plate quantityClutch platesThicknessPlate quantityMax. warpage

ThicknessPlate quantityMax. warpage

Clutch springsFree length

Spring quantity

Wet, multiple discOuter pull, rack and pinion pullCable operationLeft-hand operation10 15 mm (0.39 0.59 in)

Brown2.9 3.1 mm (0.114 0.122 in)

6Purple2.9 3.1 mm (0.114 0.122 in)

2

1.9 2.1 mm (0.07 0.08 in)7

2.2 2.4 mm (0.086 0.095 in)1

55 mm (2.17 in)

6

2.8 mm(0.110 in)

2.8 mm(0.110 in)

0.1 mm(0.0039 in)

0.1 mm(0.0039 in)

52.3 mm(2.06 in)

2-9


Item Standard Limit

TransmissionTransmission typePrimary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioOperationGear ratios1st gear2nd gear3rd gear4th gear5th gear6th gear

Max. main axle runout

Max. drive axle runout

Constant mesh, 6-speedSpur gear86/44 (1.955)Chain drive46/16 (2.875)Left-foot operation

37/13 (2.846)37/19 (1.947)28/18 (1.556)32/24 (1.333)25/21 (1.190)26/24 (1.083)

0.02 mm(0.0008 in)0.02 mm(0.0008 in)

Shifting mechanismShift mechanism typeMax. shift fork guide bar bending

Shift drum/Guide bar

0.05 mm(0.002 in)

Air filter type Oil-coated paper element

Fuel pumpPump typeModel (manufacturer)Output pressure

Electrical5VX (DENSO)250 kPa (2.5 kg/cm2, 2.5 bar, 36.3 psi)

Throttle position sensorResistanceOutput voltage (at idle)

4.0 6.0 kΩ at 20C (68F)0.63 0.73 V (Adjusted by tachometer)

Throttle bodiesModel (manufacturer) quantityIntake vacuum pressureThrottle cable free play (at the flange of the throttle grip)ID markThrottle valve size

36EIDW (MIKUNI) 229 kPa (218 mmHg, 8.5038 inHg)3 5 mm (0.12 0.20 in)

5VX1 00 (5VX1/5VX2)#50

2-10

CHASSIS SPECIFICATIONS SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

FrameFrame typeCaster angleTrail

Diamond2597.5 mm (3.84 in)

Front wheelWheel typeRimSizeMaterial

Wheel travelWheel runoutMax. radial wheel runoutMax. lateral wheel runout

Cast wheel

17 M/C MT3.50Aluminum130 mm (5.12 in)

1 mm (0.04 in)0.5 mm (0.02 in)

Rear wheelWheel typeRimSizeMaterial

Wheel travelWheel runoutMax. radial wheel runoutMax. lateral wheel runout

Cast wheel

17 M/C MT5.50Aluminum130 mm (5.12 in)

1 mm (0.04 in)0.5 mm (0.02 in)

Front tireTire typeSizeModel (manufacturer)

Tire pressure (cold)0 90 kg (0 198 lb)90 190 kg (198 419 lb)High-speed riding

Min. tire tread depth

Tubeless120/70 ZR17 M/C (58W)BT020F GG (BRIDGESTONE)D252F (DUNLOP)

225 kPa (2.25 kgf/cm2, 2.25 bar, 33 psi)250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)225 kPa (2.25 kgf/cm2, 2.25 bar, 33 psi)

1.6 mm (0.06 in)

2-11


Item Standard Limit

Rear tireTire typeSizeModel (manufacturer)

Tire pressure (cold)0 90 kg (0 198 lb)90 190 kg (198 419lb)High-speed riding

Min. tire tread depth

Tubeless180/55 ZR17 M/C (73W)BT020R GG (BRIDGESTONE)D252 (DUNLOP)

250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi)250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)

1.6 mm(0.06 in)

Front brakesBrake typeOperationRecommended fluidBrake discsDiameter thicknessMin. thickness

Max. deflection

Brake pad lining thickness

Master cylinder inside diameterCaliper cylinder inside diameter

Dual disc brakeRight hand operationDOT 4

298 5 mm (11.73 0.20 in)

6.0 mm (0.24 in)

16 mm (0.63 in)30.2 mm and 25.4 mm (1.19 in and 1.00 in)

4.5 mm(0.18 in)0.1 mm(0.004 in)0.8 mm(0.03 in)

Rear brakeBrake typeOperationBrake pedal position (below the bottom of the footrest bracket)Recommended fluidBrake discsDiameter thicknessMin. thickness

Max. deflection

Brake pad lining thickness

Master cylinder inside diameterCaliper cylinder inside diameter

Single disc brakeRight foot operation25.8 mm (1.02 in)

DOT 4

245 5 mm (9.65 0.20 in)

6.0 mm (0.24 in)

12.7 mm (0.5 in)38.1 mm (1.5 in)

4.5 mm(0.18 in)0.15 mm(0.006 in)1.0 mm(0.04 in)

2-12


Item Standard Limit

Front suspensionSuspension typeFront fork typeFront fork travelSpringFree length

Spacer lengthInstalled lengthSpring rate (K1)Spring rate (K2)Spring stroke (K1)Spring stroke (K2)

Inner tube outer diameterInner tube bending limit

Optional spring availableFork oilRecommended oilQuantity (each front fork leg)Level (from the top of the innertube, with the inner tube fullycompressed, and without thefork spring)

Telescopic forkCoil spring/oil damper130 mm (5.12 in)

354.0 mm (13.94 in)

131.5 mm (5.18 in)347.0 mm (13.66 in)7.4 N/mm (0.75 kg/mm, 42.25 lb/in)11.8 N/mm (1,20 kg/mm, 67.38 lb/in)0 70 mm (0 2.76 in)70 130 mm (2.76 5.12 in)43 mm (1.69 in)

No

Suspension oil “01” or equivalent0.467 L (0.41 lmp qt, 0.49 US qt)134 mm (5.28 in)

347 mm(13.66 in)

0.2 mm(0.01 in)

2-13


Item Standard Limit

SteeringSteering bearing type Angular bearing

Rear suspensionSuspension typeRear shock absorber assemblytypeRear shock absorber assemblytravelSpringFree lengthInstalled lengthSpring rate (K1)Spring stroke (K1)

Optional spring availableStandard spring preload gas/airpressureSpring preload adjusting positionsMinimumStandardMaximum

Swingarm (monocross)Coil spring/gas-oil damper

50 mm (1.97 in)

185.0 mm (7.28 in)172.0 mm (6.77 in)127.4 N/mm (12.99 kg/mm, 727.45 lb/in)0 50 mm (0.00 1.97 in)No1,200 kPa (12 kg/cm2, 12 bar, 170.7 psi)

137

SwingarmFree play (at the end of theswingarm)Radial

Axial

1.0 mm(0.04 in)1.0 mm(0.04 in)

Drive chainModel (manufacturer)Link quantityDrive chain slackMaximum ten-link section

50V4 (DAIDO)11845 55 mm (1.77 2.17 in)

150.1 mm(5.91 in)

2-14

ELECTRICAL SPECIFICATIONS SPEC

ELECTRICAL SPECIFICATIONS

Item Standard Limit

System voltage 12 V

Ignition systemIgnition system typeIgnition timingAdvancer typeCrankshaft position sensorresistance/colorT.C.I. unit model (manufacturer)

DC. T.C.I.5 BTDC at 1,300 r/minDigital248 372 Ω at 20C (68F)/Gy-B

F8T811 (MITSUBISHI)

Ignition coilsModel (manufacturer)Minimum ignition spark gapPrimary coil resistanceSecondary coil resistance

JO383 (DENSO)6 mm (0.24 in)1.53 2.07 Ω at 20C (68F)12.0 18.0 kΩ at 20C (68F)

Spark plug capMaterialResistance

Resin10.0 kΩ at 20C (68F)

Charging systemSystem typeModel (manufacturer)Normal outputStator coil resistance/color

A.C. magnetoF5VX (MORIC)14 V/310 W at 5,000 r/min0.22 0.34 Ω at 20C (68F)/W-W

Rectifier/regulatorRegulator typeModel (manufacture)

Semi conductor short circuitSH719AA (SHINDENGEN)

( )No-load regulated voltageRectifier capacityWithstand voltage

( )14.1 14.9 V18 A240 V

BatteryBattery typeBattery voltage/capacitySpecific gravityManufacturerTen hour rate amperage

GT12B-412 V/10 Ah1.320GS1.0 A

Headlight type Halogen bulb

Bulbs (voltage/wattage quantity)Headlight

Auxiliary lightTail /brake lightTurn signal lightLicence lightMeter light

12V 60 W/55 W 112 V 55 W 112 V 5 W 212 V 5 W/21 W12 V 10 W 412 V 5 W 1EL

2-15


Item Standard Limit

Indicator light(voltage/wattage quantity)Neutral indicator lightHigh beam indicator lightOil level warning lightTurn signal indicator lightEngine trouble warning lightImmobilizer indicator light

LED 1LED 1LED 1LED 2LED 1LED 1

Electric starting systemSystem typeStarter motorModel (manufacturer)Power outputBrushesOverall length

Spring force

Armature coil resistanceCommutator diameter

Mica undercut

Constant mesh

SM-14 (MITSUBA)0.6 kW

10 mm (0.39 in)

7.16 9.52 N (730 971 g, 25.77 34.27 oz)0.0012 0.0022 Ω at 20C (68F)28 mm (1.1 in)

0.7 mm (0.03 in)

3.5 mm(0.14 in)

27 mm(1.06 in)

Starter relayModel (manufacturer)AmperageCoil resistance

MS5F-441 (JIDECO)180 A4.18 4.62 Ω at 20C (68F)

HornHorn typeModel (manufacturer) quantityMax. amperagePerformanceCoil resistance

PlainHF-12 (NIKKO) 13 A105 118 db/2 m1.01 1.11 Ω at 20C (68F)

Turn signal relayRelay typeModel (manufacturer)Self-cancelling device built-inTurn signal blinking frequencyWattage

Full transistorFE218BH (DENSO)No75 95 cycles/min.10 W 2 + 3.4 W

Oil level switchModel (manufacturer) 5VX (SOMIC ISHIKAWA)

2-16


Item Standard Limit

Fuses (amperage quantity)Main fuseFuel injection system fuseHeadlight fuseSignaling system fuseIgnition fuseRadiator fan motor fuseBackup fuse (odometer and clock)Parking light fuseReserve fuse

30 A 110 A 120 A 110 A 110 A 120 A 110 A 110 A 130 A, 20 A, 10 A

Fuel level senderModel (manufacture)Sender unit resistance-fullSender unit resistance-empty

5VX (DENSO)20 26 Ω134 140 Ω

Starting circuit cut-off relayModel (manufacture)Coil resistance

G8R-30Y-S (OMRON)162 198 Ω

Headlight relay, Radiator fan motorrelayModel (manufacture)Coil resistance

ACM33211M05 (MATSUSHITA)86.4 105.6 Ω

Fuel injection system relayModel (manufacture)Coil resistance

G8R-30Y-R (OMRON)162 198 Ω

Water temperature sensorModel (manufacture)Resistance

K003T20191 (MITSUBISHI)0.290 0.354 Ω at 80C (176F)

2-17

EAS00030

GENERAL TIGHTENING TORQUESPECIFICATIONSThis chart specifies tightening torques for stan-dard fasteners with a standard ISO threadpitch. Tightening torque specifications for spe-cial components or assemblies are providedfor each chapter of this manual. To avoid war-page, tighten multi-fastener assemblies in acrisscross pattern and progressive stages untilthe specified tightening torque is reached. Un-less otherwise specified, tightening torquespecifications require clean, dry threads. Com-ponents should be at room temperature.

A: Distance between flatsB: Outside thread diameter

A(nut)

B(bolt)

General tighteningtorques

10 mm

12 mm

14 mm

17 mm

19 mm

22 mm

6 mm

8 mm

10 mm

12 mm

14 mm

16 mm

Nm mkg6

15

30

55

85

130

0.6

1.5

3.0

5.5

8.5

13.0

ftlb4.3

11

22

40

61

94

CONVERSION TABLE/GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC

EAS00028

CONVERSION TABLEAll specification data in this manual are listed in SI and METRIC UNITS.Use this table to convert METRIC unit data to IMPERIAL unit data.Ex.

METRIC MULTIPLIER IMPERIAL

** mm 0.03937 = ** in

2 mm 0.03937 = 0.08 in

CONVERSION TABLE

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

Tighten-ingtorque

mkgmkgcmkgcmkg

7.23386.7940.07230.8679

ftlbinlbftlbinlb

Weight kgg

2.2050.03527

lboz

Speed km/hr 0.6214 mph

Distance

kmmmcmmm

0.62143.2811.0940.39370.03937

miftydinin

Volume/Capacity

cc (cm3)cc (cm3)lt (liter)lt (liter)

0.035270.061020.87990.2199

oz (IMP liq.)cuinqt (IMP liq.)gal (IMP liq.)

Misc.

kg/mmkg/cm2

Centigrade(C)

55.99714.22349/5+32

lb/ inpsi (lb / in2)Fahrenheit(F)

2-18

TIGHTENING TORQUES SPEC

Yamaha bond No.1215

TIGHTENING TORQUESENGINE TIGHTENING TORQUES

Item FastenerThread

Q’tyTightening torque

RemarksItem Fastenersize

Q tyNm mkg ftlb

Remarks

Spark plugs – M10 4 18 1.8 13Cylinder head Bolt M10 10 1st 19

2nd 501.95.0

1436

Bolt M6 2 12 1.2 8.7Camshaft caps Bolt M6 20 10 1.0 7.2Cylinder head cover Bolt M6 6 12 1.2 8.7Camshaft cap oil check bolt Bolt M8 1 20 2.0 15Air indication system reed valve cover

Bolt M6 4 10 1.0 7.2

Air-cut valve stay Bolt M6 1 10 1.0 7.2Camshaft sprockets Bolt M7 4 20 2.0 15Connecting rod caps Nut M7 8 15 + 150 15 + 150 15 + 150

Generator rotor Bolt M12 1 75 7.5 54Timing chain tensioner Bolt M6 2 12 1.2 8.7Timing chain tensioner cap bolt Bolt M6 1 7.0 0.7 5.1Thermostat cover Bolt M6 2 12 1.2 8.7Coolant hose joint Bolt M6 2 10 1.0 7.2Water pump cover Bolt M6 2 10 1.0 7.2Water pump Bolt M6 2 12 1.2 8.7Thermo sensor Bolt M12 1 18 1.8 13Coolant hose drain bolt(water pump)

Bolt M6 1 10 1.0 7.2

Radiator and frame Bolt M6 2 7.0 0.7 5.1Radiator stay and crankcase Bolt M6 1 10 1.0 7.2Oil pump cover Bolt M6 3 12 1.2 8.7Oil pump Bolt M6 3 12 1.2 8.7Oil pan Bolt M6 12 12 1.2 8.7Oil pan (center) Bolt M6 1 12 1.2 8.7Oil cooler Bolt M20 1 63 6.3 46Engine oil drain bolt Bolt M14 1 43 4.3 31Oil filter union bolt Bolt M20 1 70 7.0 51Oil filter – M20 1 17 1.7 12Oil pump chain guide Bolt M6 2 12 1.2 8.7Oil pipe Bolt M6 2 12 1.2 8.7Throttle body joint Bolt M6 8 10 1.0 7.2Air filter case cover Screw M5 6 1.2 0.12 0.9Throttle body and throttle body joint Clamp M4 4 3.0 0.3 2.2Throttle body and air filter case Clamp M5 4 3.0 0.3 2.2Exhaust pipe and cylinder head Nut M8 8 20 2.0 15Exhaust pipe and exhaust pipe stay Bolt M8 1 20 2.0 15Catalyst pipe and catalyst pipe stay Bolt M8 1 20 2.0 15Muffler joint Bolt M8 1 20 2.0 15 See NOTE 1

Catalyst joint Bolt M8 1 20 2.0 15 See NOTE 1

Exhaust stay and frame Bolt M8 1 34 3.4 25Catalyst pipe stay and frame Bolt M8 1 20 2.0 15Muffler stay and frame Bolt M8 2 20 2.0 15

2-19

Yamaha bondNo.1215

Use a lock washerUse a lock washer

Left thread

NOTE 1:


NOTE 2:

Item Fastener Thread Q’tyTightening torque

RemarksItem Fastenersize

Q tyNm mkg ftlb

Remarks

Crankcase (main journal) Bolt M8 10 See NOTE 2Crankcase Bolt M6 2 14 1.4 1.0Crankcase Bolt M6 13 12 1.2 8.7Crankcase Bolt M8 2 24 2.4 17Generator rotor cover Bolt M6 9 12 1.2 8.7Clutch cover Bolt M6 7 12 1.2 8.7Clutch cover Bolt M6 1 12 1.2 8.7Pickup coil rotor cover Bolt M6 7 12 1.2 8.7Clutch cable holder Bolt M6 2 12 1.2 8.7Pickup coil rotor cover Bolt M8 1 15 1.5 11Shift shaft cover Bolt M6 6 12 1.2 8.7Breather plate Screw M6 3 12 1.2 8.7Stator coil Screw M6 3 10 1.0 7.2Pickup rotor cover and clamp Screw M6 1 7.0 0.7 5.1Drive sprocket cover Bolt M6 3 10 1.0 7.2Oil gallery bolt – M16 2 8 0.8 5.8Generator rotor cover and stator coil lead clamp

Screw M6 1 10 1.0 7.2

Breather hose cover Bolt M6 4 12 1.2 8.7Oil pipe Bolt M6 2 12 1.2 8.7Crankshaft position sensor Bolt M6 2 10 1.0 7.2Starter clutch Screw M8 3 32 3.2 23Starter motor cover bolt Bolt M6 2 3.4 0.34 2.5Clutch pressure plate Screw M6 6 8.0 0.8 5.8Clutch boss Nut M20 1 90 9.0 65Drive sprocket Nut M18 1 90 9.0 65Transmission bearing housing Screw M6 3 12 1.2 8.7Shift drum retainer Bolt M6 2 10 1.0 7.2Shift shaft spring stopper Screw M8 1 22 2.2 16Shift rod Nut M6 1 7 0.7 5.1Shift rod Nut M6 1 7 0.7 5.1Shift rod joint Bolt M6 1 10 1.0 7.2Shift arm Bolt M6 1 10 1.0 7.2Pickup coil rotor Bolt M8 1 35 3.5 25Starter motor Bolt M6 2 10 1.0 7.2Neutral switch – M10 1 20 2.0 14Oil level switch Bolt M6 2 10 1.0 7.2Speed sensor Bolt M6 1 10 1.0 7.2

Retighten the bolt at 1000 km (600 ml).

1. First, tighten the bolts to approximately 12 Nm (1.2 mkg, 8.7 ftlb) with a torque wrench.(Following the tightening order)

2. Retighten the bolts 25 Nm (2.5 mkg, 18 ftlb) with a torque wrench.3. Loosen the all bolts one by one following the tightening order and then tighten them to 27 Nm (2.7

mkg, 20 ftlb) again.

2-20


Cylinder head tightening sequence:

Crankcase tightening sequence.

2-21


CHASSIS TIGHTENING TORQUES

ItemThread Tightening

RemarksItem size Nm mkg ftlbRemarks

Upper bracket pinch blot M8 30 3.0 22Steering stem nut M22 110 11 80Upper bracket and upper handlebar holder M8 23 2.3 17Under bracket pinch blot – 30 3.0 22Lower ring nut M25 18 1.8 13 See NOTE 1Front fork cap bolt M35 24 2.4 17Damper rod assembly bolt M10 23 2.3 17Pinch bolt (front wheel axle) M8 23 2.3 17Front brake master cylinder and master cylinderbracket

M6 10 1.0 7.2

Front brake master cylinder cap screw M4 2 0.2 1.4Front brake hose union blot M10 30 3.0 22Front brake hose holder and front fork M6 10 1.0 7.2Front cowling stay and frame M8 33 3.3 24Front cowling bracket and frame M6 7 0.7 5.1Front fender and front fork M6 6 0.6 4.3Clutch lever holder pinch bolt M6 11 1.1 8.0Engine mount bolts (left of front side) M10 55 5.5 40Engine mount bolts (left of rear side) M10 55 5.5 40Engine mount bolts (right of front side) M10 55 5.5 40 See NOTE 2Engine mount self locking nut (upper) M10 55 5.5 40Engine mount self locking nut (lower) M10 55 5.5 40Pivot shaft and frame M18 120 12 87Rear shock absorber and frame M10 40 4.0 29Rear shock absorber and rear arm M10 40 4.0 29Seal guard and rear arm M6 7 0.7 5.1Rear fender and rear arm M6 7 0.7 5.1Rear brake hose holder and rear arm M6 7 0.7 5.1Fuel tank bracket and frame M6 7 0.7 5.1Fuel tank bracket and fuel tank M6 7 0.7 5.1Fuel tank and rear frame M6 7 0.7 5.1Fuel tank and fuel tank cap M5 6 0.6 4.3Fuel pump and fuel tank M5 4 0.4 2.9Ignition coil and battery box M6 7 0.7 5.1Seat lock and frame M6 7 0.7 5.1Rotor and mud guard M6 3 0.3 2.2Licence plate light and flap M5 4 0.4 2.9Rear reflector and flap M5 4 0.4 2.9Flap and bracket 6 M6 7 0.7 5.1Blacket 6 and rear frame M6 19 1.9 14Seat handle and tail /brake right unit M6 3 0.3 2.2Rear fender cover and seat handle M5 4 0.4 2.9Seat handle bolt M8 23 2.3 17Muffler and rear fender M6 7 0.7 5.1Side cover and rear frame M6 10 1.0 7.2Rear mud guard and rear frame M6 7 0.7 5.1

2-22


NOTE 1:

NOTE 2:

Item Thread TighteningRemarksItem

size Nm mkg ftlbRemarks

Engine stop switch and frame M4 2 0.2 1.4Coolant reserver tank bracket and stay 1, 2 M6 10 1.0 7.2Stay 1, 2 and frame M6 10 1.0 7.2Coolant reserver tank bracket and coolant reserver tank

M6 4 0.4 2.9

Front wheel axle shaft and bolt M18 72 7.2 52Front wheel axle pinch bolt M8 23 2.3 17Front brake caliper and front fork M10 40 4.0 29Front brake disc and front wheel M6 18 1.8 13Brake caliper bleed screw M7 6 0.6 4.3Rear wheel axle nut M24 120 12 87Rear brake disc and rear wheel M8 30 3.0 22Rear brake caliper bolt front and rear brake caliper bracket

M8 27 2.7 20

Rear brake caliper bolt rear and rear brakecaliper bracket

M8 22 2.2 16

Rear wheel sprocket and rear wheel drive hub M10 100 10 72Chain adjusting bolt lock nut M8 16 1.6 12Rear brake hose union bolt M10 30 3.0 22Sidestand bolt lock nut M10 46 4.6 33Sidestand bracket and frame M10 63 6.3 46Sidestand switch screw M5 4 0.4 2.9Footrest bracket and frame M8 30 3.0 22Rear brake reserver tank and coolant reserver tank bracket

M6 3 0.3 2.2

Rear master cylinder and footrest bracket M8 23 2.3 17Mainstand and nut M10 73 7.3 53Footrest and footrest bolt M8 10 1.0 7.2Brake pedal and brake shaft M6 8 0.8 5.8

1. First, tighten the ring nut to approximately 52 Nm (5.2 mkg, 38 ftlb) with a torque wrench, thenloosen the ring nut completely.

2. Retighten the lower ring nut to specification.

Refer to “INSTALLING THE ENGINE” in chapter 5.

2-23

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EAS00031

LUBRICATION POINTS AND LUBRICANT TYPESENGINE

Lubrication point Lubricant

Oil seal lips

O-rings

Bearings and bushes

Crankshaft pins

Piston surfaces

Piston pins

Connecting rod bolts

Crankshaft journals

Camshaft lobes

Camshaft journals

Valve stems (intake and exhaust)

Valve stem ends (intake and exhaust)

Valve lifter surface

Piston cooler (O-ring)

Oil pump rotors (inner and outer)

Oil pump housing

Oil strainer

Clutch (pull rod)

Starter clutch idle gear inner surface

Starter clutch assembly

Primary driven gear

Transmission gears (wheel and pinion)

Main axle and drive axle

Shift drum

Shift forks and shift fork guide bars

Shift shaft

Shift shaft boss

Cylinder head cover mating surface Yamaha bondNo.1215

Cylinder head cover semicircular Yamaha bondNo.1215

Crankcase mating surface Yamaha bondNo.1215

Generator rotor cover (stator coil assembly lead grommet) Yamaha bondNo.1215

Pickup rotor cover (crankshaft position sensor lead grommet) Yamaha bondNo.1215

2-24

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EAS00032

CHASSIS

Lubrication point Lubricant

Steering bearings and bearing races (upper and lower)

Front wheel oil seal (right and left)

Rear wheel oil seal

Rear wheel drive hub oil seal

Rear wheel drive hub mating surface

Rear brake pedal shaft

Sidestand pivoting point and metal-to-metal moving parts

Link and sidestand switch contact point

Throttle grip inner surface

Brake lever pivoting point and metal-to-metal moving parts

Clutch lever pivoting point and metal-to-metal moving parts

Rear shock absorber collar

Pivot shaft

Swingarm pivot bearing

Swingarm head pipe end, oil seal and bush

Engine mount bolts (rear upper and lower)

Shift pedal shaft

Shift shaft joint

Rear footrest ball and metal-to-metal moving parts

Main stand metal-to-metal moving parts

2-25

COOLING SYSTEM DIAGRAMS SPEC

1 Radiator2 Oil cooler

COOLING SYSTEM DIAGRAMS

2-26


1 Water pump2 Oil cooler3 Radiator

2-27


1 Oil cooler2 Water pump

2-28


1 Radiator2 Thermostat

2-29

ENGINE OIL LUBRICATION CHART SPEC

ENGINE OIL LUBRICATION CHART

2-30

LUBRICATION DIAGRAMS SPEC

1 Oil level switch2 Oil cooler3 Relief valve

LUBRICATION DIAGRAMS

2-31


1 Oil pump2 Exhaust camshaft3 Intake camshaft4 Oil strainer

2-32


1 Oil cooler2 Oil strainer3 Oil level switch4 Oil pump

2-33


1 Main axle2 Oil pump3 Relief valve

2-34


1 Cylinder head2 Intake camshaft3 Exhaust camshaft4 Crankshaft

2-35


1 Main axle2 Drive axle

2-36

CABLE ROUTING SPEC

A Clamp the right and left handlebar switch leads andhandlebars. Point the tip of the clamp downward infront of the handlebars.

B Clamp the horn lead and main switch and immobi-lizer lead to the inner tube. Point the binding sectionto the outside of the vehicle body and cut the tipdown to the length of 1 to 5 mm (0.04 to 0.20 in).

C Route the horn lead by the headmost side.D Pass the throttle cables, wire harness lead, clutch

cable, main switch and immobilizer lead and lefthandlebar switch lead in order through the framehole from the inner side of the vehicle.

E Point the lead, which comes from the terminal, tothe front side of the vehicle body.

1 Left handlebar switch lead2 Main switch and immobilizer lead3 Clutch cable4 Throttle cables5 Right handlebar switch lead

CABLE ROUTING

2-37

CABLE ROUTING SPEC

F Clamp the brake hose to the inner tube. Point thebinding section to the outside of the vehicle bodyand cut the tip down to the length of 1 to 5 mm (0.04to 0.20 in).

G Pass the throttle cables through the wire guide.Route the right handlebar switch lead by the outsideof the wire guide.

2-38

CABLE ROUTING SPEC

1 Right handlebar switch lead2 Rear brake light switch lead3 Neutral switch lead4 Fuel tank breather hose5 Crankshaft position sensor lead

A Pass the right handlebar switch lead through thehole located on the right side of the frame.

B Route the right handlebar switch lead under thebracket 2.

C Route the coolant reservoir tank hose under thecover 2. Route the radiator hose (outside) innerside.

D Route the radiator hoses (2 pieces) under the cover2.

E Route the crank shaft position sensor lead innerside of the radiator hose.

F Pull down the mark-painted sections of the fuel tankbreather hose, fuel tank drain hose and coolant res-ervoir tank breather hose to be lower than the clampposition of the muffler stay. Any order to take out thefuel tank breather hose and fuel tank drain hose canbe accepted.

G Pass the fuel tank breather hose, fuel tank drainhose, coolant reservoir tank breather hose andbrake right switch lead through the guide of the stayassembly 2.

H Clamp the tail brake light switch lead together withthe brake fluid fluid reservoir hose.

2-39

I Pass the neutral switch lead between the engineand coolant reservoir tank bracket.

J To the starter motor.K Install the right handlebar switch lead coupler

through the hole of the bracket 2 from the downside.L Route the starter motor lead by the inner side of the

air cut-off valve hose.M Pass the ignition coil leads #1 and #4 through inner

side of the air cut-off valve hose, and then betweenthe frame and bracket 2.

CABLE ROUTING SPEC

2-40

CABLE ROUTING SPEC

16 License plate light lead17 Rear turn signal light lead (right)18 Rear turn signal light lead (left)19 Speed sensor lead20 Side stand switch lead21 Oil level switch lead22 A.C. magneto lead23 Throttle cable (return side)24 Throttle cable (pull side)25 Radiator fan motor lead26 Oil level gauge lead27 Sidestand switch lead28 A. C. magneto lead29 Speed sensor lead

1 Main switch and immobilizer lead2 Stay assembly3 Left handlebar switch lead4 Clutch cable5 Throttle cables6 Battery negative lead coupler7 Starter relay lead8 Battery negative lead9 Fuel tank drain hose10 Rectifier/regulator11 Turn signal relay12 Radiator fan motor relay13 Dimmer relay14 Starting circuit cut-off relay15 Clamp

2-41

A Route the throttle cables above the stay assy 1.B Route the main switch and immobilizer lead above

the clutch cable.C Line up the left handlebar switch lead coupler and

fan motor lead coupler behind the head pipe.D To the immobilizer.E To the main switch.F Place three couplers on the flange of the cover.G To the fuel pump.H Clamp four wire leads. There should be no exces-

sive slack on the wire leads.I To the engine.J To the fuel tank.K Either installation position can be accepted, but

make sure that the leads are not crossed.

L Clamp the rear turn signal lead and license platelight lead to the frame. Hook the clamp to the brack-et. Pull out the lead sufficiently to the frame side androute it along with the side of the back stay. Cut thetip of the clamp to be between 1 and 5 mm (0.04 and0.20 in) upward.

M Clamp the rear turn signal lead and license platelight lead to the frame. Cut the tip of the clamp to bebetween 1 and 5 mm (0.04 and 0.20 in).

N Gap between the lead and muffler should be 10 mm(0.39 in) or more.

O Coupler should not run on the relay assembly.P To the tail/brake light.Q To the license plate light.R To the rear turn signal light. (right)

CABLE ROUTING SPEC

2-42

Y Make sure to pass the neutral switch lead throughthe hole of the flap.

Z Clamp the seat lock wire to the frame as shown inthe illustration. Secure the clamp to the weld of thecross member with the frame. Position the bindingsection in front of the vehicle body and cut the tip tobe between 1 and 5 mm (0.04 and 0.20 in).

S To the rear turn signal light (left)T Pass the fuel tank drain hose through the clamp lo-

cated under the coolant reservoir tank.U Route it behind the starter motor lead.V Point the bend-R section of the throttle cable (pull

side) to the inner side horizontally. It is also possibleto visually check the bend-R section.

W To the headlight lead.X Point the tip of the clamp to the inner side of the ve-

hicle body.

CABLE ROUTING SPEC

2-43

14 Seat lock cable15 Rectifier/regulator16 E.C.U17 Fuel tank drain hose18 Cover19 Starter relay lead20 Battery negative lead21 Battery negative lead coupler22 Clutch cable23 Cover 224 Spark plug lead25 Air cut-off valve hose

1 Right handlebar switch lead2 Throttle cables3 Battery positive lead4 Coolant reservoir tank hose5 Battery cover6 Connecter cover7 Fuel tank breather hose8 Brake fluid reservoir hose9 Lean angle cut-off switch10 Fuse box11 Rear turn signal light lead (right)12 Rear turn signal light lead (left)13 License plate light lead

CABLE ROUTING SPEC

2-44

CABLE ROUTING SPEC

A Either right or left side arrangement for the left han-dlebar switch lead coupler and radiator fan motorcoupler can be accepted.

B Point the L-shape terminal to the front side of the ve-hicle.

C Hook the starter motor lead to the alternate pawlson the battery cover.

D Route the crank shaft position sensor lead abovethe starter motor leads.

E To the crankshaft position sensor.F Clamp the starter motor lead and crank shaft posi-

tion sensor lead. Point the projected part of the tip tothe inner side of the vehicle.

G Pass the radiator hose, coolant reservoir hose, wireharness and starter motor lead in order through thelower side of the vehicle.

H Set the 4-pin coupler in the connector cover afterwiring it.

I To the sidestand switch.J To the speed sensor.K To the A.C. magneto.L To the oil level gauge.M To the rear brake/light switch.N To the neutral switch.O Push the wire harness in the groove of the mud

guard.P Point the opening section of the clamp upward.Q To the rear turn signal (right)R To the rear turn signal (left)

2-45

AE Press the battery negative lead into the space be-tween the ribs of the frame.

AF Pass the spark plug leads #1 and #4 through theslit of the cover 2.

AG Pass the spark plug lead #2 through the innerhole of the cover 2.

AH Pass the spark plug lead #3 through the outerhole of the cover 2.

AI Route the spark plug lead #4 behind the air cut-offvalve hose.

AJ Point the spark plug caps of #1 to #4 to the direc-tion as shown in the illustration.

AK Route the spark plug lead #3 under the air cut-offvalve hose.

AL Route the spark plug lead #2 behind the air cut-offvalve hose.

CABLE ROUTING SPEC

S To the license plate light.T To the tail/brake light.U Insert the enwinding clamp of the wire harness into

the hole of the rear frame.V Attach the rectifier regulator lead to the clamp of the

rectifier bracket.W To the engine ground.X To the fuel injection.Y To the fuel pump.Z Route the clutch cable under the fuel injection lead.AA Pass the clutch cables through the clamp, and

then install the clamp to the cover. Position of theclamp is forward of the cable stopper.

AB To the main switch.AC To the immobilizer.AD Route the starter relay lead outside of the main

switch and immobilizer lead.

2-46

CABLE ROUTING SPEC

AM Route the spark plug lead #4 by the front side ofthe spark plug leads #2 and #3.

AN Route the spark plug leads #2 and #3 behind theair cut-off valve hose. Then route the spark pluglead #3 by the front side of the spark plug lead #2.

CHKADJ

CHAPTER 3PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 3-1. . . . .

SEAT 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL TANK 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FUEL TANK 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FUEL PUMP 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FUEL PUMP 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FUEL TANK 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COWLINGS 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR FILTER CASE 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY BOX AND BATTERY BOX BRACKET 3-9. . . . . . . . . . . . . . . . .

ENGINE 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE VALVE CLEARANCE 3-10. . . . . . . . . . . . . . . . . . . . . . SYNCHRONIZING THE THROTTLE BODIES 3-16. . . . . . . . . . . . . . . . . ADJUSTING THE ENGINE IDLING SPEED 3-18. . . . . . . . . . . . . . . . . . . ADJUSTING THE THROTTLE CABLE FREE PLAY 3-19. . . . . . . . . . . . CHECKING THE SPARK PLUGS 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE COMPRESSION PRESSURE 3-23. . . . . . . . . . . . . . CHECKING THE ENGINE OIL LEVEL 3-26. . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE ENGINE OIL 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE ENGINE OIL PRESSURE 3-29. . . . . . . . . . . . . . . . . ADJUSTING THE CLUTCH CABLE FREE PLAY 3-31. . . . . . . . . . . . . . . CLEANING THE AIR FILTER ELEMENT 3-32. . . . . . . . . . . . . . . . . . . . . . CHECKING THE THROTTLE BODY JOINTS 3-33. . . . . . . . . . . . . . . . . . CHECKING THE FUEL AND BREATHER HOSES 3-34. . . . . . . . . . . . . CHECKING THE CRANKCASE BREATHER HOSE 3-34. . . . . . . . . . . . CHECKING THE EXHAUST SYSTEM 3-35. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLANT LEVEL 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLING SYSTEM 3-37. . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE COOLANT 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHKADJ

CHASSIS 3-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE 3-41. . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE FLUID LEVEL 3-43. . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE PADS 3-44. . . . . . . . . . . ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-45. . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE HOSES 3-45. . . . . . . . . BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-46. . . . . . . . . . . . . . . ADJUSTING THE SHIFT PEDAL 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE DRIVE CHAIN SLACK 3-48. . . . . . . . . . . . . . . . . . . . . LUBRICATING THE DRIVE CHAIN 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE STEERING HEAD 3-50. . . . . . . . . CHECKING THE FRONT FORK 3-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-53. . . . . CHECKING THE TIRES 3-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WHEELS 3-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND LUBRICATING THE CABLES 3-57. . . . . . . . . . . . . . . LUBRICATING THE LEVERS AND PEDALS 3-57. . . . . . . . . . . . . . . . . . LUBRICATING THE SIDESTAND 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE CENTERSTAND 3-57. . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE REAR SUSPENSION 3-58. . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM 3-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY 3-59. . . . . . . . . . . . . . . . . CHECKING THE FUSES 3-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULBS 3-67. . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAMS 3-68. . . . . . . . . . . . . . . . . . . . . .

3-1

INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

CHKADJ

NOTE:

EAS00036

PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjustments. Iffollowed, these preventive maintenance procedures will ensure more reliable vehicle operation, alonger service life and reduce the need for costly overhaul work. This information applies to vehiclesalready in service as well as to new vehicles that are being prepared for sale. All service techniciansshould be familiar with this entire chapter.

EAS00037

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

The annual checks must be performed every year, except if a kilometer-based maintenance is per-formed instead.

From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,data and technical skills.

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING( 1,000 km) ANNUAL

CHECK1 10 20 30 40

CHECK

1 *Fuel line(See page 3-34)

Check fuel hoses for cracks or damage.

2 *Spark plugs(See page 3 22)

Check condition. Clean and regap.

(See page 3-22) Replace.

3 *Valves(See page 3-10)

Check valve clearance. Adjust.

Every 40,000 km

4Air filter element(See page 3-32)

Replace.

5Clutch(See page 3-31)

Check operation. Adjust.

6 *Front brake Check operation, fluid level and vehicle for fluid leakage.

6 * (See page 3-41, 43, 45) Replace brake pads. Whenever worn to the limit

7 *Rear brake Check operation, fluid level and vehicle for fluid leakage.

7 * (See page 3-42, 43, 45) Replace brake pads. Whenever worn to the limit

8 *Brake hoses Check for cracks or damage.

8 * (See page 3-45) Replace. Every 4 years

9 *Wheels(See page 4-3)

Check runout and for damage.

10 *Tires(See page 3-54)

Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.

11 *Wheel bearings(See page 4-3)

Check bearing for looseness or damage.

12 *Swingarm Check operation and for excessive play.

12 *g

(See page 4-70) Lubricate with lithium-soap-based grease. Every 50,000 km

13 *Steering bearings Check bearing play and steering for roughness.

13 *g g

(See page 3-50) Lubricate with lithium-soap-based grease. Every 20,000 km

14 *Chassis fasteners(See page 2-21)

Make sure that all nuts, bolts and screws are properly tight-ened.

15Sidestand, centerstand(See page 3-57)

Check operation. Lubricate.

3-2

NOTE:

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

CHKADJ

NO. ITEM CHECK OR MAINTENANCE JOB

ODOMETER READING( 1,000 km) ANNUAL

CHECK1 10 20 30 40

CHECK

16 *Sidestand switch(See page 3-57, 8-4)

Check operation.

17 *Front fork(See page 3-52)

Check operation and for oil leakage.

18 *Shock absorber assembly(See page 3-53, 4-65)

Check operation and shock absorber for oil leakage.

19 *Electronic fuel injection(See page 3-16, 18)

Adjust engine idling speed and synchronization.

20Engine oil(See page 3-26, 27)

Change. Check oil level and vehicle for oil leakage.

21Engine oil filter cartridge(See page 3-27)

Replace.

22 *Cooling system Check coolant level and vehicle for coolant leakage.

22 *g y

(See page 3-36, 37) Change. Every 3 years

23Drive chain(See page 3-48, 49)

Check chain slack. Make sure that the rear wheel is properly aligned. Clean and lubricate.

Every 800 km and after washingthe motorcycle or riding in the rain

24 *

Front and rear brakeswitches(See page 3-45)(See page 8-4)

Check operation.

25Moving parts and cables(See page 3-57)

Lubricate.

26 *Throttle grip housingand cable(See page 3-19)

Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable.

27 *Air induction system(See page 7-29)

Check the air cut-off valve, reed valve, and hose for dam-age

Replace the entire air induction system if necessary.

28 *Muffler and exhaustpipe(See page 3-35)

Check the screw clamp for looseness.

29 *Lights, signals andswitches(See page 3-67)

Check operation. Adjust headlight beam.

EAU03884

The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.Every two years replace the internal components of the brake master cylinders and calipers, andchange the brake fluid.

Replace the brake hoses every four years and if cracked or damaged.

3-3

SEATCHKADJ

Order Job/Part Q’ty Remarks

1Removing the seatSeat 1

Remove the parts in the order listed.

For installation, reverse the removalprocedure.

EAS00038

SEAT

3-4

FUEL TANKCHKADJ


12345

67

Removing the fuel tank

SeatFront cowling inner panel (left andright)Fuel hoseFuel sender couplerFuel pump couplerFuel tank drain hoseFuel tank breather hose

Fuel tankFuel pump

11111

11

Remove the parts in the order listed.Disconnect.Refer to “SEAT”.Refer to “COWLINGS”.

There is a white paint mark on the fuel tankbreather hose.


7 Nm (0.7 mkg, 5.1 ftlb)7 Nm (0.7 mkg, 5.1 ftlb)

NOTE:

EAS00040

FUEL TANK

3-5

FUEL TANKCHKADJ

CAUTION:

NOTE:

NOTE:

CAUTION:

REMOVING THE FUEL TANK1. Extract the fuel in the fuel tank through the

fuel tank cap with a pump.2. Remove: fuel hose

Although the fuel has been removed fromthe fuel tank, be careful when removing thefuel hoses, since there may be fuel remain-ing in it.

Before removing the hoses, place a few rags inthe area under where it will be removed.

3. Remove: fuel tank

Do not set the fuel tank down so that the installa-tion surface of the fuel pump is directly under thetank. Be sure to lean the fuel tank in an uprightposition.

REMOVING THE FUEL PUMP1. Remove: fuel pump

Do not drop the fuel pump or give it astrong shock.

Do not touch the base section of the fuelsender.

3-6

FUEL TANKCHKADJ

4 Nm (0.4 mkg, 2.9 ftlb)

NOTE:

CAUTION:

NOTE:

INSTALLING THE FUEL PUMP1. Install: fuel pump

Do not damage the installation surfaces of thefuel tank when installing the fuel pump.

Always use a new fuel pump gasket. Install the fuel pump as shown in the illustra-tion.

Tighten the fuel pump bolts in stages in a criss-cross pattern and to the specified torque.

INSTALLING THE FUEL TANK1. Install: fuel hose

When installing the fuel hose, make surethat it is securely connected, and that thefuel hose holders are in the correct position,otherwise the fuel hose will not be properlyinstalled.

2. Install: fuel sender coupler fuel pump coupler fuel tank breather hose fuel tank drain hose

There is a white paint mark on the fuel tankbreather hose.Refer to “CABLE ROUTING” in chapter 2.

3-7


1234567

Removing the cowlingsSeatFront cowling inner panel (left and right)Front turn signal light lead couplersFront cowlingRear view mirrors (left and right)WindshieldRear cowlingFrame side cover

2212112

Remove the parts in the order listed.Refer to “SEAT”.

Disconnect.

For installation, reverse the removal procedure.

33 Nm (3.3 mkg, 24 ftlb)23 Nm (2.3 mkg, 17 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

5 Nm (0.5 mkg, 3.6 ftlb)

COWLINGSCHKADJ

COWLINGS

3-8

AIR FILTER CASECHKADJ


123456789

1011

12141111111

Remove the parts in the order listed.Refer to “SEAT”.Refer to “COWLINGS”.

Refer to “FUEL TANK”.Disconnect.Disconnect.Disconnect.Loosen.Disconnect.

Disconnect.Disconnect.


7 Nm (0.7 mkg, 5.1 ftlb)

Removing the air filter caseSeatFront cowling inner panel (left andright)Fuel tankIntake temperature sensor couplerThrottle body hoseAir induction system hoseClampCrankcase breather hoseStarter relayBattery negative leadBattery positive leadBattery coverBatteryAir filter case

EAS00043

AIR FILTER CASE

3-9

BATTERY BOX AND BATTERY BOX BRACKETCHKADJ


1

23

Battery box

Battery box bracketIgnition coil assembly

1

32


This part has to be set properly.


7 Nm (0.7 mkg, 5.1 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

NOTE:

BATTERY BOX AND BATTERY BOX BRACKET

3-10

ADJUSTING THE VALVE CLEARANCECHKADJ

NOTE:

EAS00045

ENGINEADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves.

Valve clearance adjustment should be madeon a cold engine, at room temperature.

When the valve clearance is to be measured oradjusted, the piston must be at top dead center(TDC) on the compression stroke.

1. RemoveseatRefer to “SEAT”.

front cowling inner panel (left and right)Refer to “COWLINGS”.

fuel tankRefer to “FUEL TANK”.

batteryRefer to “CHECKING AND CHARGING THEBATTERY” in chapter 3.

air filter caseRefer to “AIR FILTER CASE”.

battery boxbattery box bracketRefer to “BATTERY BOX AND BATTERYBOX BRACKET”.

throttle body assemblyRefer to “THROTTLE BODIES” in chapter 7.

air cut-off valveRefer to “AIR INDUCTION SYSTEM” inchapter 7.

radiator radiator fan motorRefer to “RADIATOR” in chapter 6.

2. Remove ignition coilsspark plugscylinder head covercylinder head cover gasketRefer to “CAMSHAFTS” in chapter 5.

3. Removepickup rotor cover 1

3-11


NOTE:

NOTE:

4. Measure:valve clearanceOut of specification Adjust.

Valve clearance (cold)Intake valve0.13 0.20 mm (0.0051 0.0079 in)Exhaust valve0.23 0.30 mm (0.0091 0.0118 in)

a. Turn the crankshaft counterclockwise.b. When piston #1 is at TDC on the compres-

sion stroke, align the TDC mark a on thepickup rotor with the crankcase mating sur-face b .

TDC on the compression stroke can be foundwhen the camshaft lobes are turned away fromeach other.

c. Measure the valve clearance with a thick-ness gauge 1 .

If the valve clearance is incorrect, record themeasured reading.

Measure the valve clearance in the followingsequence.

Valve clearance measuring sequenceCylinder #1 #2 #4 #3

A Frontd. To measure the valve clearances of the other

cylinders, starting with cylinder #1 at TDC,turn the crankshaft counterclockwise as spe-cified in the following table.

B Degrees that the crankshaft is turned counter-clockwise

C CylinderD Combustion cycle

Cylinder #2 180

Cylinder #4 360

Cylinder #3 540

3-12


NOTE:

NOTE:

NOTE:

5. Remove:camshafts

Refer to “CAMSHAFTS” in chapter 5.When removing the timing chain and cam-shafts, fasten the timing chain with a wire to re-trieve it if it falls into the crankcase.

6. Adjust:valve clearance

a. Remove the valve lifter 1 and the valve pad2 with a valve lapper 3 .

Valve lapper90890-04101

Cover the timing chain opening with a rag toprevent the valve pad from falling into thecrankcase.

Make a note of the position of each valve lifter1 and valve pad 2 so that they can beinstalled in the correct place.

b. Select the proper valve pad from the follow-ing table.

Valve padthickness range

Available valvepads

Nos.120

240

1.20(0.0472) 2.40 mm

(0.0945 in)

25 thicknesses in0.05 mm (0.002 in)

increments

The thickness a of each valve pad is markedin hundredths of millimeters on the side thattouches the valve lifter.

Since valve pads of various sizes are originallyinstalled, the valve pad number must berounded in order to reach the closest equiva-lent to the original.

3-13


NOTE:

NOTE:

c. Round off the original valve pad number ac-cording to the following table.

Last digit Rounded value

0 or 2 0

5 5

8 10

EXAMPLE:Original valve pad number = 148 (thickness =1.48 mm (0.058 in))Rounded value = 150d. Locate the rounded number of the original

valve pad and the measured valve clearancein the valve pad selection table. The pointwhere the column and row intersect is thenew valve pad number.

The new valve pad number is only an approxi-mation. The valve clearance must be measuredagain and the above steps should be repeated ifthe measurement is still incorrect.

e. Install the new valve pad 1 and the valve lift-er 2 .

Lubricate the valve pad with molybdenum dis-ulfide grease.

Lubricate the valve lifter with molybdenum dis-ulfide oil.

Install the valve lifter and the valve pad in thecorrect place.

The valve lifter must turn smoothly when ro-tated by hand.

f. Install the exhaust and intake camshafts,timing chain and camshaft caps.

Camshaft cap bolt10 Nm (1.0 mkg, 7.2 ftlb)

3-14


NOTE:Refer to “CAMSHAFTS” in chapter 5.Lubricate the camshaft bearings, camshaftlobes and camshaft journals.

First, install the exhaust camshaft.Align the camshaft marks with the camshaftcap marks.

Turn the crankshaft counterclockwise severalfull turns to seat the parts.

g. Measure the valve clearance again.h. If the valve clearance is still out of specifica-

tion, repeat all of the valve clearance adjust-ment steps until the specified clearance isobtained.

3-15


VALVE CLEARANCE (cold): 0.13 0.20 mm (0.0051 0.0079 in)Example: Installed is 175 Measured clearance is 0.27 mm (0.0106 in)Replace 175 pad with 185 pad Pad number: (example) Pad No.175 = 1.75 mm (0.0689 in) Pad No.185 = 1.85 mm (0.0728 in)

MEASURED

CLEARANCE

INSTALLED PAD NUMBER

VALVE CLEARANCE (cold): 0.23 0.30 mm (0.0091 0.0118 in)Example: Installed is 175 Measured clearance is 0.35 mm (0.0138 in)Replace 175 pad with 185 pad Pad number: (example) Pad No.175 = 1.75 mm (0.0689 in) Pad No.185 = 1.85 mm (0.0728 in)

MEASURED

CLEARANCE

INSTALLED PAD NUMBER

STANDARD CLEARANCE

STANDARD CLEARANCE

INTAKE

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 2250.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 2300.08 0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 2350.13 0.200.21 0.25 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.26 0.30 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.31 0.35 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.36 0.40 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.41 0.45 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.46 0.50 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.51 0.55 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.56 0.60 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.61 0.65 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.66 0.70 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.71 0.75 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.76 0.80 180 185 190 195 200 205 210 215 220 225 230 235 2400.81 0.85 185 190 195 200 205 210 215 220 225 230 235 2400.86 0.90 190 195 200 205 210 215 220 225 230 235 2400.91 0.95 195 200 205 210 215 220 225 230 235 2400.96 1.00 200 205 210 215 220 225 230 235 2401.01 1.05 205 210 215 220 225 230 235 2401.06 1.10 210 215 220 225 230 235 2401.11 1.15 215 220 225 230 235 2401.16 1.20 220 225 230 235 2401.21 1.25 225 230 235 2401.26 1.30 230 235 2401.31 1.35 235 2401.36 1.40 240

EXHAUST

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 2150.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 2200.08 0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 2250.13 0.17 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 2300.18 0.22 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 2350.23 0.300.31 0.35 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.36 0.40 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.41 0.45 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.46 0.50 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.51 0.55 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.56 0.60 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.61 0.65 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.66 0.70 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.71 0.75 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.76 0.80 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.81 0.85 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.86 0.90 180 185 190 195 200 205 210 215 220 225 230 235 2400.91 0.95 185 190 195 200 205 210 215 220 225 230 235 2400.96 1.00 190 195 200 205 210 215 220 225 230 235 2401.01 1.05 195 200 205 210 215 220 225 230 235 2401.06 1.10 200 205 210 215 220 225 230 235 2401.11 1.15 205 210 215 220 225 230 235 2401.16 1.20 210 215 220 225 230 235 2401.21 1.25 215 220 225 230 235 2401.26 1.30 220 225 230 235 2401.31 1.35 225 230 235 2401.36 1.40 230 235 2401.41 1.45 235 2401.46 1.50 240

3-16

ADJUSTING THE VALVE CLEARANCE/SYNCHRONIZING THE THROTTLE BODIES

CHKADJ

NOTE:

NOTE:

NOTE:

7. Install:all removed parts


SYNCHRONIZING THE THROTTLE BODIES

Prior to synchronizing the throttle bodies, thevalve clearance and the engine idling speedshould be properly adjusted and the ignition tim-ing should be checked.

1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

2. Remove:seatRefer to “SEAT”.

front cowling inner panel (left and right)Refer to “COWLINGS”



3. Install:vacuum gauge 1(onto the synchronizing hose 2 )

Vacuum gauge90890-03094, YU-08030

4. Install:air filter caseRefer to “AIR FILTER CASE”.


changing the meter display.Refer to “FEATURES” in chapter 1.

5. Start the engine and let it warm up for severalminutes.

3-17

SYNCHRONIZING THE THROTTLE BODIESCHKADJ

NOTE:

CAUTION:

NOTE:

6. Measure:engine idling speedOut of specification Adjust.Refer to “ADJUSTING THE ENGINE IDLINGSPEED”.

Engine idling speed1,250 1,350 r/min

7. Adjust: throttle body synchronization

a. With throttle body #1 as standard, adjustthrottle bodies #2, #3, and #4 using the airscrews 1 .#1 2 , #2 3 , #3 4 , #4 5

After each step, rev the engine two or threetimes, each time for less than a second, andcheck the synchronization again.

If the air screw is removed, turn the screw 3/4turn in and be sure to synchronize the throttlebody.

Do not use the throttle valve adjustingscrews to adjust the throttle body synchro-nization.

Vacuum pressure at engine idling speed

29 kPa(218 mmHg, 8.5827 inHg)

The difference in vacuum pressure betweentwo throttle bodies should not exceed 1.33 kPa(10 mmHg, 0.39 inHg).

3-18

ADJUSTING THE ENGINE IDLING SPEEDCHKADJ

NOTE:

a

b

EAS00052

ADJUSTING THE ENGINE IDLING SPEED

Prior to adjusting the engine idling speed, thethrottle bodies synchronization should be ad-justed properly, the air filter element should beclean, and the engine should have adequatecompression.

1. Start the engine and let it warm up for severalminutes.

2. Check:engine idling speedOut of specification Adjust.

Engine idling speed1250 1350 r/min

3. Adjust:engine idling speed

a. Turn the idle adjusting screw 1 in directiona or b until the specified engine idlingspeed is obtained.

Direction Engine idling speed isincreased.

Direction Engine idling speed isdecreased.

4. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY”.

Throttle cable free play(at the flange of the throttle grip)

3 5 mm (0.12 0.20 in)

3-19

ADJUSTING THE THROTTLE CABLE FREE PLAYCHKADJ

NOTE:

NOTE:

a

b

NOTE:

EAS00055

ADJUSTING THE THROTTLE CABLE FREEPLAY

Prior to adjusting the throttle cable free play, theengine idling speed and throttle bodies synchro-nization should be adjusted properly.

1. Check: throttle cable free play aOut of specification Adjust.

Throttle cable free play(at the flange of the throttle grip)

3 5 mm (0.12 0.20 in)

2. Remove:seatRefer to “SEAT”.





3. Adjust: throttle cable free play

When the throttle is opened, the acceleratorcable 1 is pulled.

Throttle bodya. Loosen the locknut 2 on the decelerator

cable.b. Turn the adjusting nut 3 in direction a or b

to take up any slack on the decelerator cable.

Direction Throttle cable free play isincreased.

Direction Throttle cable free play isdecreased.

c. Tighten the locknuts.

If the specified throttle cable free play cannot beobtained on the carburetor side of the cable, usethe adjusting nut on the handlebar side.

3-20

ADJUSTING THE THROTTLE CABLE FREE PLAYCHKADJ

a

b

WARNING

NOTE:

NOTE:

Handlebar sidea. Loosen the locknut 1 .b. Turn the adjusting nut 2 in direction a or b

until the specified throttle cable free play isobtained.

Direction Throttle cable free play isincreased.

Direction Throttle cable free play isdecreased.

c. Tighten the locknut.4. Install:battery assemblyRefer to “CHECKING AND CHARGING THEBATTERY” in chapter 3.




seatRefer to “SEAT”.

After adjusting the throttle cable free play,start the engine and turn the handlebar tothe right and to the left to ensure that thisdoes not cause the engine idling speed tochange.

ADJUSTING THE EXHAUST GAS VOLUME

Be sure to set the carbon monoxide density tostandard, and then adjust the exhaust gas.

1. Turn the main switch to “OFF” and enginestop switch “ON”.

2. While keeping the “SELECT” and “RESET”buttons pressed simultaneously, turn “ON”the main switch (keep them pressed for 8 se-conds or more).

All indications on the meter disappear exceptthe clock and trip indications.

Letters “dIAG” appear on the odo meter LCD.

3-21

ADJUSTING THE EXHAUST GAS VOLUMECHKADJ

NOTE:

NOTE:

3. Using the “SELECT” button, select either theCo adjustment mode (which appears as“Co”) or the diagnosis mode (which appearsas “dIAG”)

4. After “Co” appears as a result of pressing the“SELECT” button, simultaneously press the“SELECT” and “RESET” buttons for 2 se-conds or more to excute the selection.

5. Press the “SELECT” or “RESET” buttons toselect the “C1” or “C2”.C1=“#1” and “#4”C2=“#2” and “#3”

The adjustment cylinder appears on the odo-meter LCD.“RESET” button = decrement“SELECT” button = increment

6. Execute the selection of the cylinder by si-multaneously pressing the “SELECT” and“RESET” buttons for approximately 2 se-conds.

7. After selecting the adjustment cylinder,change the “Co” adjustment volume bypressing the “SELECT” and “RESET” but-tons.

The Co adjustment volume appears on theodo meter LCD.“RESET” button = decrement“SELECT” button = increment

8. The selection is executed upon releasing thefinger from the switch.

9. Simultaneously press the “SELECT” and“RESET” buttons to return to the cylinderselection. (step 5)

10. Cancel the mode by turning “OFF” the mainswitch.

3-22

A

B

CHECKING THE SPARK PLUGSCHKADJ

CAUTION:

EAS00059

CHECKING THE SPARK PLUGSThe following procedure applies to all of thespark plugs.1. Remove: radiator lower bolt 1 radiator lower hose bracket bolt 2

2. Remove:spark plug capsspark plugs

A Right side #1 and #2 and #3B Left side #4

Before removing the spark plugs, blow awayany dirt accumulated in the spark plug wellswith compressed air to prevent it from fal-ling into the cylinders.

3. Check:spark plug typeIncorrect Change.

Spark plug type (manufacturer)CR9EK (NGK)

4. Check:electrode 1Damage/wear Replace the spark plug.

insulator 2Abnormal color Replace the spark plug.Normal color is medium-to-light tan.

5. Clean:spark plug(with a spark plug cleaner or wire brush)

6. Measure:spark plug gap a(with a wire Thickness gauge)Out of specification Regap.

Spark plug gap0.6 0.7 mm (0.0236 0.0276 in)

3-23

CHECKING THE SPARK PLUGS/MEASURING THE COMPRESSION PRESSURE

CHKADJ

18 Nm (1.8 mkg, 13 ftlb)

NOTE:

NOTE:

7. Install:spark plugspark plug caps

Before installing the spark plug, clean the sparkplug and gasket surface.

8. Install: radiator lower hose bracket bolt radiator lower bolt

EAS00065

MEASURING THE COMPRESSION PRESSUREThe following procedure applies to all of the cyl-inders.

Insufficient compression pressure will result in aloss of performance.

1. Measure:valve clearanceOut of specification Adjust.Refer to “ADJUSTING THE VALVE CLEAR-ANCE”.

2. Start the engine, warm it up for several min-utes, and then turn it off.

3. Remove: rider seatRefer to “SEAT”.

front cowling inner panel (letf and right)Refer to “COWLINGS”.




battery boxbattery box bracketRefer to “BATTERY BOX AND BATTERYBOX BRACKET”.

heat protector plate4. Remove:cover ignition coilsspark plug capsspark plugs

3-24

MEASURING THE COMPRESSION PRESSURECHKADJ

CAUTION:

WARNING

NOTE:

Before removing the spark plugs, use com-pressed air to blow away any dirt accumu-lated in the spark plug wells to prevent itfrom falling into the cylinders.

5. Install:compression gauge 1adapter

Compression gauge90890-03081, YU-33223

Adapter90890-04136

6. Measure:compression pressureOut of specification Refer to steps (c) and(d).

Compression pressure (at sea level)

Minimum1,350 kPa (13.50 kg/cm2,13.50 bar, 191.87 psi)

Standard1,550 kPa (15.50 kg/cm2,15.50 bar, 220.46 psi)

Maximum1,736 kPa (17.36 kg/cm2,17.36 bar, 246.92 psi)

a. Turn the main switch to “ON”.b. With the throttle wide open, crank the engine

until the reading on the compression gaugestabilizes.

To prevent sparking, ground all spark plugleads before cranking the engine.

The difference in compression pressure be-tween cylinders should not exceed 100 kPa (1kg/cm2, 1 bar, 14.22 psi).

c. If the compression pressure is above themaximum specification, check the cylinderhead, valve surfaces and piston crown forcarbon deposits.Carbon deposits Eliminate.

3-25

MEASURING THE COMPRESSION PRESSURECHKADJ

18 Nm (1.8 mkg, 13 ftlb)

d. If the compression pressure is below theminimum specification, pour a teaspoonful ofengine oil into the spark plug bore and mea-sure again.Refer to the following table.

Compression pressure(with oil applied into the cylinder)

Reading Diagnosis

Higher thanwithout oil

Piston ring(s) wearor damage Repair.

Same as withoutoil

Piston, valves,cylinder head gasket or piston possibly defective Repair.

7. Install:spark plug

8. Install:spark plug caps ignition coils

9. Install:heat protector platebattery box bracketbattery boxRefer to “BATTERY BOX AND BATTERYBOX BRACKET”.




front cowling inner panel (letf and right)Refer to “COWLINGS”.

rider seatRefer to “SEAT”.

3-26

CHECKING THE ENGINE OIL LEVELCHKADJ

NOTE:

CAUTION:

EAS00069

CHECKING THE ENGINE OIL LEVEL1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.Make sure the motorcycle is upright.


3. Check:engine oil levelThe engine oil level should be between theminimum level mark a and maximum levelmark b .Below the minimum level mark Add therecommended engine oil to the proper level.

Recommended oilRefer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures.

API standardSE or higher grade

ACEA standardG4 or G5

Engine oil also lubricates the clutch andthe wrong oil types or additives couldcause clutch slippage. Therefore, do notadd any chemical additives or use engineoils with a grade of CD a or higher and donot use oils labeled “ENERGY CONSERV-ING II” b or higher.

Do not allow foreign materials to enter thecrankcase.

3-27

CHECKING THE ENGINE OIL LEVEL/CHANGING THE ENGINE OIL

CHKADJ

NOTE:

NOTE:

Before checking the engine oil level, wait a fewminutes until the oil has settled.


5. Check the engine oil level again.

Before checking the engine oil level, wait a fewminutes until the oil has settled.

EAS00074

CHANGING THE ENGINE OIL1. Start the engine, warm it up for several min-

utes, and then turn it off.2. Place a container under the engine oil drain

bolt.

3. Remove:engine oil filler cap 1engine oil drain bolt 2(along with the gasket)

4. Drain:engine oil(completely from the crankcase)

3-28

CHANGING THE ENGINE OILCHKADJ

CAUTION:

43 Nm (4.3 mkg, 31 ftlb)

5. If the oil filter cartridge is also to be replaced,perform the following procedure.

a. Remove the oil filter cartridge 1 with an oilfilter wrench 2 .

Oil filter wrench90890-01426, YU-38411

b. Lubricate the O-ring 3 of the new oil filtercartridge with a thin coat of engine oil.

Make sure the O-ring 3 is positioned cor-rectly in the groove of the oil filter cartridge.

c. Tighten the new oil filter cartridge to specifi-cation with an oil filter wrench.

Oil filter cartridge17 Nm (1.7 mkg, 12 ftlb)

6. Replace:engine oil drain bolt gasket New

7. Install:engine oil drain bolt(along with the new gasket)

8. Fill:crankcase(with the specified amount of the recom-mended engine oil)

QuantityTotal amount

3.4 L (2.99 Imp qt, 3.59 US qt)Without oil filter cartridgereplacement

2.5 L (2.20 Imp qt, 2.64 US qt)With oil filter cartridgereplacement

2.8 L (2.47 Imp qt, 2.96 US qt)

3-29

CHANGING THE ENGINE OIL/MEASURING THE ENGINE OIL PRESSURE

CHKADJ

CAUTION:

WARNING

9. Install:engine oil filler cap


11. Check:engine (for engine oil leaks)

12. Check:engine oil levelRefer to “CHECKING THE ENGINE OILLEVEL”.

EAS00077

MEASURING THE ENGINE OIL PRESSURE1. Check:engine oil levelBelow the minimum level mark Add therecommended engine oil to the proper level.


When the engine is cold, the engine oil willhave a higher viscosity, causing the engineoil pressure to increase. Therefore, be sureto measure the engine oil pressure afterwarming up the engine.

3. Remove:oil gallery bolt 1

The engine, muffler and engine oil are ex-tremely hot.

4. Install:oil pressure gauge 1adapter 2

Pressure gauge90890-03153, YU-03153

Oil pressure adapter90890-03139

3-30

MEASURING THE ENGINE OIL PRESSURECHKADJ

NOTE:

8 Nm (0.8 mkg, 5.8 ftlb)

5. Measure:engine oil pressure(at the following conditions)

Engine oil pressure240 kPa(2.4 kg/cm2, 2.4 bar, 34.1 psi)

Engine speedApprox. 6,600 r/min

Engine oil temperature96C (205F)

Regarding the oil pressure as its own data mayfluctuate depending on the oil temperature andviscosity, the oil pressure may fluctuate whenmeasuring. The following data should be usedonly as a reference when measuring the engineoil pressure.

Engine oil pressure Possible causes

Below ifi i

Faulty oil pumpspecification Clogged oil filter

Leaking oil passage

Broken or damaged oil seal

Above specification

Leaking oil passage

Faulty oil filter

Oil viscosity too high

6. Install:oil gallery bolt 1

3-31

ADJUSTING THE CLUTCH CABLE FREE PLAYCHKADJ

c

b

NOTE:

a

b

EAS00078

ADJUSTING THE CLUTCH CABLE FREE PLAY1. Check:clutch cable free play aOut of specification Adjust.

Clutch cable free play (at the end of the clutch lever)

10 15 mm (0.39 0.59 in)

2. Adjust:clutch cable free play

Handlebar sidea. Turn the adjusting dial 1 in direction b or c

until the specified clutch cable free play is ob-tained.

Direction Clutch cable free play isincreased.

Direction Clutch cable free play isdecreased.

If the specified clutch cable free play cannot beobtained on the handlebar side of the cable, usethe adjusting nut on the engine side.

Engine side3. Remove:seatRefer to “SEAT”.




a. Loosen the locknuts 1 .b. Turn the adjusting nut 2 in direction a or b

until the specified clutch cable free play is ob-tained.

Direction Clutch cable free play isincreased.

Direction Clutch cable free play isdecreased.

d. Tighten the locknuts.

3-32

ADJUSTING THE CLUTCH CABLE FREE PLAY/CLEANING THE AIR FILTER ELEMENT

CHKADJ

CAUTION:

4. Install:air filter caseRefer to “AIR FILTER CASE”.




EAS00086

CLEANING THE AIR FILTER ELEMENT1. Remove: rider seatRefer to “SEAT”.



2. Remove:air filter case cover 1air filter element 2

3. Clean:air filter element 2

4. Check:air filter elementDamage Replace.

5. Install:air filter element 2air filter case cover 1

Never operate the engine without the air fil-ter element installed. Unfiltered air willcause rapid wear of engine parts and maydamage the engine. Operating the enginewithout the air filter element will also affectthe throttle bodies tuning, leading to poorengine performance and possible overheat-ing.

3-33

CLEANING THE AIR FILTER ELEMENT/CHECKING THE THROTTLE BODY JOINTS

CHKADJ

NOTE:When installing the air filter element into the airfilter case cover, make sure their sealing sur-faces are aligned to prevent any air leaks.

6. Install: fuel tankRefer to “FUEL TANK”.



EAS00095

CHECKING THE THROTTLE BODY JOINTSThe following procedure applies to all of thethrottle body joints and intake manifolds.1. Remove: throttle bodiesRefer to “THROTTLE BODIES” in chapter 7.

2. Check: throttle body joints 1Cracks/damage Replace.

3. Install: throttle bodiesRefer to “THROTTLE BODIES” in chapter 7.

3-34

CHECKING THE FUEL AND BREATHER HOSES/CHECKING THE CRANKCASE BREATHER HOSE

CHKADJ

NOTE:

CAUTION:

EAS00096

CHECKING THE FUEL AND BREATHER HOSESThe following procedure applies to all of the fueland breather hoses.1. Remove: rider seatRefer to “SEAT”.

front cowling inner panel (left and right)Refer to “COWLINGS”


2. Check:breather hose 1 fuel hose 2Cracks/damage Replace.Loose connection Connect properly.

Before removing the fuel hose, place a fewrags in the area under where it will be re-moved.

There is a white mark on the fuel tank breatherhose.Refer to “CABLE ROUTING” in chapter 2.




EAS00098

CHECKING THE CRANKCASE BREATHER HOSE1. Remove: rider seatRefer to “SEAT”.



2. Check:crankcase breather hose 1Cracks/damage Replace.Loose connection Connect properly.

Make sure the crankcase breather hose isrouted correctly.

3-35

CHECKING THE CRANKCASE BREATHER HOSE/CHECKING THE EXHAUST SYSTEM

CHKADJ




EAS00099

CHECKING THE EXHAUST SYSTEMThe following procedure applies to all of the ex-haust pipes and gaskets.1. Remove: radiatorRefer to “RADIATOR” in chapter 6.

2. Check:exhaust pipe 1catalyst pipe 2muffler 3Cracks/damage Replace.

gasket 4Exhaust gas leaks Replace.

3. Check: tightening torque

Exhaust pipe nut 520 Nm (2.0 mkg, 15 ftlb)

Catalyst joint bolt 620 Nm (2.0 mkg, 15 ftlb)

Muffler joint bolt 7Muffler and muffler stay 8

20 Nm (2.0 mkg, 15 ftlb)Exhaust pipe and exhaust pipestay 9

20 Nm (2.0 mkg, 15 ftlb)Catalyst pipe and catalyst pipestay 10

20 Nm (2.0 mkg, 15 ftlb)

4. Install: radiatorRefer to “RADIATOR” in chapter 6.

3-36

CHECKING THE COOLANT LEVELCHKADJ

NOTE:

CAUTION:

NOTE:

EAS00102

CHECKING THE COOLANT LEVEL1. Stand the motorcycle on a level surface.


2. Check:coolant levelThe coolant level should be between themaximum level mark a and minimum levelmark b .Below the minimum level mark Add therecommended coolant to the proper level.

Adding water instead of coolant lowers theantifreeze content of the coolant. If water isused instead of coolant check, and if nec-essary, correct the antifreeze concentra-tion of the coolant.

Use only distilled water. However, if dis-tilled water is not available, soft water maybe used.


4. Check:coolant level

Before checking the coolant level, wait a fewminutes until it settles.

3-37

CHECKING THE COOLING SYSTEM/CHANGING THE COOLANT

CHKADJ

EAS00104

CHECKING THE COOLING SYSTEM1. Check: radiator 1 radiator inlet hose 2 radiator outlet hose 3oil cooler 4oil cooler inlet hose 5oil cooler outlet hose 6water jacket outlet joint 7water jacket hose 8water pump outlet pipe 9water pump outlet hose 10

Cracks/damage Replace.Refer to “COOLING SYSTEM” in chapter 6.

EAS00105

CHANGING THE COOLANT1. Remove:seatRefer to “SEAT”.



2. Remove:coolant reservoir tank

3-38

CHANGING THE COOLANTCHKADJ

CAUTION:

10 Nm (1.0 mkg, 7.2 ftlb)

3. Disconnect:coolant reservoir cap 1

4. Drain:coolant(from the coolant reservoir tank)

5. Remove: radiator cap lock bolt 1 radiator cap 2

A hot radiator is under pressure. Therefore,do not remove the radiator cap when the en-gine is hot. Scalding hot fluid and steam maybe blown out, which could cause serious in-jury. When the engine has cooled, open theradiator cap as follows:Place a thick rag or a towel over the radiatorcap and slowly turn the radiator cap coun-terclockwise toward the detent to allow anyresidual pressure to escape. When the his-sing sound has stopped, press down on theradiator cap and turn it counterclockwise toremove.

The following procedure applies to all of thecoolant drain bolts and copper washers.6. Remove:coolant drain bolt (water pump) 1(along with the copper washer)

7. Drain:coolant(from the engine and radiator)

8. Check:copper washer 1 New(coolant drain bolt-water pump 2 )

9. Install:coolant drain bolt (water pump)(with copper washer)

3-39


WARNING

CAUTION:

10. Install:coolant reservoir tank

11. Connect:coolant reservoir hose

12. Fill:cooling system(with the specified amount of the recom-mended coolant)

Recommended antifreezeHigh-quality ethylene glycol antifreeze containing corrosioninhibitors for aluminum engines

Mixing ratio1:1 (antifreeze:water)

QuantityTotal amount

2.0 L (1.76 Imp qt, 2.11 US qt)

Coolant reservoir capacity0.27 L (0.24 Imp qt, 0.29 US qt)

Handling notes for coolantCoolant is potentially harmful and should behandled with special care.

If coolant splashes in your eyes, thorough-ly wash them with water and consult a doc-tor.

If coolant splashes on your clothes, quick-ly wash it away with water and then withsoap and water.

If coolant is swallowed, induce vomitingand get immediate medical attention.

Adding water instead of coolant lowers theantifreeze content of the coolant. If water isused instead of coolant check, and if nec-essary, correct the antifreeze concentra-tion of the coolant.

3-40


NOTE:

Use only distilled water. However, if dis-tilled water is not available, soft water maybe used.

If coolant comes into contact with paintedsurfaces, immediately wash them with wa-ter.

Do not mix different types of antifreeze.

13. Install: radiator cap

14. Fill:coolant reservoir tank(with the recommended coolant to the maxi-mum level mark a )

15. Install:coolant reservoir cap

16. Start the engine, warm it up for several min-utes, and then stop it.

17. Check:coolant levelRefer to “CHECKING THE COOLANT LEV-EL”.

Before checking the coolant level, wait a fewminutes until the coolant has settled.




3-41

ADJUSTING THE FRONT BRAKECHKADJ

NOTE:

a

a

WARNING

CAUTION:

EAS00107

CHASSISADJUSTING THE FRONT BRAKE1. Adjust:brake lever position(distance a from the throttle grip to the brakelever)

While pushing the brake lever forward, turn theadjusting dial 1 until the brake lever is in thedesired position.

Be sure to align the setting on the adjusting dialwith the arrow mark 2 on the brake lever hold-er.

Position #1 Distance is the largest.

Position #5 Distance is the smallest.

After adjusting the brake lever position,make sure the pin on the brake lever holderis firmly inserted in the hole in the adjust-ing dial.

A soft or spongy feeling in the brake levercan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brakesystem. Air in the brake system will consid-erably reduce in loss of control and possi-bly an accident. Therefore, check and ifnecessary, bleed the brake system.

After adjusting the brake lever position,make sure there is no brake drag.

3-42

ADJUSTING THE REAR BRAKECHKADJ

a

b

WARNING

WARNING

CAUTION:

EAS00110

ADJUSTING THE REAR BRAKE1. Check:brake pedal position(distance a from the top of the rider footrestto the top of the brake pedal)Out of specification Adjust.

Brake pedal position (below thetop of the rider footrest)

25.8 mm (1.02 in)

2. Adjust:brake pedal position

a. Loosen the locknut 1 .b. Turn the adjusting bolt 2 in direction a or b

until the specified brake pedal position is ob-tained.

Direction Brake pedal is raised.

Direction Brake pedal is lowered.

After adjusting the brake pedal position,check that the end of the adjusting bolt c isvisible through the hole d .

c. Tighten the locknut 1 to specification.

Locknut18 Nm (1.8 mkg, 13 ftlb)

A soft or spongy feeling in the brake pedalcan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brakesystem. Air in the brake system will consid-erably reduce braking performance andcould result in loss of control and possiblyan accident. Therefore, check and, if neces-sary, bleed the brake system.

After adjusting the brake pedal position,make sure there is no brake drag.

3-43

A

B

ADJUSTING THE REAR BRAKE/CHECKING THE BRAKE FLUID LEVEL

CHKADJ

NOTE:

WARNING

3. Adjust: rear brake light switchRefer to “ADJUSTING THE REAR BRAKELIGHT SWITCH”.

EAS00115

CHECKING THE BRAKE FLUID LEVEL1. Stand the motorcycle on a level surface.


2. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.

Recommended brake fluidDOT 4

A Front brakeB Rear brake

Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.

Refill with the same type of brake fluid thatis already in the system. Mixing brakefluids may result in a harmful chemicalreaction, leading to poor brake perfor-mance.

When refilling, be careful that water doesnot enter the brake fluid reservoir. Waterwill significantly lower the boiling point ofthe brake fluid and could cause vapor lock.

3-44

A

B

CHECKING THE BRAKE FLUID LEVEL/CHECKING THE FRONT AND REAR BRAKE PADS

CHKADJ

CAUTION:

NOTE:

Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.

In order to ensure a correct reading of the brakefluid level, make sure the top of the brake fluidreservoir is horizontal.

EAS00118

CHECKING THE FRONT AND REAR BRAKEPADSThe following procedure applies to all of thebrake pads.1. Operate the brake.

2. Check: front brake pad rear brake padBrake pad wear limit a , bWear limit reached Replace the brakepads as a set.Refer to “FRONT AND REAR BRAKES” inchapter 4.

A Front brakeB Rear brake

3-45

ADJUSTING THE REAR BRAKE LIGHT SWITCH/CHECKING THE FRONT AND REAR BRAKE HOSES

CHKADJ

A

B

NOTE:

a

b

EAS00128

ADJUSTING THE REAR BRAKE LIGHTSWITCH

The rear brake light switch is operated by move-ment of the brake pedal. The rear brake lightswitch is properly adjusted when the brake lightcomes on just before the braking effect starts.

1. Check: rear brake light operation timingIncorrect Adjust.

2. Adjust: rear brake light operation timing

a. Hold the main body 1 of the rear brake lightswitch so that it does not rotate and turn theadjusting nut 2 in direction a or b until therear brake light comes on at the proper time.

Direction Brake light comes on sooner.

Direction Brake light comes on later.

EAS00131

CHECKING THE FRONT AND REAR BRAKEHOSESThe following procedure applies to all of thebrake hoses and brake hose clamps.1. Check:brake hoseCracks/damage/wear Replace.

A FrontB Rear2. Check:brake hose clampLoose Tighten the clamp bolt.

3. Hold the motorcycle upright and apply thebrake several times.

4. Check:brake hoseBrake fluid leakage Replace the damagedhose.Refer to “FRONT AND REAR BRAKES” inchapter 4.

3-46

A

B

BLEEDING THE HYDRAULIC BRAKE SYSTEMCHKADJ

WARNING

NOTE:

NOTE:

EAS00135

BLEEDING THE HYDRAULIC BRAKESYSTEM

Bleed the hydraulic brake system whenev-er: the system is disassembled.a brake hose is loosened, disconnected orreplaced.

the brake fluid level is very low.brake operation is faulty.

Be careful not to spill any brake fluid or allowthe brake fluid reservoir to overflow.

When bleeding the hydraulic brake system,make sure there is always enough brake fluidbefore applying the brake. Ignoring this pre-caution could allow air to enter the hydraulicbrake system, considerably lengthening thebleeding procedure.

If bleeding is difficult, it may be necessary to letthe brake fluid settle for a few hours. Repeatthe bleeding procedure when the tiny bubblesin the hose have disappeared.

1. Bleed:hydraulic brake system

a. Fill the brake fluid reservoir to the proper lev-el 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 .A FrontB Reard. Place the other end of the hose into a con-

tainer.e. Slowly apply the brake several times.f. Fully pull the brake lever or fully press down

the brake pedal and hold it in position.g. Loosen the bleed screw.

Loosening the bleed screw will release the pres-sure and cause the brake lever to contact thethrottle grip or the brake pedal to fully extend.

3-47

BLEEDING THE HYDRAULIC BRAKE SYSTEM/ADJUSTING THE SHIFT PEDAL

CHKADJ

WARNING

a

b

h. Tighten the bleed screw and then release thebrake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the airbubbles have disappeared from the brakefluid in the plastic hose.

j. Tighten the bleed screw to specification.

Bleed screw6 Nm (0.6 mkg, 4.3 ftlb)

k. Fill the brake fluid reservoir to the proper lev-el with the recommended brake fluid.Refer to “CHECKING THE BRAKE FLUIDLEVEL”.

After bleeding the hydraulic brake system,check the brake operation.

EAS00136

ADJUSTING THE SHIFT PEDAL1. Check:shift pedal positionAlign the center of shift pedal 1 and centerof footrest bracket bolt 2 in a straight line.Incorrect Adjust.

2. Adjust:shift pedal position

a. Loosen both locknuts 2 .b. Turn the shift rod 3 in direction a or b to

obtain the correct shift pedal position.

Direction Shift pedal is raised.

Direction Shift pedal is lowered.

c. Tighten both locknuts.

3-48

ADJUSTING THE DRIVE CHAIN SLACKCHKADJ

NOTE:

CAUTION:

WARNING

NOTE:

a

b

NOTE:

EAS00140

ADJUSTING THE DRIVE CHAIN SLACK

The drive chain slack must be checked at thetightest point on the chain.

A drive chain that is too tight will overloadthe engine and other vital parts, and one thatis too loose can skip and damage the swin-garm or cause an accident. Therefore, keepthe drive chain slack within the specifiedlimits.

1. Stand the motorcycle on a level surface.

Securely support the motorcycle so thatthere is no danger of it falling over.

Place the motorcycle on a suitable stand so thatthe rear wheel is elevated.

2. Spin the rear wheel several times and findthe tightest position of drive chain.

3. Check:drive chain slack aOut of specification Adjust.

Drive chain slack45 55 mm (1.77 2.17 in)

4. Adjust:drive chain slack

a. Loosen the wheel axle nut 1 .b. Loosen both locknuts 2 .c. Turn both adjusting nuts 3 in direction a or

b until the specified drive chain slack is ob-tained.

Direction Drive chain is tightened.

Direction Drive chain is loosened.

To maintain the proper wheel alignment, adjustboth sides evenly.

3-49

ADJUSTING THE DRIVE CHAIN SLACK/LUBRICATING THE DRIVE CHAIN

CHKADJ

f. Tighten both locknuts to specification.

Locknut16 Nm (1.6 mkg, 12 ftlb)

g. Tighten the wheel axle nut to specification.

Wheel axle nut120 Nm (12 mkg, 87 ftlb)

EAS00142

LUBRICATING THE DRIVE CHAINThe drive chain consists of many interactingparts. If the drive chain is not maintained proper-ly, it will wear out rapidly. Therefore, the drivechain should be serviced, especially when themotorcycle is used in dusty areas.This motorcycle has a drive chain with smallrubber O-rings between each side plate. Steamcleaning, high-pressure washing, certain sol-vents, and the use of a coarse brush can dam-age these O-rings. Therefore, use only kerosineto clean the drive chain. Wipe the drive chain dryand thoroughly lubricate it with engine oil orchain lubricant that is suitable for O-ring chains.Do not use any other lubricants on the drivechain since they may contain solvents thatcould damage the O-rings.

Recommended lubricantEngine oil or chain lubricant suitable forO-ring chains

3-50

CHECKING AND ADJUSTING THE STEERING HEADCHKADJ

WARNING

NOTE:

NOTE:

EAS00146

CHECKING AND ADJUSTING THESTEERING HEAD1. Stand the motorcycle on a level surface.


Place the motorcycle on a suitable stand so thatthe front wheel is elevated.

2. Check:steering headGrasp the bottom of the front fork legs andgently rock the front fork.Binding/ looseness Adjust the steeringhead.

3. Remove:upper bracketRefer to “HANDLEBAR” and “STEERINGHEAD” in chapter 4.

4. Adjust:steering head

a. Remove the lock washer 1 , the upper ringnut 2 , and the rubber washer 3 .

b. Loosen the lower ring nut 4 and then tightenit to specification with a steering nut wrench5 .

Set the torque wrench at a right angle to thesteering nut wrench.

Steering nut wrench90890-01403, YU-33975

Lower ring nut(initial tightening torque)

52 Nm (5.2 mkg, 38 ftlb)

3-51

CHECKING AND ADJUSTING THE STEERING HEADCHKADJ

WARNING

NOTE:

NOTE:

c. Loosen the lower ring nut 6 completely, thentighten it to specification.

Do not overtighten the lower ring nut.

Lower ring nut(final tightening torque)

18 Nm (1.8 mkg, 13 ftlb)

d. Check the steering head for looseness orbinding by turning the front fork all the way inboth directions. If any binding is felt, removethe lower bracket and check the upper andlower bearings.Refer to “STEERING HEAD” in chapter 4.

e. Install the rubber washer 7 .f. Install the upper ring nut 8 .g. Finger tighten the upper ring nut 8 , then

align the slots of both ring nuts. If necessary,hold the lower ring nut and tighten the upperring nut until their slots are aligned.

h. Install the lock washer 9 .

Make sure the lock washer tabs a sit correctlyin the ring nut slots b .

5. Install:upper bracketRefer to “HANDLEBAR” and “STEERINGHEAD” in chapter 4.

6. Measure:steering head tension

Make sure all of the cables and wires are prop-erly routed.

a. Point the front wheel straight ahead.b. Install a plastic locking tie 1 loosely around

the end of the handlebar as shown.c. Hook a spring gauge 2 onto the plastic lock-

ing tie.d. Hold the spring gauge at a 90 angle from the

handlebar, pull the spring gauge, and thenrecord the measurement when the handle-bar starts to run.

3-52

CHECKING AND ADJUSTING THE STEERING HEAD/CHECKING THE FRONT FORK

CHKADJ

WARNING

Steering head tension200 500 g

e. Repeat the above procedure on the oppositehandlebar.

f. If the steering head tension is out of specifi-cation (both handlebars should be withinspecification), remove the upper bracket andloosen or tighten the upper ring nut.

g. Reinstall the upper bracket and measure thesteering head tension again as describedabove.

h. Repeat the above procedure until the steer-ing head tension is within specification.

i. Grasp the bottom of the front fork legs andgently rock the front fork.Binding/ looseness Adjust the steeringhead.

EAS00149

CHECKING THE FRONT FORK1. Stand the motorcycle on a level surface.


2. Check: inner tube 1Damage/scratches Replace.

oil seal 2Oil leakage Replace.

3. Hold the motorcycle upright and apply thefront brake.

4. Check: front fork operationPush down hard on the handlebar severaltimes and check if the front fork reboundssmoothly.Rough movement Repair.Refer to “FRONT FORK” in chapter 4.

3-53

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLYCHKADJ

WARNING

CAUTION:

a

b

EAS00156

ADJUSTING THE REAR SHOCKABSORBER ASSEMBLY


Spring preload

Never go beyond the maximum or minimumadjustment positions.

1. Adjust:spring preload

a. Adjust the spring preload with a ring nutwrench.

Ring nut wrench90890-01268, YU-01268

b. Turn the adjusting ring 1 in direction a orb .

c. Align the desired position on the adjustingring with the stopper 2 .

DirectionSpring preload isincreased (suspension isharder).

DirectionSpring preload isdecreased (suspension is softer).

Adjusting positionsMinimum: 1Standard: 3Maximum: 7

3-54

CHECKING THE TIRESCHKADJ

WARNING

WARNING

EAS00162

CHECKING THE TIRESThe following procedure applies to both of thetires.1. Check: tire pressureOut of specification Regulate.

The tire pressure should only be checkedand regulated when the tire temperatureequals the ambient air temperature.

The tire pressure and the suspension mustbe adjusted according to the total weight(including cargo, rider, passenger and ac-cessories) and the anticipated ridingspeed.

Operation of an overloaded motorcyclecould cause tire damage, an accident or aninjury.

NEVER OVERLOAD THE MOTORCYCLE.

Basicweight(with oiland a fullfuel tank)

207 kg (456 lb)

Maximumload* 190 kg (419 lb)

Cold tirepressure Front Rear

Up to90 kg(198 lb)load*

225 kPa(2.25 kgf/cm2,

2.25 bar,33psi)

250 kPa(2.5 kgf/cm2,

2.5 bar,35.6 psi)

90 kg 190 kg(198 419 lb)maximumload*


2.5 bar,35.6 psi)


2.9 bar,41.3 psi)

High-speedriding

225 kPa(2.25 kgf/cm2,

2.25 bar,33 psi)


2.5 bar,35.6 psi)

* Total weight of rider, passenger, cargo and ac-cessories

It is dangerous to ride with a worn-out tire.When the tire tread reaches the wear limit,replace the tire immediately.

3-55

CHECKING THE TIRESCHKADJ

WARNING

WARNING

2. Check: tire surfacesDamage/wear Replace the tire.

Minimum tire tread depth1.6 mm (0.06 in)

1 Tire tread depth2 Sidewall3 Wear indicator

Do not use a tubeless tire on a wheel de-signed only for tube tires to avoid tire fail-ure and personal injury from sudden defla-tion.

When using a tube tire, be sure to install thecorrect tube.

Always replace a new tube tire and a newtube as a set.

To avoid pinching the tube, make sure thewheel rim band and tube are centered in thewheel groove.

Patching a punctured tube is not recom-mended. If it is absolutely necessary to doso, use great care and replace the tube assoon as possible with a good quality re-placement.

A TireB Wheel

Tube wheel Tube tire only

T beless wheelTube or tubeless

Tubeless wheel tire

After extensive tests, the tires listed belowhave been approved by Yamaha Motor Co.,Ltd. for this model. The front and rear tiresshould always be by the same manufactur-er and of the same design. No guaranteeconcerning handling characteristics canbe given if a tire combination other thanone approved by Yamaha is used on thismotorcycle.

3-56

CHECKING THE TIRES/CHECKING THE WHEELSCHKADJ

WARNING

NOTE:

WARNING

NOTE:

Front tire

Manufacturer Size Model

BRIDGESTONE 120/70ZR 17M/C (58W)

BT020FGG

DUNLOP 120/70ZR 17M/C (58W)

D252F

Rear tire

Manufacturer Size Model

BRIDGESTONE 180/55ZR 17M/C (73W)

BT020RGG

DUNLOP 180/55ZR 17M/C (73W)

D252

New tires and wheels have a relatively lowgrip on the road surface until they have beenslightly worn. Therefore, approximately 100km should be traveled at normal speed be-fore any high-speed riding is done.

For tires with a direction of rotation mark 1 : Install the tire with the mark pointing in thedirection of wheel rotation.

Align the mark 2 with the valve installationpoint.

EAS00168

CHECKING THE WHEELSThe following procedure applies to both of thewheels.1. Check:wheelDamage/out-of-round Replace.

Never attempt to make any repairs to thewheel.

After a tire or wheel has been changed or re-placed, always balance the wheel.

3-57

CHECKING AND LUBRICATING THE CABLES/LUBRICATING THE LEVERS AND PEDALS/

LUBRICATING THE SIDESTAND/LUBRICATING THE CENTERSTAND

CHKADJ

WARNING

NOTE:

EAS00170

CHECKING AND LUBRICATING THECABLESThe following procedure applies to all of the in-ner and outer cables.

Damaged outer cable may cause the cable tocorrode and interfere with its movement. Re-place damaged outer cable and inner cablesas soon as possible.

1. Check:outer cableDamage Replace.

2. Check:cable operationRough movement Lubricate.

Recommended lubricantEngine oil or a suitable cablelubricant

Hold the cable end upright and pour a few dropsof lubricant into the cable sheath or use a suit-able lubricating device.

EAS00171

LUBRICATING THE LEVERS AND PEDALSLubricate the pivoting point and metal-to-metalmoving parts of the levers and pedals.

Recommended lubricantLithium-soap-based grease

EAS00172

LUBRICATING THE SIDESTANDLubricate the pivoting point and metal-to-metalmoving parts of the sidestand.


EAS00173

LUBRICATING THE CENTERSTANDLubricate the pivoting point and metal-to-metalmoving parts of the centerstand.


3-58

LUBRICATING THE REAR SUSPENSIONCHKADJ

EAS00174

LUBRICATING THE REAR SUSPENSIONLubricate the pivoting point and metal-to-metalmoving parts of the rear suspension.

Recommended lubricantMolybdenum disulfide grease

3-59

CHECKING AND CHARGING THE BATTERYCHKADJ

WARNING

CAUTION:

EAS00178

ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERY

Batteries generate explosive hydrogen gasand contain electrolyte which is made of poi-sonous and highly caustic sulfuric acid.Therefore, always follow these preventivemeasures:Wear protective eye gear when handling orworking near batteries.

Charge batteries in a well-ventilated area.Keep batteries away from fire, sparks oropen flames (e.g., welding equipment,lighted cigarettes).

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTEOUT OF REACH OF CHILDREN.

Avoid bodily contact with electrolyte as itcan cause severe burns or permanent eyeinjury.

FIRST AID IN CASE OF BODILY CONTACT:EXTERNALSkin – Wash with water.Eyes – Flush with water for 15 minutes andget immediate medical attention.

INTERNALDrink large quantities of water or milk fol-lowed with milk of magnesia, beaten egg orvegetable oil. Get immediate medical atten-tion.

This is a sealed battery. Never remove thesealing caps because the balance betweencells will not be maintained and battery per-formance will deteriorate.

Charging time, charging amperage andcharging voltage for an MF battery are dif-ferent from those of conventional batter-ies. The MF battery should be charged asexplained in the charging method illustra-tions. If the battery is overcharged, theelectrolyte level will drop considerably.Therefore, take special care when chargingthe battery.

3-60


Relationship between the open-circuit voltageand the charging time at 20C

Ope

n-ci

rcui

t vol

tage

(V

)

These values vary with the temperature, the condition ofthe battery plates, and the electrolyte level.

13.0

12.5

12.0

11.5

5 6.5 10Charging time (hours)

Ambienttemperature20C

Ope

n-ci

rcui

t vol

tage

(V

)

Charging condition of the battery (%)

NOTE:

CAUTION:

NOTE:

Since MF batteries are sealed, it is not possibleto check the charge state of the battery by mea-suring the specific gravity of the electrolyte.Therefore, the charge of the battery has to bechecked by measuring the voltage at the batteryterminals.

1. Remove: rider seatRefer to “SEAT”.



2. Disconnect:battery leads(from the battery terminals)

First, disconnect the negative battery lead1 , and then the positive battery lead 2 .

3. Remove:battery

4. Check:battery charge

a. Connect a pocket tester to the battery termi-nals.

Positive tester probe positive battery terminal

Negative tester probe negative battery terminal

The charge state of an MF battery can bechecked by measuring its open-circuit voltage(i.e., the voltage when the positive battery ter-minal is disconnected).

No charging is necessary when the open-cir-cuit voltage equals or exceeds 12.8 V.

b. Check the charge of the battery, as shown inthe charts and the following example.

Examplec. Open-circuit voltage = 12.0 Vd. Charging time = 6.5 hourse. Charge of the battery = 20 30%

3-61

ChargingAmbient temperature 20C

Ope

n-ci

rcui

t vol

tage

(V

)

Check the open-circuitvoltage.

Time (minutes)


WARNING

CAUTION:

5. Charge:battery(refer to the appropriate charging method il-lustration)

Do not quick charge a battery.

Never remove the MF battery sealing caps.Do not use a high-rate battery chargersince it forces a high-amperage currentinto the battery quickly and can cause bat-tery overheating and battery plate damage.If it is impossible to regulate the chargingcurrent on the battery charger, be carefulnot to overcharge the battery.

When charging a battery, be sure to removeit from the motorcycle. (If charging has tobe done with the battery mounted on themotorcycle, disconnect the negative bat-tery lead from the battery terminal.)

To reduce the chance of sparks, do notplug in the battery charger until the batterycharger leads are connected to the battery.

Before removing the battery charger leadclips from the battery terminals, be sure toturn off the battery charger.

Make sure the battery charger lead clipsare in full contact with the battery terminaland that they are not shorted. A corrodedbattery charger lead clip may generate heatin the contact area and a weak clip springmay cause sparks.

If the battery becomes hot to the touch atany time during the charging process, dis-connect the battery charger and let the bat-tery cool before reconnecting it. Hot batter-ies can explode!

As shown in the following illustration, theopen-circuit voltage of an MF battery stabi-lizes about 30 minutes after charging hasbeen completed. Therefore, wait 30 min-utes after charging is completed beforemeasuring the open-circuit voltage.

3-62


Measure the open-circuitvoltage prior to charging.

Connect a charged andAMP meter to the batteryand start charging.

Make sure that the currentis higher than the standardcharging current written onthe battery.

By turning the chargingvoltage adjust dial, set thecharging voltage at 20 24 V.

Adjust the voltage so that thecurrent is at the standardcharging level.

Monitor the amperage for3 5 minutes to check if thestandard charging current isreached.

Set the time according to thecharging time suitable for theopen-circuit voltage.Refer to “Battery conditionchecking steps”.

If the current does notexceed the standardcharging current after 5minutes, replace the battery.

If charging requires more than 5 hours, it is advisable to check thecharging current after a lapse of 5 hours. If there is any change in theamperage, readjust the voltage to obtain the standard chargingcurrent.

Measure the battery open-circuit voltage after leaving the batteryunused for more than 30 minutes.12.8 V or more --- Charging is complete.12.7 V or less --- Recharging is required.Under 12.0 V --- Replace the battery.

YES NO

YES

NO

NOTE:Voltage should be measured 30minutes after the machine is stopped.

NOTE:Set the charging voltage at 16 17 V.(If the setting is lower, charging will beinsufficient. If too high, the battery willbe over-charged.)

Charging method using a variable-current (voltage) charger

3-63


Measure the open-circuitvoltage prior to charging.

Connect a charger andAMP meter to the batteryand start charging.

Make sure that the currentis higher than the standardcharging current written onthe battery.

Charge the battery until the battery’scharging voltage is 15 V.

This type of battery charger cannotcharge the MF battery. A variablevoltage charger is recommended.

Measure the battery open-circuitvoltage after leaving the batteryunused for more than 30 minutes.12.8 V or more --- Charging iscomplete.12.7 V or less --- Recharging isrequired.Under 12.0 V --- Replace the battery.

Set the charging time at 20 hours(maximum).

YES NO

NOTE:Voltage should be measured 30minutes after the machine is stopped.

NOTE:

Charging method using a constant voltage charger

3-64


CAUTION:

Charging method using a variable-current(voltage) chargerCharging method using a constant voltagecharger6. Install:battery

7. Connect:battery leads(to the battery terminals)

First, connect the positive battery lead 1 ,and then the negative battery lead 2 .

8. Check:battery terminalsDirt Clean with a wire brush. Loose con-nection Connect properly.

9. Lubricate:battery terminals

Recommended lubricantDielectric grease




3-65

CHECKING THE FUSESCHKADJ

CAUTION:

NOTE:

EAS00181

CHECKING THE FUSESThe following procedure applies to all of thefuses.

To avoid a short circuit, always set the mainswitch to “OFF” when checking or replacinga fuse.

1. Remove: right side coverRefer to “COWLINGS”.

2. Check:fuse

a. Connect the pocket tester to the fuse andcheck the continuity.

Set the pocket tester selector to “Ω 1”.


b. If the pocket tester indicates “∞”, replace thefuse.

3. Replace:blown fuse

a. Set the main switch to “OFF”.b. Install a new fuse of the correct amperage

rating.c. Set on the switches to verify if the electrical

circuit is operational.d. If the fuse immediately blows again, check

the electrical circuit.

Fuses Amperagerating

Q’ty

Main 30A 1

Headlight 20A 1

Signaling system 10A 1

Ignition 10A 1

Fuel injection 10A 1

Radiatorfan motor

20A 1

Park 10A 1

Back up 10A 1

Reserve 10A, 20A, 30A 1

3-66

CHECKING THE FUSESCHKADJ

WARNING

Never use a fuse with an amperage ratingother than that specified. Improvising or us-ing a fuse with the wrong amperage ratingmay cause extensive damage to the electri-cal system, cause the lighting and ignitionsystems to malfunction and could possiblycause a fire.

4. Install: right side coverRefer to “COWLINGS”.

3-67

REPLACING THE HEADLIGHT BULBSCHKADJ

WARNING

CAUTION:

EAS00183

REPLACING THE HEADLIGHT BULBSThe following procedure applies to both of theheadlight bulbs.1. Remove: front cowling inner panelsRefer to “COWLINGS”.

2. Disconnect:headlight bulb coverheadlight coupler 1

3. Remove:headlight bulb holder 1

4. Remove:headlight bulb 2

Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

5. Install:headlight bulb NewSecure the new headlight bulb with the head-light bulb holder.

Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverselyaffected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.

6. Install:headlight bulb holder

7. Install:headlight bulb cover

8. Connect:headlight coupler

9. Install: front cowling inner panelsRefer to “COWLINGS”.

3-68

ADJUSTING THE HEADLIGHT BEAMSCHKADJ

a

b

a

b

a

b

EAS00185

ADJUSTING THE HEADLIGHT BEAMSThe following procedure applies to both of theheadlights.1. Adjust:headlight beam (vertically)

a. Turn the adjusting screw 1 in direction a orb .

Direction Headlight beam is raised.

Direction Headlight beam is lowered.

2. Adjust:headlight beam (horizontally)

a. Turn the adjusting knob 2 in direction a orb .

Left headlight

Direction Headlight beam moves tothe right.

Direction Headlight beam moves tothe left.

Right headlight

Direction Headlight beam moves tothe left.

Direction Headlight beam moves tothe right.

CHAS

CHAPTER 4CHASSIS

FRONT WHEEL AND BRAKE DISCS 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE DISCS 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT WHEEL 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7. . . . . . . . .

REAR WHEEL AND BRAKE DISC 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE DISC AND REAR WHEEL SPROCKET 4-10. . . . . . . . . REMOVING THE REAR WHEEL 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL DRIVE HUB 4-13. . . . . . . . . . . . . . . . . CHECKING AND REPLACING THE REAR WHEELSPROCKET 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE REAR WHEEL 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR WHEEL STATIC BALANCE 4-15. . . . . . . . . . .

FRONT AND REAR BRAKES 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE PADS 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FRONT BRAKE PADS 4-19. . . . . . . . . . . . . . . . . . . . . REPLACING THE REAR BRAKE PADS 4-21. . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER 4-23. . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE MASTER CYLINDER 4-26. . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4-28. . CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-29. . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-32. . . . . . . FRONT BRAKE CALIPERS 4-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE CALIPER 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE CALIPERS 4-38. . . . . . . . . . . DISASSEMBLING THE REAR BRAKE CALIPER 4-39. . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE CALIPERS 4-40. . . . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE REAR BRAKECALIPER 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAS

FRONT FORK 4-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK LEGS 4-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT FORK LEGS 4-48. . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT FORK LEGS 4-48. . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK LEGS 4-50. . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FRONT FORK LEGS 4-51. . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT FORK LEGS 4-54. . . . . . . . . . . . . . . . . . . . . .

HANDLEBAR 4-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE HANDLEBAR 4-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HANDLEBAR 4-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE HANDLEBAR 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING HEAD 4-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDER BRACKET 4-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE UNDER BRACKET 4-61. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING HEAD 4-61. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STEERING HEAD 4-62. . . . . . . . . . . . . . . . . . . . . . . . .

REAR SHOCK ABSORBER ASSEMBLY 4-64. . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4-65. . . . . HANDLING THE REAR SHOCK ABSORBER 4-66. . . . . . . . . . . . . . . . . DISPOSING OF A REAR SHOCK ABSORBER 4-66. . . . . . . . . . . . . . . . CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-66. . . . . . INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-67. . . . .

SWINGARM AND DRIVE CHAIN 4-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE SWINGARM 4-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE DRIVE CHAIN 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWINGARM 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SWINGARM 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE DRIVE CHAIN 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

FRONT WHEEL AND BRAKE DISCS CHAS


1234567

Removing the front wheel and brakediscs

Brake hose holder (left and right)Front brake caliper (left and right)Front wheel axle pinch boltFront wheel axleCollar (left and right)Front wheelFront brake disc (left and right)

2211212


Place the motorcycle on a suitable standso that the front wheel is elevated.

Loosen.


NOTE:

40 Nm (4.0 mkg, 29 ftlb)

18 Nm (1.8 mkg, 13 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

72 Nm (7.2 mkg, 52 ftlb)


6 Nm (0.6 mkg, 4.3 ftlb)

EAS00514

CHASSISFRONT WHEEL AND BRAKE DISCS

4-2



Disassembling the front wheelOil seal (left and right)Wheel bearing (left and right)Spacer

221

Disassemble the parts in the order listed.

For assembly, reverse the disassemblyprocedure.

123

EAS00518

4-3


WARNING

NOTE:

NOTE:

NOTE:

WARNING

EAS00521

REMOVING THE FRONT WHEEL1. Stand the motorcycle on a level surface.



2. Remove: left brake caliper right brake caliper

Do not apply the brake lever when removing thebrake calipers.

3. Elevate: front wheel


4. Loosen: front wheel axle pinch bolt

5. Remove: front wheel axle front wheel

EAS00525

CHECKING THE FRONT WHEEL1. Check:wheel axleRoll the wheel axle on a flat surface.Bends Replace.

Do not attempt to straighten a bent wheelaxle.

4-4


NOTE:

2. Check: tire front wheelDamage/wear Replace.Refer to “CHECKING THE TIRES” and“CHECKING THE WHEELS” in chapter 3.

3. Measure: radial wheel runout 1 lateral wheel runout 2Over the specified limits Replace.

Radial wheel runout limit1 mm (0.04 in)

Lateral wheel runout limit0.5 mm (0.02 in)

4. Check:wheel bearingsFront wheel turns roughly or is loose Re-place the wheel bearings.

oil sealsDamage/wear Replace.

5. Replace:wheel bearings Newoil seals New

a. Clean the outside of the front wheel hub.b. Remove the oil seals 1 with a flat-head

screwdriver.

To prevent damaging the wheel, place a rag 2between the screwdriver and the wheel surface.

4-5


CAUTION:

c. Remove the wheel bearings 3 with a gener-al bearing puller.

d. Install the new wheel bearings and oil sealsin the reverse order of disassembly.

Do not contact the wheel bearing inner race1 or balls 2 . Contact should be made onlywith the outer race 3 .

Use a socket 4 that matches the diameter ofthe wheel bearing outer race and oil seal.

EAS00531

CHECKING THE BRAKE DISCSThe following procedure applies to all of thebrake discs.1. Check:brake discDamage/galling Replace.

2. Measure:brake disc deflectionOut of specification Correct the brake discdeflection or replace the brake disc.

Brake disc deflection limit(maximum)

Front: 0.1 mm (0.004 in)Rear: 0.15 mm (0.006 in)

a. Place the motorcycle on a suitable stand sothat the wheel is elevated.

b. Before measuring the front brake disc deflec-tion, turn the handlebar to the left or right toensure that the front wheel is stationary.

c. Remove the brake caliper.d. Hold the dial gauge at a right angle against

the brake disc surface.e. Measure the deflection 2 3 mm (0.08

0.12 in) below the edge of the brake disc.

4-6


NOTE:

3. Measure:brake disc thicknessMeasure the brake disc thickness at a fewdifferent locations.Out of specification Replace.

Brake disc thickness limit(minimum)

Front: 4.5 mm (0.18 in)Rear: 4.5 mm (0.18 in)

4. Adjust:brake disc deflection

a. Remove the brake disc.b. Rotate the brake disc by one bolt hole.c. Install the brake disc.

Tighten the brake disc bolts in stages and in acrisscross pattern.

Brake disc bolt18 Nm (1.8 mkg, 13 ftlb)LOCTITE

d. Measure the brake disc deflection.e. If out of specification, repeat the adjustment

steps until the brake disc deflection is withinspecification.

f. If the brake disc deflection cannot be broughtwithin specification, replace the brake disc.

EAS00545

INSTALLING THE FRONT WHEELThe following procedure applies to both brakediscs.1. Lubricate:wheel axleoil seal lips


2. Lift the wheel up between the fork legs.

4-7


NOTE:

72 Nm (7.2 mkg, 52 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

CAUTION:

40 Nm (4.0 mkg, 29 ftlb)

NOTE:

10 Nm (1.0 mkg, 7.2 ftlb)

WARNING

NOTE:

NOTE:

3. Insert the wheel axle.

Install the tire and wheel with the mark 1 point-ing in the direction of wheel rotation.

4. Lower the front wheel so that it is on theground.

5. Tighten:wheel axlewheel axle pinch bolt

Before tightening the wheel axle pinch bolt,push down hard in the handlebar severaltimes and check if the front fork reboundssmoothly.

6. Install:brake calipers (left and right)

Make sure that there is enough space betweenthe brake pads before installing the brake cali-pers onto the brake discs.

7. Install:brake hose holder

Make sure the brake hose is routed properly.

EAS00549

ADJUSTING THE FRONT WHEEL STATICBALANCE

After replacing the tire, wheel or both, the frontwheel static balance should be adjusted.

Adjust the front wheel static balance with thebrake discs installed.

1. Remove:balancing weight(s)

2. Find: front wheel’s heavy spot

Place the front wheel on a suitable balancingstand.

4-8


NOTE:

a. Spin the front wheel.b. When the front wheel stops, put an “X1” mark

at the bottom of the wheel.c. Turn the front wheel 90 so that the “X1” mark

is positioned as shown.d. Release the front wheel.e. When the wheel stops, put an “X2” mark at

the bottom of the wheel.f. Repeat steps (d) through (f) several times

until all the marks come to rest at the samespot.

g. The spot where all the marks come to rest isthe front wheel’s heavy spot “X”.

3. Adjust: front wheel static balance

a. Install a balancing weight 1 onto the rim ex-actly opposite the heavy spot “X”.

Start with the lightest weight.

b. Turn the front wheel 90 so that the heavyspot is positioned as shown.

c. If the heavy spot does not stay in that posi-tion, install a heavier weight.

d. Repeat steps (b) and (c) until the front wheelis balanced.

4. Check: front wheel static balance

a. Turn the front wheel and make sure it stays ateach position shown.

b. If the front wheel does not remain stationaryat all of the positions, rebalance it.

4-9

REAR WHEEL AND BRAKE DISC CHAS


123456789

10

Removing the rear wheel

Brake caliperLock nut (left and right)Adjusting nut (left and right)Wheel axle nutWasherRear wheel axleWasherDrive chain puller (left and right)Rear wheelRear brake caliper bracket

1221111211


Place the motorcycle on a suitable standso that the rear wheel is elevated.

Loosen.Loosen.


NOTE:

27 Nm (2.7 mkg, 20 ftlb)

22 Nm (2.2 mkg, 16 ftlb)

120 Nm (12 mkg, 87 ftlb)

EAS00551

REAR WHEEL AND BRAKE DISCREAR WHEEL

4-10



12345678

Removing the rear brake disc andrear wheel sprocketRear brake discRear wheel sprocketCollarOil sealBearingRear wheel drive hubRear wheel drive hub damperRear wheel

11222161



30 Nm (3.0 mkg, 22 ftlb)

100 Nm (10 mkg, 72 ftlb)

EAS00556

REAR BRAKE DISC AND REAR WHEEL SPROCKET

4-11



Disassembling the rear wheelCollarBearingSpacerOil sealCirclipBearing

111111


For assembly, reverse the disassembly procedure.

1

32

456

EAS00560

4-12


WARNING

NOTE:

NOTE:

NOTE:

EAS00561

REMOVING THE REAR WHEEL1. Stand the motorcycle on a level surface.



2. Remove:brake caliper 1

Do not depress the brake pedal when removingthe brake caliper.

3. Loosen: locknut 1adjusting nut 2

4. Remove:wheel axle nut 3wheel axle 4washer rear wheel

Push the rear wheel forward and remove thedrive chain from the rear wheel sprocket.

5. Remove: left collar 1 rear wheel drive hub 2 rear wheel drive hub damper right collar

4-13


EAS00565

CHECKING THE REAR WHEEL1. Check:wheel axle rear wheelwheel bearingsoil sealsRefer to “CHECKING THE FRONTWHEEL”.

2. Check: tire rear wheelDamage/wear Replace.Refer to “CHECKING THE TIRES” and“CHECKING THE WHEELS” in chapter 3.

3. Measure: radial wheel runout lateral wheel runoutRefer to “CHECKING THE FRONTWHEEL”.

EAS00567

CHECKING THE REAR WHEEL DRIVE HUB1. Check: rear wheel drive hub 1Cracks/damage Replace.

rear wheel drive hub dampers 2Damage/wear Replace.

EAS00568

CHECKING AND REPLACING THE REARWHEEL SPROCKET1. Check: rear wheel sprocketMore than 1/4 tooth a wear Replace therear wheel sprocket.Bent teeth Replace the rear wheel sprock-et.

b Correct1 Drive chain roller2 Rear wheel sprocket

4-14


NOTE:

120 Nm (12 mkg, 87 ftlb)

27 Nm (2.7 mkg, 20 ftlb)

22 Nm (2.2 mkg, 16 ftlb)

2. Replace: rear wheel sprocket

a. Remove the self-locking nuts and the rearwheel sprocket.

b. Clean the rear wheel drive hub with a cleancloth, especially the surfaces that contact thesprocket.

c. Install the new rear wheel sprocket.

Rear wheel sprocket self-locking nut

100 Nm (10 mkg, 72 ftlb)

Tighten the self-locking nuts in stages and in acrisscross pattern.

EAS00572

INSTALLING THE REAR WHEEL1. Lubricate:wheel axlewheel bearingsoil seal lips


2. Install:collars rear brake caliper bracket rear wheelwasher rear wheel axle

3. Adjust:drive chain slack

Drive drain slack45 55 mm (1.77 2.17 in)

Refer to “ADJUSTING THE DRIVE CHAINSLACK” in chapter 3.4. Tighten:wheel axle nutbrake caliper bolts (front)

brake caliper bolts (rear)

4-15


NOTE:

EAS00575

ADJUSTING THE REAR WHEEL STATIC BALANCE

After replacing the tire, wheel or both, the rearwheel static balance should be adjusted.

Adjust the rear wheel static balance with thebrake disc and rear wheel drive hub installed.

1. Adjust: rear wheel static balanceRefer to “ADJUSTING THE FRONT WHEELSTATIC BALANCE”.

4-16

FRONT AND REAR BRAKES CHAS


1234

Removing the front brake pads

Front brake caliperBrake padBrake pad springBleed screw

1221


The following procedure applies to both ofthe front brake calipers.


NOTE:

10 Nm (1.0 mkg, 7.2 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

6 Nm (0.6 mkg, 4.3 ftlb)

EAS00577

FRONT AND REAR BRAKESFRONT BRAKE PADS

4-17



1234567

Removing the rear brake pads.Screw plugBrake pad pinRear brake caliperBrake pad shimBrake padBrake screwBrake pad spring

1114211

Remove the parts in the order listed


3 Nm (0.3 mkg, 2.2 ftlb)

17 Nm (1.7 mkg, 12 ftlb)

6 Nm (0.6 mkg, 4.3 ftlb)

27 Nm (2.7 mkg, 20 ftlb)

22 Nm (2.2 mkg, 16 ftlb)

REAR BRAKE PADS

4-18


CAUTION:

WARNING

EAS00579

Disc brake components rarely require dis-assembly.Therefore, always follow these preventivemeasures:

Never disassemble brake components un-less absolutely necessary.

If any connection on the hydraulic brakesystem is disconnected, the entire brakesystem must be disassembled, drained,cleaned, properly filled, and bled after reas-sembly.

Never use solvents on internal brake com-ponents.

Use only clean or new brake fluid for clean-ing brake components.


Avoid brake fluid coming into contact withthe eyes as it can cause serious injury.FIRST AID FOR BRAKE FLUID ENTERINGTHE EYES:

Flush with water for 15 minutes and get im-mediate medical attention.

4-19


NOTE:

NOTE:

EAS00582

REPLACING THE FRONT BRAKE PADSThe following procedure applies to both brakecalipers.

When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disas-semble the brake caliper.

1. Remove:brake hose holder 1brake caliper 2

2. Remove:brake pads 1(along with the brake pad shims)

brake pad shims(onto the brake pads)

brake pad spring

3. Measure:brake pad wear limit aOut of specification Replace the brakepads as a set.

Brake pad wear limit0.8 mm (0.03 in)

4. Install:brake pad springbrake pad shims(onto the brake pads)

brake pads

Always install new brake pads, brake padshims, and a brake pad spring as a set.

4-20


40 Nm (4.0 mkg, 29 ftlb)

a. Connect a clear plastic hose 1 tightly to thebleed screw 2 . Put the other end of the hoseinto an open container.

b. Loosen the bleed screw and push the brakecaliper pistons into the brake caliper withyour finger.

c. Tighten the bleed screw.


d. Install a new brake pad shim onto each newbrake pad.

5. Install:brake caliper

6. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3.

7. Check:brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

4-21


NOTE:

NOTE:

EAS00583

REPLACING THE REAR BRAKE PADS

When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disas-semble the brake caliper.

1. Remove:screw plug 1brake pad pin 2brake caliper 3brake pad spring 4

2. Remove:brake pads 1(along with the brake pad shims)

3. Measure:brake pad wear limit aOut of specification Replace the brakepads as a set.

Brake pad wear limit1.0 mm (0.04 in)

4. Install:brake pad springbrake pad shims(onto the brake pads)

brake pads

Always install new brake pads, brake padshims, and a brake pad spring as a set.

a. Connect a clear plastic hose 1 tightly to thebleed screw 2 . Put the other end of the hoseinto an open container.

4-22


27 Nm (2.7 mkg, 20 ftlb)

22 Nm (2.2 mkg, 16 ftlb)

17 Nm (1.7 mkg, 12 ftlb)

3 Nm (0.3 mkg, 2.2 ftlb)

b. Loosen the bleed screw and push the brakecaliper pistons into the brake caliper withyour finger.

c. Tighten the bleed screw.


d. Install a new brake pad shim 3 onto eachnew brake pad 4 .

5. Install:brake pad coverbrake caliper

(front)(rear)

brake pad pinscrew plug


7. Check:brake pedal operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

4-23



12

3

456789

Removing the front brake master cylinderBrake fluid

Brake master cylinder reservoir capBrake master cylinder reservoirdiaphragm holderBrake master cylinder reservoirdiaphragmBrake leverFront brake light switch lead couplerFront brake light switchUnion boltCopper washerMaster cylinder holder

11

1

111121


Drain.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

Disconnect.

2 Nm (0.2 mkg, 1.4 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

10 Nm (1.0 mkg, 72 ftlb)

EAS00584

FRONT BRAKE MASTER CYLINDER

4-24



10 Master cylinder assembly 1For installation, reverse the removal procedure.

2 Nm (0.2 mkg, 1.4 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

10 Nm (1.0 mkg, 72 ftlb)

4-25



Disassembling the front brake master cylinderDust bootCirclipMaster cylinder kitSpringMaster cylinderPush rod

111111



123456

EAS00585

4-26



12

3456789

Removing the rear brake master cylinderBrake fluid

Brake fluid reservoir capRear brake fluid reservoir diaphragmholderRear brake fluid reservoir diaphragm Brake fluid reservoir tankBrake fluid reservoir hoseUnion boltCopper washerBrake hoseMaster cylinder assembly

11

1111111




30 Nm (3.0 mkg, 22 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

EAS00586

REAR BRAKE MASTER CYLINDER

4-27



Disassembling the rear brake mastercylinderDust bootCirclipMaster cylinder kitSpringMaster cylinder body

11111



12345

EAS00587

4-28

A B

C D


NOTE:

NOTE:

EAS00588

DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER

Before disassembling the front brake mastercylinder, drain the brake fluid from the entirebrake system.

1. Disconnect:brake light switch coupler 1(from the brake light switch)

2. Remove:union bolt 1copper washers 2brake hoses 3

To collect any remaining brake fluid, place acontainer under the master cylinder and the endof the brake hose.

3. Remove:brake levermaster cylinder bracketmaster cylinder assembly

4. Remove:circlip (from the master cylinder assembly)master cylinder kit

EAS00592

CHECKING THE FRONT AND REAR BRAKEMASTER CYLINDERSThe following procedure applies to the both ofthe brake master cylinders.1. Check:brake master cylinder 1Damage/scratches/wear Replace.

brake fluid delivery passages (brake master cylinder body)Obstruction Blow out with compressed air.

A FrontB Rear2. Check:brake master cylinder kit 1Damage/scratches/wear Replace.

C FrontD Rear

4-29


NOTE:

3. Check: rear brake fluid reservoir 1Cracks/damage Replace.

rear brake fluid reservoir diaphragm 2Cracks/damage Replace.

4. Check: front brake master cylinder reservoir 1Cracks/damage Replace.

front brake master cylinder reservoir dia-phragm 2Damage/wear Replace.

5. Check:brake hosesCracks/damage/wear Replace.Refer to “CHECKING THE FRONT ANDREAR BRAKE HOSES” in chapter 3.

EAS00589

DISASSEMBLING THE REAR BRAKE MASTER CYLINDER1. Remove:union bolt 1copper washers 2brake hose 3

To collect any remaining brake fluid, place acontainer under the master cylinder and the endof the brake hose.

2. Disconnect:brake fluid reservoir hose

3. Remove:pin (from the brake pedal link)

4. Remove: rear brake master cylinder assembly

5. Remove:circlip (from the rear brake master cylinderassembly)

master cylinder kit

4-30


a

WARNING

NOTE:

30 Nm (3.0 mkg, 22 ftlb)

WARNING

CAUTION:

EAS00598

ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER

Before installation, all internal brake com-ponents should be cleaned and lubricatedwith clean or new brake fluid.

Never use solvents on internal brake com-ponents.


1. Install:master cylinder kitcirclip Newbrake master cylinder 1

Install the brake master cylinder holder withthe “UP” mark facing up.

Align the end of the brake master cylinderholder with the punch mark a on the handle-bar.

First, tighten the upper bolt, then the lower bolt.

2. Install:copper washers 1 Newbrake hose 2union bolt 3

Proper brake hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING” in chapter 2.

When installing the brake hose onto thebrake master cylinder, make sure that thebrake pipe touches the projection a on thebrake master cylinder.

4-31


NOTE:

WARNING

While holding the brake hose, tighten theunion bolt as shown.

Turn the handlebar to the left and right to makesure the brake hose does not touch other parts(e.g., wire harness, cables, leads). Correct ifnecessary.

3. Fill:brake master cylinder reservoir(with the specified amount of the recom-mended brake fluid)




When refilling, be careful that water doesnot enter the brake master cylinder reser-voir. Water will significantly lower the boil-ing point of the brake fluid and could causevapor lock.


4. Bleed:brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.



4-32


30 Nm (3.0 mkg, 22 ftlb)

WARNING

CAUTION:

WARNING

EAS00608

ASSEMBLING THE REAR BRAKE MASTERCYLINDER1. Install:brake master cylinder kitcirclipdust boot

2. Install:copper washers Newbrake hosesunion bolt


When installing the brake hose onto thebrake master cylinder, make sure the brakepipe touches the projection a as shown.

3. Fill:brake fluid reservoir(to the maximum level mark a )





4-33


CAUTION:




6. Adjust:brake pedal position aRefer to “ADJUSTING THE REAR BRAKE”in chapter 3.

Brake pedal position (below the top of the rider footrest)

25.8 mm (1.02 in)

7. Adjust: rear brake light operation timingRefer to “ADJUSTING THE REAR BRAKELIGHT SWITCH” in chapter 3.

4-34



123456

Removing the front brake calipers

Brake fluid

Union boltCopper washerBrake hoseBrake caliperBrake padBrake caliper bracket

121121





NOTE:

10 Nm (1.0 mkg, 72 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

EAS00613

FRONT BRAKE CALIPERS

4-35



Disassembling the front brake calipers

Brake padBrake caliper pistonBrake caliper piston sealBrake pad springBleed screw

22411




NOTE:

12345

6 Nm (0.6 mkg, 4.3 ftlb)

EAS00615

4-36



1234

Removing the rear brake caliperBrake fluid

Union boltCopper washerBrake hoseBrake caliper

1211

Remove the parts in the order listed.Drain.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.


22 Nm (2.2 mkg, 16 ftlb)

27 Nm (2.7 mkg, 20 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

EAS00616

REAR BRAKE CALIPER

4-37



Disassembling the rear brake caliperScrew plugBrake pad pinBrake padBrake pad shimBrake pad springBrake caliper pistonBrake caliper piston sealBleed screw

11241121



12345678

6 Nm (0.6 mkg, 4.3 ftlb)

17 Nm (1.7 mkg, 12 ftlb)

3 Nm (0.3 mkg, 2.2 ftlb)

EAS00617

4-38


NOTE:

NOTE:

WARNING

EAS00625

DISASSEMBLING THE FRONT BRAKE CALIPERSThe following procedure applies to both of thebrake calipers.

Before disassembling the brake caliper, drainthe brake fluid from the entire brake system.

1. Remove:union bolt 1copper washers 2brake hose 3

Put the end of the brake hose into a containerand pump out the brake fluid carefully.

2. Remove:brake caliper pistons 1brake caliper piston seals 2

a. Secure the right side brake caliper pistonswith a piece of wood a .

b. Blow compressed air into the brake hosejoint opening b to force out the left side pis-tons from the brake caliper.

Cover the brake caliper piston with a rag.Be careful not the get injured when the pis-tons are expelled from the brake caliper.

Never try to pry out the brake caliper pis-tons.

c. Remove the brake caliper piston seals.

4-39


NOTE:

NOTE:

WARNING

EAS00627

DISASSEMBLING THE REAR BRAKE CALIPER

Before disassembling the brake caliper, drainthe brake fluid from the entire brake system.

1. Remove:union bolt 1copper washers 2brake hose 3brake caliper 4

Put the end of the brake hose into a containerand pump out the brake fluid carefully.

2. Remove:brake caliper piston 1brake caliper piston seals 2

a. Blow compressed air into the brake hosejoint opening a to force out the pistons fromthe brake caliper.

Cover the brake caliper piston with a rag.Be careful not to get injured when the pis-tons are expelled from the brake caliper.

Never try to pry out the brake caliper pis-tons.

b. Remove the brake caliper piston seals.

4-40

A

B


WARNING

EAS00633

CHECKING THE FRONT AND REAR BRAKECALIPERS

Recommended brake componentpreplacement schedule

Brake pads If necessary

Piston seals Every two years

Brake hoses Every four years

Brake fluid Every two yearsand whenever thebrake is disas-sembled

1. Check:brake caliper pistons 1Rust/scratches/wear Replace the brakecaliper pistons.

brake caliper cylinders 2Scratches/wear Replace the brake cali-per assembly.

brake caliper body 3Cracks/damage Replace the brake cali-per assembly.

brake fluid delivery passages(brake caliper body)Obstruction Blow out with compressed air.

Whenever a brake caliper is disassembled,replace the brake caliper piston seals.

A FrontB Rear

2. Check:Rear brake caliper brackets 1Cracks/damage Replace.

4-41


WARNING

22 Nm (2.2 mkg, 16 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

WARNING

CAUTION:

EAS00638

ASSEMBLING AND INSTALLINGTHE FRONT BRAKE CALIPERSThe following procedure applies to both of thebrake calipers.


Never use solvents on internal brake com-ponents as they will cause the piston sealsto swell and distort.



1. Install:brake caliper bracket

brake padsbrake caliper 1copper washers Newbrake hose 2union bolt 3


When installing the brake hose onto thebrake caliper 1 , make sure the brake pipe atouches the projection b on the brake cali-per.

4-42


WARNING

CAUTION:

2. Fill:brake master cylinder reservoir(with the specified amount of the recom-mended brake fluid)




When refilling, be careful that water doesnot enter the brake master cylinder reser-voir. Water will significantly lower the boil-ing point of the brake fluid and could causevapor lock.





4-43


WARNING

27 Nm (2.7 mkg, 20 ftlb)

22 Nm (2.2 mkg, 16 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

WARNING

CAUTION:

EAS00642

ASSEMBLING AND INSTALLING THE REARBRAKE CALIPER


Never use solvents on internal brake com-ponents as they will cause the piston sealsto swell and distort.



1. Install:brake caliper 1

(front)(rear)

brake pad pinscrew plugcopper washers Newbrake hose 2union bolt 3

Proper brake hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING”.

When installing the brake hose onto thebrake caliper 1 , make sure the brake pipe atouches the projection b on the brake cali-per.

2. Fill:brake fluid reservoir(with the specified amount of the recom-mended brake fluid)


4-44


WARNING

CAUTION:







5. Check:brake pedal operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

4-45

FRONT FORK CHAS


12345

Removing the front fork legsFront wheel

Front brake calipersFront fenderCap boltUpper bracket pinch boltUnder bracket pinch boltFront fork leg

11111

Remove the parts in the order listed.Refer to “FRONT WHEEL AND BRAKEDISCS”.Refer to “FRONT AND REAR BRAKES”.

Loosen.Loosen.Loosen.


30 Nm (3.0 mkg, 22 ftlb)

6 Nm (0.6 mkg, 4.3 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

EAS00647

FRONT FORKFRONT FORK LEGS

4-46

FRONT FORK CHAS


Disassembling the front fork legs

Cap boltO-ringSpacerWasherFront fork springDust sealOil seal clipDamper rod assembly boltCopper washerDamper rod assemblyOil sealWasher

111111111111


The following the procedure applies toboth of the front fork legs.

NOTE:

1

32

456789101112

24 Nm (2.4 mkg, 17 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

EAS00648

4-47

FRONT FORK CHAS


Inner tubeOuter tube bushingInner tube bushingOil flow stopperOuter tube

11111


1314151617

24 Nm (2.4 mkg, 17 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

4-48

FRONT FORK CHAS

WARNING

WARNING

NOTE:

EAS00649

REMOVING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Stand the motorcycle on a level surface.


Place the motorcycle on a suitable stand so thatthe front wheel is elevated.2. Loosen:upper bracket pinch bolt 1cap bolt 2under bracket pinch bolt 3

Before loosening the upper and underbracket pinch bolts, support the front forkleg.

3. Remove: front fork leg

EAS00652

DISASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Remove:cap boltwasherspacer fork spring

2. Drain: fork oil

Stroke the inner tube several times while drain-ing the fork oil.

4-49

FRONT FORK CHAS

CAUTION:

NOTE:

CAUTION:

3. Remove:dust seal 1oil seal clip 2(with a flat-head screwdriver)

Do not scratch the inner tube.

4. Remove:damper rod assembly bolt

While holding the damper rod assembly with thedamper rod holder 1 and T-handle 2 , loosenthe damper rod assembly bolt.

Damper rod holder90890-01294

T-handle90890-01326

5. Remove: inner tube

a. Hold the front fork leg horizontally.b. Securely clamp the brake caliper bracket in a

vise with soft jaws.c. Separate the inner tube from the outer tube

by pulling the inner tube forcefully but care-fully.

Excessive force will damage the oil sealand bushing. A damaged oil seal or bush-ing must be replaced.

Avoid bottoming the inner tube into theouter tube during the above procedure, asthe oil flow stopper will be damaged.

4-50

FRONT FORK CHAS

WARNING

CAUTION:

EAS00657

CHECKING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Check: inner tube 1outer tube 2Bends/damage/scratches Replace.

Do not attempt to straighten a bent innertube as this may dangerously weaken it.

2. Measure:spring free length aOut of specification Replace.

Spring free length354 mm (13.94 in)<Limit> : 347 mm (13.66 in)

3. Check:damper rod 1Damage/wear Replace.Obstruction Blow out all of the oil pas-sages with compressed air.

oil flow stopper 2Damage Replace.

The front fork leg has a built-in damper ad-justing rod and a very sophisticated inter-nal construction, which are particularlysensitive to foreign material.

When disassembling and assembling thefront fork leg, do not allow any foreign ma-terial to enter the front fork.

4. Check:cap bolt O-ringDamage/wear Replace.

4-51

FRONT FORK CHAS

WARNING

NOTE:

WARNING

CAUTION:

23 Nm (2.3 mkg, 17 ftlb)

NOTE:

EAS00659

ASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.

Make sure the oil levels in both front forklegs are equal.

Uneven oil levels can result in poor han-dling and a loss of stability.

When assembling the front fork leg, be sure toreplace the following parts:– inner tube bushing– outer tube bushing– oil seal– dust seal– before assembling the front fork leg, make

sure all of the components are clean.

1. Install: inner tube busingouter tube busingoil flow stopperdamper rod assembly 1copper washer New

Always use new copper washer.

Allow the damper rod assembly to slideslowly down the inner tube until it protrudesfrom the bottom of the inner tube. Be carefulnot to damage the inner tube.

2. Lubricate: inner tube’s outer surface

Recommended lubricantSuspension oil “01” orequivalent

3. Tighten:damper rod assembly bolt 1

LOCTITE

While holding the damper rod assembly with thedamper rod holder 2 and T-handle 3 , tightenthe damper rod assembly bolt.

4-52

FRONT FORK CHAS

CAUTION:

NOTE:

NOTE:

Damper rod holder90890-01294

T-handle90890-01326

4. Install:outer tube bushing 1(with the fork seal driver weight 2 and forkseal driver attachment 3 )

Fork seal driver weight90890-01367

Fork seal driver attachment90890-01374

5. Install:washeroil seal 1(with the fork seal driver weight and fork sealdriver attachment)

Make sure the numbered side of the oil sealfaces up.

Before installing the oil seal, lubricate its lipswith lithium-soap-based grease.

Lubricate the outer surface of the inner tubewith fork oil.

Before installing the oil seal, cover the top ofthe front fork leg with a plastic bag 2 to protectthe oil seal during installation.

6. Install:oil seal clip 1

Adjust the oil seal clip so that it fits into the outertube’s groove.

4-53

FRONT FORK CHAS

CAUTION:

NOTE:

7. Install:dust seal 1(with the fork seal driver weight)

Fork seal driver weight90890-01367

8. Fill: front fork leg(with the specified amount of the recom-mended fork oil)

Quantity (each front fork leg)0.467 L (0.41 Imp qt, 0.49 US qt)

Recommended oilSuspension oil “01” orequivalent

Be sure to use the recommended fork oil.Other oils may have an adverse effect onfront fork performance.

When disassembling and assembling thefront fork leg, do not allow any foreign ma-terial to enter the front fork.

9. Measure: front fork leg oil level aOut of specification Correct.

Front fork leg oil level (from the top of the inner tube, with theinner tube fully compressed andwithout the fork spring)

134 mm (5.28 in)

While filling the front fork leg, keep it upright.After filling, slowly pump the front fork leg upand down to distribute the fork oil.

4-54

FRONT FORK CHAS

NOTE:

NOTE:

30 Nm (3.0 mkg, 22 ftlb)

24 Nm (2.4 mkg, 17 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

WARNING

10. Install:spring 1spring seat 2spacer 3cap bolt

Install the spring with the smaller pitch a fac-ing up.

Before installing the cap bolt, lubricate its O-ring with grease.

b Larger pitch

EAS00662

INSTALLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Install: front fork legTemporarily tighten the upper and underbracket pinch bolts.

Make sure the inner fork tube is flush with thetop of the upper bracket.

2. Tighten:under bracket pinch bolt 1

cap bolt 2upper bracket pinch bolt 3

Make sure the brake hoses are routed prop-erly.

4-55

HANDLEBAR CHAS


123456789

1011121314

Removing the handlebarGrip endHandlebar grip (left)Clutch switch connectorLeft handlebar switchClutch cableClutch leverRight handlebar switchThrottle gripThrottle cableFront brake light switch connectorFront brake master cylinder holderFront brake master cylinderUpper handlebar holderHandlebar

21111111211121


Disconnect.

Disconnect.


23 Nm (2.3 mkg, 17 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

26 Nm (2.6 mkg, 19 ftlb)

11 Nm (1.1 mkg, 8.0 ftlb)

EAS00664

HANDLEBAR

4-56

1

HANDLEBAR CHAS

WARNING

NOTE:

WARNING

EAS00666

REMOVING THE HANDLEBAR1. Stand the motorcycle on a level surface.


2. Remove:grip endhandlebar grip 1

Blow compressed air between the handlebarand the handlebar grip, and gradually push thegrip off the handlebar.

3. Disconnect:clutch switch connector

4. Remove: left handlebar switch 1clutch cable 2clutch lever holder 3

5. Remove:grip end front brake light switch connector right handlebar switch 1 throttle grip 2 front brake master cylinder holder 3 front brake master cylinder

EAS00668

CHECKING THE HANDLEBAR1. Check:handlebar 1Bends/cracks/damage Replace.

Do not attempt to straighten a bent handle-bar as this may dangerously weaken it.

4-57

HANDLEBAR CHAS

WARNING

23 Nm (2.3 mkg, 17 ftlb)

CAUTION:

NOTE:

NOTE:

NOTE:

EAS00672

INSTALLING THE HANDLEBAR1. Stand the motorcycle on a level surface.


2. Install:handlebar 1upper handlebar holders 2

upper handlebar holder caps 3

First, tighten the bolts on the front side ofthe handlebar holder, and then on the rearside.

Turn the handlebar all the way to the leftand right. If there is any contact with thefuel tank, adjust the handlebar position.

Align the match marks a on the handlebar withthe upper surface of the lower handlebar hold-ers.

3. Install: throttle cables right handlebar switch 1 throttle grip 2

Align the projections a on the handlebar switchwith the holes b in the handlebar.

4. Install: front brake master cylinder 1 front brake master cylinder holder 2Refer to “ASSEMBLING AND INSTALLINGTHE FRONT BRAKE MASTER CYL-INDER”.

There should be 17 mm (0.67 in) of clearancebetween the right handlebar switch and frontbrake master cylinder.

Align the mating surfaces of the master cylin-der bracket with the punch mark (right handle-bar switch side) a on the handlebar.

4-58

HANDLEBAR CHAS

26 Nm (2.6 mkg, 19 ftlb)

NOTE:

NOTE:

26 Nm (2.6 mkg, 19 ftlb)

WARNING

5. Install:grip end

6. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY” in chapter 3.

Throttle cable free play (at the flange of the throttle grip)

3 5 mm (0.12 0.20 in)

7. Install:clutch lever holder 1clutch cable

Align the slit on the clutch lever holder with thepunch mark a on the handlebar.

8. Adjust:clutch cable free playRefer to “ADJUST THE CLUTCH CABLEFREE PLAY” in chapter 3.

Clutch cable free play (at the endof the clutch lever)

10 15 mm (0.39 0.59 in)

9. Install: left handlebar switch

Align the projection a on the left handlebarswitch with the hole b on the handlebar.

10. Install:handlebar gripgrip end

a. Apply a thin coat of rubber adhesive onto theleft end of the handlebar.

b. Slide the handlebar grip over the left end ofthe handlebar.

c. Wipe off any excess rubber adhesive with aclean rag.

Do not touch the handlebar grip until therubber adhesive has fully dried.

4-59

STEERING HEAD CHAS


1234567

Removing the under bracketFront wheel

Front fenderFront forkHandlebarFront cowling inner panel (left and right)Fuel tankMain switch couplerImmobilizer couplerSteering stem nutWasherUpper bracketHorn stayLock washer

2111111

Remove the parts in the order listed.Refer to “FRONT WHEEL AND BRAKEDISCS”.

Refer to “HANDLEBAR”.Refer to “COWLINGS” in chapter3.Refer to “FUEL TANK” in chapter 3.Disconnect.Disconnect.

Refer to “FRONT FORK”.

30 Nm (3.0 mkg, 22 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

110 Nm (11 mkg, 80 ftlb)

EAS00676

STEERING HEADUNDER BRACKET

4-60

STEERING HEAD CHAS


89

1011121314151617

Upper ring nutRubber washerLower ring nutUnder bracketBearing coverBearing inner raceUpper bearingLower bearingDust sealBearing outer race

1111121112


30 Nm (3.0 mkg, 22 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

110 Nm (11 mkg, 80 ftlb)

4-61

STEERING HEAD CHAS

WARNING

NOTE:

WARNING

EAS00677

REMOVING THE UNDER BRACKET1. Stand the motorcycle on a level surface.


2. Remove:steering stem nutwasherupper bracket lock washer rubber washer ring nut 1(with the steering nut wrench 2 )

Hold the lower ring nut with the exhaust andsteering nut wrench, and then remove the upperrung nut with the ring nut wrench.

Steering nut wrench90890-01403, YU-33975

Securely support the under bracket so thatthere is no danger of it falling over.

EAS00682

CHECKING THE STEERING HEAD1. Wash:bearing ballsbearing races

Recommended cleaning solventKerosene

2. Check:bearing balls 1bearing races 2Damage/pitting Replace.

4-62

STEERING HEAD CHAS

CAUTION:

NOTE:

3. Replace:bearing ballsbearing races

a. Remove the bearing races 1 from the steer-ing head pipe with a long rod 2 and hammer.

b. Remove the bearing race 3 from the lowerbracket with a floor chisel 4 and hammer.

c. Install a new dust seal and new bearingraces.

If the bearing race is not installed properly,the steering head pipe could be damaged.

Always replace the bearing balls and bearingraces as a set.

Whenever the steering head is disassembled,replace the dust seal.

4. Check:upper bracket lower bracket(along with the steering stem)Bends/cracks/damage Replace.

EAS00683

INSTALLING THE STEERING HEAD1. Lubricate:upper bearing lower bearingbearing races


2. Install:under bracket lower ring nut 1 rubber washer 2upper ring nut 3 lock washer 4Refer to “CHECKING THE STEERINGHEAD”.

4-63

STEERING HEAD CHAS

110 Nm (11 mkg, 80 ftlb)

3. Install:upper bracketwashersteering stem nut

4. Install: front fork legsRefer to “INSTALLING THE FRONT FORKLEGS”.

4-64

REAR SHOCK ABSORBER ASSEMBLY CHAS


1

2

34

Removing the rear shock absorber assemblyRear wheel

Self-locking nut/collar/bolt(Swingarm-rear shock absorber)Self-locking nut/washer/bolt(Frame-rear shock absorber)Rear shock absorberOil seal/bearing

1/1/1

1/1/1

12/1


Refer to “REAR WHEEL AND BRAKEDISC”.


40 Nm (4.0 mkg, 29 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

EAS00685

REAR SHOCK ABSORBER ASSEMBLY

4-65


WARNING

NOTE:

NOTE:

EAS00694

REMOVING THE REAR SHOCK ABSORBERASSEMBLY1. Stand the motorcycle on a level surface.



2. Remove: rear wheelRefer to “REAR WHEEL AND BRAKEDISC”.

3. Remove: rear shock absorber assembly lower bolt 1

While removing the rear shock absorber as-sembly lower bolt, hold the swingarm so that itdoes not drop down.

4. Remove: rear shock absorber assembly upper bolt 1 rear shock absorber assembly

4-66


WARNING

WARNING

EAS00686

HANDLING THE REAR SHOCK ABSORBER

This rear shock absorber contains highlycompressed nitrogen gas. Before handlingthe rear shock absorber, read and make sureyou understand the following information.The manufacturer cannot be held responsi-ble for property damage or personal injurythat may result from improper handling ofthe rear shock absorber.Do not tamper or attempt to open the rearshock absorber.

Do not subject the rear shock absorber toan open flame or any other source of highheat. High heat can cause an explosion dueto excessive gas pressure.

Do not deform or damage the rear shockabsorber in any way. Rear shock absorberdamage will result in poor damping perfor-mance.

EAS00688

DISPOSING OF A REAR SHOCKABSORBERGas pressure must be released before dispos-ing of a rear shock absorber. To release the gaspressure, drill a 2 3 mm hole through the rearshock absorber at a point 15 20 mm from itsend as shown.

Wear eye protection to prevent eye damagefrom released gas or metal chips.

EAS00695

CHECKING THE REAR SHOCK ABSORBERASSEMBLY1. Check: rear shock absorber rodBends/damage Replace the rear shockabsorber assembly.

rear shock absorberGas leaks/oil leaks Replace the rearshock absorber assembly.

4-67


NOTE:

40 Nm (4.0 mkg, 29 ftlb)

40 Nm (4.0 mkg, 29ftlb)

springDamage/wear Replace the rear shock ab-sorber assembly.

bushingsDamage/wear Replace.

dust sealsDamage/wear Replace.

boltsBends/damage/wear Replace.

EAS00697

INSTALLING THE REAR SHOCK ABSORB-ER ASSEMBLY1. Lubricate:collarbearingsoil seals


2. Install:collar rear shock absorber assembly

When installing the rear shock absorber assem-bly, lift up the swingarm.

3. Tighten: rear shock absorber assembly upper nut 1

rear shock absorber assembly lower nut 2

4. Install: rear wheelRefer to “REAR WHEEL AND BRAKEDISC”.

5. Adjust:drive chain slackRefer to “ADJUSTING THE DRIVE CHAINSLACK” in chapter 3.


4-68


1234567

Removing the swingarm and drivechainMuffler assemblyCatalyst assemblyExhaust pipe assemblyRear wheel

Rear shock absorber assembly

Drive sprocket coverLock nutAdjusting nutRear fenderPivot shaft nut/washerPivot shaftSwingarmDrive chain

221

1/1111


Refer to “REAR WHEEL AND BRAKEDISC”.Refer to “REAR SHOCK ABSORBERASSEMBLY”.Refer to “ENGINE” in chapter 5.Loosen.Loosen.

Refer to “EXHAUST PIPE” in chapter 5.

120 Nm (12 mkg, 87 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)16 Nm (1.6 mkg, 12 ftlb)

SWINGARM AND DRIVE CHAIN CHAS

SWINGARM AND DRIVE CHAIN

4-69



89

1011

Drive chain guideDust coverBearingSpacer

1221


120 Nm (12 mkg, 87 ftlb)


4-70


WARNING

NOTE:

EAS00703

REMOVING THE SWINGARM1. Stand the motorcycle on a level surface.



2. Remove: rear wheelRefer to “REAR WHEEL AND BRAKEDISC”.

rear shock absorber assemblyRefer to “REAR SHOCK ABSORBER AS-SEMBLY”.

3. Measure:swingarm side playswingarm vertical movement

a. Measure the tightening torque of the pivotshaft nut.

Pivot shaft nut120 Nm (12 mkg, 87 ftlb)

b. Measure the swingarm side play A by mov-ing the swingarm from side to side.

c. If the swingarm side play is out of specifica-tion, check the spacers, bearings, washers,and dust covers.

Swingarm side play (at the end of the swingarm)

1.0 mm (0.04 in)

d. Check the swingarm vertical movement Bby moving the swingarm up and down.If swingarm vertical movement is not smoothor if there is binding, check the spacer, bear-ings, and dust covers.

4-71


WARNING

NOTE:

WARNING

EAS00704

REMOVING THE DRIVE CHAIN1. Stand the motorcycle on a level surface.



2. Remove:drive chain (with the drive chain cutter)

EAS00707

CHECKING THE SWINGARM1. Check:swingarmBends/cracks/damage Replace.

2. Check:pivot shaftRoll the pivot shaft on a flat surface.Bends Replace.

Do not attempt to straighten a bent pivotshaft.

3. Wash:pivot shaftdust coversspacerwashersbearings

Recommended cleaning solventKerosene

4-72


120 Nm (12 mkg, 87 ftlb)

4. Check:dust covers 1spacer 2Damage/wear Replace.

bearingsDamage/pitting Replace.

AS00711

INSTALLING THE SWINGARM1. Lubricate:bearingsspacerdust coverspivot shaft


2. Install:swingarm 1pivot shaft nut 2

3. Install: rear shock absorber assembly rear wheelRefer to “INSTALLING THE REAR SHOCKABSORBER ASSEMBLY” and “INSTAL-LING THE REAR WHEEL”.

4. Adjust:drive chain slackRefer to “ADJUSTING THE DRIVE CHAINSLACK” in chapter 3.


4-73


NOTE:

CAUTION:

EAS00709

CHECKING THE DRIVE CHAIN1. Measure: ten-link section a of the drive chainOut of specification Replace the drivechain.

Ten-link drive chain section limit (maximum)

150.1 mm (5.91 in)

While measuring the ten-link section, pushdown on the drive chain to increase its tension.

Measure the length between drive chain roller1 and 11 as shown.

Perform this measurement at two or three dif-ferent places.

2. Check:drive chainStiffness Clean and lubricate or replace.

3. Clean:drive chain

a. Wipe the drive chain with a clean cloth.b. Put the drive chain in kerosene and remove

any remaining dirt.c. Remove the drive chain from the kerosene

and completely dry it.

This motorcycle has a drive chain with smallrubber O-rings 1 between the drive chainside plates. Never use high-pressure wateror air, steam, gasoline, certain solvents(e.g., benzine), or a coarse brush to clean thedrive chain. High-pressure methods couldforce dirt or water into the drive chain’s in-ternals, and solvents will deteriorate the O-rings. A coarse brush can also damage theO-rings. Therefore, use only kerosine toclean the drive chain.

4-74


4. Check:O-rings 1Damage Replace the drive chain.

drive chain rollers 2Damage/wear Replace the drive chain.

drive chain side plates 3Damage/wear Replace the drive chain.Cracks Replace the drive chain and makesure that the battery breather hose is proper-ly routed away from the drive chain and be-low the swingarm.

5. Lubricate:drive chain

Recommended lubricantEngine oil or chain lubricantsuitable for O-ring chains

6. Check:drive sprocket rear wheel sprocketMore than 1/4 tooth a wear Replace thedrive chain sprockets as a set.Bent teeth Replace the drive chain sprock-ets as a set.

b Correct1 Drive chain roller2 Drive chain sprocket

ENG

CHAPTER 5ENGINE

ENGINE 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SPROCKET 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST PIPE 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEADS AND HOSES 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE ENGINE 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFTS 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD COVER 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFTS 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CAMSHAFTS 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CAMSHAFTS 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,AND TIMING CHAIN GUIDES 5-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN TENSIONER 5-14. . . . . . . . . . . . . . . . INSTALLING THE CAMSHAFTS 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CYLINDER HEAD 5-20. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CYLINDER HEAD 5-20. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CYLINDER HEAD 5-21. . . . . . . . . . . . . . . . . . . . . . . . .

VALVES AND VALVE SPRINGS 5-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE VALVES 5-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVES AND VALVE GUIDES 5-25. . . . . . . . . . . . . . . CHECKING THE VALVE SEATS 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE SPRINGS 5-29. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE LIFTERS 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE VALVES 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER CLUTCH AND GENERATOR 5-32. . . . . . . . . . . . . . . . . . . . . . . . . STATOR COIL ASSEMBLY 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE GENERATOR 5-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE STARTER CLUTCH 5-35. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER CLUTCH 5-36. . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STARTER CLUTCH 5-36. . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE GENERATOR 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHIFT SHAFT 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT SHAFT AND STOPPER LEVER 5-39. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT SHAFT 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STOPPER LEVER 5-41. . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SHIFT SHAFT 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENG

CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR 5-42. . . . . . . REMOVING THE PICKUP ROTOR 5-44. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE PICKUP ROTOR 5-44. . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH 5-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH COVER 5-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH 5-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CLUTCH 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRICTION PLATES 5-49. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PLATES 5-50. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH SPRINGS 5-50. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH HOUSING 5-51. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH BOSS 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRESSURE PLATE 5-51. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PULL LEVER SHAFT AND PULL ROD 5-52. . . . . . . INSTALLING THE CLUTCH 5-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PAN AND OIL PUMP 5-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE OIL PAN 5-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL PUMP 5-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RELIEF VALVE 5-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 5-59. . . . . . . . . CHECKING THE OIL STRAINER 5-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL NOZZLES 5-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE OIL PUMP 5-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PUMP 5-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL STRAINER 5-61. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PAN 5-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKCASE 5-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CRANKCASE 5-64. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKCASE 5-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BEARINGS AND OIL SEALS 5-65. . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN 5-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CRANKCASE 5-65. . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING RODS AND PISTONS 5-67. . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CONNECTING RODS AND PISTONS 5-68. . . . . . . . REMOVING THE CRANKSHAFT ASSEMBLY 5-69. . . . . . . . . . . . . . . . . CHECKING THE CYLINDER AND PISTON 5-69. . . . . . . . . . . . . . . . . . . CHECKING THE PISTON RINGS 5-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PISTON PINS 5-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BIG END BEARINGS 5-72. . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CONNECTING ROD AND PISTON 5-75. . . . . . . . . .

ENG

CRANKSHAFT 5-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT 5-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT JOURNAL BEARINGS 5-80. . . . . . . . INSTALLING THE CRANKSHAFT 5-83. . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION 5-84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION, SHIFT DRUM ASSEMBLY ANDSHIFT FORKS 5-84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE TRANSMISSION 5-90. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT FORKS 5-90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT DRUM ASSEMBLY 5-91. . . . . . . . . . . . . . . . . . . CHECKING THE TRANSMISSION 5-91. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE TRANSMISSION 5-92. . . . . . . . . . . . . . . . . . . . . . . . . .

5-1


1234567

Removing the drive sprocketDrive chain

Lock nutShift rodShift armDrive sprocket coverNutLock washerDrive sprocket

2111111

Loosen.Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3.Loosen.


10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

90 Nm (9.0 mkg, 65 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

ENGINE ENG

EAS00188

ENGINEENGINEDRIVE SPROCKET.

5-2


12345

Removing the exhaust pipeExhaust pipe assemblyExhaust pipe gasketCatalyst pipe assemblyMuffler protector assemblyMuffler

14111



20 Nm (2.0 mkg, 15 ftlb)

16 Nm (1.6 mkg, 11.6 ftlb)

20 Nm (2.0 mkg, 15 ftlb)

20 Nm (2.0 mkg, 15 ftlb)

20 Nm (2.0 mkg, 15 ftlb)

20 Nm (2.0 mkg, 15 ftlb)

20 Nm (2.0 mkg, 15 ftlb)

9 Nm (0.9 mkg, 6.5 ftlb)

34 Nm (3.4 mkg, 26 ftlb)

ENGINE ENG

EAS00189

EXHAUST PIPE

5-3


Disconnecting the leads and hosesSeatFront cowling inner panel (left and right)Fuel tankBattery

Air filter caseBattery box and battery box bracket

Throttle body assembly

Engine oilOil filter cartridge

Oil coolerAir cut-off valve

Disconnect the parts in the order listed.Refer to “SEAT” in chapter 3.Refer to “COWLINGS” in chapter 3.Refer to “FUEL TANK” in chapter 3.Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3.Refer to “AIR FILTER CASE” in chapter 3.Refer to “BATTERY BOX AND BATTERYBOX BRACKET” in chapter 3.Refer to “THROTTLE BODIES” in chapter 7.

Refer to “OIL COOLER” in chapter 6.Refer to “AIR INDUCTION SYSTEM” in chapter 7.

DrainRefer to “CHANGING THE ENGINEOIL” in chapter 3.

ENGINE ENG

EAS00191

LEADS AND HOSES

5-4


123456789

Radiator

Starter motor

Battery negative leadBattery positive leadClutch cableGround leadStator coil assembly couplerCrankshaft position sensor couplerOil level switch connectorNeutral switch connectorSpeed sensor coupler

111111111

Refer to “COOLING SYSTEM” in chapter 6.Refer to “STARTER MOTOR” in chapter 8.

Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.For installation, reverse the removalprocedure.

ENGINE ENG

5-5


12345

Removing the engine

Right front engine mounting boltLeft front engine mounting boltSelf locking nutRear engine mounting boltEngine

12221


Place a suitable stand under the frame andengine.


NOTE:

Refer to “INSTALLING THE ENGINE”.

55 Nm (5.5 mkg, 40 ftlb)

55 Nm (5.5 mkg, 40 ftlb)

55 Nm (5.5 mkg, 40 ftlb)

55 Nm (5.5 mkg, 40 ftlb)

ENGINE ENG

EAS00191

ENGINE

5-6

ENGINE ENG

NOTE:

NOTE:

55 Nm (5.5 mkg, 40 ftlb)

NOTE:

55 Nm (5.5 mkg, 40 ftlb)

EAS00192

INSTALLING THE ENGINE1. Install: rear engine mounting bolts 1

Lubricate the rear engine mounting bolt threadswith lithium-soap-based grease.

2. Install: right front engine mounting bolt 2 left front engine mounting bolts 3

Do not fully tighten the bolts.

3. Tighten:self-locking nut 4

First tighten the lower self-locking nut.

4. Tighten left front engine mounting bolts 5

5-7

ENGINE ENG

55 Nm (5.5 mkg, 40 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

5. Tighten right front engine mounting bolts 6

6. Install:shift arm 7

Align the punch mark a in the shift shaft withthe slot in the shift arm.

Align the bottom edge of the shift pedal withthe mark on the frame-to-swingarm bracket.

5-8


12345

Removing the cylinder head coverBattery



Radiator assembly

Air cut-off valve

Ignition coilSpark plugCylinder head coverCylinder head cover gasketTiming chain guide (top side)

44111

Remove the parts in the order listed.Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3.Refer to “AIR FILTER CASE” in chapter 3.Refer to “BATTERY BOX AND BATTERYBOX BRACKET” in chapter 3.Refer to “THROTTLE BODIES” in chapter 7.Refer to “COOLING SYSTEM” in chapter 6.Refer to “AIR INDUCTION SYSTEM” in chapter 7.


18 Nm (1.8 mkg, 13 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

CAMSHAFTS ENG

EAS00194

CAMSHAFTSCYLINDER HEAD COVER

5-9


123456789

Removing the camshaftsPickup rotor cover

Camshaft sprocket boltTiming chain tensionerTiming chain tensioner gasketTiming chain guide (exhaust side)Intake camshaft capDowel pinExhaust camshaft capDowel pinIntake camshaft

411136361

Remove the parts in the order listed.Refer to “CRANKSHAFT POSITIONSENSOR AND PICKUP ROTOR”Loosen.

During removal, the dowel pins may stillbe connected to the camshaft caps.

NOTE:

10 Nm (1.0 mkg, 7.2 ftlb)

20 Nm (2.0 mkg, 15 ftlb)

20 Nm (2.0 mkg, 15 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

CAMSHAFTS ENG

EAS00196

CAMSHAFTS

5-10

CAMSHAFTS ENG


10111213

Exhaust camshaftPinTiming chain guide (intake side)Cam sprocket

1112


10 Nm (1.0 mkg, 7.2 ftlb)

20 Nm (2.0 mkg, 15 ftlb)

20 Nm (2.0 mkg, 15 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

5-11

CAMSHAFTS ENG

NOTE:

CAUTION:

EAS00198

REMOVING THE CAMSHAFTS1. Remove:pickup rotor coverRefer to “CRANKSHAFT POSITION SEN-SOR AND PICKUP ROTOR”.

2. Align: “T” mark a on the pickup rotor(with the crankcase mating surface b )

a. Turn the crankshaft clockwise.b. When piston #1 is at TDC on the compres-

sion stroke, align the “T” mark a on the pick-up rotor with the crankcase mating surfaceb .

TDC on the compression stroke can be foundwhen the camshaft lobes are turned away fromeach other.

3. Loosen:camshaft sprocket bolts 1

4. Loosen:cap bolt 2

5. Remove: timing chain tensioner 3gasket

6. Remove: timing chain guide (exhaust side)camshaft caps 4dowel pins

To prevent damage to the cylinder head,camshafts or camshaft caps, loosen thecamshaft cap bolts in stages and in a criss-cross pattern, working from the outside in.

5-12

CAMSHAFTS ENG

NOTE:

7. Remove: intake camshaft 1exhaust camshaft 2

To prevent the timing chain from falling into thecrankcase, fasten it with a wire a .

8. Remove:camshaft sprockets

EAS00204

CHECKING THE CAMSHAFTS1. Check:camshaft lobesBlue discoloration/pitting/scratches Re-place the camshaft.

2. Measure:camshaft lobe dimensions a and bOut of specification Replace the cam-shaft.

Camshaft lobe dimension limitIntake camshaft

a 32.45 32.55 mm(1.278 1.282 in)<Limit>: 32.40 mm (1.276 in)b 24.95 mm 25.05 mm(0.982 0.986 in)<Limit>: 24.90 mm (0.980 in)

Exhaust camshafta 32.45 32.55 mm(1.278 1.282 in)<Limit>: 32.40 mm (1.276 in)b 24.95 25.05 mm(0.982 0.986 in)<Limit>: 24.90 mm (0.980 in)

5-13

CAMSHAFTS ENG

NOTE:

3. Measure:camshaft runoutOut of specification Replace.

Camshaft runout limit0.06 mm (0.0024 in)

4. Measure:camshaft-journal-to-camshaft-cap clear-anceOut of specification Measure the camshaftjournal diameter.

Camshaft-journal-to-camshaft-cap clearance

0.028 0.062 mm (0.0011 0.0024 in)<Limit>: 0.08 mm (0.0032 in)

a. Install the camshaft into the cylinder head(without the dowel pins and camshaft caps).

b. Position strip of Plastigauge 1 onto thecamshaft journal as shown.

c. Install the dowel pins and camshaft caps.

Tighten the camshaft cap bolts in stages and ina crisscross pattern, working from the innercaps out.

Do not turn the camshaft when measuring thecamshaft journal-to-camshaft cap clearancewith the Plastigauge.

Camshaft cap bolt10 Nm (1.0 mkg, 7.2 ftlb)

d. Remove the camshaft caps and then mea-sure the width of the Plastigauge 2 .

5. Measure:camshaft journal diameter aOut of specification Replace the cam-shaft.Within specification Replace the cylinderhead and the camshaft caps as a set.

Camshaft journal diameter22.967 22.980 mm (0.9042 0.9047 in)

5-14

CAMSHAFTS ENG

NOTE:

EAS00208

CHECKING THE TIMING CHAIN, CAMSHAFTSPROCKETS, AND TIMING CHAIN GUIDESThe following procedure applies to all of thecamshaft sprockets and timing chain guides.1. Check: timing chain 1Damage/stiffness Replace the timingchain and camshaft sprockets as a set.

2. Check:camshaft sprocketMore than 1/4 tooth wear a Replace thecamshaft sprockets and the timing chain as aset.

a 1/4 toothb Correct1 Timing chain roller2 Camshaft sprocket

3. Check: timing chain guide (exhaust side) 1 timing chain guide (intake side) 2 timing chain guide (top side) 3Damage/wear Replace the defectivepart(s).

EAS00210

CHECKING THE TIMING CHAIN TENSIONER1. Check: timing chain tensionerCracks/damage Replace.

2. Check:one-way cam operationRough movement Replace the timingchain tensioner assembly.

a. Lightly press the timing chain tensioner rodinto the timing chain tensioner housing byhand.

While pressing the timing chain tensioner rod,wind it clockwise with a thin screwdriver 1 untilit stops.

5-15

CAMSHAFTS ENG

NOTE:

b. Remove the screwdriver and slowly releasethe timing chain tensioner rod.

c. Make sure that the timing chain tensioner rodcomes out of the timing chain tensionerhousing smoothly. If there is rough move-ment, replace the timing chain tensioner.

3. Check:cap boltaluminum washer Newgasket NewDamage/wear Replace the defectivepart(s).

EAS00215

INSTALLING THE CAMSHAFTS1. Align: “T” mark a on the pickup rotor(with the crankcase mating surface b )

a. Turn the crankshaft clockwise.b. When piston #1 is at TDC, align the “T” mark

a with the crankcase mating surface b .

2. Install:exhaust camshaft 1 intake camshaft 2(with the camshaft sprocket temporarilytightened)

Make sure the match mark a on the camshaftsprocket is aligned with the cylinder head edgeb .

5-16

CAMSHAFTS ENG

NOTE:

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

CAUTION:

NOTE:

3. Install:dowel pinsexhaust camshaft caps intake camshaft caps

Make sure each camshaft cap is installed in itsoriginal place.

Make sure the arrow mark a on each cam-shaft cap points towards the right side of theengine.

4. Install:camshaft cap bolts

Tighten the camshaft cap bolts in stages and ina crisscross pattern, working from the innercaps out.

I1, I2: Intake side camshaft cap markE1, E2: Exhaust side camshaft cap mark

Lubricate the camshaft cap bolts with theengine oil.

The camshaft cap bolts must be tightenedevenly or damage to the cylinder head,camshaft caps, and camshafts will result.

Do not turn the crankshaft when installingthe camshaft to avoid damage or impropervalve timing.

5. Install: timing chain guide (exhaust side)

When installing the timing chain guide, be sureto keep the timing chain as tight as possible onthe exhaust side.

5-17

CAMSHAFTS ENG

WARNING

20 Nm (2.0 mkg, 15 ftlb)

CAUTION:

6. Install: timing chain tensioner

a. While lightly pressing the timing chain ten-sioner rod by hand, turn the tensioner rod ful-ly clockwise with a thin screwdriver 1 .

b. With the timing chain tensioner rod turned allthe way into the timing chain tensioner hous-ing (with the thin screwdriver still installed),install the gasket and the timing chain ten-sioner 2 onto the cylinder block.

Always use a new gasket.

c. Tighten the timing chain tensioner bolts 3 tothe specified torque.

Timing chain tensioner bolt12 Nm (1.2 mkg, 8.7 ftlb)

d. Remove the screwdriver, make sure that thetiming chain tensioner rod releases, and thentighten the cap bolt to the specified torque.

Cap bolt7 Nm (0.7 mkg, 5.1 ftlb)

7. Turn:crankshaft(several full turns clockwise)

8. Check: “T” mark aMake sure the “T” mark on the pickup rotor isaligned with the crankcase mating sure faceb .

camshaft sprocket match mark cMake sure the match marks on the camshaftsprockets are aligned with the crankcasemating surface d .Out of alignment Adjust.Refer to the installation steps above.

9. Tighten:camshaft sprocket bolts 1

Be sure to tighten the camshaft sprocketbolts to the specified torque to avoid thepossibility of the bolts coming loose anddamaging the engine.

5-18

CAMSHAFTS ENG

10. Measure:valve clearanceOut of specification Adjust.Refer to “ADJUSTING THE VALVE CLEAR-ANCE” in chapter 3.

5-19


123

Removing the cylinder headIntake and exhaust camshaftEngine bracketCylinder headCylinder head gasketDowel pin

112

Remove the parts in the order listed.Refer to “CAMSHAFTS”.Refer to “ENGINE”.


12 Nm (1.2 mkg, 8.7 ftlb)

19 Nm (1.9 mkg, 14 ftlb)50 Nm (5.0 mkg, 36 ftlb)

1st2nd

CYLINDER HEAD ENG

EAS00221

CYLINDER HEAD

5-20

CYLINDER HEAD ENG

NOTE:

NOTE:

NOTE:

EAS00222

REMOVING THE CYLINDER HEAD1. Remove:cylinder head bolts

Loosen the bolts in the proper sequence asshown.

Loosen each bolt 1/2 of a turn at a time. Afterall of the bolts are fully loosened, removethem.

EAS00229

CHECKING THE CYLINDER HEAD1. Eliminate:combustion chamber carbon deposits(with a rounded scraper)

Do not use a sharp instrument to avoid damag-ing or scratching:spark plug bore threadsvalve seats

2. Check:cylinder headDamage/scratches Replace.

cylinder head water jacketMineral deposits/rust Eliminate.

3. Measure:cylinder head warpageOut of specification Resurface the cylin-der head.

Maximum cylinder head warpage0.05 mm (0.002 in)

a. Place a straightedge 1 and a thicknessgauge 2 across the cylinder head.

b. Measure the warpage.c. If the limit is exceeded, resurface the cylinder

head as follows.d. Place a 400 600 grit wet sandpaper on the

surface plate and resurface the cylinderhead using a figure-eight sanding pattern.

To ensure an even surface, rotate the cylinderhead several times.

5-21

CYLINDER HEAD ENG

NOTE:

19 Nm (1.9 mkg, 14 ftlb)

50 Nm (5.0 mkg, 36 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

NOTE:

EAS00233

INSTALLING THE CYLINDER HEAD1. Install:gasket New 1dowel pins 2

2. Install:cylinder head

Pass the timing chain through the timing chain cavity.

3. Tighten:cylinder head bolts 1 10

1st2nd

cylinder head bolts 11 , 12

Lubricate the cylinder head bolts with engineoil.

Tighten the cylinder head bolts in the propertightening sequence as shown and torquethem in two stages.

First, tighten the bolts 1 10 to approximate-ly 19 Nm (1.9 mkg, 14 ftlb) with a torquewrench and then tighten the 50 Nm (5.0 mkg,36 ftlb).

4. Install:exhaust camshaft intake camshaftRefer to “INSTALLING THE CAMSHAFTS”.

5-22


123456789

10111213

Remove the valves and valve springsCylinder headIntake valve lifterIntake valve padIntake valve cotterIntake valve upper spring seatIntake valve spring outerIntake valve spring innerIntake valve stem sealIntake valve lower spring seatIntake valveIntake valve guideExhaust valve lifterExhaust valve padExhaust valve cotter

88

16888888888

16

Remove the parts in the order listed.Refer to “CYLINDER HEAD”.

Refer to “REMOVING/INSTALLINGTHE VALVES”.

VALVES AND VALVE SPRINGS ENG

EAS00236

VALVES AND VALVE SPRINGS

5-23



141516171819

Exhaust valve upper spring seatExhaust valve springExhaust valve stem sealExhaust valve lower spring seatExhaust valveExhaust valve guide

888888


Refer to “REMOVING/INSTALLINGTHE VALVES”.

5-24


NOTE:

NOTE:

NOTE:

NOTE:

EAS00238

REMOVING THE VALVESThe following procedure applies to all of thevalves and related components.

Before removing the internal parts of the cylin-der head (e.g., valves, valve springs, valveseats), make sure the valves properly seal.

1. Remove:valve lifter 1valve pad 2

Make a note of the position of each valve lifterand valve pad so that they can be reinstalled intheir original place.

2. Check:valve sealingLeakage at the valve seat Check the valveface, valve seat, and valve seat width.Refer to “CHECKING THE VALVE SEATS”.

a. Pour a clean solvent a into the intake andexhaust ports.

b. Check that the valves properly seal.

There should be no leakage at the valve seat 1 .

3. Remove:valve cotters 1

Remove the valve cotters by compressing thevalve springs with the valve spring compressor2 and the valve spring compressor attachment3 .

5-25


NOTE:

Valve spring compressor90890-04019, YM-04019

Valve spring compressor attachment

90890-04108, YM-01253

4. Remove:upper spring seat 1valve spring outer 2valve spring inner (intake only) 3valve 4valve stem seal 5 lower spring seat 6

Identify the position of each part very carefullyso that it can be reinstalled in its original place.

EAS00239

CHECKING THE VALVES AND VALVEGUIDESThe following procedure applies to all of thevalves and valve guides.1. Measure:valve-stem-to-valve-guide clearance

Valve-stem-to-valve-guide clearance =Valve guide inside diameter a –Valve stem diameter b

Out of specification Replace the valveguide.

Valve-stem-to-valve-guide clearance

Intake0.010 0.037 mm (0.0004 0.0015 in)<Limit>: 0.08 mm (0.0031 in)

Exhaust0.025 0.052 mm (0.0010 0.0020 in)<Limit>: 0.10 mm (0.0039 in)

5-26


NOTE:

NOTE:

2. Replace:valve guide

To ease valve guide removal and installation,and to maintain the correct fit, heat the cylinderhead to 100C (212F) in an oven.

a. Remove the valve guide with the valve guideremover 1 .

b. Install the new valve guide with the valveguide installer 2 and valve guide remover1 .

c. After installing the valve guide, bore thevalve guide with the valve guide reamer 3 toobtain the proper valve-stem-to-valve-guideclearance.

After replacing the valve guide, reface the valveseat.

Valve guide remover (4 mm, 0.16 in)

90890-04111,Valve guide installer (4 mm, 0.16 in)

90890-04112,Valve guide reamer (4 mm, 0.16 in)

90890-04113, YM-04113

3. Eliminate:carbon deposits(from the valve face and valve seat)

4. Check:valve facePitting/wear Grind the valve face.

valve stem endMushroom shape or diameter larger than thebody of the valve stem Replace the valve.

5-27


NOTE:

5. Measure:valve margin thickness aOut of specification Replace the valve.

Valve margin thickness0.6 0.8 mm (0.0236 0.0315 in)<Limit>: 0.5 mm (0.02 in)

6. Measure:valve stem runoutOut of specification Replace the valve.

When installing a new valve, always replacethe valve guide.

If the valve is removed or replaced, always re-place the oil seal.

Valve stem runout<Limit>: 0.04 mm (0.0016 in)

EAS00240

CHECKING THE VALVE SEATSThe following procedure applies to all of thevalves and valve seats.1. Eliminate:carbon deposits(from the valve face and valve seat)

2. Check:valve seatPitting/wear Replace the cylinder head.

3. Measure:valve seat width aOut of specification Replace the cylinderhead.

Valve seat width0.9 1.1 mm (0.0354 0.0433 in)<Limit>: 1.6 mm (0.06 in)

a. Apply Mechanic’s blueing dye (Dykem) bonto the valve face.

b. Install the valve into the cylinder head.c. Press the valve through the valve guide and

onto the valve seat to make a clear impres-sion.

d. Measure the valve seat width.

5-28


NOTE:

NOTE:

CAUTION:

NOTE:

Where the valve seat and valve face contactedone another, the blueing will have been re-moved.

4. Lap:valve facevalve seat

After replacing the cylinder head or replacingthe valve and valve guide, the valve seat andvalve face should be lapped.

a. Apply a coarse lapping compound a to thevalve face.

Do not let the lapping compound enter thegap between the valve stem and the valveguide.

b. Apply molybdenum disulfide oil onto thevalve stem.

c. Install the valve into the cylinder head.d. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all ofthe lapping compound.

For the best lapping results, lightly tap the valveseat while rotating the valve back and forth be-tween your hands.

e. Apply a fine lapping compound to the valveface and repeat the above steps.

f. After every lapping procedure, be sure toclean off all of the lapping compound fromthe valve face and valve seat.

g. Apply Mechanic’s blueing dye (Dykem) bonto the valve face.

h. Install the valve into the cylinder head.i. Press the valve through the valve guide and

onto the valve seat to make a clear impres-sion.

5-29


j. Measure the valve seat width c again. If thevalve seat width is out of specification, refaceand lap the valve seat.

EAS00241

CHECKING THE VALVE SPRINGSThe following procedure applies to all of thevalve springs.1. Measure:valve spring free length aOut of specification Replace the valvespring.

Valve spring free lengthIntake valve spring (inner)37.0 mm (1.46 in)<Limit>: 35.2 mm (1.39 in)Intake valve spring (outer)38.4 mm (1.51 in)<Limit>: 36.5 mm (1.44 in)Exhaust valve spring41.8 mm (1.65 in)<Limit>: 39.7 mm (1.56 in)

2. Measure:compressed valve spring force aOut of specification Replace the valvespring.

b Installed length

Compressed valve spring force (installed)

Intake valve spring (inner)69.0 79.0 N(7.03 8.05 kg,15.50 17.75 lb)

Intake valve spring (outer)114.0 132.0 N(11.62 13.46 kg, 25.63 29.67 lb)

Exhaust valve spring160 184 N (16.32 18.76 kg,35.97 41.36 lb)

5-30


3. Measure:valve spring tilt aOut of specification Replace the valvespring.

Spring tilt limitIntake valve spring (inner)

2.5 /1.6 mm (0.06 in)(outer)2.5 /1.7 mm (0.07 in)Exhaust valve spring2.5 /1.8 mm (0.07 in)

EAS00242

CHECKING THE VALVE LIFTERSThe following procedure applies to all of thevalve lifters.1. Check:valve lifterDamage/scratches Replace the valve lift-ers and cylinder head.

EAS00246

INSTALLING THE VALVESThe following procedure applies to all of thevalves and related components.1. Deburr:valve stem end(with an oil stone)

2. Lubricate:valve stem 1valve stem seal 2(with the recommended lubricant)

Recommended lubricantMolybdenum disulfide oil

3. Install:valve 1 lower spring seat 2valve stem seal 3valve spring inner (intake only) 4valve spring outer 5upper spring seat 6(into the cylinder head)

5-31


NOTE:

NOTE:

CAUTION:

NOTE:

Make sure that each valve is installed in itsoriginal place.

Install the valve springs with the larger pitch afacing up.

b Smaller pitch

4. Install:valve cotters 1

Install the valve cotters by compressing thevalve springs with the valve spring compressor2 and the valve spring compressor attachment3 .

Valve spring compressor90890-04019, YM-04019

Valve spring compressor attachment

90890-04108, YM-01253

5. To secure the valve cotters onto the valvestem, lightly tap the valve tip with a soft-facehammer.

Hitting the valve tip with excessive forcecould damage the valve.

6. Install:valve pad 1valve lifter 2

Lubricate the valve lifter and valve pad withmolybdenum disulfide oil.

The valve lifter must move smoothly when ro-tated with a finger.

Each valve lifter and valve pad must be rein-stalled in its original position.

5-32


12345

Removing the stator coil assemblySeat and fuel tank

CoolantCoolant reservoir tank

Engine oil

Stator coil assembly couplerGenerator rotor coverGenerator rotor cover gasketDowel pinStator coil assembly lead holder

11121

Remove the parts in the order listed.Refer to “SEAT” and “FUEL TANK” in chapter 3.

Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Disconnect.

32 Nm (3.2 mkg, 23 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

75 Nm (7.5 mkg, 54 ftlb)

Drain.Refer to “CHANGING THE COOLANT”in chapter 3.

10 Nm (1.0 mkg, 7.2 ftlb)

STARTER CLUTCH AND GENERATOR ENG

EAS00341

STARTER CLUTCH AND GENERATORSTATOR COIL ASSEMBLY

5-33



6789

10111213

Stator coil assemblyGenerator rotor boltWasherGenerator rotorStarter clutch assemblyIdler gear shaftIdler gearStarter clutch drive gear

11111111


Refer to “REMOVING/INSTALLINGTHE GENERATOR”.

32 Nm (3.2 mkg, 23 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

75 Nm (7.5 mkg, 54 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

5-34


NOTE:

NOTE:

EAS00347

REMOVING THE GENERATOR1. Remove:seatRefer to “SEAT” in chapter 3.

front cowling inner panel (left and right)Refer to “COWLINGS” in chapter 3.

fuel tankRefer to “FUEL TANK” in chapter 3.

2. Drain:coolantRefer to “CHANGING THE COOLANT” inchapter 3.

engine oilRefer to “CHANGING THE ENGINE OIL” inchapter 3.

3. Remove:generator rotor cover

Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern. After all ofthe bolts are fully loosened, remove them.

4. Remove:generator rotor bolt 1washer

While holding the generator rotor 2 with thesheave holder 3 , loosen the generator rotorbolt.

Do not allow the sheave holder to touch theprojection on the generator rotor.

Sheave holder90890-01701, YS-01880-A

5-35


CAUTION:

NOTE:

NOTE:

5. Remove:generator rotor 1(with the flywheel puller 2 and flywheel pull-er attachment)

woodruff key

To protect the end of the crankshaft, placean appropriate sized socket between the fly-wheel puller set’s center bolt and the crank-shaft.

Make sure the flywheel puller is centered overthe generator rotor.

Flywheel puller90890-01362, YU-33270

Flywheel puller attachment90890-04089, YM-33282

REMOVING THE STARTER CLUTCH1. Remove:starter clutch bolt 1

While holding the generator rotor with thesheave holder, remove the starter clutch bolt.



5-36


32 Nm (3.2 mkg, 23 ftlb)LOCTITE

NOTE:

EAS00351

CHECKING THE STARTER CLUTCH1. Check:starter clutch rollers 1Damage/wear Replace.

2. Check:starter clutch idle gear 1starter clutch drive gear 2Burrs/chips/roughness/wear Replacethe defective part(s).

3. Check:starter clutch gear’s contacting surfaces aDamage/pitting/wear Replace the starterclutch gear.

4. Check:starter clutch operation

a. Install the starter clutch drive gear 1 ontothe starter clutch 2 and hold the starterclutch.

b. When turning the starter clutch drive gearclockwise A , the starter clutch and the start-er clutch drive gear should engage, other-wise the starter clutch is faulty and must bereplaced.

c. When turning the starter clutch drive gearcounterclockwise B , it should turn freely,otherwise the starter clutch is faulty and mustbe replaced.

EAS00355

INSTALLING THE STARTER CLUTCH1. Install:starter clutch

While holding the generator rotor 1 with thesheave holder 2 , tighten the starter clutchbolt.

5-37


NOTE:

75 Nm (7.5 mkg, 54 ftlb)

NOTE:

12 Nm (1.2 mkg, 8.7 ftlb)



EAS00354

INSTALLING THE GENERATOR1. Install:generator rotorwasher Newgenerator rotor bolt

Clean the tapered portion of the crankshaftand the generator rotor hub.

Replace the washer with a new one.

2. Tighten:generator rotor bolt 1

While holding the generator rotor 2 with thesheave holder 3 , tighten the generator rotorbolt.



3. Apply:sealant(onto the stator coil assembly lead grommet)

Yamaha bond No.121590890-85505, ACC-11001-05-01

4. Install:stator coil

5. Install:generator rotor cover

5-38


NOTE:Tighten the generator rotor cover bolts in stagesand in a crisscross pattern.

6. Fill:engine oilRefer to “CHANGING THE ENGINE OIL” inchapter 3.

coolantRefer to “CHANGING THE COOLANT” inchapter 3.

7. Install: fuel tankRefer to “FUEL TANK” in chapter 3.

front cowling inner panel (left and right)Refer to “COWLINGS” in chapter 3.

seatRefer to “SEAT” in chapter 3.

5-39


123456789

10

Removing the shift shaft and stopperleverCoolantCoolant reservoir tank

Drive sprocket coverShift shaft coverShift shaft cover gasketDowel pinOil sealShift shaftShift shaft springCollarStopper lever springCirclipWasher

1111111111


Refer to “ENGINE”.

Drain.Refer to “CHANGING THE COOLANT”in chapter 3.

22 Nm (2.2 mkg, 16 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

SHIFT SHAFT ENG

EAS00327

SHIFT SHAFTSHIFT SHAFT AND STOPPER LEVER

5-40

SHIFT SHAFT ENG


11121314

Stopper leverCollarWasherShift shaft spring stopper

1111


22 Nm (2.2 mkg, 16 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

5-41

SHIFT SHAFT ENG

22 Nm (2.2 mkg, 16 ftlb)

NOTE:

NOTE:

EAS00328

CHECKING THE SHIFT SHAFT1. Check:shift shaft 1Bends/damage/wear Replace.

shift shaft spring 2Damage/wear Replace.

EAS00330

CHECKING THE STOPPER LEVER1. Check:stopper lever 1Bends/damage Replace.Roller turns roughly Replace the stopperlever.

EAS00332

INSTALLING THE SHIFT SHAFT1. Install:shift shaft spring stopper 1

washersshift shaft 2

Apply LOCTITE to the threads of the shiftshaft spring stopper.

Hook the ends 3 of the stopper lever springonto the stopper lever 4 and the crankcaseboss.

Mesh the stopper lever with the shift drum seg-ment assembly.

2. Install:shift shaft cover

Lubricate the oil seal lips with lithium-soap-based grease.

5-42


1234

Removing the crankshaft positionsensor and pickup rotorSeatFront cowling inner panel (left and right)Fuel tankEngine oil

Generator cover

Crankshaft position sensor lead couplerPickup rotor coverPickup rotor cover gasketDowel pin

1112


Refer to “SEAT” in chapter 3.Refer to “COWLINGS” in chapter 3.Refer to “FUEL TANK” in chapter 3.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Refer to “STARTER CLUTCH AND GENERATOR”.Disconnect.

10 Nm (1.0 mkg, 7.2 ftlb)

15 Nm (1.5 mkg, 11 ftlb)

35 Nm (3.5 mkg, 25 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR ENG

CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR

5-43



567

Crankshaft position sensorPickup rotorPlug screw

111


10 Nm (1.0 mkg, 7.2 ftlb)

15 Nm (1.5 mkg, 11 ftlb)

35 Nm (3.5 mkg, 25 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

5-44


NOTE:

NOTE:

NOTE:

REMOVING THE PICKUP ROTOR1. Remove:pickup rotor cover 1


2. Remove:pickup rotor bolt 1washer 2pickup rotor 3

While holding the generator rotor 4 with the ro-tor holding tool 5 , loosen the pickup rotor bolt.


INSTALLING THE PICKUP ROTOR1. Install:pickup rotor 1washerpickup rotor bolt

When installing the pickup rotor, align thegroove 2 in the crankshaft sprocket with thepoint a in the pickup rotor.

5-45


35 Nm (3.5 mkg, 25 ftlb)

NOTE:

NOTE:

2. Tighten:pickup rotor bolt 1

While holding the generator rotor 2 with thesheave holder 3 , tighten the pickup rotor bolt.


3. Apply:sealant(onto the crankshaft position sensor leadgrommet)

Yamaha bond No.121590890-85505, ACC-11001-5-01

4. Install:pickup rotor covergasket New

When installing the pickup rotor cover, alignthe timing chain guide (intake side) pin 1 withthe hole 2 in the pickup rotor cover.

Tighten the pickup rotor cover bolts in stagesand in a crisscross pattern.

5-46


123456

Removing the clutch coverEngine oil

Coolant

Coolant hoseClutch cableClutch cable holderClutch coverClutch cover gasketDowel pin

111112

Remove the parts in the order listed.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Drain.Refer to “CHANGING THE COOLANT” inchapter 3.Disconnect.Disconnect.


12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

CLUTCH ENG

: YAMAHA BOND No. 1215

EAS00273

CLUTCHCLUTCH COVER

5-47

CLUTCH ENG


Disassembling the clutch coverCirclipWasherPull leverPull lever springWasherOil sealBearingPull lever shaftWasher

211111211



123456789

5-48


123456789

101112

Removing the clutchCompression springPressure platePull rodBearingFriction plate (Brown)Clutch plate (t=2.0 mm, 0.08 in)Friction plateClutch plate (t=2.3 mm, 0.09 in)Clutch boss nutLock plateClutch bossThrust plate

611167211111



90 Nm (9.0 mkg, 65 ftlb)

8 Nm (0.8 mkg, 5.8 ftlb)

CLUTCH ENG

EAS00274

CLUTCH

5-49

CLUTCH ENG

NOTE:

NOTE:

EAS00276

REMOVING THE CLUTCH1. Remove:clutch cable holder 1clutch cover 2gasket

Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern.After all of the bolts are fully loosened, removethem.

2. Remove:compression spring bolts 1compression springspressure plate 2pull rod 3 friction platesclutch plates

3. Straighten the lock washer tab.4. Loosen:clutch boss nut 1

While holding the clutch boss 2 with the univer-sal clutch holder, loosen the clutch boss nut.

Universal clutch holder90890-04086, YM-91042

5. Remove:clutch boss nut 1 lock washer 2clutch boss 3 thrust plate 4

EAS00280

CHECKING THE FRICTION PLATESThe following procedure applies to all of the fric-tion plates.1. Check: friction plateDamage/wear Replace the friction platesas a set.

5-50

CLUTCH ENG

NOTE:

2. Measure: friction plate thicknessOut of specification Replace the frictionplates as a set.

Measure the friction plate at four places.

Friction plate thickness2.9 3.1 mm (0.114 0.122 in)<Limit>: 2.8 mm (0.110 in)

EAS00281

CHECKING THE CLUTCH PLATESThe following procedure applies to all of theclutch plates.1. Check:clutch plateDamage Replace the clutch plates as aset.

2. Measure:clutch plate warpage(with a surface plate and thickness gauge 1 )Out of specification Replace the clutchplates as a set.

Clutch plate warpage limit0.1 mm (0.0039 in)

EAS00282

CHECKING THE CLUTCH SPRINGSThe following procedure applies to all of theclutch springs.1. Check:clutch springDamage Replace the clutch springs as aset.

5-51

CLUTCH ENG

NOTE:

NOTE:

2. Measure:clutch spring free length aOut of specification Replace the clutchsprings as a set.

Clutch spring free length55 mm (2.17 in)<Limit>: 52.3 mm (2.06 in)

EAS00284

CHECKING THE CLUTCH HOUSING1. Check:clutch housing dogs Damage/pitting/wear Deburr the clutchhousing dogs or replace the clutch housing.

Pitting on the clutch housing dogs will cause er-ratic clutch operation.

2. Check:bearing Damage/wear Replace the bearing andclutch housing.

EAS00285

CHECKING THE CLUTCH BOSS1. Check:clutch boss splinesDamage/pitting/wear Replace the clutchboss.

Pitting on the clutch boss splines will cause er-ratic clutch operation.

EAS00286

CHECKING THE PRESSURE PLATE1. Check:pressure plate 1Cracks/damage Replace.

bearing 2Damage/wear Replace.

5-52

CLUTCH ENG

90 Nm (9.0 mkg, 65 ftlb)

NOTE:

EAS00287

CHECKING THE PULL LEVER SHAFT ANDPULL ROD1. Check:pull lever shaft pinion gear teeth apull rod teeth bDamage/wear Replace the pull rod andpull lever shaft pinion gear as a set.

2. Check:pull rod bearing Damage/wear Replace.

EAS00299

INSTALLING THE CLUTCH1. Install: thrust plate 1clutch boss 2 lock washer 3 Newclutch boss nut 4

While holding the clutch boss 2 with the clutchholding tool 5 , tighten the clutch boss nut.

Universal clutch holder90890-04089, YM-91042

3. Bend the lock washer tab along a flat side ofthe nut.

4. Lubricate: friction platesclutch plates(with the recommended lubricant)

Recommended lubricantEngine oil

5-53

CLUTCH ENG

NOTE:

NOTE:

8 Nm (0.8 mkg, 5.8 ftlb)

NOTE:

5. Install: friction platesclutch plates

First, install a clutch plate and then alternate be-tween a friction plate and a friction plate.

a. Install the clutch plate and friction plate asshown in the illustration.Clutch plate 1 : t=2.3 mm (0.09 in)Clutch plate 2 : t=2.0 mm (0.08 in)Friction plate 3Friction plate 4 : Color/Brown

6. Install:pressure plate 1

Align the punch mark b in the pressure platewith the punch mark a in the clutch boss.

7. Install:bearing 1pull rod 2pressure plate 3clutch springsclutch pressure plate screw

Tighten the clutch spring bolts in stages and in acrisscross pattern.

8. Install:pull lever

5-54

CLUTCH ENG

NOTE:

9. Install:clutch covergasket Newclutch cable holder

Install the pull rod so that the teeth a face to-wards the rear of the motorcycle. Then, installthe clutch cover.

Apply oil onto the bearing.Apply molybdenum disulfide grease onto thepull rod.

When installing the clutch cover, push the pulllever and check that the punch mark a on thepull lever aligns with the mark b on the clutchcover. Make sure that the pull rod teeth andpull lever shaft pinion gear are engaged.

Tighten the clutch cover bolts in stages and ina crisscross pattern.

10. Adjust:clutch cable free playRefer to “ADJUSTING THE CLUTCHCABLE FREE PLAY” in chapter 3.

5-55


12345678

Removing the oil pan and oil pumpEngine oil

Coolant

Exhaust pipe assemblyWater pumpOil level switch couplerOil level switchOil level switch lead holderOil panOil pan gasketDowel pinOil strainerOil strainer gasket

11111211

Remove the parts in the order listed.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Refer to “CHANGING THE COOLANT” inchapter 3.Refer to “ENGINE”.Refer to “WATER PUMP” in chapter 6.Disconnect.

12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)


12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

OIL PAN AND OIL PUMP ENG

EAS00356

OIL PAN AND OIL PUMP

5-56


910111213

Oil pipeOil delivery pipeOil pump assemblyDowel pinRelief valve assembly

11121


12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)


12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)


5-57



Disassembling the oil pump assemblyOil pump coverPinOil pump inner rotorOil pump outer rotorPinWasherOil pump rotor housingOil pump driver sprocket

12111111



12345678

12 Nm (1.2 mkg, 8.7 ftlb)

5-58


NOTE:

EAS00362

REMOVING THE OIL PAN1. Remove:oil level switch 1oil pan 2oil pan gasketdowel pins


EAS00364

CHECKING THE OIL PUMP1. Check:oil pump driven gear 1oil pump rotor housing 2oil pump cover Cracks/damage/wear Replace the de-fective part(s).

2. Measure: inner-rotor-to-outer-rotor-tip clearance aouter-rotor-to-oil-pump-housing clearance

b1 Inner rotor2 Outer rotor3 Oil pump housing

Inner-rotor-to-outer-rotor-tip clearance

0.03 0.09 mm (0.0012 0.0035 in)<Limit>: 0.15 mm (0.0059 in)

Outer-rotor-to-oil-pump-housing clearance

0.03 0.08 mm (0.0012 0.0032 in)<Limit>: 0.15 mm (0.0059 in)

5-59


3. Check:oil pump operationRough movement Repeat steps (1) and(2) or replace the defective part(s).

EAS00365

CHECKING THE RELIEF VALVE1. Check: relief valve body 1 relief valve 2spring 3O-ring 4Damage/wear Replace the defectivepart(s).

EAS00367

CHECKING THE OIL DELIVERY PIPE ANDOIL PIPE1. Check:oil delivery pipe 1oil pipe 2Damage Replace.Obstruction Wash and blow out with com-pressed air.

EAS00368

CHECKING THE OIL STRAINER1. Check:oil strainer 1Damage Replace.Contaminants Clean with solvent.

EAS00373

CHECKING THE OIL NOZZLESThe following procedure applies to all of the oilnozzles.1. Check:oil nozzle 1Damage/wear Replace the oil nozzle.

O-ring 2Damage/wear Replace.

oil nozzle passageObstruction Blow out with compressed air.

5-60


12 Nm (1.2 mkg, 8.7 ftlb)

NOTE:

12 Nm (1.2 mkg, 8.7 ftlb)

CAUTION:

EAS00374

ASSEMBLING THE OIL PUMP1. Lubricate: inner rotorouter rotoroil pump shaft(with the recommended lubricant)


2. Install:oil pump housing 1oil pump shaft 2washer 3pin 4 inner rotor 5outer rotor 6dowel pins 7oil pump cover 8

When installing the inner rotor, align the pin 4 inthe oil pump shaft with the groove in the inner ro-tor 5 .

3. Check:oil pump operationRefer to “CHECKING THE OIL PUMP”.

EAS00376

INSTALLING THE OIL PUMP1. Install:oil pump drive chaingear coveroil pump

After tightening the bolts, make sure the oilpump turns smoothly.

5-61


NOTE:

12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

43 Nm (4.3 mkg, 31 ftlb)

WARNING

NOTE:

EAS00378

INSTALLING THE OIL STRAINER1. Install:oil strainer 1 relief valve 2

Make sure to check the arrow mark a locatedon the oil strainer housing for the front and reardirection of the engine and then install the oilstrainer so that its arrow mark points to the frontside of the engine.

EAS00380

INSTALLING THE OIL PAN1. Install:oil pipeoil delivery pipe

2. Install:dowel pinsgasket Newoil pan 1oil level switch 2

engine oil drain bolt

Always use new copper washers.

Tighten the oil pan bolts in stages and in acrisscross pattern.

Lubricate the oil level switch O-ring with en-gine oil.

5-62


12345

Removing the crankcaseEngineCylinder headStarter clutch and generator

Shift shaftCrankshaft position sensor and pickuprotorClutchWater pump assemblyOil pan and oil pumpTiming chainOil pump drive chainOil pump drive chain guideLower crankcaseDowel pin

11113

Remove the parts in the order listed.Refer to “ENGINE”.Refer to “CYLINDER HEAD”.Refer to “STARTER CLUTCH AND GENERATOR”.Refer to “SHIFT SHAFT”.Refer to “CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR”.Refer to “CLUTCH”.Refer to “WATER PUMP” in chapter 6.Refer to “OIL PAN AND OIL PUMP”.

12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

CRANKCASE ENG

CRANKCASE

5-63


678

Thrust plateWasherPlate

111


12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

CRANKCASE ENG

5-64

CRANKCASE ENG

NOTE:

CAUTION:

NOTE:

EAS00384

DISASSEMBLING THE CRANKCASE1. Place the engine upside down.2. Remove:crankcase bolts


Loosen the bolts in decreasing numerical or-der (refer to the numbers in the illustration).

The numbers embossed on the crankcase in-dicate the crankcase tightening sequence.

M8 85 mm (3.3 in) bolts: 1 7 , 10

M8 115 mm (4.5 in) bolts: 8 , 9M8 65 mm (2.6 in) bolts: 11 , 12

M6 65 mm (2.6 in) bolts: 13 , 14

M6 55 mm (2.2 in) bolts: 15 , 22 26

M6 45 mm (1.8 in) bolts: 16 , 19 , 20

M6 65 mm (2.6 in) bolts: 17 , 27

M6 75 mm (3.0 in) bolt: 18

M6 100 mm (3.9 in) bolts: 21

3. Remove: lower crankcase

Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced por-tions of the crankcase, not on the crankcasemating surfaces. Work slowly and carefullyand make sure the crankcase halves sepa-rate evenly.

4. Remove:dowel pins

5. Remove:crankshaft journal lower bearing(from the lower crankcase)

Identify the position of each crankshaft journallower bearing so that it can be reinstalled in itsoriginal place.

5-65

CRANKCASE ENG

EAS00399

CHECKING THE CRANKCASE1. Thoroughly wash the crankcase halves in a

mild solvent.2. Thoroughly clean all the gasket surfaces and

crankcase mating surfaces.3. Check:crankcaseCracks/damage Replace.

oil delivery passagesObstruction Blow out with compressed air.

EAS00401

CHECKING THE BEARINGS AND OILSEALS1. Check:bearingsClean and lubricate the bearings, then rotatethe inner race with your finger.Rough movement Replace.

2. Check:oil sealsDamage/wear Replace.

CHECKING THE TIMING CHAIN1 Check: timing chain 2Damage/stiffness Replace the timingchain and crankshaft sprocket as a set.

oil /water pump assembly drive chain 1Damage/stiffness Replace the oil /waterpump assembly drive chain and oil /waterpump assembly drive sprocket as a set.

ASSEMBLING THE CRANKCASE1. Lubricate:crankshaft journal bearings(with the recommended lubricant)


2. Apply:sealant

Yamaha bond No. 121590890-85505, ACC-1109-05-01

5-66

CRANKCASE ENG

NOTE:

CAUTION:

NOTE:

Do not allow any sealant to come into contactwith the oil gallery or crankshaft journal bear-ings. Do not apply sealant to within 2 3 mm ofthe crankshaft journal bearings.

3. Install:dowel pin

4. Set the shift drum assembly and transmis-sion gears in the neutral position.

5. Install: lower crankcase 1(onto the upper crankcase 2 )

Before tightening the crankcase bolts, makesure that the transmission gears shift cor-rectly when the shift drum assembly isturned by hand.

6. Install:crankcase bolts

Lubricate the bolt threads with engine oil. Install a washer on bolts 1 10 .Seal bolt 18

Tighten the bolts in the tightening sequencecast on the crankcase.

M8 85 mm (3.3 in) bolts: 1 7 , 10M8 115 mm (4.5 in) bolts: 8 , 9M8 65 mm (2.6 in) bolts: 11 , 12M6 65 mm (2.6 in) bolts: 13 , 14M6 55 mm (2.2 in) bolts: 15 , 22 26M6 45 mm (1.8 in) bolts: 16 , 19 , 20M6 65 mm (2.6 in) bolts: 17 , 27M6 75 mm (3.0 in) bolt: 18 M6 100 mm (3.9 in) bolt: 21

Crankcase boltBolt 1 10

1st: 12 Nm (1.2 mkg, 8.7 ftlb)2nd: 25 Nm (2.5 mkg, 18 ftlb)*3rd: 27 Nm (2.7 mkg, 20 ftlb)Bolt 11 , 12

24 Nm (2.4 mkg, 17 ftlb)Bolt 13 , 14

14 Nm (1.4 mkg, 1.0 ftlb)Bolt 15 27

12 Nm (1.2 mkg, 8.7 ftlb)

* Loosen the bolts following the tightening orderand then tighten to specification torque.

5-67


123456789

10

Removing the connecting rods andpistonsLower crankcaseConnecting rod capBig end lower bearingBig end upper bearingPiston pin clipPiston pinPistonConnecting rodTop ring2nd ringOil ring

4448444444


Refer to “CRANKCASE”.


15 Nm (1.5 mkg, 11 ftlb) +150

CONNECTING RODS AND PISTONS ENG

EAS00252

CONNECTING RODS AND PISTONS

5-68


NOTE:

CAUTION:

NOTE:

NOTE:

EAS00393

REMOVING THE CONNECTING RODS ANDPISTONSThe following procedure applies to all of theconnecting rods and pistons.1. Remove:connecting rod cap 1big end bearings

Identify the position of each big end bearing sothat it can be reinstalled in its original place.

2. Remove:piston pin clips 1piston pin 2piston 3

Do not use a hammer to drive the piston pinout.

For reference during installation, put identifica-tion marks on the piston crown.

Before removing the piston pin, deburr the pis-ton pin clip groove and the piston pin borearea. If both areas are deburred and the pistonpin is still difficult to remove, remove it with thepiston pin puller set 4 .

Piston pin puller set90890-01304, YU-01304

3. Remove: top ring2nd ringoil ring

When removing a piston ring, open the end gapwith your fingers and lift the other side of the ringover the piston crown.

5-69


NOTE:

NOTE:

EAS00387

REMOVING THE CRANKSHAFT ASSEMBLY1. Remove:crankshaft assemblycrankshaft journal upper bearings(from the upper crankcase)Refer to “CRANKSHAFT”.

Identify the position of each crankshaft journalupper bearing so that it can be reinstalled in itsoriginal place.

EAS00261

CHECKING THE CYLINDER AND PISTON1. Check:piston wallcylinder wallVertical scratches Replace the cylinder,and the piston and piston rings as a set.

2. Measure:piston-to-cylinder clearance

a. Measure cylinder bore “C” with the cylinderbore gauge.

Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cyl-inder. Then, find the average of the measure-ments.

5-70


NOTE:

Cylinder bore “C” 65.50 65.51 mm(2.5787 2.5791 in)

Wear limit 65.56 mm(2.5811 in)

Taper limit “T” 0.05 mm (0.002 in)

Out of round “R” 0.05 mm (0.002 in)

“C” = maximum of D1 D6

“T” = maximum of D1 or D2 – maximumof D5 or D6

“R” = maximum of D1 D3 or D5 –minimum of D2 D4 or D6

b. If out of specification, replace the cylinder,and the pistons and piston rings as a set.

c. Measure piston skirt diameter “P” with themicrometer.

a 4 mm (0.16 in) from the bottom edge of the piston

Piston size “P”65.475 65.490 mm (2.5778 2.5783 in)

d. If out of specification, replace the piston andpiston rings as a set.

e. Calculate the piston-to-cylinder clearancewith the following formula.

Piston-to-cylinder clearance =Cylinder bore “C” –Piston skirt diameter “P”

Piston-to-cylinder clearance0.010 0.035 mm (0.0004 0.0014 in)<Limit>: 0.055 mm (0.0022 in)

f. If out of specification, replace the cylinder,and the piston and piston rings as a set.

EAS00263

CHECKING THE PISTON RINGS1. Measure:piston ring side clearanceOut of specification Replace the pistonand piston rings as a set.

Before measuring the piston ring side clear-ance, eliminate any carbon deposits from thepiston ring grooves and piston rings.

5-71


NOTE:

NOTE:

Piston ring side clearanceTop ring

0.030 0.065 mm (0.0012 0.0026 in)<Limit>: 0.115 mm (0.0045 in)

2nd ring0.030 0.065 mm (0.0012 0.0026 in)<Limit>: 0.125 mm (0.0049 in)

2. Install:piston ring(into the cylinder)

Level the piston ring into the cylinder with thepiston crown.

a 5 mm (0.20 in)3. Measure:piston ring end gapOut of specification Replace the pistonring.

The oil ring expander spacer’s end gap cannotbe measured. If the oil ring rail’s gap is exces-sive, replace all three piston rings.

Piston ring end gapTop ring

0.25 0.35 mm (0.0098 0.0138 in)<Limit>: 0.60 mm (0.0236 in)

2nd ring0.7 0.8 mm (0.0276 0.0315 in)<Limit>: 1.15 mm (0.0453 in)

Oil ring0.10 0.35 mm (0.0039 0.0138 in)

CHECKING THE PISTON PINSThe following procedure applies to all of the pis-ton pins.1. Check:piston pinBlue discoloration/grooves Replace thepiston pin and then check the lubrication sys-tem.

5-72


2. Measure:piston pin outside diameter aOut of specification Replace the pistonpin.

Piston pin outside diameter15.991 16.000 mm (0.6296 0.6299 in)<Limit>: 15.971 mm (0.6288 in)

3. Measure:piston pin bore inside diameter bOut of specification Replace the piston.

Piston pin bore inside diameter16.002 16.013 mm (0.6300 0.6304 in)<Limit>: 16.043 mm (0.6316 in)

4. Calculate:piston-pin-to-piston clearanceOut of specification Replace the piston pinand piston as a set.

Piston-pin-to-piston clearance =Piston pin bore size –Piston pin outside diameter

Piston-pin-to-piston clearance0.002 0.022 mm(0.0001 0.0009 in)<Limit>: 0.072 mm (0.0028 in)

CHECKING THE BIG END BEARINGS1. Measure:crankshaft-pin-to-big-end-bearing clear-anceOut of specification Replace the big endbearings.

Crankshaft-pin-to-big-end-bearingclearance

0.038 0.062 mm (0.0015 0.0024 in)

The following procedure applies to all of theconnecting rods.

5-73

CAUTION:


NOTE:

NOTE:

Do not interchange the big end bearings andconnecting rods. To obtain the correctcrankshaft-pin-to-big-end-bearing clear-ance and prevent engine damage, the bigend bearings must be installed in their origi-nal positions.

a. Clean the big end bearings, crankshaft pins,and the inside of the connecting rod halves.

b. Install the big end upper bearing into the con-necting rod and the big end lower bearinginto the connecting rod cap.

Align the projections a on the big end bearingswith the notches b in the connecting rod andconnecting rod cap.

c. Put a piece of Plastigauge 1 on the crank-shaft pin.

d. Assemble the connecting rod halves.

Do not move the connecting rod or crankshaftuntil the clearance measurement has beencompleted.

Lubricate the bolt threads and nut seats withmolybdenum disulfide grease.

Make sure that the “Y” mark c on the connect-ing rod faces towards the left side of the crank-shaft.

Make sure that the characters d on both theconnecting rod and connecting rod cap arealigned.

5-74


CAUTION:

WARNING

CAUTION:

NOTE:

e. Tighten the connecting rod nuts.

Connecting rod nut15 Nm (1.5 mkg, 11 ftlb) + 150

f. Replace the connecting rod bolts with newones.

Tighten the connecting rod bolts using theplastic-region tightening angle method.Always install new bolts and nuts.

g. Clean the connecting rod bolts.h. Tighten the connecting rod bolts.i Put a mark 1 on the corner of the connecting

rod nut 2 and the connecting rod 3 .

j. Tighten the nut further to reach the specifiedangle (150).

When the nut is tightened more than the spe-cified angle, do not loosen the nut and thenretighten it.Replace the bolt with a new one and performthe procedure again.

Do not use a torque wrench to tighten thenut to the specified angle.

Tighten the nut until it is at the specifiedangles.

When using a hexagonal nut, note that theangle from one corner to another is 60

k. Remove the connecting rod and big endbearings.Refer to “REMOVING THE CONNECTINGRODS AND PISTONS”.

l. Measure the compressed Plastigauge

width on the crankshaft pin.If the crankshaft-pin-to-big-end-bearingclearance is out of specification, select re-placement big end bearings.

5-75


NOTE:

NOTE:

2. Select:big end bearings (P1 P4)

The numbers A stamped into the crankshaftweb and the numbers 1 on the connectingrods are used to determine the replacementbig end bearing sizes.

“P1” “P4” refer to the bearings shown in thecrankshaft illustration.

For example, if the connecting rod “P1” and thecrankshaft web “P1” numbers are “5” and “2” re-spectively, then the bearing size for “P1” is:

“P1” (connecting rod) – “P1”(crankshaft) =5 – 2 = 3 (brown)

BIG END BEARING COLOR CODE

1 Blue

2 Black

3 Brown

4 Green

INSTALLING THE CONNECTING ROD ANDPISTONThe following procedure applies to all of theconnecting rods and pistons.1. Install: top ring 12nd ring 2upper oil ring rail 3oil ring expander 4 lower oil ring rail 5

Be sure to install the piston rings so that themanufacturer’s marks or numbers a face up.

5-76


NOTE:

2. Install:piston 1(onto the respective connecting rod 2 )

piston pin 3piston pin clip New 4

Apply engine oil onto the piston pin.Make sure that the “Y” mark a on the connect-ing rod faces left when the arrow mark b onthe piston is pointing up. Refer to the illustra-tion.

Reinstall each piston into its original cylinder(numbering order starting from the left: #1 to#4).

3. Lubricate:pistonpiston ringscylinder(with the recommended lubricant)


4. Offset:piston ring end gaps

a Top ringb Lower oil ring railc Upper oil ring raild 2nd ringe Oil ring expander5. Lubricate:crankshaft pinsbig end bearingsconnecting rod big end inner surface(with the recommended lubricant)


5-77


NOTE:

15 Nm (1.5 mkg, 11 ftlb) + 150

CAUTION:

6. Install:big end bearingsconnecting rod assembly(into the cylinder and onto the crankshaft pin)

connecting rod cap(onto the connecting rod)

Align the projections on the big end bearingswith the notches in the connecting rods andconnecting rod caps.

Be sure to reinstall each big end bearing in itsoriginal place.

While compressing the piston rings with onehand, install the connecting rod assembly intothe cylinder with the other hand.

Make sure that the “Y” marks a on the con-necting rods face towards the left side of thecrankshaft.

Make sure that the characters b on both theconnecting rod and connecting rod cap arealigned.

7. Align:bolt heads(with the connecting rod caps)

8. Tighten:connecting rod nuts

a. Replace the connecting rod bolts and nutswith new ones.

Tighten the connecting rod bolts using theplastic-region tightening angle method.Always install new bolts and nuts.

b. Clean the connecting rod bolts.c. Tighten the connecting rod bolts.d. Put a mark 1 on the corner of the connecting

rod nut 2 and the connecting rod 3 .

5-78


WARNING

CAUTION:

NOTE:

e. Tighten the nut further to reach the specifiedangle (150).

When the nut is tightened more than the spe-cified angle, do not loosen the bolt and thenretighten it.Replace the bolt with a new one and performthe procedure again.

Do not use a torque wrench to tighten thenut to the specified angle.

Tighten the nut until it is at the specifiedangles.

When using a hexagonal nut, note that theangle from one corner to another is 60.

5-79


123

Removing the crankshaftCrankcase

Connecting rod caps

CrankshaftCrankshaft journal lower bearingCrankshaft journal upper bearing

155

Remove the parts in the order listed.Separate.Refer to “CRANKCASE”.Refer to “CONNECTING RODS AND PISTONS”.


CRANKSHAFT ENG

EAS00381

CRANKSHAFT

5-80

CRANKSHAFT ENG

CAUTION:

EAS00395

CHECKING THE CRANKSHAFT1. Measure:crankshaft runoutOut of specification Replace the crank-shaft.

Crankshaft runoutLess than 0.03 mm (0.0012 in)

2. Check:crankshaft journal surfacescrankshaft pin surfacesbearing surfacesScratches/wear Replace the crankshaft.

CHECKING THE CRANKSHAFT JOURNALBEARINGS1. Measure:crankshaft-journal-to-crankshaft-journal-bearing clearanceOut of specification Replace the crank-shaft journal bearings.

Crankshaft-journal-to-crankshaft-journal-bearing clearance

0.028 0.052 mm (0.0011 0.0020 in)

Do not interchange the crankshaft journalbearings. To obtain the correct crankshaft-journal-to-crankshaft-journal-bearing clear-ance and prevent engine damage, the crank-shaft journal bearings must be installed intheir original positions.

a. Clean the crankshaft journal bearings,crankshaft journals, and bearing portions ofthe crankcase.

b. Place the upper crankcase upside down on abench.

5-81

CRANKSHAFT ENG

NOTE:

NOTE:

NOTE:

NOTE:

c. Install the crankshaft journal upper bearings1 and the crankshaft into the upper crank-case.

Align the projections a on the crankshaft jour-nal upper bearings with the notches b in the up-per crankcase.

d. Put a piece of Plastigauge 2 on eachcrankshaft journal.

Do not put the Plastigauge over the oil hole inthe crankshaft journal.

e. Install the crankshaft journal lower bearings1 into the lower crankcase and assemblethe crankcase halves.

Align the projections a of the crankshaft jour-nal lower bearings with the notches b in thelower crankcase.

Do not move the crankshaft until the clearancemeasurement has been completed.

f. Tighten the bolts to specification in the tight-ening sequence cast on the crankcase.

Crankcase boltBolt 1 10

1st: 12 Nm (1.2 mkg, 8.7 ftlb)2nd: 25 Nm (2.5 mkg, 18 ftlb)*3rd: 27 Nm (2.7 mkg, 20 ftlb)Bolt 11 , 12

24 Nm (2.4 mkg, 17 ftlb)Bolt 13 , 14

14 Nm (1.4 mkg, 1.0 ftlb)Bolt 15 27

12 Nm (1.2 mkg, 8.7 ftlb)

* Loosen the bolts following the tightening orderand then tighten to specification torque.

Lubricate the crankcase bolt threads with en-gine oil.Refer to “CRANKCASE”.

5-82

CRANKSHAFT ENG

NOTE:

g. Remove the lower crankcase and the crank-shaft journal lower bearings.

h. Measure the compressed Plastigauge

width c on each crankshaft journal.If the crankshaft-journal-to-crankshaft-jour-nal-bearing clearance is out of specification,select replacement crankshaft journal bear-ings.

2. Select:crankshaft journal bearings (J1 J5)

The numbers A stamped into the crankshaftweb and the numbers 1 stamped into the low-er crankcase are used to determine the re-placement crankshaft journal bearing sizes.

“J1 J5” refer to the bearings shown in thecrankshaft illustration.

If “J1 J5” are the same, use the same sizefor all of the bearings.

If the size is the same for all “J1 to J5” one digitfor that size is indicated. (Crankcase side only)

For example, if the crankcase “J1” and crank-shaft web “J1” numbers are “6” and “2” respec-tively, then the bearing size for “J1” is:

“J1” (crankcase) – “J1”(crankshaft web) – 1 =6 – 2 – 1 = 3 (brown)

CRANKSHAFT JOURNAL BEARINGCOLOR CODE

0 White

1 Black

2 Brown

3 Green

4 Yellow

5-83

CRANKSHAFT ENG

NOTE:

EAS00407

INSTALLING THE CRANKSHAFT1. Install:crankshaft journal upper bearings 1(into the upper crankcase)

Align the projections a on the crankshaft jour-nal upper bearings with the notches b in theupper crankcase.

Be sure to install each crankshaft journal up-per bearing in its original place.

2. Install:crankshaft

3. Install:crankcase (lower)Refer to “CRANKCASE”.

5-84


123456789

1011

Removing the transmission, shift drum assembly, and shift forksCrankcase lower

Drive axle assemblyCirclipOil sealBearingShift drum retainerShift fork guide barSpringShift fork “L”Shift fork “R”Shift drum assemblyShift fork “C”

11111241111

Remove the part in the order listed.

Separate.Refer to “CRANKCASE”.

12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)


TRANSMISSION ENG

EAS00419

TRANSMISSIONTRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS

5-85

TRANSMISSION ENG


1213141516

Main axle assemblyOil pipeOil baffle plateThrust plateWasher

11111


12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)


5-86


Disassembling the main axle assemblyBearing2nd pinion gearToothed lock washerToothed lock washer retainer6th pinion gearCollarWasherCirclip3rd pinion gearCirclipWasher5th pinion gearCollarMain axle

11111111111111


1234567891011121314

TRANSMISSION ENG

5-87


Bearing housingBearing

11


1516

TRANSMISSION ENG

5-88


Disassembling the drive axleassemblyWasher1st wheel gearCollar5th wheel gearCirclipWasherCollar3rd wheel gearToothed lock washerToothed lock washer retainer4th wheel gearCollarWasherCirclip

11111111111111


1234567891011121314

TRANSMISSION ENG

5-89

TRANSMISSION ENG


6th wheel gearCirclipWasher2nd wheel gearCollarCollarOil sealBearingCirclipDrive axle

1111111111


15161718192021222324

5-90

TRANSMISSION ENG

WARNING

EAS00420

REMOVING THE TRANSMISSION1. Remove:main axle assembly 1(with the Torx wrench T30)

a. Insert two bolts 2 of the proper size, asshown in the illustration, into the main axleassembly bearing housing.

b. Tighten the bolts until they contact the crank-case surface.

c. Continue tightening the bolts until the mainaxle assembly comes free from the uppercrankcase.

EAS00421

CHECKING THE SHIFT FORKSThe following procedure applies to all of the shiftforks.1. Check:shift fork cam follower 1shift fork pawl 2Bends/damage/scoring/wear Replacethe shift fork.

2. Check:shift fork guide barRoll the shift fork guide bar on a flat surface.Bends Replace.

Do not attempt to straighten a bent shift forkguide bar.

3. Check:shift fork movement(along the shift fork guide bar)Rough movement Replace the shift forksand shift fork guide bar as a set.

5-91

TRANSMISSION ENG

EAS00422

CHECKING THE SHIFT DRUM ASSEMBLY1. Check:shift drum groovesDamage/scratches/wear Replace theshift drum assembly.

shift drum segment 1Damage/wear Replace the shift drum as-sembly.

shift drum bearing 2Damage/pitting Replace the shift drumassembly.

EAS00425

CHECKING THE TRANSMISSION1. Measure:main axle runout(with a centering device and dial gauge 1 )Out of specification Replace the mainaxle.

Main axle runout limit0.02 mm (0.0008 in)

2. Measure:drive axle runout(with a centering device and dial gauge 1 )Out of specification Replace the driveaxle.

Drive axle runout limit0.02 mm (0.0008 in)

3. Check: transmission gearsBlue discoloration/pitting/wear Replacethe defective gear(s).

transmission gear dogsCracks/damage/rounded edges Replacethe defective gear(s).

5-92

TRANSMISSION ENG

NOTE:

NOTE:

4. Check: transmission gear engagement(each pinion gear to its respective wheelgear)Incorrect Reassemble the transmissionaxle assemblies.

5. Check: transmission gear movementRough movement Replace the defectivepart(s).

6. Check:circlipsBends/damage/looseness Replace.

EAS00430

INSTALLING THE TRANSMISSION1. Install:oil pipe 1main axle assembly 2(with the Torx wrench T30)

Make sure to caulk the bolts at three positionsafter installing the bearing housing.

2. Install:shift fork “C” 3shift drum assembly 4shift fork guide bar

The embossed marks on the shift forks shouldface towards the right side of the engine andbe in the following sequence: “R”, “C”, “L”.

Carefully position the shift forks so that theyare installed correctly into the transmissiongears.

Install shift fork “C” into the groove in the 3rdand 4th pinion gear on the main axle.

5-93

TRANSMISSION ENG

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

NOTE:

3. Install:shift fork “R” 1 and “L” 2drive axle 3shift fork guide barshift drum retainer

Install shift fork “L” into the groove in the 6thwheel gear and shift fork “R” into the groove inthe 5th wheel gear on the drive axle.

Make sure that the drive axle bearing circlip ais inserted into the grooves in the upper crank-case.

4. Check: transmissionRough movement Repair.

Oil each gear, shaft, and bearing thoroughly.

COOL 6

COOL

CHAPTER 6COOLING SYSTEM

RADIATOR 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RADIATOR 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE RADIATOR 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL COOLER 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL COOLER 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL COOLER 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THERMOSTAT 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE THERMOSTAT 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE THERMOSTAT 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE WATER PUMP 6-13. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WATER PUMP 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE WATER PUMP 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE WATER PUMP 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1


12345678

Removing the radiatorSeatFront cowling inner panel (left and right)Fuel tankAir filter caseCoolant

Coolant reservoir hoseThrottle body hoseWater pump breather hoseRadiator outlet hoseRadiator inlet hoseOil cooler outlet hoseRadiatorRadiator cap

11111111

Remove the parts in the order listed.Refer to “SEAT” in chapter 3.Refer to “COWLINGS”Refer to “FUEL TANK” in chapter 3.Refer to “AIR FILTER CASE” in chapter 3.Drain.Refer to “CHANGING THE COOLANT” inchapter 3.Disconnect.Disconnect.Disconnect.


7 Nm (0.7 mkg, 5.1 ftlb)

RADIATOR COOL

EAS00454

COOLING SYSTEMRADIATOR

6-2

RADIATOR COOL


9 Radiator fan 1For installation, reverse the removalprocedure.


7 Nm (0.7 mkg, 5.1 ftlb)

6-3

RADIATOR COOL

NOTE:

EAS00455

CHECKING THE RADIATOR1. Check: radiator finsObstruction Clean.Apply compressed air to the rear of the radia-tor.Damage Repair or replace.

Straighten any flattened fins with a thin, flat-head screwdriver.

2. Check: radiator hoses radiator pipesCracks/damage Replace.

3. Measure: radiator cap opening pressureBelow the specified pressure Replace theradiator cap.

Radiator cap opening pressure93 123 kPa(0.93 1.23 kg/cm2, 13.2 17.5 psi)

a. Install the radiator cap tester 1 and radiatorcap tester adapter 2 to the radiator cap 3 .

Radiator cap tester90890-01325, YU-24460-01

Radiator cap tester adapter90890-01352, YU-33984

b. Apply the specified pressure for ten secondsand make sure there is no drop in pressure.

4. Check: radiator fanDamage Replace.Malfunction Check and repair.Refer to “COOLING SYSTEM” in chapter 8.

6-4

RADIATOR COOL

EAS00456

INSTALLING THE RADIATOR1. Install: radiatorcoolant hoses

2. Fill:cooling system(with the specified amount of the recom-mended coolant)Refer to “CHANGING THE COOLANT” inchapter 3.

3. Check:cooling systemLeaks Repair or replace any faulty part.

4. Measure: radiator cap opening pressureBelow the specified pressure Replace theradiator cap.Refer to “CHECKING THE RADIATOR”.

6-5


123456789

Removing the oil coolerRadiator assemblyEngine oil

Oil cooler outlet hoseUnion boltWasherOil coolerO-ringOil cooler inlet hoseOil cooler inlet pipeWater jacket joint hoseWater jacket joint

111111111

Remove the parts in the order listed.Refer to “RADIATOR”.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.

10 Nm (1.0 mkg, 7.2 ftlb)

63 Nm (6.3 mkg, 46 ftlb)

OIL COOLER COOL

EAS00457

OIL COOLER

6-6

OIL COOLER COOL


101112

O-ringWater pump outlet hoseRadiator outlet hose

111


10 Nm (1.0 mkg, 7.2 ftlb)

63 Nm (6.3 mkg, 46 ftlb)

6-7

OIL COOLER COOL

63 Nm (6.3 mkg, 46 ftlb)

NOTE:

EAS00458

CHECKING THE OIL COOLER1. Check:oil coolerCracks/damage Replace.

2. Check:oil cooler inlet hoseoil cooler outlet hoseCracks/damage/wear Replace.

EAS00459

INSTALLING THE OIL COOLER1. Clean:mating surfaces of the oil cooler and thecrankcase(with a cloth dampened with lacquer thinner)

2. Install:O-ring Newoil cooler 1washer 2 Newunion bolt 3

Before installing the oil cooler, lubricate theunion bolt and O-ring with a thin coat of engineoil.

Make sure the O-ring is positioned properly.


4. Fill:crankcase(with the specified amount of the recom-mended engine oil)Refer to “CHANGING THE ENGINE OIL” inchapter 3.



6-8


123

Removing the thermostatSeatFront cowling inner panel (left and right)Fuel tankAir filter caseCoolant


Radiator inlet hoseThermostat coverThermostat

111

Remove the parts in the order listed.Refer to “SEAT” in chapter 3.Refer to “COWLINGS”Refer to “FUEL TANK”Refer to “AIR FILTER CASE” in chapter 3.Drain.Refer to “CHANGING THE COOLANT” inchapter 3.Refer to “THROTTLE BODIES” in chapter 7.


12 Nm (1.2 mkg, 8.7 ftlb)

THERMOSTAT COOL

EAS00460

THERMOSTAT

6-9

1

THERMOSTAT COOL

NOTE:

EAS00462

CHECKING THE THERMOSTAT1. Check: thermostat 1Does not open at 71 85C (160 185F) Replace.

a. Suspend the thermostat in a container filledwith water.

b. Slowly heat the water.c. Place a thermometer in the water.d. While stirring the water, observe the thermo-

stat and thermometer’s indicated tempera-ture.

1 Thermometer2 Water3 Thermostat4 ContainerA Fully closedB Fully open

If the accuracy of the thermostat is in doubt, re-place it. A faulty thermostat could cause seriousoverheating or overcooling.

2. Check: thermostat coverCracks/damage Replace.

6-10

THERMOSTAT COOL

NOTE:

12 Nm (1.2 mkg, 8.7 ftlb)

NOTE:

EAS00466

INSTALLING THE THERMOSTAT1. Install: thermostat

Install the thermostat with its breather hole afacing up.

2. Install: thermostat cover

Before installing the thermostat cover to the cyl-inder head, lubricate the O-ring with a thin coatof lithium soap based grease.




6-11


1234

Removing the water pump

Coolant

Radiator outlet hoseWater pump outlet hoseWater pump breather hoseWater pump

1111


It is not necessary to remove the waterpump unless the coolant level is extremelylow or the coolant contains engine oil.

Drain.Refer to “CHANGING THE COOLANT” inchapter 3.Disconnect.

Disconnect.


NOTE:


WATER PUMP COOL

EAS00468

WATER PUMP

6-12


Disassembling the water pumpWater pump coverO-ringImpeller shaftCirclipWater pump sealOil sealBearingWater pump housingO-ringCopper washer

1111111111



1234567

10 Nm (1.0 mkg, 7.2 ftlb)

89

10

WATER PUMP COOL

6-13

WATER PUMP COOL

NOTE:

NOTE:

NOTE:

NOTE:

EAS00471

DISASSEMBLING THE WATER PUMP1. Remove:water pump coverO-ringcirclip impeller shaft

2. Remove:water pump seal 1

Remove the water pump seal from the outsideof the water pump housing.

2 Water pump housing

3. Remove:oil seal 1(with a thin, flat-head screwdriver)

Remove the oil seal from the outside of the wa-ter pump housing.

4. Remove:bearing 1

Remove the bearing from inside of the waterpump housing.

5. Remove: rubber damper holder 1 rubber damper 2(from the impeller, with a thin, flat-headscrewdriver)

Do not scratch the impeller shaft.

6-14

WATER PUMP COOL

NOTE:

CAUTION:

NOTE:

EAS00473

CHECKING THE WATER PUMP1. Check:water pump housing 1water pump cover 2 impeller 3 rubber damper 4 rubber damper holder 5water pump sealsoil seal Cracks/damage/wear Replace.

2. Check:bearing Rough movement Replace.

3. Check:water pump outlet hose radiator outlet hoseCracks/damage/wear Replace.

EAS00475

ASSEMBLING THE WATER PUMP1. Install:bearingoil seal New 1

(into the water pump housing 2 )

Before installing the oil seal, apply tap water orcoolant onto its out surface.

Install the oil seal with a socket that matches itsoutside diameter.

2. Install:water pump seal New 1

Never lubricate the water pump seal surfacewith oil or grease.

Install the water pump seal with the specialtools.

Before installing the water pump seal, applyYamaha bond No.1215 or Quick Gasket 2 tothe water pump housing 3 .

6-15

WATER PUMP COOL

NOTE:

CAUTION:

10 Nm (1.0 mkg, 7.2 ftlb)

Mechanical seal installer90890-04078, YM-33221 4

Middle driven shaft bearing driver90890-04058, YM-04058 5

Quick GasketACC-11001-05-01

Yamaha bond #121590890-85505

A Push down.

3. Install: rubber damper New 1 rubber damper holder New 2

Before installing the rubber damper, apply tapwater or coolant onto its outer surface.

4. Measure: impeller shaft tiltOut of specification Repeat steps (3) and(4).

Make sure the rubber damper and rubberdamper holder are flush with the impeller.

Impeller shaft tilt limit0.15 mm (0.006 in)

1 Straightedge2 Impeller

5. Install: impeller shaftcirclip NewO-ring Newwater pump cover

6-16

WATER PUMP COOL

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

NOTE:

INSTALLING THE WATER PUMP1. Install:O-ring Newcopper washer Newwater pump assembly

Align the projection a at the oil pump shaft andwater pump shaft groove b .

2. Install:water pump outlet hose 1 radiator outlet hose 2

Install the radiator outlet hose with white amark positioned outside.

Install the hose clamp with its screw headpointed to the inner side.



5. Measure: radiator cap opening pressureBelow the specified pressure !I! Replace theradiator cap.Refer to “CHECKING THE RADIATOR”.

FI

CHAPTER 7FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECU’S SELF-DIAGNOSTIC FUNCTION 7-3. . . . . . . . . . . . . . . . . . . . . . ALTERNATE INSTRUCTIONS OPERATION CONTROL(FAIL-SAFE ACTION) 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAIL-SAFE ACTIONS TABLE 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING CHART 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSTIC MODE 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING DETAILS 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THROTTLE BODIES 7-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INJECTORS 7-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE INJECTORS 7-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE THROTTLE BODIES 7-27. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP AND PRESSURE REGULATOROPERATION 7-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE THROTTLE POSITIONSENSOR 7-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INDUCTION SYSTEM 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INJECTION 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CUT-OFF VALVE 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM DIAGRAMS 7-32. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE AIR INDUCTION SYSTEM 7-33. . . . . . . . . . . . . . . . . .

7-1

FUEL INJECTION SYSTEM FI

1 Ignition coil2 Air filter case3 Intake air temperature sensor4 Fuel delivery hose5 Fuel tank6 Fuel pump7 Intake air pressure sensor

8 Throttle position sensor9 Fuel injector10 Catalytic converter11 Crankshaft position sensor12 Coolant temperature sensor13 Spark plug14 Pressure regulator

15 Battery16 ECU17 Fuel injection system relay18 Engine trouble warning light19 Lean angle cut-off switch

FUEL INJECTION SYSTEMFUEL INJECTION SYSTEM

7-2

1 Main switch5 Fuse (fuel injection)7 Fuse (main)10 Battery11 Starting circuit cut-off relay12 Sidestand switch13 Neutral switch14 Fuel pump15 Throttle position sensor16 Intake air pressure sensor17 Lean angle cut-off switch18 Crankshaft position sensor19 Intake air temperature sensor20 Coolant temperature sensor21 ECU22 Cylinder #1-injector23 Cylinder #2-injector24 Cylinder #3-injector25 Cylinder #4-injector27 Speed sensor28 Ignition coil #1 and #429 Ignition coil #2 and #330 Spark plug

34 Engine trouble warning light36 Multi-function meter43 Engine stop switch50 Fuse (ignition)


WIRING DIAGRAM

7-3

41: Lean angle cut-off switch(open or short circuit)

50: ECU internal malfunction(memory check error)


EAS00899

ECU’S SELF-DIAGNOSTIC FUNCTIONThe ECU is equipped with a self-diagnostic function in order to ensure that the engine control system isoperating normally. If this function detects a malfunction in the system, it immediately operates the en-gine under substitute characteristics and illuminates the engine trouble warning light to alert the riderthat a malfunction has occurred in the system. Once a malfunction has been detected, a fault code isstored in the memory of the ECU.To inform the rider that the fuel injection system is not functioning, the engine trouble warning lightflashes when the start switch is being pushed to start the engine.

If a malfunction is detected in the system by the self-diagnostic function, this mode provides an ap-propriate substitute characteristic operation, and alerts the rider of the detected malfunction by illumi-nating an engine trouble warning light.

After the engine has been stopped, the lowest fault code number appears on the LCD meter. Once afault code has been displayed, it remains stored in the memory of the ECU until it is deleted.

EAS00900

Engine trouble warning light indication and FI system operating condition

Warning light indication

ECU’s operation FI operation Vehicle operation

Flashing* Warning providedwhen unable to startengine

Operation stopped Unable

Remains ON Malfunction detected Operated with substitute characteristics in accordance with thedescription of the malfunction

Able/Unable depend-ing on the self-diag-nostic fault code

* The warning light flashes when any one of the conditions listed below is present and the start switch ispushed.

12: Crankshaft position sensor

19: Sidestand switch(open circuit in wire to ECU)

30: Lean angle cut-off switch(latch up detected)

EAS00901

Checking for a defective engine trouble warning light bulbThe engine trouble warning light comes on for 1.4 seconds after the main switch has been turned “ON”and when the start switch is being pushed. If the warning light does not come on under these condi-tions, the warning light bulb may be defective.

7-4


EAS00902

ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION)If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-nates the engine trouble warning light and provides the engine with alternate operating instructionsthat are appropriate for the type of malfunction.When an abnormal signal is received from a sensor, the ECU processes the specified values that areprogrammed for each sensor in order to provide the engine with alternate operating instructions thatenable the engine to continue to operate or stop operating, depending on the conditions.The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value,and the other in which the ECU directly operates an actuator. Details on the fail-safe actions are givenin the table below.FAIL-SAFE ACTIONS TABLE

FaultCode No. Item Symptom Fail-safe action Engine

startabilityVehicle

drivability

12 Crankshaft positionsensor

No normal signals are received fromthe crankshaft position sensor.

Stops the engine (by stopping theinjection and ignition). Unable Unable

1314

Intake air pressuresensor (open or shortcircuit) (pipe system)

Intake air pressure sensor-open orshort circuit detected.Faulty intake air pressure sensor pipesystem.

Fixes the intake air pressure to101.3 kpa. Able Able

1516

Throttle position sensor(open or short circuit)(stuck)

Throttle position sensor-open or shortcircuit detected.A stuck throttle position sensor isdetected.

Fixes the throttle position sensor tofully open. Able Able

19Sidestand switch (opencircuit in wire to ECU)

Open circuit in the input line of ECUNo.4 terminal is detected when the startswitch is pressed.

-- (No start)Unable Unable


Coolant temperature sensor-open orshort circuit detected.

Fixes the coolant temperature to60C. Able Able

22 Intake temperaturesensor

Intake temperature sensor-open orshort circuit detected.

Fixes the intake temperature to 20C. Able Able

33Faulty ignition Open circuit detected in the primary

lead of the ignition coil. (#1, #4) Cut the injection of other cylinder in

the same group with the cylinder thatthe error is detected. (Example: whenthe #1 cylinder is defective cut the in-

Able(dependingon the num

Able(dependingon the num

34Open circuit detected in the primarylead of the ignition coil. (#2, #3)

the #1 cylinder is defective cut the in-jection of #1 and #4 cylinders)

Turn on the power to the air inductionsolenoid to always cut-off the air.

on the num-ber of faultycylinders)

on the num-ber of faultycylinders)

3041

Lean angle cut-offswitch (latch updetected) (open or shortcircuit)

The motorcycle has over turned.Lean angle cut-off switch-open or shortcircuit detected.

Turns OFF the fuel injection systemrelay of the fuel system. Unable Unable

42Speed sensor, neutralswitch

No normal signals are received from thespeed sensor; or, an open or shortcircuit is detected in the neutral switch.

Fixes the gear to the top gear.Able Able

43

Fuel system voltage(monitor voltage)

Supply power to the injector and fuelpump is not normal.

Fixes the battery voltage to 12 V. Dependingon the mal-

functioncase.

Dependingon the mal-

functioncase.

44

Error in writing theamount of COadjustment onEEPROM

An error is detected while reading orwriting on EEPROM (CO adjustmentvalue).

--

Able Able

46 Vehicle system powersupply (Monitor voltage)

Power supply to the FI system notnormal

-- Able Able

50ECU internalmalfunction (memorycheck error)

Faulty ECU memory. When thismalfunction is detected, the codenumber might not appear on the meter.

Shut down all functions except thecommunication with the meter. Unable Unable

—

Start unable warning Relay is not turned ON even if the cranksignal is input while the start switch isturned ON. When the start switch isturned ON while an error is detectedwith the fault code of No.12, 19, 30, 41,43 or 50.

Engine trouble warning light flasheswhen the start switch is turned ON.

Unable Unable

7-5


Communication error with the meter

Er-1ECU internal malfunction(output signal error)

No signals are received fromthe ECU.

– Unable Unable


No signals are received fromthe ECU within the specifiedduration.

– Unable Unable


Data from the ECU cannot bereceived correctly.

– Unable Unable

Er-4ECU internal malfunction(input signal error)

Non-registered data has beenreceived from the meter.

– Unable Unable

7-6

Engine operation is not normal or the engine trouble warning light is on.* Engine trouble warning light may not come on even if the engine operation is not normal.

The engine trouble warning light comes on.

Check the fault code number displayed on the me-ter.

Identify the system with the malfunction. (Refer tothe “FAIL-SAFE ACTIONS TABLE”.)

Identify the probable cause of malfunction. (Referto the “Fault code table”.)

Check and repair the probable case of malfunc-tion.

Fault code No. YES Fault code No. NO

Check and repair.(Refer to “TROU-BLESHOOTING DE-TAILS”.)Monitor the operationof the sensors andactuators in the diag-nostic mode. (Referto “Diagnostic modetable” in chapter 7)

Check and repair.(Refer to “TROU-BLESHOOTING DE-TAILS”.)

Perform ECU reinstatement action. (Refer to “Re-instatement method” in “TROUBLESHOOTINGDETAILS”.)

Turn the main switch to “OFF”, turn the main switchback to “ON”, and then check if the fault code num-ber is still displayed.

Erasing the malfunction history:*The malfunction history is stored even if the mainswitch is turned OFF.The malfunction history must be erased in thediagnostic mode. (Refer to the “Diagnostic modetable (Diagnostic code No.62)”)

Repairs completed

The engine trouble warning light does not comeon.

Check the operation of following sensors and ac-tuators in the diagnostic mode (Refer to “Diagnos-tic mode table” in chapter 7.)01: Throttle position sensor (throttle angle)30: Ignition coil #1, #431: Ignition coil #2, #336: Injector #1, #437: Injector #2, #348: Al system solenoid

Malfunction of en-gine

Defective sensoror actuator

Check and repairthe inner parts ofengine. (Refer toChapter 5)

Check and repairthe correspondingsensor or actua-tor.

* Operated when the engine trouble warning light is on.

Fault code number displayed

Fault code number not displayed

OK NG

OK OK

Check the engine condition.

OK

NG


EAS00904

TROUBLESHOOTING CHART

7-7


NOTE:

NOTE:

EAS00905

DIAGNOSTIC MODEIt is possible to monitor the sensor output dataor check the activation of actuators without con-necting the measurement equipment by simplyswitching the meter indication from the normalmode to the diagnostic monitoring mode.

Setting the diagnostic mode1. Turn the main switch to “OFF” and set the en-

gine stop switch to “OFF”.2. Disconnect the wire harness coupler from

the fuel pump.3. Simultaneously press and hold the “SE-

LECT” and “RESET” buttons, turn the mainswitch to “ON”, and continue to press the but-tons for 8 seconds or more.

All displays on the meter disappear except theclock and tripmeter displays.

“dIAG” appears on the LCD meter.

4. Press the “SELECT” button to select the COadjustment mode “Co” or the diagnosticmode “dIAG”.

5. After selecting “dIAG”, simultaneously pressthe “SELECT” and “RESET” buttons for 2 se-conds or more to execute the selection.

6. Select the diagnostic code number that ap-plies to the item that was verified with thefault code number by pressing the “SELECT”and “RESET” buttons.

The diagnostic code number appears on theLCD meter (01-70).

To decrease the selected diagnostic codenumber, press the “RESET” button. Press the“RESET” button for 1 second or longer to auto-matically decrease the diagnostic code num-bers.

To increase the selected diagnostic code num-ber, press the “SELECT” button. Press the“SELECT” button for 1 second or longer to au-tomatically increase the diagnostic code num-bers.

7-8


NOTE:

7. Verify the operation of the sensor or actuator.Sensor operationThe data representing the operating condi-tions of the sensor appears on the trip LCD.

Actuator operationSet the engine stop switch to “ON” to operatethe actuator.

* If the engine stop switch is set to “ON”, set itto “OFF”, and then set it to “ON” again.

8. Turn the main switch to “OFF” to cancel thethe diagnostic mode.

To perform a reliable diagnosis, make sure toturn “OFF” the power supply before every checkand then start right from the beginning.

7-9


Fault code table

Faultcode No. Symptom Probable cause of malfunction

Diagnosticcode

12

No normal signals are received fromthe crankshaft position sensor.

Open or short circuit in wiring harness. Defective crankshaft position sensor. Malfunction in pickup rotor. Malfunction in ECU. Improperly installed sensor.

—

13

Intake air pressure sensor-open orshort circuit detected.

Open or short circuit in wiring sub lead. Open or short circuit in wiring harness. Defective intake air pressure sensor. Malfunction in ECU.

03

14

Faulty intake air pressure sensor pipesystem detected hose clogged hose

Intake air pressure sensor hose is detached, clogged,kinked, or pinched.

Malfunction in ECU. 03

15

Throttle position sensor-open orshort circuit detected.

Open or short circuit in wiring sub lead. Open or short circuit in wiring harness. Defective throttle position sensor. Malfunction in ECU. Improperly installed throttle position sensor.

01

16A stuck throttle position sensor isdetected.

Stuck throttle position sensor. Malfunction in ECU. 01

19Open circuit in the input line of ECUNo4 terminal is detected when thestart switch is pressed.

Open circuit in wiring harness (ECU coupler). Malfunction in ECU. 20

21

Coolant temperature sensor-open orshort circuit detected.

Open or short circuit in wiring harness. Defective coolant temperature sensor. Malfunction in ECU. Improperly installed sensor.

06

22

Intake air temperature sensor-open orshort circuit detected.

Open or short circuit in wiring harness. Defective intake temperature sensor. Malfunction in ECU. Improperly installed sensor.

05

30The motorcycle has overturned. Overturned.

Malfunction in ECU. 08

33

Open circuit is detected in the primarylead of the ignition coil (#1, #4).

Open circuit in wiring harness. Malfunction in ignition coil. Malfunction in ECU. Malfunction in a component of ignition cut-off circuit system.

30

34

Open circuit is detected in the primarylead of the ignition coil (#2, #3).

Open circuit in wiring harness. Malfunction in ignition coil. Malfunction in ECU. Malfunction in a component of ignition cut-off circuit system.

31

41Lean angle cut-off switch-open orshort circuit detected.

Open or short circuit in wiring harness. Defective lean angle cut-off switch. Malfunction in ECU.

08

42

No normal signals are received fromthe speed sensor; or, an open orshort circuit is detected in the neutralswitch.

Open or short circuit in wiring harness. Defective speed sensor. Malfunction in vehicle speed sensor detected unit. Defective neutral switch. Malfunction in the engine side of the neutral switch. Malfunction in ECU.

0721

43Supply power to the injector and fuelpump is not normal

Open circuit in wiring harness. (red /blue line or blue /yellowline)

Malfunction in ECU.09

44An error is detected while reading orwriting on EEPROM.

Malfunction in ECU. (The CO adjustment value is notproperly written on or read from the internal memory). 60

46Power supply to the FI system is notnormal.

Malfunction in “CHARGING SYSTEM”.—

7-10


Faultcode No. Symptom Probable cause of malfunction

Diagnosticcode

50

Faulty ECU memory. When thismalfunction is detected, the codenumber might not appear on themeter.

Malfunction in ECU. (The program and data are notproperly written on or read from the internal memory.) —

Er-1No signals are received from the ECU. Open or short circuit in wiring sub lead.

Malfunction in meter. Malfunction in ECU.

—

Er-2No signals are received from the ECUwithin the specified duration.

Improper connection in wiring sub lead. Malfunction in meter. Malfunction in ECU.

—

Er-3Data from the ECU cannot bereceived correctly.


—

Er-4Non-registered data has beenreceived from the meter.


—

7-11


NOTE:

EAS00907

Diagnostic mode tableSwitch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to“DIAGNOSTIC MODE”.

Check the intake air temperature and coolant temperature as close as possible to the intake air tem-perature sensor and the coolant temperature sensor respectively.

If it is not possible to check the intake air temperature, use the ambient temperature as reference.

Diagnosticcode

Item Description of actionData displayed on meter

(reference value)

01Throttle angle Displays the throttle angle.

Check with throttle fully closed. Check with throttle fully open.

0 125 degrees Fully closed position (15 17) Fully open position (97 100)

03

Intake air pressure Displays the intake air pressure.Engine stop switch is on.* Generate the pressure difference by cranking the engine

with the starter, without actually starting the engine.

Not cranking-atmosphericpressure

Cranking-intake air pressure Itchanges at the value whitch issmaller than in the atomo-spheric pressure.

05Intake airtemperature

Displays the intake air temperature.* Check the temperature in the air cleaner case.

Compare it to the valuedisplayed on the meter.

06Coolant temperature Displays the coolant temperature.

* Check the temperature of the coolant.Compare it to the valuedisplayed on the meter.

07Vehicle speed pulse Displays the accumulation of the vehicle pulses that are

generated when the tire is spun.(0 999; resets to 0 after 999)OK if the numbers appear onthe meter.

08Lean angle cut-offswitch

Displays the lean angle cut-off switch values. Upright: 0.4 1.4 VOverturned: 3.7 4.4 V

09Fuel system voltage(battery voltage)

Displays the fuel system voltage (battery voltage).Engine stop switch is on.

0 18.7 VNormally, approximately 12.0 V

20Sidestand switch Displays that the switch is ON or OFF. (When the gear is in a

position other than neutral.)Stand retracted: ONStand extended: OFF

21Neutral switch Displays that the switch is ON or OFF. Neutral: ON

In gear: OFF

30

Ignition coil #1, #4 After 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates ignitioncoil #1 and #4 for five times every second and illuminatesthe engine trouble warning light.* Connect an ignition checker.* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check that spark is generated,5 times with the engine stopswitch ON.

31

Ignition coils #2, #3 After 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates ignitioncoil #2 and #3 for five times every second and illuminatesthe engine trouble warning light.* Connect an ignition checker.* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check that spark is generated,5 times with the engine stopswitch ON.

36

Injector #1, #4 After 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates theinjector #1 and #4 five times every second and illuminatesthe engine trouble warning light.* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the operating sound ofthe injector five times withengine stop switch ON.

37

Injector #2, #3 After 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates theinjector #2 and #3 five times every second and illuminatesthe engine trouble warning light.* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the operating sound ofthe injector five times withengine stop switch ON.

7-12


Diagnosticcode

Item Description of actionData displayed on meter

(reference value)

48

AI system solenoid After 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates the AIsystem solenoid five times every second and illuminates theengine trouble warning light.* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the operating sound ofthe AI system solenoid 5 timeswith the engine stopswitch ON.

50

Fuel injection systemrelay

After 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates the fuelinjection system relay five times every second andilluminates the engine trouble warning light (the light is OFFwhen the relay is ON, and the light is ON when the relay isOFF).* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the fuel injection systemrelay operating sound 5 timeswith the engine stopswitch ON.

51

Radiator fan motorrelay

After 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates theradiator fan motor relay five times every 5 seconds andilluminates the engine trouble warning light. (ON 2 seconds,OFF 3 seconds)* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the radiator fan motorrelay operating sound 5 timeswith the engine stopswitch ON.(At that time, the fan motorrotates.)

52

Headlight relay 1 After 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates theheadlight relay five times every 5 seconds and illuminatesthe engine trouble warning light. (ON 2 seconds, OFF 3seconds)* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the headlight relayoperating sound 5 times with theengine stop switch ON.(At that time, the headlight turnsON.)

60

EEPROM fault codedisplay

Transmits the abnormal portion of the data in the EEPROMthat has been detected as a fault code 44.

If multiple malfunctions have been detected, differentcodes are displayed at 2-second intervals, and thisprocess is repeated.

(01 02) Displays the cylindernumber.01: #1 and #4 02: #2 and #3(00) Displays when there is nomalfunction.

61

Malfunction historycode display

Displays the codes of the history of the self-diagnosismalfunctions (i.e., a code of a malfunction that occurredonce and which has been corrected).

If multiple malfunctions have been detected, differentcodes are displayed at 2-second intervals, and thisprocess is repeated.

12 50(00) Displays when there is nomalfunction.

62

Malfunction historycode erasure

Displays the total number of codes that are being detectedthrough self diagnosis and the fault codes in the pasthistory.

Erases only the history codes when the engine stop switchis turned from OFF to ON. If the engine stop switch is ON,turn it OFF once, and then turn it back ON.

00 17(00) Displays when there is nomalfunction.

70 Control number Displays the program control number. 00 255

7-13


Crankshaft position sensorresistance

248 372 Ω at 20C (68F)(between gray and black)

Tester positive probe gray Tester negative probe black

12

When installing or removing the con-nector, main switch turn to “OFF”.

NOTE:

EAS00908

TROUBLESHOOTING DETAILSThis section describes the countermeasures per fault code number displayed on the meter. Check andservice the items or components that are the probable cause of the malfunction following the order.After the check and service of the malfunctioned part has been completed, reset the meter display ac-cording to the “Reinstatement method”.Fault code No.:

Fault code number displayed on the meter when the engine failed to work normally. (Refer to the“Fault code table”.)

Diagnostic code No.:Diagnostic code number to be used when the diagnostic mode is operated. (Refer to “DIAGNOSTICMODE”.)

Fault code No. 12 Symptom No normal signals are received from the crankshaft position sensor.

Used diagnostic code No. – –

Order Inspection operation item and probablecause

Operation item and countermeasure Reinstatementmethod

1 Installed condition of sensor. Check the installed area for looseness orpinching.

Reinstated bycranking the

2 Connected condition of connector.Inspect the coupler for any pins thatmay have pulled out.Check the locking condition of thecoupler.

If there is a malfunction, repair it and connect itsecurely.

Crankshaft position sensor couplerMain wiring harness ECU coupler

engine.

3 Open or short circuit in wiring harness. Repair or replace if there is an open or shortcircuit between the main wiring harnesses.Between sensor coupler and ECU coupler.

Gray - GrayBlack /Blue - Black/Blue

4 Defective crankshaft position sensor. Replace if defective.1. Disconnect the crankshaft position sensor cou-

pler from the wire harness.2. Connect the pocket tester (Ω 100) to the

crankshaft position sensor coupler as shown.

3. Measure the crankshaft position sensor resis-tance.

4. Is the crankshaft position sensor OK?

7-14

Intake air pressure sensor outputvoltage

3.75 4.25 V

Tester positive probe pink/white Tester negative probe black/blue

12

12

When installing or removing the con-nector, main switch turn to “OFF”.

NOTE:


Fault code No. 13 Symptom Intake air pressure sensor - open or short circuit detected.

Used diagnostic code No. 03 (intake air pressure sensor)



1 Connected condition of connectorInspect the coupler for any pins thatmay have pulled out.Check the locking condition of thecoupler.


Intake air pressure sensor couplerMain wiring harness ECU couplerSub-wire harness coupler

Reinstated byturning themain switchON.

2 Open or short circuit in wiring harnessand/or sub lead.

Repair or replace if there is an open or shortcircuit.Between sensor coupler and ECU coupler

Black /Blue - Black/BluePink/White - Pink/WhiteBlue - Blue

3 Defective intake air pressure sensor Execute the diagnostic mode (code No. 03)Replace if defective.1. Connect the pocket tester (DC 20 V) to the

intake air pressure sensor coupler terminal asshown.

2. Set the main switch to “ON”.3. Measure the intake air pressure sensor output

voltage.

4. Is the intake air pressure sensor OK?

7-15


Fault code No. 14 Symptom Intake air pressure sensor - hose system malfunction (clogged or detachedhose).

Used diagnostic code No. 03 (intake air pressure sensor)



1 Intake air pressure sensor hose de-tached, clogged, kinked, or pinched.Intake air pressure sensor malfunctionat intermediate electrical potential.

Repair or replace the sensor hose.Inspect and repair the connection.

Reinstated bystarting the en-gine and oper-ating it at idle.

2 Connected state of connectorIntake air pressure sensor couplerMain wiring harness ECU coupler

Check the coupler for any pins that may havepulled out.Check the looking condition of the coupler.


3 Defective intake air pressure sensor. Execute the diagnostic mode (code No. 03)Replace if defective.Refer to “Fault code No. 13”.

Fault code No. 15 Symptom Throttle position sensor - open or short circuit detected.

Used diagnostic code No. 01 (throttle position sensor)



1 Installed condition of throttle positionsensor.

Check the installed area for looseness orpinching.Check that it is installed in the specifiedposition.Refer to “THROTTLE BODIES” section.


2 Connected condition of connectorInspect the coupler for any pins that may have pulled out.Check the locking condition of thecoupler.


Throttle position sensor couplerMain wiring harness ECU couplerSub-wire harness coupler



black /blue - black/blueyellow - yellowblue - blue

4 Throttle position sensor lead wire opencircuit output voltage check.

Check for open circuit and replace the throttleposition sensor.

Black /Blue - Yellow

Open circuit item Output voltage

Ground wire open 5 Vcircuit

Output wire open 0Vcircuit

Power supply wire 0Vopen circuit

5 Defective throttle position sensor. Execute the diagnostic mode (code No. 01)Replace if defective.Refer to “THROTTLE BODIES” section.

7-16


Fault code No. 16 Symptom Stuck throttle position sensor detected.

Used diagnostic code No. 01 (throttle position sensor)



1 Installed condition of throttle positionsensor.

Check the installed area for looseness or pinching.Check that it is installed in the specified position.Refer to “THROTTLE BODIES” section.

Reinstated bystarting theengine,

ti it2 Defective throttle position sensor Execute the diagnostic mode (code No. 01)Replace if defective.Refer to “THROTTLE BODIES” section.

operating itat idle, andthen racing it.

3 When detecting fault code No. 15 Refer to “Fault code No. 15”. Refer to “Faultcode No. 15”.

Fault code No. 19 Symptom Open circuit in the input line of ECU No. 4 terminal is detected.

Used diagnostic code No. 20 (sidestand switch)



1 Connected state of connectorMain wiring harness ECU coupler(No. 4 pin)

Execute the diagnostic mode (code No. 20)Check the coupler for any pins that may havepulled out.Check the locking condition of the coupler.

If there is a malfunction, repair it and connect it securely.

If the transmis-sion is in gear,it is reinstatedby retractingthe sidestand.If the transmis-sion is in neu-tral it is rein-


Repair or replace if there is an open circuit.Sidestand switch signal input line of ECU coupler

black / red

tral, it is rein-stated by re-connecting thewiring.

Fault code No. 21 Symptom Open or short circuit is detected from the coolant temperature sensor.

Used diagnostic code No. 06 (coolant temperature sensor)



1 Installed condition of sensor Check the installed area for looseness or pinching.

Reinstated byturning the



Coolant temperature sensor couplerMain wiring harness ECU couplerSub-wire harness coupler

main switchON.



black /blue - black/bluegreen/white - green/white

4 Defective coolant temperature sensor. Execute the diagnostic mode (code No. 06)Replace if defective.Refer to “COOLING SYSTEM” in chapter 8.

7-17


Intake air temperature sensorresistance

2.2 2.7 kΩ at 20C (68F)

Tester positive probe brown/white Tester negative probe black/blue

12

Handle the intake air temperature sensorwith special care.

Never subject the intake air temperature sen-sor to strong shocks. If the intake air temper-ature sensor is dropped, replace it.

WARNING

Fault code No. 22 Symptom Open or short circuit detected from the intake air temperature sensor.

Used diagnostic code No. 05 (intake air temperature sensor)



1 Installed condition of sensor Check the installed area for looseness orpinching.

Reinstated byturning the



Intake air temperature sensor couplerMain wiring harness ECU couplerSub-wire harness coupler

mainswitchON.



black /blue - black/bluebrown/white - brown/white

4 Defective intake air temperature sensor. Execute the diagnostic mode (code No. 05)Replace if defective.1. Remove the intake air temperature sensor

from the air filter case.2. Connect the pocket tester (Ω 100) to the

intake air temperature sensor terminal asshown.

3. Measure the intake air temperature sensorresistance.

4. Is the intake air temperature sensor OK?

7-18


Tester positive prove yellow/green Tester negative prove black/blue

12

Fault code No. 30 Symptom The motorcycle has overturned.

Used diagnostic code No. 08 (lean angle cut-off switch)



1 The motorcycle has overturned. Raise the motorcycle upright. Reinstated by

2 Installed condition of the lean angle cut-off switch

Check the installed area for looseness orpinching.

turning themain switchON (however



Lean angle cut-off switch couplerMain wiring harness ECU coupler

ON (however,the engine can-not be re-started unlessthe main switchis first turned

4 Defective lean angle cut-off switch Execute the diagnostic mode (code No. 08)Replace if defective.1. Remove the lean angle cut-off switch from the

motorcycle.2. Connect the lean angle cut-off switch coupler

to the wireharness.3. Connect the pocket tester (DC 20 V) to the

lean angle cut-off switch coupler as shown.

4. When turning the lean angle cut-off switchapprox. 65, the voltage reading change from1.0 V to 4.0 V.

5. Is the emergency stop switch OK?

is first turnedOFF).

7-19


Fault code No. 33 Symptom Malfunction detected in the primary lead of the ignition coil (#1, #4).

Used diagnostic code No. 30 (ignition coil #1, #4)



1 Connected condition of connectorInspect the coupler for any pinsthat may have pulled out.Check the locking condition ofthe coupler.


Ignition coil primary side coupler - orange/blackMain wiring harness ECU couplerSub-wire harness coupler

Reinstated bystarting the en-gine and oper-ating it at idle.In case of mul-ti l li d2 Open or short circuit in lead. Repair or replace if there is an open or short

circuit.Between ignition coil coupler (#1 and #4) andECU coupler /main harness

orange/black – orange/blackred/black – red/black

tiple cylinderopen or shortcircuit in lead,make sure toturn ON andOFF the mainswitch after

3 Defective ignition coil (test the primaryand secondary coils for continuity).

Execute the diagnostic mode (code No. 30)Replace if defective.Refer to “IGNITION SYSTEM” in chapter 8.

switch aftereach time ofcranking.

Fault code No. 34 Symptom Malfunction detected in the primary lead of the ignition coil (#2, #3).

Used diagnostic code No. 31 (ignition coil #2, #3)





Ignition coil primary side coupler - gray/blackMain wiring harness ECU couplerSub-wire harness coupler

Reinstated bystarting the en-gine and oper-ating it at idle.In case of mul-ti l li d2 Open or short circuit in lead wire. Repair or replace if there is an open or short

circuit.Between ignition coil coupler (#2 and #3) andECUcoupler /main harness

gray/black – gray/blackred/black – red/black

tiple cylinderopen or shortcircuit in lead,make sure toturn ON andOFF the mainswitch aftereach time of

3 Defective ignition coil (test the primaryand secondary coils for continuity).

Execute the diagnostic mode (code No. 31)Replace if defective.Refer to “IGNITION SYSTEM” in chapter 8.

each time ofcranking.

Fault code No. 41 Symptom Open or short circuit detected in the lean angle cut-off switch.

Used diagnostic code No. 08 (lean angle cut-off switch)





Lean angle cut-off switch couplerMain wiring harness ECU coupler

Reinstated byturning themains witchON.

2 Open or short circuit in wiring harness. Repair or replace if there is an open or shortcircuit.Between switch coupler and ECU coupler

black /blue - black/blueyellow/green - yellow/greenblue - blue

3 Defective lean angle cut-off switch Execute the diagnostic mode (code No. 08)Replace if defective.Refer to Fault code No. 30.

7-20


Speed sensor output voltageWhen sensor is on

DC 4.8 V or moreWhen sensor is off

DC 0.6 V or less

Tester positive probe pinkTester negative probe black/white

12

Fault code No. 42 Symptom 1 No normal signals are received from the speed sensor.2 Open or short circuit is detected in the neutral switch.

Used diagnostic code No. 07 (speed sensor) A1 A4No. 21 (neutral switch) B1 B4



A1 Connected condition of speed sensorconnectorInspect the coupler for any pins thatmay have pulled out.Check the locking condition of the cou-pler.

If there is a malfunction, repair it and connect itsecurely.Speed sensor coupler

Main wiring harness ECU coupler

Reinstated bystarting the engine, and inputting thevehicle speedsignals by

ti thA2 Open or short circuit in speed sensorlead.

Repair or replace if there is an open or shortcircuit.Between sensor coupler and ECU coupler.

blue - bluewhite /yellow - white /yellowblack /blue - black/blue

operating the motorcycle at alow speed of20 to 30 km/h.

A3 Gear for detecting vehicle speed hasbroken.

Replace if defective.Refer to “TRANSMISSION” in chapter 5.

A4 Defective speed sensor Execute the diagnostic mode (code No. 07)Replace if defective.1. Measure the speed sensor output voltage.2. Connect the pocket tester (DC 20 V) to the

speed sensor coupler terminal as shown.

3. Measure the speed sensor output voltage.

4. Is the speed sensor OK?



B1 Connected condition of connectorInspect the coupler for any pins thatmay have pulled out.Check the locking condition of the cou-pler.


Neutral switch connectorMain wiring harness ECU coupler

Reinstated bystarting the engine, and inputting thevehicle speedi l bB2 Open or short circuit in neutral switch

lead.Repair or replace if there is an open or shortcircuit.Between switch connector and ECU coupler

sky blue - black/yellow

signals by operating the motorcycle at alow speed of20 to 30 km/h

B3 Faulty shift drum(neutral detection area)

Replace if defective.Refer to “TRANSMISSION” in chapter 5.

20 to 30 km/h.

B4 Defective neutral switch Execute the diagnostic mode (code No. 21)Replace if defective.Refer to “CHECKING THE SWITCHES” inchapter 8.

7-21


Battery positive terminal red/black Battery positive terminal blue/yellow

12

Tester positive probe red Tester negative probe red/blue

34

When the leads are disconnected, the voltagecheck by the code No. 09 is impossible.

NOTE:

Fault code No. 43 Symptom The ECU is unable to monitor the battery voltage.

Used diagnostic code No. 09 (fuel system voltage)





Starting circuit cut-off relay coupler(fuel injection system relay)Fuel pump couplerInjector couplerECU coupler

Reinstated bystarting theengine andoperating it atidle.

2 Malfunction in ECU Fuel injection system relay is on.

3 Open or short circuit in the wiring har-ness.

Repair or replace if there is an open or shortcircuit.Between starting circuit cut-off relay (fuel injectionsystem relay), fuel pump, injector (#1 #4)

red/blue – red/blue

4 Malfunction or open circuit in fuel injec-tion system relay

Execute the diagnostic mode (code No. 09)

Replace if defective.1. Disconnect the starting circuit cut-off relay

from the wire harness.2. Connect the pocket tester (Ω 1) and battery

(12 V) to the starting circuit cut-off relay termi-nals as shown.

3. Does the starting circuit cut-off relay have con-tinuity between red and red/blue?

7-22


Fault code No. 44 Symptom Error is detected while reading or writing on EEP-ROM(CO adjustment value).

Used diagnostic No. 60 (EEP-ROM improper cylinder indication)



1 Malfunction in ECU Execute diagnostic code 601.Check the faulty cylinder. (If there are multiple

cylinders, the number of the faulty cylinders ap-pear alternately at 2-second intervals.)

2.Readjust the CO of the displayed cylinder.Refer to “ADJUSTING THE EXHAUST GASVOLUME” in chapter 3.

Replace ECU if defective.


Fault code No. 46 Symptom Power supply to the FI system relay is not normal.





If there is a malfunction, repair it and connect itsecurely.ECU coupler.

Reinstated bystarting the en-gine and oper-ating it at idle.

2 Faulty battery Replace or change the battery Refer to “CHECKING AND CHARGING THE BAT-TERY” in chapter 3.

3 Open or short circuit in wiring harness. Repair or replace if there is an open or short cir-cuit. Between battery and main switch

red – red Between main switch and fuse (ignition)

brown/blue – brown/blue Between fuse (ignition) and ECU

red/white – red/white

Fault code No. 50 Symptom Faulty ECU memory. (When this malfunction is detected in the ECU, the faultcode number might not appear on the meter.)




1 Malfunction in ECU Replace the ECU. Reinstated byturning themain switchON.

7-23


Fault code No. Er-1 Symptom No signals are received from the ECU.






Main wiring harness ECU couplerSub-wire harness coupler

Reinstated byturning themain switchON andreceives a


Repair or replace if there is an open or shortcircuit.Between meter coupler and ECU coupler

yellow/blue - yellow/blueblack /white - black/white

normal signal.

3 Malfunction in meter Replace the meter.

4 Malfunction in ECU Replace the ECU.

Fault code No. Er-2 Symptom No signals are received from the ECU within the specified duration.











normal signal.



Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly.











normal signal.



7-24


Fault code No. Er-4 Symptom Non-registered data has been received from the meter.











normal signal.



7-25


1234567

Removing the throttle bodiesSeatFront cowling inner panel (left and right)Fuel tankBattery


Sub-wire harness couplerCoolant temperature sensor couplerThrottle body joint clamp screwThrottle bodiesThrottle cableThrottle body jointHeat protector

2141241

Remove the parts in the order listed.Refer to “SEAT” in chapter 3.Refer to “COWLINGS” in chapter 3.Refer to “FUEL TANK” in chapter 3.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.Refer to “AIR FILTER CASE” in chapter 3.Refer to “BATTERY BOX AND BATTERYBOX BRACKET” in chapter 3.DisconnectDisconnect

Disconnect


THROTTLE BODIES FI

EAS00909

THROTTLE BODIES

7-26

THROTTLE BODIES FI


123456789

1011121314

Removing the injectorsThrottle position sensor couplerIntake air pressure sensor couplerCylinder #1-injector couplerCylinder #2-injector couplerCylinder #3-injector couplerCylinder #4-injector couplerSub wire harnessNegative pressure hoseIntake air pressure sensorFuel distributorInjectorThrottle position sensorFuel pulsation damperThrottle body assembly

11111111114111

Remove the parts in the order listed.DisconnectDisconnect

For installation, reverse the removal pro-cedure.

EAS00910

INJECTORS

7-27

THROTTLE BODIES FI

CAUTION:

CAUTION:

EAS00911

The throttle bodies should not be disas-sembled.

EAS00912

CHECKING THE INJECTORS1. Check: injectorsDamage Replace.

EAS00913

CHECKING THE THROTTLE BODIES1. Check: throttle bodiesCracks/damage Replace the throttle bo-dies as a set.

2. Check: fuel passagesObstructions Clean.

a. Wash the throttle bodies in a petroleum-based solvent.Do not use any caustic carburetor cleaningsolution.

b. Blow out all of the passages with com-pressed air.

fuel pulsation damper

Do not adjust the fuel pulsation damper.

7-28

THROTTLE BODIES FI

CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION1. Check: fuel pump operationRefer to “FUEL TANK” in chapter 3.

a. Remove the seat fuel tank.Refer to “SEAT AND FUEL TANK” in chapter3.

b. Connect the pressure gauge 1 and adapter2 onto the fuel injection pipe.

Pressure gauge90890-03153, YU-03153

Adapter90890-03176, YM-03176

c. Install the fuel tank.Refer to “FUEL TANK” in chapter 3.

d. Start the engine.e. Measure the fuel pressure.

Fuel pressure250 kPa (2.5 kg/cm2, 36.3 psi)

Faulty Replace the fuel pump assembly.

7-29

THROTTLE BODIES FI

NOTE:

EAS00916

CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR

Before adjusting the throttle position sensor, theengine idling speed should be properly ad-justed.

1. Check: throttle position sensor

a. Disconnect the throttle position sensor cou-pler.

b. Remove the throttle position sensor from thethrottle body.

c. Connect the pocket tester (Ω 1k) to thethrottle position sensor.

Positive tester probe blue terminal 1Negative tester probe black/blue

terminal 2

d. Measure the maximum throttle position sen-sor resistance.Out of specification Replace the throttleposition sensor.

Maximum throttle positionsensor resistance

3.5 6.5 kΩ at 20C (68F)(blue - black/blue)

e. Connect the pocket tester (Ω 1k) to thethrottle position sensor.

Positive tester probe yellow terminal 3Negative tester probe black/blue

terminal 2

7-30

THROTTLE BODIES FI

NOTE:

Tester positive probe yellow terminal Tester negative probe

black/blue terminal

1

2

f. While slowly opening the throttle, check thatthe throttle position sensor resistance is with-in the specified range.The resistance does not change or itchanges abruptly Replace the throttleposition sensor.The slot is worn or broken Replace thethrottle position sensor.

Check mainly that the resistance changes grad-ually when turning the throttle, since the read-ings (from closed to wide-open throttle) may dif-fer slightly from those specified.

Throttle position sensorresistance

0 5 1.5 kΩ at 20C (68F)(yellow – black/blue)

2. Adjust: throttle position sensor angle

a. Connect the throttle position sensor couplerto the wire harness.

b. Connect the digital circuit tester to the throttleposition sensor.

Digital circuit tester90890-03174

c. Measure the throttle position sensor voltage.d. Adjust the throttle position sensor angle so

the measured voltage is within the specifiedrange.

Throttle position sensor voltage0.63 0.73 V(yellow – black/blue)

g. After adjusting the throttle position sensorangle, tighten the throttle position sensorscrews.

7-31

AIR INDUCTION SYSTEM FI

EAS00507

AIR INDUCTION SYSTEMAIR INJECTIONThe air induction system burns unburned ex-haust gases by injecting fresh air (secondaryair) into the exhaust port, reducing the emissionof hydrocarbons.When there is negative pressure at the exhaustport, the reed valve opens, allowing secondaryair to flow into the exhaust port. The requiredtemperature for burning the unburned exhaustgases is approximately 600 to 700C (1112 to1292F).

EAS0097

AIR CUT-OFF VALVEThe air cut-off valve is controlled by the signalsfrom the ECU in accordance with the combus-tion conditions. Ordinarily, the air cut-off valveopens to allow the air to flow during idle andcloses to cut-off the flow when the motorcycle isbeing driven. However, if the coolant tempera-ture is below the specified value, the air cut-offvalve remains open and allows the air to flowinto the exhaust pipe until the temperature be-comes higher than the specified value.A From the air cleanerB To the cylinder head

7-32


A To cylinder #1 and #2B To cylinder #3 and #4

1 Air cut-off valve2 Reed valve3 To air filter case

EAS00509

AIR INDUCTION SYSTEM DIAGRAMS

7-33


EAS00510

CHECKING THE AIR INDUCTION SYSTEM1. Check:hosesLoose connection Connect properly.Cracks/damage Replace.

pipesCracks/damage Replace.

2. Check: reed valve 1 reed valve stopper reed valve seatCracks/damage Replace the reed valve.

3. Measure: reed valve bending limit aOut of specification Replace the reedvalve.

Reed valve bending limit0.4 mm (0.016 in)

1 Surface plate

4. Check:air cut-off valveCracks/damage Replace.

7-34


5. CheckAI system solenoid

a. Remove the AI system solenoid coupler fromthe wire harness.

b. Connect the pocket tester (Ω 1) to the AIsystem solenoid terminal as shown.

Tester positive probe brown/red 1Tester negative probe red/white 2

c. Measure the AI system solenoid resistance.

AI system solenoid resistance18 22 Ω at 20C (68F)

d. Out of specification Replace.

ELEC 8

ELEC

CHAPTER 8ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING SWITCH CONTINUITY 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE SWITCHES 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE BULBS AND BULB SOCKETS 8-5. . . . . . . . . . . . . . . . . TYPES OF BULBS 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULBS 8-5. . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULB SOCKETS 8-6. . . . . . . CHECKING THE LED’s 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION SYSTEM 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC STARTING SYSTEM 8-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 8-15. . . . . . . . . TROUBLESHOOTING 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER MOTOR 8-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER MOTOR 8-21. . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE STARTER MOTOR 8-22. . . . . . . . . . . . . . . . . . . . . .

CHARGING SYSTEM 8-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 8-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE LIGHTING SYSTEM 8-31. . . . . . . . . . . . . . . . . . . . . . . .

SIGNALING SYSTEM 8-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SIGNALING SYSTEM 8-36. . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM 8-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELEC

FUEL PUMP SYSTEM 8-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP SYSTEM 8-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP 8-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMMOBILIZER SYSTEM 8-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SYSTEM DIAGRAM 8-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 8-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KEY ID REGISTRATION METHOD 8-55. . . . . . . . . . . . . . . . . . . . . . . . . . . SELF-DIAGNOSIS ERROR CODE INDICATION 8-57. . . . . . . . . . . . . . . TROUBLESHOOTING 8-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE IMMOBILIZER SYSTEM 8-59. . . . . . . . . . . . . . . . . . . . REPLACEMENT PARTS ON TROUBLES 8-61. . . . . . . . . . . . . . . . . . . . .

SELF-DIAGNOSIS 8-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1

ELECTRICAL COMPONENTS ELEC

9 Oil level switch10 Radiator fan motor11 Horn12 Ignition coil

1 Main switch (immobilizer unit)2 Front brake light switch3 Starter relay4 Battery5 Fuse box6 Rear brake light switch7 Neutral switch8 Sidestand switch

EAS00729

ELECTRICAL SYSTEMELECTRICAL COMPONENTS

8-2

9 Radiator fan motor relay10 Turn signal relay11 Rectifier / regulator12 Throttle position sensor

1 Coolant temperature sensor2 Intake air temperature sensor3 Intake air pressure sensor4 Fuel pump5 ECU6 Lean angle cut-off switch7 Starting circuit cut-off relay8 Dimmer relay

ELECTRICAL COMPONENTS ELEC

8-3

CHECKING SWITCH CONTINUITY ELEC

CAUTION:

NOTE:

NOTE:

EAS00730

CHECKING SWITCH CONTINUITYCheck each switch for continuity with the pockettester. If the continuity reading is incorrect,check the wiring connections and if necessary,replace the switch.

Never insert the tester probes into the cou-pler terminal slots. Always insert the probesfrom the opposite end of the coupler 1 tak-ing care not to loosen or damage the leads.


Before checking for continuity, set the pockettester to “0” and to the “Ω 1” range.

When checking for continuity, switch back andforth between the switch positions a few times.

The terminal connections for switches (e.g.,main switch, engine stop switch) are shown inan illustration similar to the one on the left.The switch positions a are shown in the far leftcolumn and the switch lead colors b are shownin the top row in the switch illustration.

“ ” indicates a continuity of electricitybetween switch terminals (i.e., a closed circuitat the respective switch position).

The example illustration on the left showsthat:There is continuity between red and brown/redwhen the switch is set to “P”.There is continuity between red, brown/blueand brown/red when the switch is set to “ON”.

8-4

11 Oil level switch12 Neutral switch13 Rear brake light switch14 Fuse box15 Hazard switch

1 Main switch2 Horn switch3 Dimmer switch4 Pass switch5 Turn signal switch

6 Clutch switch7 Sidestand switch8 Engine stop switch9 Front brake light switch10 Start switch

CHECKING THE SWITCHES ELEC

EAS00731

CHECKING THE SWITCHESCheck each switch for damage or wear, proper connections, and also for continuity between the termi-nals. Refer to “CHECKING SWITCH CONTINUITY”.Damage/wear Repair or replace.Improperly connected Properly connect.Incorrect continuity reading Replace the switch.

8-5

CHECKING THE BULBS AND BULB SOCKETS ELEC

WARNING

EAS00732

CHECKING THE BULBS ANDBULB SOCKETSCheck each bulb and bulb socket for damage orwear, proper connections, and also for continu-ity between the terminals.Damage/wear Repair or replace the bulb,bulb socket or both.Improperly connected Properly connect.No continuity Repair or replace the bulb, bulbsocket or both.

TYPES OF BULBSThe bulbs used on this motorcycle are shown inthe illustration on the left.Bulbs A and B are used for the headlightsand usually use a bulb holder that must bedetached before removing the bulb. The ma-jority of these types of bulbs can be removedfrom their respective socket by turning themcounterclockwise.

Bulbs C are used for turn signal andtail /brake lights and can be removed fromthe socket by pushing and turning the bulbcounterclockwise.

CHECKING THE CONDITION OF THEBULBSThe following procedure applies to all of thebulbs.1. Remove:bulb

Since the headlight bulb gets extremelyhot, keep flammable products and yourhands away from the bulb until it hascooled down.

When changing the tail /brake light bulb,comfirm that the frame has cooled accord-ing to the warning label and change thetail /brake light bulb.

8-6


CAUTION:

NOTE:

Be sure to hold the socket firmly when re-moving the bulb. Never pull the lead, other-wise it may be pulled out of the terminal inthe coupler.

Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb, and the luminous flux will be adverse-ly affected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.

2. Check:bulb (for continuity)(with the pocket tester)No continuity Replace.


Before checking for continuity, set the pockettester to “0” and to the “Ω 1” range.

a. Connect the positive tester probe to terminal1 and the negative tester probe to terminal2 , and check the continuity.

b. Connect the positive tester probe to terminal1 and the negative tester probe to terminal3 , and check the continuity.

c. If either of the readings indicate no continuity,replace the bulb.

CHECKING THE CONDITION OF THE BULBSOCKETSThe following procedure applies to all of the bulbsockets.1. Check:bulb socket (for continuity)(with the pocket tester)No continuity Replace.

8-7


NOTE:

NOTE:

WARNING


Check each bulb socket for continuity in thesame manner as described in the bulb section;however, note the following.

a. Install a good bulb into the bulb socket.b. Connect the pocket tester probes to the re-

spective leads of the bulb socket.c. Check the bulb socket for continuity. If any of

the readings indicate no continuity, replacethe bulb socket.

CHECKING THE LEDsThe following procedures applies to all of theLEDs.1. Check:LED (for proper operation)Improper operation Replace.

a. Disconnect the meter assembly coupler (me-ter assembly side).

b. Connect two jumper leads 1 from the bat-tery terminals to the respective coupler ter-minal.

As for connecting with which coupler terminal,refer to “CABLE ROUTING” in chapter 2.

A wire that is used as a jumper lead musthave at least the same capacity of the bat-tery lead, otherwise the jumper lead mayburn.

This check is likely to produce sparks,therefore, make sure no flammable gas orfluid is in the vicinity.

c. When the jumper leads are connected to theterminals the respective LED should illumi-nate.Does not light Replace the meter assem-bly.

8-8

1 Main switch7 Fuse (main)10 Battery11 Starting circuit cut-off relay12 Sidestand switch13 Neutral switch17 Lean angle cut-off switch18 Crankshaft position sensor21 ECU28 Ignition coil #1 and #429 ignition coil #2 and #330 Spark plug43 Engine stop switch50 Fuse (ignition)57 Clutch switch

IGNITION SYSTEM ELEC

EAS00735

IGNITION SYSTEMCIRCUIT DIAGRAM

8-9

YES NO

2. Battery

Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.

Minimum open-circuit voltage12.8 V or more at 20C (68F)

Is the battery OK?

Clean the batteryterminals.

Recharge or re-place the battery.

EAS00739

YES NO

EAS00741

3. Spark plugs

The following procedure applies to all of thespark plugs.Check the condition of the spark plug.Check the spark plug type.Measure the spark plug gap.Refer to “CHECKING THE SPARK PLUGS”in chapter 3.

Standard spark plugCR9EK (NGK)

Spark plug gap0.6 0.7 mm (0.0236 0.0276 in)

Is the spark plug in good condition, is it of thecorrect type, and is its gap within specifica-tion?

Re-gap or replacethe spark plug.


NOTE:

YES NO

1. Main and ignition fuses

Check the main and ignition fuses for conti-nuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main and ignition fuses OK?

Replace the fuse(s).

EAS00737

TROUBLESHOOTING

The ignition system fails to operate (nospark or intermittent spark).

Check:1. main and ignition fuses2. battery3. spark plugs4. ignition spark gap5. spark plug cap resistance6. ignition coil resistance7. crankshaft position sensor8. main switch9. engine stop switch10. neutral switch11. sidestand switch12. clutch switch13. starting circuit cut-off relay (diode)14. lean angle cut-off switch15. wiring connections

(of the entire ignition system)

Before troubleshooting, remove the followingpart(s):

1. seat2. fuel tank3. side cowlingsTroubleshoot with the following special tool(s).

Dynamic spark testerYM-34487

Ignition checker90890-06754


EAS00738

8-10


NO YES

1

a

2

4. Ignition spark gap

The following procedure applies to all of thespark plugs.Disconnect the spark plug cap from thespark plug.

Connect the ignition checker and sparkplug cap as shown.

Set the main switch to “ON”.Measure the ignition spark gap .Crank the engine by pushing the starterswitch and gradually increase the spark gapuntil a misfire occurs.

Minimum ignition spark gap6 mm (0.24 in)

Is there a spark and is the spark gap withinspecification?

The ignition systemis OK.

EAS00745

5. Spark plug cap resistance

The following procedure applies to all of thespark plug caps.Remove the spark plug cap from the sparkplug lead.

Connect the pocket tester (Ω 1k) to thespark plug cap as shown.

Measure the spark plug cap resistance.

YES NO

Spark plug cap resistance10 kΩ at 20C (68F)

Is the spark plug cap OK?

Replace the sparkplug cap.

EAS00747

6. Ignition coil resistance

The following procedure applies to all of theignition coils.Disconnect the ignition coil leads from thewire harness.

Connect the pocket tester (Ω 1) to theignition coil as shown.

Positive tester probe red/blackNegative tester probe

orange/black (gray/black)

Connect the pocket tester (Ω 1k) to theignition coil as shown.

Measure the primary coil resistance.

Primary coil resistance1.53 2.07 Ω at 20C (68F)

EAS00743

8-11


Negative tester probe spark plug lead

Positive tester probe spark lug lead

1

2

Measure the secondary coil resistance.

Secondary coil resistance12 18 kΩ at 20C (68F)

Is the ignition coil OK?

YES NO

Replace the ignitioncoil.

7. Crankshaft position sensor resistance

Disconnect the crankshaft position sensorcoupler from the wire harness.

Connect the pocket tester (Ω 100) to thecrankshaft position sensor coupler as shown.

Positive tester probe grayNegative tester probe black

12

Measure the crankshaft position sensor re-sistance.

EAS00748

Crankshaft position sensor resis-tance

248 372 Ω at 20C (68F)(between gray and black)

Is the crankshaft position sensor OK?

YES NO

Replace the crank-shaft position sen-sor.

EAS00749

8. Main switch

Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the main switch OK?

YES NO

Replace the mainswitch.

EAS00750

9. Engine stop switch

Check the engine stop switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the engine stop switch OK?

YES NO

Replace the righthandlebar switch.

EAS00751

10. Neutral switch

Check the neutral switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the neutral switch OK?

YES NO

Replace the neutralswitch.

8-12


EAS00752

11. Sidestand switch

Check the sidestand switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the sidestand switch OK?

YES NO

Replace the side-stand switch.

EAS00763

12. Clutch switch

Check the clutch switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the clutch switch OK?

YES NO

Replace the clutchswitch.

13. Starting circuit cut-off relay (diode)

Disconnect the starting circuit cut-off relaycoupler from the wire harness.

Connect the pocket tester (Ω 1) to thestarting circuit cut-off relay coupler asshown.

Check the starting circuit cut-off relay forcontinuity.

Positive tester probe black/red

Negative tester probe sky blue

1

2

EAS00753


Negative tester probe blue/green

Continuity

1

3

Positive tester probe sky blue

Negative tester probe black/red

2

1

Positive tester probe blue/green


No continuity

3

1

YES NO

Replace the startingcircuit cut-off relay.

When you switch the positive and negativetester probes, the readings in the above chartwill be reversed.

Are the tester readings correct?

NOTE:

14. Lean angle cut-off switch

Check the lean angle cut-off switch.Refer to “FUEL INJECTION SYSTEM” inchapter 7.

Is the lean angle cut-off switch OK?

YES NO

Replace the leanangle cut-off switch.

8-13


EAS00754

15. Wiring

Check the entire ignition system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the ignition system’s wiring properly con-nected and without defects?

YES NO

Properly connect orrepair the ignitionsystem’s wiring.

Replace the ECU.

8-14

1 Main switch7 Fuse (main)8 Starter relay9 Starter motor10 Battery11 Starting circuit cut-off relay12 Sidestand switch13 Neutral switch43 Engine stop switch44 Start switch50 Fuse (ignition)57 Clutch switch

ELECTRIC STARTING SYSTEM ELEC

EAS00755

ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM

8-15


EAS00756

STARTING CIRCUIT CUT-OFF SYSTEM OPERATIONIf the engine stop switch is set to “ ” and themain switch is set to “ON” (both switches areclosed), the starter motor can only operate if atleast one of the following conditions is met:The transmission is in neutral (the neutralswitch is closed).

The clutch lever is pulled to the handlebar (theclutch switch is closed) and the sidestand is up(the sidestand switch is closed).

The starting circuit cut-off relay prevents thestarter motor from operating when neither ofthese conditions has been met. In this instance,the starting circuit cut-off relay is open so cur-rent cannot reach the starter motor. When atleast one of the above conditions has been metthe starting circuit cut-off relay is closed and theengine can be started by pressing the starterswitch.

WHEN THE TRANSMISSION IS INNEUTRAL

WHEN THE SIDESTAND IS UP ANDTHE CLUTCH LEVER IS PULLED TOTHE HANDLEBAR

1 Battery2 Main fuse3 Main switch4 Ignition fuse5 Engine stop switch6 Starting circuit cut-off relay7 Diode8 Clutch switch9 Sidestand switch10 Neutral switch11 Start switch12 Starter relay13 Starter motor

8-16

YES NO

3. Starter motor

Connect the positive battery terminal andstarter motor lead with a jumper lead .

Repair or replace thestarter motor.

A wire that is used as a jumper leadmust have at least the same capacity ormore as that of the battery lead, other-wise the jumper lead may burn.

This check is likely to produce sparks,therefore make sure nothing flammableis in the vicinity.

Does the starter motor turn?

WARNING

12 3

EAS00758

YES NO

2. Battery



Is the battery OK?



EAS00739


NOTE:

YES NO

1. Main and ignition fuses

Check the main and ignition fuses for conti-nuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main and ignition fuses OK?


EAS00757

TROUBLESHOOTING

The starter motor fails to turn.

Check:1. main and ignition fuses2. battery3. starter motor4. starting circuit cut-off relay5. starter relay6. main switch7. engine stop switch8. neutral switch9. sidestand switch

10. clutch switch11. start switch12. wiring connections

(of the entire starting system)


1. seat2. front cowling inner panel (left and right)3. fuel tank4. left side coverTroubleshoot with the following special tool(s).


EAS00738

8-17

4. Starting circuit cut-off relay


Connect the pocket tester (Ω 1) and bat-tery (12 V) to the starting circuit cut-off relaycoupler as shown.

YES NO


Positive tester probe white/blue Negative tester probe blue/white

Does the starting circuit cut-off relay havecontinuity between white/blue andblue/white?

1

2

34

EAS00759

Positive battery terminal red/black Negative battery terminal

black/yellow

EAS00761

5. Starter relay

Disconnect the starter relay coupler from thecoupler.

Connect the pocket tester (Ω 1) and battery(12 V) to the starter relay coupler as shown.

YES NO

Replace the starterrelay.

Positive battery terminal red/white Negative battery terminal blue/white

Positive tester probe red Negative tester probe black

12

34

Does the starter relay have continuity be-tween red and black?

EAS00749

6. Main switch



YES NO


EAS00750




YES NO


EAS00751

8. Neutral switch



YES NO



8-18

Check the entire starting system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the starting system’s wiring properly con-nected and without defects?

EAS00766

12. Wiring

YES NO

Properly connect orrepair the startingsystem’s wiring.

The starting systemcircuit is OK.

11. Start switch

Check the start switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the start switch OK?

YES NO


EAS00764

10. Clutch switch

Check the clutch switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the clutch switch OK?

YES NO

Replace the clutchswitch.

EAS00763

EAS00752

9. Sidestand switch

Check the sidestand switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the sidestand switch OK?

YES NO

Replace the side-stand switch.


8-19

STARTER MOTOR ELEC


12

Removing the starter motorSeatFront cowling inner panel (left and right)Fuel tankThrottle bodies

Starter motor leadStarter motor

11

Remove the parts in the order listed.Refer to “SEAT” in chapter 3.Refer to “COWLINGS” in chapter 3.Refer to “FUEL TANK” in chapter 3.Refer to “THROTTLE BODIES” in chapter 7.


10 Nm (1.0 mkg, 7.2 ftlb)

5 Nm (0.5 mkg, 3.6 ftlb)

EAS00767

STARTER MOTOR

8-20

STARTER MOTOR ELEC


Disassembling the starter motorO-ringFront coverLock washerOil sealBearingWasher setRear coverWasher setO-ringBrush holderArmature assemblyStarter motor yokeO-ring

1111111121112

Disassembly the parts in the order listed.


123456789101112

3.4 Nm (0.34 mkg, 2.5 ftlb)

7.8 Nm (0.78 mkg, 5.6 ftlb)

13

EAS00768

8-21

STARTER MOTOR ELEC

NOTE:

EAS00770

CHECKING THE STARTER MOTOR1. Check:commutatorDirt Clean with 600 grit sandpaper.

2. Measure:commutator diameter aOut of specification Replace the startermotor.

Commutator wear limit27 mm (1.06 in)

3. Measure:mica undercut aOut of specification Scrape the mica to theproper measurement with a hacksaw bladethat has been grounded to fit the commuta-tor.

Mica undercut0.7 mm (0.03 in)

The mica of the commutator must be undercutto ensure proper operation of the commutator.

4. Measure:armature assembly resistances (commuta-tor and insulation)Out of specification Replace the startermotor.

a. Measure the armature assembly resistanceswith the pocket tester.


Armature coilCommutator resistance 1

0.0012 0.0022 Ω at 20C (68F)

Insulation resistance 2Above 1 MΩ at 20C (68F)

b. If any resistance is out of specification, re-place the starter motor.

8-22

STARTER MOTOR ELEC

NOTE:

5. Measure:brush length a .Out of specification Replace the brushesas a set.

Brush length wear limit3.5 mm (0.14 in)

6. Measure:brush spring forceOut of specification Replace the brushsprings as a set.

Brush spring force7.16 9.52 N(730 971 gf, 25.77 34.27 oz)

7. Check:gear teethDamage/wear Replace the gear.

8. Check:bearingoil sealDamage/wear Replace the defectivepart(s).

EAS00772

ASSEMBLING THE STARTER MOTOR1. Install:brush seat 1

2. Install:armature 2O-ring 3 New

Align the tab a on the brush seat with the slot bin the starter motor rear cover.

8-23

STARTER MOTOR ELEC

3.4 Nm (0.34 mkg, 2.5 ftlb)

NOTE:

3. Install:starter motor yoke 1O-ring 2 New front cover 3rear cover 4bolts 5

Align the match marks a on the starter motoryoke with the match marks b on the front andstarter motor rear covers.

8-24

2 A.C. magneto3 Rectifier / regulator7 Fuse (main)10 Battery

CHARGING SYSTEM ELEC

EAS00773

CHARGING SYSTEMCIRCUIT DIAGRAM

8-25

NO YES

3. Charging voltage

Set the engine tachometer to the ignition coilof cylinder #1.

Connect the pocket tester (DC 20 V) to thebattery as shown.

The charging circuitis OK.

Positive tester probe positive battery terminal

Negative tester probe negative battery terminal

Start the engine and let it run at approxi-mately 5,000 r/min.

Measure the charging voltage.

Charging voltage14 V at 5,000 r/min

Is the charging voltage within specification?

EAS00775

YES NO



Make sure the battery is fully charged.NOTE:


Is the battery OK?


NOTE:

YES NO

1. Main fuse

Check the main fuse for continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Is the main fuse OK?

Replace the fuse.

2. Battery


EAS00739

EAS00774

TROUBLESHOOTING

The battery is not being charged.

Check:1. main fuse2. battery3. charging voltage4. stator coil lead5. stator coil resistance6. wiring connections

(of the entire charging system)


1. seat2. front cowling inner panel (left and right)3. fuel tankTroubleshoot with the following special tool(s).


EAS00738

8-26


YES NO

5. Stator coil resistance

Remove the generator cover.Connect the pocket tester (Ω 1) to the sta-tor coils as shown.

Replace the statorcoil assembly.

EAS00776

Positive tester probe white Negative tester probe white

Positive tester probe white Negative tester probe white

1

1

2

3

Measure the stator coil resistances.

Stator coil resistance0.22 0.34 Ω at 20C (68F)

Is the stator coil OK?

YES NO

6. Wiring

Check the wiring connections of the entirecharging system.Refer to “CIRCUIT DIAGRAM”.

Is the charging system’s wiring properly con-nected and without defects?

Properly connect orrepair the chargingsystem’s wiring.

EAS00779

Replace the rectifi-er/regulator.

4. Stator coil lead

Disconnect stator coil lead coupler.Connect the pocket tester (Ω 1) to the sta-tor coil lead coupler as shown.

Positive tester probe white

Negative tester probe ground

3



1



No continuity

2

YES NO

Replace the statorcoil lead.


8-27

Ch

B

Ch

B

R/B

R/B

C

G/B

G/B

C

LL

C

B/L

B/L

D

P/W

P/W

D

YY

D

Br/

W

Br/WD

G/W

G/WD

R/L

R/L

C

B/L

G/W

B

B/L

B

B

B

B

B/L

Dg

G/L

R/W

Ch

R/G

Y

Dg

B Dg

B

LgW

B/W

G/W

Y/L

L/R

Dg

G/L

R/W

Ch

R/G

Y

L

G/B

R/B

BB

BB

B/Y

B

B/G

B

L/R

B

L/R

B

B B

Ch

Dg

Y

B

B/L

YL

P/W

B/L

L

Br/W

B/L

L/R

L/R

B

B/GB/GB

Dg

Dg

R/L

R/B

R/L

G/B

R/L

G/B

R/L

R/B

B

R/L

R/L

R/L

B/L

Ch

ChB

W

W B

B

LgW

B/W

G/W

Y/L

B/W

B/W

A

Y/L

A

R/G

R/GA

G/W

G/WB

R/W

R/WBLg

LgA

G/L

G/LA

B/YB/YB

R/L

B/L

R/W

R

R

R

WW

WW

W

W

R

R

R/W

L/W

R-

B

WW

W

L/G

L/G

B/Y

B/L

Y/G

L

R Br/

L

R/W

R/W

Br/

L

B

YL

B

B/R

HI

LO

R/G

W/L

W/L

B B

B

B

OF

F

ON

L N R

YL

B

L/W

Br/

L

Br/L

Br/

L

OF

F

ON

Dg

YL/

BBr

/WR

/Y

Ch

B/R

G-

BB

/YB

r

R/Y G

Y/B

R/Y

BB

BB

BB

R/Y

Br/B L

G/Y

R/W

Dg

YL/

BBr

/WR

/Y

Ch

B/R

-B

B/Y

Br

BB

BB

BB

Br/R

B/L

W/Y

W/Y

B

BB

Br

Y

Br

G/Y

R

R

L/W

L/W

R/B

R/W

B L

B L

B

B/Y

B/Y

BB L/

GB

B/R

B/R

R/L

W/L

R/B

L/W

R

LgB

/YS

bB

/RL/

GR/

WL/

YL/

W

Ch

B

B

Ch

B

R Br/

L

Dg

B

BB

R/G

Y/L

G/L

R/W

FR

EE

PU

SH

OF

F

RU

N

Ch

Dg

BG

/W

R/W

BR

/L

L/Y

B/Y

Dg

B

W/Y

L B/L

B

Br

B

B

R/W

Sb

Sb

Y/L

Y/L

BB

R/G

Y/L

LgR

/W

R/L

R/L

Gy

B

Gy

B/L

Br/

R

Br/R

Br/R

ON

OF

F

P

R/B

B

R/B

R/B

PO

/R

B/W

R/L

L/Y

L/Y

R/W

Gy

Gy

R/W

Br/R

Br/

R

Br/

R

B

L

L/W

Sb

Sb

Br/BBr/

B

B/W

Y/B

Y/B

LL

G/Y

G/Y

R/Y

R/Y

Lg

Lg

B/G

L/W

R/W

R/B

BB

/R

Br/G

Br/

G

Br/W

Br/W

R/W

G/W

Br/W

Y

P/W

B/L

G/W

Br/W

Y

P/W

B/L

R/B

R/L

G/B

L

B

YG/

WL

B/R

B/L

R/W

R/L

Gy

Y/L

Br/R

G/B

R/B

O/B

W/Y

Br/W

P/W

Y/G

B/W

B/Y

L/W

BL/

YY

/BG

/YGy

/B

R/B

R/L

G/B

L

G/L

Y/L

R/G

LgB

/W

G/L

Y/L

R/G

LgB

/W

Ch

Ch

Dg

Dg

W

G/W

G/W

L/R

W

Y/L

R/Y

BB

B

WW

WW

WW

B

R

G/L

G/L

Br

Br

L

OF

F

ON

Y

Y

B

B

L

R/W

R

Y

Y

L/B

Br/W

Br/G

B/L

G

G

B

B

R/G

R/GWW

Y/G

Y/G

B

B/W

BL

O/B

O/B

Gy/

B

Gy/

B

LL

P/W

P/W

B/L

B/L

G/Y

W/L

R/W

R/B

BB

r

R/W

L/R

B/Y

BB/

G

G/W

WC

hD

g

R/W

L/R

YB

G

G/W

WC

hD

g

Y

Y

Br/

W

Br/W

G/W

G/W

R/B

R/B

G/B

G/B

6

4

SUB-

WIR

E H

ARN

ESS

1W

IRE

HA

RN

ES

SW

IRE

HA

RN

ES

SW

IRE

HA

RN

ES

SW

IRE

HA

RN

ES

SH

EA

DLI

GH

T S

UB

WIR

E H

AR

NE

SS

2HE

ADLIG

HT SU

B WIRE

HARN

ESS 1

SUB-

WIR

E H

ARN

ESS

2

DC

BA

23

1

40

45

46

47

48 49 50 51

52

54

55

53

5

10

7 8

9

41

4243

44

56

57

64

6567

6665

6869

7071

63

5859

6061

62

14

12

13

11

15 16 17

343332 35

36

37 38 38

36

39

31

28 29

30 30

19 20

18

21

27

2322 24 25

26

LIGHTING SYSTEM ELEC

EAS00780

LIGHTING SYSTEMCIRCUIT DIAGRAM

8-28


1 Main switch7 Fuse (main)10 Battery21 ECU37 High beam indicator light49 Fuse (headlight)50 Fuse (ignition)51 Fuse (park)54 License plate light55 Tail /brake light58 Pass switch59 Dimmer switch64 Dimmer relay65 Auxiliary light66 Headlight (high beam)67 Headlight (low beam)

8-29

YES NO



EAS00749

3. Main switch



YES NO


EAS00784

YES NO

4. Dimmer switch

Check the dimmer switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the dimmer switch OK?

The dimmer switch isfaulty. Replace theleft handlebar switch.


Is the battery OK?

EAS00786

YES NO

5. Pass switch

Check the pass switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the pass switch OK?

The pass switch isfaulty. Replace theleft handlebar switch.


NOTE:

YES NO

1. Main, headlight, ignition and park fuses

Check the main, park, ignition and headlightfuses for continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main, park, ignition and headlightfuses OK?


2. Battery


EAS00739

EAS00781

TROUBLESHOOTING

Any of the following fail to light: headlight,high beam indicator light, taillight, licencelight or meter light.

Check:1. main, park, ignition and headlight fuses2. battery3. main switch4. dimmer switch5. pass switch6. dimmer relay7. wiring connections

(of the entire lighting system)


1. seat2. front cowling inner panel (left and right)3. fuel tank4. side coverTroubleshoot with the following special tool(s).


EAS00738

8-30

Does the dimmer relay have continuity be-tween red/yellow and green?

NOYES

Replace the dimmerrelay.

Positive tester probe red/yellow Negative tester probe green

12

34

6. Dimmer relay

Disconnect the dimmer relay from the cou-pler.

Connect the pocket tester (Ω 1) and bat-tery (12 V) to the dimmer relay as shown.

Positive battery lead red/yellow Negative battery lead yellow/black

EAS00787

YES NO

7. Wiring

Check the entire lighting system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the lighting system’s wiring properly con-nected and without defects?

Properly connect orrepair the lightingsystem’s wiring.

Check the conditionof each of the lightingsystem’s circuits.Refer to “CHECK-ING THE LIGHTINGSYSTEM”.


8-31

High beam indicator light (LEDs)Positive tester probe yellow Negative tester probe

black/white

YES NO

1. Headlight bulb and socket

Check the headlight bulb and socket for con-tinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the headlight bulb and socket OK?

Replace the head-light bulb, socket orboth.

YES NO

2. Voltage

Connect the pocket tester (DC 20 V) to theheadlight and meter assembly couplers asshown.

The wiring circuitfrom the main switchto the headlight cou-pler is faulty andmust be repaired.

When the dimmer switch is set to “ ”When the dimmer switch is set to “ ”

Headlight coupler (wire harness side)Low beam

HeadlightPositive tester probe black Negative tester probe black/green

12

Meter assembly coupler (wire harness side)

Turn the main switch to “ON”.Start the engine.Set the dimmer switch to “ ” or “ ”.Measure the voltage (DC 12 V) ofblack/green or black/yellow on theheadlight coupler (wire harness side).

Is the voltage within specification?

2

This circuit is OK.

AB

HeadlightPositive tester probe black Negative tester probe black/yellow

A

Headlight coupler (wire harness side)High beamB

5

6

34

4


EAS00788

CHECKING THE LIGHTING SYSTEM1. The headlight and the high beam indicator

light fail to come on.

8-32


YES NO

1. License plate light bulb and socket

Check the license plate light bulb and socketfor continuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the license plate light bulb and socketOK?

Replace the licenseplate light bulb, sock-et or both.

EAS00792

2. The license plate light fails to come on.

YES NO

2. Voltage

Connect the pocket tester (DC 20 V) to thelicense plate light coupler (wire harness lightside) as shown.

The wiring circuitfrom the main switchto the license platelight coupler is faultyand must be re-paired.

Positive tester probe blue Negative tester probe black

12

Turn the main switch to “ON”.Measure the voltage (DC 12 V) of blue onthe license plate light coupler (wire harnessside).


1

This circuit is OK.

8-33


YES NO

1. Tail /brake light bulb and socket

Check the tail /brake light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the tail /brake light bulb and socket OK?

Replace the tail /brake light bulb,socket or both.

EAS00790

3. The tail /brake light fails to come on.

YES NO

2. Voltage

Connect the pocket tester (DC 20 V) to thetail /brake light coupler (wire harness side)as shown.

Wiring circuit fromthe main switch tothe tail /brake lightcoupler is faulty andmust be repaired.

Positive tester probe blueNegative tester probe black

12

Turn the main switch to “ON”.Measure the voltage (DC 12 V) of blue onthe tail /brake light coupler (wire harnessside).


2

This circuit is OK.

EAS00791

4. The auxiliary light fails to come on.

YES NO

1. Auxiliary light and socket

Check the auxiliary light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the auxiliary light .bulb and socket OK?

Replace the auxiliarylight bulb, socket orboth.

YES NO

2. Voltage

Connect the pocket tester (DC 20 V) to theauxiliary light coupler (auxiliary light side) asshown.

The wiring circuitfrom the main switchto the auxiliary lightcoupler is faulty andmust be repaired.

Positive tester probe blackNegative tester probe blue/red

12

Turn the main switch to “ON”.Measure the voltage (DC 12 V) of blue/red

on the auxiliary light coupler (auxiliarylight side).


2

This circuit is OK.

8-34

SIGNALING SYSTEM ELEC

EAS00793

SIGNALING SYSTEMCIRCUIT DIAGRAM

8-35


1 Main switch4 Fuse (backup)7 Fuse (main)10 Battery11 Starting circuit cut-off relay13 Neutral switch14 Fuel pump21 ECU33 Oil level waning light35 Neutral indicator light36 Multi-function meter38 Turn signal indicator light39 Oil level switch42 Front brake light switch48 Fuse (signal)50 Fuse (ignition)51 Fuse (park)52 Turn signal relay53 Rear brake light switch55 Tail /brake light60 Hazard switch61 Turn signal switch62 Horn switch63 Horn68 Rear turn signal light (right)69 Rear turn signal light (left)70 Front turn signal light (right)71 Front turn signal light (left)

8-36

YES NO



EAS00749

3. Main switch



YES NO


YES NO

1. Horn switch

Check the horn switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the horn switch OK?

Replace the left han-dlebar switch.

EAS00796

CHECKING THE SIGNALING SYSTEM1. The horn fails to sound.

EAS00795

4. Wiring

Check the entire signaling system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the signaling system’s wiring properlyconnected and without defects?

YES NO

Properly connect orrepair the signalingsystem’s wiring.

Check the conditionof each of the signal-ing system’s circuits.Refer to “CHECK-ING THE LIGHTINGSYSTEM”.


NOTE:

YES NO

1. Backup, main, ignition, signal and parkfuses

Check the backup, main, ignition, signal andpark fuses for continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the backup, main, ignition, signal andpark fuses OK?


2. Battery



Is the battery OK?

EAS00739

EAS00794

TROUBLESHOOTING

Any of the following fail to light: turn sig-nal light, brake light or an indicator light.

The horn fails to sound.

Check:1. backup, main, ignition, signal, and park

fuses2. battery3. main switch4. wiring connections

(of the entire signaling system)




EAS00738

8-37


YES NO

1. Tail /brake light bulb and socket

Check the tail /brake light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the tail /brake light bulb and socket OK?

Replace the tail /brake light bulb,socket or both.

EAS00797

2. The tail /brake light fails to come on.

YES NO

2. Brake light switches

Check the brake light switches for continuity.Refer to “CHECKING THE SWITCHES”.

Is the brake light switch OK?

Replace the brakelight switch.

3. Voltage

Connect the pocket tester (DC 20 V) to thetail /brake light coupler (wire harness side)as shown.

Negative tester probe black Positive tester probe yellow

12

Turn the main switch to “ON”.Pull in the brake lever or push down on thebrake pedal.

Measure the voltage (DC 12 V) of yellow on the tail /brake light coupler (wire harnessside).


2

YES NO

2. Voltage

Connect the pocket tester (DC 20 V) to thehorn connector at the horn terminal asshown.

The wiring circuitfrom the main switchto the horn connec-tor is faulty and mustbe repaired.

Negative tester probe groundPositive tester probe black/white 1

Turn the main switch to “ON”.Push the horn switch.Measure the voltage (DC 12 V) ofblack/white at the horn terminal.


NOYES

3. Horn

Disconnect the black connector at the hornterminal.

Connect a jumper lead to the horn termi-nal and ground the jumper lead.

Turn the main switch to “ON”.Push the horn switch.Does the horn sound?

The horn is OK.

1

Replace the horn.

8-38


NO

YES NO

The wiring circuitfrom the main switchto the tail /brake lightcoupler is faulty andmust be repaired.

This circuit is OK.

YES

1. Turn signal indicator light (LEDs)

Check the turn signal indicator light for conti-nuity.Refer to “CHECKING THE LEDs”.

Are the turn signal indicator light OK?

Replace the meterassembly.

EAS00799

3. The turn signal light, turn signal indicatorlight or both fail to blink.

YES

2. Turn signal switch

Check the turn signal switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the turn signal switch OK?

Replace the left han-dlebar switch.

3. Voltage

Connect the pocket tester (DC 20 V) to theturn signal relay coupler (wire harness side)as shown.

Negative tester probe groundPositive tester probe brown/green 1

Turn the main switch to “ON”.Measure the voltage (DC 12 V) on brown/green at the turn signal relay coupler (wireharness side).


1

YES NO

The wiring circuitfrom the main switchto the turn signalrelay coupler is faultyand must be re-paired.

YES NO

4. Voltage

Connect the pocket tester (DC 20 V) to theturn signal relay coupler (wire harness side)as shown.

The turn signal relayis faulty and must bereplaced.

Positive tester probe groundNegative tester probe brown/white 1

Turn the main switch to “ON”.Measure the voltage (DC 12 V) onbrown/white at the turn signal relay cou-pler (wire harness side).


1

5. Voltage

Connect the pocket tester (DC 20 V) to theturn signal light connector or meter assem-bly coupler (wire harness side) as shown.

Left turn signal lightRight turn signal lightTurn signal indicator light

ABC

NO

8-39


YES NO

The wiring circuitfrom the turn signalswitch to the turn sig-nal light connector isfaulty and must berepaired.

Left turn signal lightPositive tester probe groundNegative tester probe chocolate

Right turn signal lightPositive tester probe groundNegative tester probe dark green

1

2

Turn the main switch to “ON”.Set the turn signal switch to “ ” or “ ”.Measure the voltage (DC 12 V) of the choco-late or dark green at the turn signal lightconnector (wire harness side).


1 2

This circuit is OK.

A B

C

1. Neutral indicator light (LEDs)

Check the neutral indicator light for continu-ity.Refer to “CHECKING THE LEDs”.

Are the neutral indicator light OK?

EAS00801

4. The neutral indicator light fails to come on.

YES NO


YES NO

2. Neutral switch




When you switch the positive and negativetester probes, the readings in the abovechart will be reversed.

3. Starting circuit cut-off relay (diode)


Connect the pocket tester (Ω 1) to thestarting circuit cut-off relay coupler asshown.

Check the starting circuit cut-off relay forcontinuity.


Negative tester probe sky blue

Continuity

Positive tester probe sky blue


Nocontinuity

1

2

2

1

EAS00753

NOTE:

8-40


YES NO


YES NO

4. Voltage

Connect the pocket tester (DC 20 V) to themeter assembly coupler (wire harness side)as shown.

The wiring circuitfrom the main switchto the meter assem-bly coupler is faultyand must be re-paired.

Negative tester probe groundPositive tester probe red/white 1

Turn the main switch to “ON”.Measure the voltage (DC 12 V) of red/whiteat the meter assembly coupler (wire harnessside).


This circuit is OK.


YES NO

1. Oil level warning light (LEDs)

Check the oil level warning light for continu-ity.When the main switch is turn to “ON”, the oillevel warning light is come on.

Are the oil level warning light OK?


EAS00802

5. The oil level warning light fails to come on.

YES NO

2. Oil level switch

Drain the engine oil and remove the oil levelswitch from the oil pan.

Connect the pocket tester (Ω 100) to theoil level switch as shown.

Replace the oil levelswitch.

Positive tester probe Connector (white)

Negative tester probe Body ground1

1 2

Measure the oil level switch resistance.

Oil level switch resistance114 126 Ω at 20C (68F)484 536 Ω at 20C (68F)

12

Is the oil level switch OK?

2

8-41


3. Voltage


Positive tester probe black/whiteNegative tester probe red/white

12

Turn the main switch to “ON”.Measure the voltage (DC 12V) of black/white and red/white at the meter as-sembly coupler.


1 2

YES NO

The wiring circuitfrom the main switchto the meter assem-bly is faulty and mustbe repaired.

This circuit is OK.

EAS00803

6. The fuel level warning light fails to come on.

1. Fuel sender

Drain the fuel from the fuel tank and removethe fuel pump from the fuel tank.

Disconnect the fuel sender coupler from thewire harness.

Connect the pocket tester (Ω 10) to thefuel sender terminals as shown.

Tester positive probe green/whiteTester negative probe black

12

Fuel sender resistanceFull position of the float

20 26 Ω at 20C (68F)Empty position of the float

134 140 Ω at 20C (68F)

Is the fuel sender OK?

Measure the resistances when the float armis in contact with the full position and emptyposition of the stopper.

NOTE:

Measure the fuel sender resistances.

YES NO

Replace the fuelpump.

8-42


YES NO

2. Voltage


The wiring circuitfrom the main switchto the meter assem-bly coupler is faultyand must be re-paired.

Positive tester probe green/white Negative tester probe black/white

12

Turn the main switch to “ON”.Measure the voltage (DC 12 V) ofgreen/white and black/white at themeter assembly coupler.


This circuit is OK.

1 2

8-43

1 Main switch7 Fuse (main)10 Battery20 Coolant temperature sensor21 ECU45 Fuse (radiator fan motor)46 Radiator fan motor relay47 Radiator fan motor50 Fuse (ignition)

COOLING SYSTEM ELEC

EAS00807

COOLING SYSTEMCIRCUIT DIAGRAM

8-44

YES NO

2. Battery



Is the battery OK?



EAS00739

EAS00749

3. Main switch



YES NO


COOLING SYSTEM ELEC

NOTE:

YES NO

1. Main, ignition and radiator fan motor fuses

Check the main, ignition and radiator fanmotor fuses for continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main, ignition and radiator fan motorfuses OK?


EAS00808

TROUBLESHOOTING

The radiator fan motor fails to turn.The coolant temperature indicator lightfails to light when the engine is warm.

Check:1. main, ignition, and radiator fan motor fuses2. battery3. main switch4. radiator fan motor5. radiator fan motor relay6. coolant temperature sensor7. wiring connections

(the entire cooling system)




EAS00738

8-45

YES NO

4. Radiator fan motor

Disconnect the radiator fan motor couplerfrom the wire harness.

Connect the battery (DC 12 V) as shown.

The radiator fan mo-tor is faulty and mustbe replaced.

Positive battery lead blueNegative battery lead black

12

Does the radiator fan motor turn?

5. Radiator fan motor relay

Disconnect the radiator fan motor relayform the wire harness.

Connect the pocket tester (Ω 1) and bat-tery (12 V) to the radiator fan motor terminalas shown.

Check the radiator fan motor for continuity.

Replace the radiatorfan motor.

NOYES

Battery positive terminal red/white Battery negative terminal

green/yellow

1

2

Does the radiator fan motor relay have conti-nuity between brown/black and blue?

Tester positive probe brown/black Tester negative probe blue

34

COOLING SYSTEM ELEC

EAS00809

8-46

COOLING SYSTEM ELEC

Remove the coolant temperature sensor.Connect the pocket tester (Ω 1k) to thecoolant temperature sensor as shown.

Immerse the coolant temperature sensor ina container filled with coolant .

Make sure the coolant temperature sensorterminals do not get wet.

Place a thermometer in the coolant.Slowly heat the coolant, and then let it cool tothe specified temperature indicated in thetable.

Check the coolant temperature sensor forcontinuity at the temperatures indicated inthe table.

EAS00812

1

Coolant temperature sensor resistance

0C (32F): 5.21 6.37 kΩ80C (176F): 0.29 0.35 kΩ

WARNINGHandle the coolant temperature sensorwith special care.

Never subject the coolant temperaturesensor to strong shocks. If the coolanttemperature sensor is dropped, replaceit.

6. Coolant temperature sensor

Replace the coolanttemperature sensor.

NOYES

Coolant temperature sensor20 Nm (2.0 mkg, 14 ftlb)Three bond sealock10

Does the coolant temperature sensor oper-ate properly?

7. Wiring

Check the entire cooling system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the cooling system’s wiring properly con-nected and without defects?

Properly connect orrepair the coolingsystem’s wiring.

NOYES

This circuit is OK.

EAS00813

2NOTE:

3

8-47

1 Main switch5 Fuse (fuel injection)7 Fuse (main)10 Battery11 Starting circuit cut-off relay14 Fuel pump21 ECU43 Engine stop switch50 Fuse (ignition)

FUEL PUMP SYSTEM ELEC

EAS00814

FUEL PUMP SYSTEMCIRCUIT DIAGRAM

8-48


1 Battery2 Fuse (main)3 Main switch4 Fuse (ignition)5 Engine stop switch6 ECU7 Fuse (fuel injection)8 Starting circuit cut-off relay

(fuel injection system relay)9 Fuel pump

EAS00815

FUEL PUMP SYSTEMThe ECU includes the control unit for thefuel pump.

8-49


YES NO

2. Battery

Check the condition of the batteryRefer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.


Is the battery OK?



EAS00739

EAS00749

3. Main switch


YES NO



EAS00750



YES NO



NOTE:

YES NO

1. Main, ignition and fuel injection systemfuses

Check the main, ignition and fuel systemfuses for continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.


Are the main, ignition and fuel injection sys-tem fuses OK?

EAS00816

TROUBLESHOOTING

If the fuel pump fails to operate.

Check:1. main, ignition and fuel injection fuses2. battery3. main switch4. engine stop switch5. starting circuit cut-off relay

(the fuel injection system relay)6. fuel pump7. wiring connections

(the entire fuel system)


1. seat2. front cowling inner panel (left and right)3. fuel tankTroubleshoot with the following special tool(s).


EAS00738

8-50


YES NO

5 Starting circuit cut-off relay (fuel injectionsystem relay)


Connect the pocket tester (Ω 1) and bat-tery (12V) to the starting circuit cut-off relaycoupler as shown.


Positive battery lead red/black Negative battery lead blue/yellow

12

Positive tester probe redNegative tester probe red/blue

34

Does the starting circuit cut-off relay havecontinuity between red and red/blue?

YES NO

6. Fuel pump resistance

Disconnect the fuel pump coupler from thewire harness.

Connect the pocket tester (Ω 1) to the fuelpump coupler as shown.

Properly connect orrepair the fuel sys-tem’s wiring.

12

Positive tester probe red/blueNegative tester probe black

EAS00817

YES NO

Fuel pump resistance0.2 3.0 Ω at 20C (68F)

Is the fuel pump OK?


Measure the fuel pump resistance.

7. Wiring

Check the entire fuel pump system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the fuel system’s wiring properly con-nected and without defects?

EAS00818

Replace the ECU.

EAS00759

8-51


WARNING

EAS00819

CHECKING THE FUEL PUMP

Gasoline is extremely flammable and undercertain circumstances there can be a dangerof an explosion or fire. Be extremely carefuland note the following points:Stop the engine before refueling.Do not smoke, and keep away from openflames, sparks, or any other source of fire.

If you do accidentally spill gasoline, wipe itup immediately with dry rags.

If gasoline touches the engine when it ishot, a fire may occur. Therefore, make surethe engine is completely cool before per-forming the following test.

1. Check:Fuel pump operation

a. Fill the fuel tank.b. Put the end of the fuel hose into an open con-

tainer.c. Connect the battery (DC 12 V) to the fuel

pump coupler as shown.

Positive battery lead red/blue 1Negative battery lead black 2

d. If fuel flows out of the fuel hose, the fuel pumpis OK. If fuel does not flow, replace the fuelpump.

8-52

IMMOBILIZER SYSTEM ELEC

Br Brown. . . . . Lg Light green. . . . . Br/L Brown/Blue. . . R/G Red/Green. . . R/W Red/White. . . Y/L Yellow/Blue. . . .

1 MAIN SWITCH AND IMMOBILIZER UNIT2 IMMOBILIZER INDICATOR LIGHT3 ECU

IMMOBILIZER SYSTEMSYSTEM DIAGRAM

8-53

1 Main switch4 Fuse (backup)6 Immobilizer unit7 Fuse (main)10 Battery21 ECU32 Immobilizer indicator light36 Multi-function meter50 Fuse (ignition)


CIRCUIT DIAGRAM

8-54


GENERAL INFORMATION

When the main switch is turned “ON” with the registered key, the immobilizer system indicator lightcomes on for about 0.5 second and then goes off.

To check the immobilizer system, follow the steps in the troubleshooting chart.To use the immobilizer key, keep it away from other keys. Otherwise, the key code signal may not workor the correct action may be disturbed.

The key contains the electronic component (transponder). Do not drop or hit it with a solid metal. Donot leave it on the dashboard of vehicle where the temperature may rise.

Do not put it in the water. (when washing clothes for example)Do not place it near a magnet or a loud speaker. If all keys are missing, the engine control unit (ECU) is required to replace together with the keys andthe immobilizer unit.

Immobilizer unit cannot be operated with the copy key until the transponder code of the code re-regis-tering key is registered to the immobilizer unit.

Total three key codes are registered to the immobilizer unit, which are one code re-registering keycode and two standard key codes.

Among them, two of standard key codes can be registered to prepare for the case when the key is lost.To register, the code re-registering key is needed.

1. Code re-registering key (red bow)2. Standard key (black bow)

8-55


NOTE:

KEY ID REGISTRATION METHOD

Initially one code re-registering key and two standard keys have been registered with the immobilizersystem.In the course of use, you may encounter the following case where re-registration of code re-register-ing/standard key is required.

Code re-registering key registration:

When the immobilizer unit or ECU, failed and the unit was replaced, the unit cannot be used until thekey ID is registered because it is not registered to the unit.a. As usual steps, when the main switch is turned “ON”, the immobilizer indicator light goes on for

about one second.b. If the indicator light goes off, it shows that the code re-registering key registration is finished.c. Check that the engine can be started.d. Consequently, carry out the standard key registration, according the section below.

Standard key registration:

When you lost a standard key and need a new one. Or when the code re-registering key is re-registeredafter the immobilizer unit or the ECU, are replaced.a. Check that the indicator light shows the standby mode.

To initiate the standby mode, turn “OFF” the main switch and then it will be the standby mode when itpasses 30 seconds. When 24 hours passed, the standby mode ends and the indicator light stopsflashing.

b. After the main switch is turned “ON” with the code re-registering key, within 5 seconds, turn “OFF”the main switch and then turn “ON” the main switch with the standard key (the first new key) that youwant to register.

c. It becomes the key registration mode and two standard key IDs that have been stored in the memoryare erased and the first new standard key ID will be registered. At this time, the indicator light quicklyblinks (“OFF” for 0.5 sec. and “ON” for 0.5 sec.).

d. In the condition as mentioned above (while the indicator light continues quick flashing), after themain switch is turned “ON” with the first new standard key, turn “OFF” the main switch within 5 se-conds, and then turn “ON” the main switch with the standard key that you want to register (which isthe second new key or the standard key remained in hand).

Fast flashing goes off when it elapses 5 seconds and the registration mode is finished. In this case, thesecond standard key cannot be registered and only the first standard key is registered.

8-56


When one standard key is registered.

Code re-registeringkey

First unregisteredstandard key

Flashing ends when it elapses 5 seconds and the registration for the seconds standard key is impossible.

When two standard keysare registered.

Code re-registeringkey

First unregisteredstandard key

Flashing ends when the registration of the secondsunregistered standard key is complete.

e. When the registration is finished, the indicator light goes off.f. Check that the engine can be started with the registered two standard keys.

Important note:If you lost a standard key, immediately re-register your code re-registering key and the remaining stan-dard key (if any). This will delete the stored registration data, protecting the motorcycle against beingstarted with the lost key.

8-57


<Example> 52

Light ON

Light OFF

SELF-DIAGNOSIS ERROR CODE INDICATION

When the system failure occurred, the error code number is indicated in the LCD display of meter andthe immobilizer indicator light flashes at the same time. The pattern of flashing also shows the errorcode.

Error code Detection Symptoms Trouble Measures

51 Immobilizer Cannot transmit code be-tween the key and immobiliz-er unit.

1) Objects that may keep off radiowaves exist around the keys andantennas.

2) Immobilizer unit failure3) Key failure

1) Keep clear of magnets, metalsand other keys from the sur-roundings of keys and antennas.

2) Replace the immobilizer unit.3) Replace the key.

52 Immobilizer Codes do not match betweenthe key and immobilizer unit.

1) Disturbed by other transponder.Failed to verify continually for tentimes.

2) Unregistered standard key wasused.

1) Place the immobilizer unit awaymore than 50 mm from the trans-ponder of other vehicle.

2) Register the standard key.

53 Immobilizer Cannot transmit code be-tween the ECU and immobi-lizer unit.

Noise interference or disconnectedlead/cable.1) Obstruction due to radio wave

noise.2) Error by disconnection of the

communication harness.3) Immobilizer unit failure.4) ECU failure.

1) Check the wire harness and con-nector.

2) Replace the immobilizer unit.3) Replace the ECU.

54 Immobilizer Codes do not match betweenECU and immobilizer unit.



communication harness.3) Immobilizer unit failure4) ECU failure

(When the used parts from othervehicles are used, the code re-registering key ID is not regis-tered to the ECU.)

1) Register the code re-registeringkey ID.



55 Immobilizer Key code registration error. Same standard key was attemptedto continuously two times register.

Prepare the new standard key andregister it.

56 ECU Undefinition code is re-ceived.



communication harness.3) Immobilizer unit failure.4) ECU failure.



Immobilizer warning light code indication

Digit of 10 : Cycles of 1 sec. “ON” and 1.5 sec. “OFF”.Digit of 1 : Cycles of 0.5 sec. “ON” and 0.5 sec. “OFF”.

8-58

YES NO



EAS00749

3. Main switch



YES NO


2. Battery



Is the battery OK?

EAS00739

EAS00787

4. Wiring

Check the entire immobilizer system’s wir-ing.Refer to “CIRCUIT DIAGRAM”.

Is the immobilizer system’s wiring properlyconnected and without defects?

YES NO

Properly connect orrepair the immobiliz-er system’s wiring.

Check the conditionof each of the immo-bilizer system’s cir-cuits.Refer to “CHECK-ING THE IMMOBI-LIZER SYSTEM”.


NOTE:

YES NO

1. Main, ignition and backup fuses

Check the main, ignition and backup fusesfor continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main, ignition and back up fusesOK?


EAS00794

TROUBLESHOOTING

When the main switch is turn “ON”, theindicator light does not come on or flash.

Check:1. main, ignition, and backup fuses2. battery3. main switch4. wiring connections

(of the entire immobilizer system)


1. seat2. front cowling inner panel (left and right)3. fuel tank4. side coversTroubleshoot with the following special tool(s).


EAS00738

8-59

YES NO

1. Immobilizer system indicator light (LEDs)

Check the immobilizer system indicator lightfor continuity.Refer to “CHECKING THE LEDs”.

Are the immobilizer system indicator lightOK?


EAS00788

CHECKING THE IMMOBILIZER SYSTEM1. The immobilizer system indicator light

does not come on.

2. Voltage

Connect the pocket tester (DC 20 V) to theimmobilizer unit coupler as shown.

Negative tester probe blackPositive tester probe

red/white or red/green1

3. Wiring

Disconnect the meter coupler and immobi-lizer unit coupler.

Check the immobilizer system indicator lightlead (light green) continuity.(meter coupler – immobilizer unit coupler).

Is the immobilizer system indicator light leadOK?

YES NO

The wiring circuitfrom the meter to im-mobilizer unit isfaulty and must berepaired.

Replace the immobi-lizer unit.

1. Voltage

Connect the pocket tester (DC 20 V) to themeter coupler as shown.

3LCD display

Positive tester probe red/white or red/green

Negative tester probe black/white 23

2

YES NO

The wiring circuitfrom the main switchto the immobilizerunit coupler is faultyand must be re-paired.

Turn the main switch to “ON”.Measure the voltage (DC 12 V) on the immo-bilizer unit coupler (wire harness side).


YES NO

The wiring circuitfrom the main switchto the meter coupleris faulty and must berepaired.

Turn the main switch to “ON”.Measure the voltage (DC 12 V) meter cou-pler (wire harness side).


Replace the meter.

2. The LCD display does not indicated.

1


8-60


Correct

Turn “ON” the main switch with anotherstandard key and check the indicator.The indicator goes on for about one se-cond and then goes off.

First standard key (Transponder) de-fective

Correct

Failure

Check the self-diagnosis code indica-tion.

Read the error code and inspect thecorresponding part.Refer to “SELF-DIAGNOSIS ERRORCODE INDICATION”.

Indicated

No indication

Immobilizer Unit failure or ECU failure

Check the signal lead (yellow/blue)between the immobilizer unit and ECUconnector.

Yellow/blue lead is disconnected orshort-circuited. Repair or replace thecircuit.

Correct

Replace the immobilizer unit.

Failure

Turn “ON” the main switch with codere-registering key and check the indi-cator.

Failure

Two standardkey (Transpond-er) defective

Registeragain

Failure

Replacethe key

2. When the main switch is turned “ON”, the indicator light is flashing.Check if the metallic obstacle or the transponder of other vehicle exists near the immobilizer unit. Ifit exists, remove it and recheck the condition.

8-61


NOTE:

REPLACEMENT PARTS ON TROUBLES

Replacement parts

Transponder Key ImmobilizerUnit

ECU *1MainSwitch

*2AccessoryLock And Key

When standard key is missingand the replace standard keyis required

All keys have been lost (includ-ing code re-registering key)

ECU is defective

When the immobilizer unit is defective

When the main switch is defective

When the accessory lock is defective

*1 There is no parts setting as a single unit. It will be the replacement in a set with the IMMOBILIZER UNIT.*2 Accessory lock means the seat lock, fuel filler cap or the helmet holder.

To replace the single unit of ECU, first turn “ON” the main switch with the code re-registering key. Thisoperation allows the code re-registering key ID to be registered to the new ECU. Register the stan-dard key subsequently.

To replace the single unit of immobilizer unit, first turn “ON” the main switch with the code re-register-ing key. This operation allows the code re-registering key ID to be registered to the new immobilizerunit. Register the standard key subsequently.

8-62

SELF-DIAGNOSIS ELEC

SELF-DIAGNOSISThe FZ6-S(S) features a self-diagnosing system for the following circuit(-s):Fuel pump thermistorOil level switch

If any of these circuits are defective, their respective condition codes will be displayed on the warninglight when the main switch is turned “ON” (irrespective of whether the engine is running or not).

Circuit Defect(-s) System response Condition code

Fuel pumpthermistor

Open-circuitShort-circuit

The fuel warning light indicate thecondition code.

Refer to *1

Oil level gauge Open-circuitShort-circuit

The oil level warning light indicatethe condition code.

Refer to *2

*1 Condition codeFuel warning light

*2 Condition codeOil level warning light

8-63

SELF-DIAGNOSIS ELEC

Repair or replace thewire harness.

NO

1. Wire harness

Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.

Is the wire harness OK?

YES

NO

2. Fuel pump thermistor

Check the fuel pump thermistor for continuity.Refer to “The fuel level indicator light fails tocome on”.

Is the fuel pump thermistor OK?

YES


Replace the multi-function meter.

NOTE:

14 Fuel pump36 Multi-function meter

TROUBLESHOOTING

The warning light starts to indicate theself-diagnosis sequence.

Check:1. fuel pump thermistor2. oil level switch

Before troubleshooting, remove the followingpart(-s):

1. seat2. front cowling inner panel (left and right)3. fuel tankTroubleshoot with the following specialtool(-s).


1. Fuel pump thermistorCIRCUIT DIAGRAM

8-64

SELF-DIAGNOSIS ELEC

Replace the oil levelswitch.

NO

2. Oil level switch

Check the oil level switch for continuity.Refer to “The oil level warning light fails tocome on”.

Is the oil level switch OK?

YES

Repair or replace thewire harness.

NO

1. Wire harness

Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.

Is the wire harness OK?

YES

Replace the multi-function meter.

36 Multi-function meter39 Oil level switch

2. Oil level switchCIRCUIT DIAGRAM

9TRBLSHTG

TRBLSHTG

CHAPTER 9TROUBLESHOOTING

STARTING FAILURES 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INCORRECT ENGINE IDLING SPEED 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE 9-2. . . . . . . . . . . . ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY GEAR SHIFTING 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFTING IS DIFFICULT 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT PEDAL DOES NOT MOVE 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . JUMPS OUT OF GEAR 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY CLUTCH 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH SLIPS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH DRAGS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OVERHEATING 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OVERCOOLING 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POOR BRAKING PERFORMANCE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY FRONT FORK LEGS 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAKING OIL 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MALFUNCTION 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNSTABLE HANDLING 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRBLSHTG

FAULTY LIGHTING OR SIGNALING SYSTEM 9-6. . . . . . . . . . . . . . . . . . . HEADLIGHT DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB BURNT OUT 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . TAIL/BRAKE LIGHT DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . TAIL/BRAKE LIGHT BULB BURNT OUT 9-6. . . . . . . . . . . . . . . . . . . . . TURN SIGNAL DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL BLINKS SLOWLY 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL REMAINS LIT 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL BLINKS QUICKLY 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . HORN DOES NOT SOUND 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1

STARTING FAILURESTRBLSHTG

NOTE:

Air filter Improperly installed air filterClogged air filter element

Crankcase and crankshaft Improperly assembled crankcaseSeized crankshaft

FUEL SYSTEMFuel tankEmpty fuel tankClogged fuel filterClogged fuel tank drain hoseDeteriorated or contaminated fuel

Fuel pumpFaulty fuel pumpFaulty fuel pump relay

Throttle body(-ies)Deteriorated or contaminated fuelSucked-in air

Ignition coil(s)Cracked or broken ignition coil bodyBroken or shorted primary or secondarycoils

Faulty spark plug leadIgnition systemFaulty ECUFaulty crankshaft position sensor

EAS00844

TROUBLESHOOTING

The following guide for troubleshooting does not cover all the possible causes of trouble. It should behelpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual forchecks, adjustments, and replacement of parts.

STARTING FAILURESENGINECylinder(s) and cylinder head(s)Loose spark plugLoose cylinder head or cylinderDamaged cylinder head gasketWorn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timingFaulty valve springSeized valve

Piston(s) and piston ring(s) Improperly installed piston ringDamaged, worn or fatigued piston ringSeized piston ringSeized or damaged piston

ELECTRICAL SYSTEMSBatteryDischarged batteryFaulty battery

Fuse(s)Blown, damaged or incorrect fuse Improperly installed fuse

Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat rangeFouled spark plugWorn or damaged electrodeWorn or damaged insulatorFaulty spark plug cap

9-2

STARTING FAILURE/INCORRECT ENGINE IDLING SPEED/POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

TRBLSHTG

Starting systemFaulty starter motorFaulty starter relayFaulty starting circuit cut-off relayFaulty starter clutch

ELECTRICAL SYSTEMSBatteryDischarged batteryFaulty battery

Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat rangeFouled spark plugWorn or damaged electrodeWorn or damaged insulatorFaulty spark plug cap

Ignition coil(s)Broken or shorted primary or secondarycoils

Faulty spark plug leadCracked or broken ignition coil

Ignition systemFaulty ECUFaulty crankshaft position sensor

Switches and wiringFaulty main switchFaulty engine stop switchBroken or shorted wiringFaulty neutral switchFaulty start switchFaulty sidestand switchFaulty clutch switch Improperly grounded circuitLoose connections

EAS00846

INCORRECT ENGINE IDLING SPEEDENGINECylinder(s) and cylinder head(s) Incorrect valve clearanceDamaged valve train components

Air filterClogged air filter element

FUEL SYSTEMThrottle body(-ies)Damaged or loose throttle body joint Improperly synchronized throttle bodies Improperly adjusted engine idling speed(throttle stop screw)

Improper throttle cable free playFlooded throttle bodyFaulty air induction system

EAS00849

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCERefer to “STARTING FAILURES”.ENGINEAir filterClogged air filter element

FUEL SYSTEMFuel pumpFaulty fuel pump

9-3

FAULTY GEAR SHIFTING/FAULTY CLUTCHTRBLSHTG

JUMPS OUT OF GEARShift shaft Incorrect shift pedal position Improperly returned stopper lever

Shift forksWorn shift fork

Shift drum Incorrect axial playWorn shift drum groove

TransmissionWorn gear dog

CLUTCH DRAGSClutchUnevenly tensioned clutch springsWarped pressure plateBent clutch plateSwollen friction plateBent clutch push rodDamaged clutch bossBurnt primary driven gear bushingMatch marks not aligned

Engine oil Incorrect oil level Incorrect oil viscosity (high)Deteriorated oil

EAS00850

FAULTY GEAR SHIFTINGSHIFTING IS DIFFICULTRefer to “CLUTCH DRAGS”.SHIFT PEDAL DOES NOT MOVEShift shaft Improperly adjusted shift rodBent shift shaft.

Shift drum and shift forksForeign object in a shift drum grooveSeized shift forkBent shift fork guide bar

TransmissionSeized transmission gearForeign object between transmission gears Improperly assembled transmission

EAS00852

FAULTY CLUTCHCLUTCH SLIPSClutch Improperly assembled clutch Improperly adjusted clutch cableLoose or fatigued clutch springWorn friction plateWorn clutch plateDamaged clutch release cylinder

Engine oil Incorrect oil level Incorrect oil viscosity (low)Deteriorated oil

9-4

OVERHEATING/OVERCOOLING/POOR BRAKING PERFORMANCE

TRBLSHTG

FUEL SYSTEMThrottle body(-ies)Damaged or loose carburetor joint

Air filterClogged air filter element

CHASSISBrake(s)Dragging brake

ELECTRICAL SYSTEMSSpark plug(s) Incorrect spark plug gap Incorrect spark plug heat range

Ignition systemFaulty ECU

Cooling systemFaulty radiator fan motor relayFaulty coolant temperature sensorFaulty ECU

EAS00855

OVERHEATINGENGINEClogged coolant passagesCylinder head(s) and piston(s)Heavy carbon buildup

Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality

COOLING SYSTEMCoolantLow coolant level

RadiatorDamaged or leaking radiatorFaulty radiator capBent or damaged radiator fin

Water pumpDamaged or faulty water pumpThermostatThermostat stays closedOil coolerClogged or damaged oil coolerHose(s) and pipe(s)Damaged hose Improperly connected hoseDamaged pipe Improperly connected pipe

EAS00856

OVERCOOLINGCOOLING SYSTEMThermostatThermostat stays open

EAS00857

POOR BRAKING PERFORMANCEWorn brake padWorn brake discAir in hydraulic brake systemLeaking brake fluidFaulty brake caliper kitFaulty brake caliper sealLoose union boltDamaged brake hoseOil or grease on the brake discOil or grease on the brake pad Incorrect brake fluid level

9-5

FAULTY FRONT FORK LEGS/UNSTABLE HANDLINGTRBLSHTG

Rear shock absorber assembly(-ies)Faulty rear shock absorber springLeaking oil or gas

Tire(s)Uneven tire pressures (front and rear) Incorrect tire pressureUneven tire wear

Wheel(s) Incorrect wheel balanceDeformed cast wheelDamaged wheel bearingBent or loose wheel axleExcessive wheel runout

FrameBent frameDamaged steering head pipe Improperly installed bearing race

EAS00861

FAULTY FRONT FORK LEGSLEAKING OILBent, damaged or rusty inner tubeCracked or damaged outer tube Improperly installed oil sealDamaged oil seal lip Incorrect oil level (high)Loose damper rod assembly boltDamaged damper rod assembly bolt copper washerCracked or damaged cap bolt O-ring

MALFUNCTIONBent or damaged inner tubeBent or damaged outer tubeDamaged fork springWorn or damaged outer tube bushingBent or damaged damper rod Incorrect oil viscosity Incorrect oil level

EAS00862

UNSTABLE HANDLINGHandlebarBent or improperly installed handlebar

Steering head components Improperly installed upper bracket Improperly installed lower bracket(improperly tightened ring nut)

Bent steering stemDamaged ball bearing or bearing race

Front fork leg(s)Uneven oil levels (both front fork legs)Unevenly tensioned fork spring (both frontfork legs)

Broken fork springBent or damaged inner tubeBent or damaged outer tube

SwingarmWorn bearing or bushingBent or damaged swingarm

9-6

FAULTY LIGHTING OR SIGNALING SYSTEMTRBLSHTG

TURN SIGNAL DOES NOT COME ONFaulty turn signal switchFaulty turn signal relayBurnt-out turn signal bulb Incorrect connectionDamaged or faulty wire harness Improperly grounded circuitFaulty batteryBlown, damaged or incorrect fuse

TURN SIGNAL BLINKS SLOWLYFaulty turn signal relayFaulty main switchFaulty turn signal switch Incorrect turn signal bulb

TURN SIGNAL REMAINS LITFaulty turn signal relayBurnt-out turn signal bulb

TURN SIGNAL BLINKS QUICKLY Incorrect turn signal bulbFaulty turn signal relayBurnt-out turn signal bulb

HORN DOES NOT SOUND Improperly adjusted hornDamaged or faulty hornFaulty main switchFaulty horn switchFaulty batteryBlown, damaged or incorrect fuseFaulty wire harness

EAS00866

FAULTY LIGHTING OR SIGNALING SYSTEMHEADLIGHT DOES NOT COME ONWrong headlight bulbToo many electrical accessoriesHard charging Incorrect connection Improperly grounded circuitPoor contacts (main or light switch)Burnt-out headlight bulb

HEADLIGHT BULB BURNT OUTWrong headlight bulbFaulty batteryFaulty rectifier/regulator Improperly grounded circuitFaulty main switchFaulty light switchHeadlight bulb life expired

TAIL/BRAKE LIGHT DOES NOT COME ONWrong tail /brake light bulbToo many electrical accessories Incorrect connectionBurnt-out tail /brake light bulb

TAIL/BRAKE LIGHT BULB BURNT OUTWrong tail /brake light bulbFaulty battery Incorrectly adjusted rear brake light switchTail /brake light bulb life expired

56 Left handlebar switch57 Clutch switch58 Pass switch59 Dimmer switch60 Hazard switch61 Turn signal switch62 Horn switch63 Horn64 Dimmer relay65 Auxiliary light66 Headlight (high beam)67 Headlight (low beam)68 Rear turn signal light (right)69 Rear turn signal light (left)70 Front turn signal light (right)71 Front turn signal light (left)

1 Main switch2 A.C. magneto3 Rectifier / regulator4 Fuse (backup)5 Fuse (fuel injection)6 Immobilizer unit7 Fuse (main)8 Starter relay9 Starter motor10 Battery11 Starting circuit cut-off relay12 Sidestand switch13 Neutral switch14 Fuel pump15 Throttle position sensor16 Intake air presser sensor17 Lean angle cut-off switch18 Crankshaft position sensor19 Intake air temperature sensor20 Coolant temperature sensor21 ECU22 Cylinder #1-injector23 Cylinder #2-injector24 Cylinder #3-injector25 Cylinder #4-injector26 Air cut-off valve27 Speed sensor28 Ignition coil #1 and #429 Ignition coil #2 and #330 Spark plug31 Meter assembly32 Immobilizer indicator light33 Oil level warning light34 Engine trouble warning light35 Neutral indicator light36 Multi-function meter37 High beam indicator light38 Turn signal indicator light39 Oil level switch40 CYCLELOCK (OPTION)41 Right handlebar switch42 Front brake light switch43 Engine stop switch44 Start switch45 Fuse (radiator fan motor)46 Radiator fan motor relay47 Radiator fan motor48 Fuse (signal)49 Fuse (headlight)50 Fuse (ignition)51 Fuse (park)52 Turn signal relay53 Rear brake light switch54 License plate light55 Tail /brake light

FZS-6(S) 2004 WIRING DIAGRAM

B

L

B

L

COLOR CODEB Black. . . . Br Brown. . . . Ch Chocolate. . . . Dg Dark green. . . . G Green. . . . Gy Gray. . . . L Blue. . . . Lg Light green. . . . P Pink. . . . R Red. . . . Sb Sky blue. . . . W White. . . . Y Yellow. . . . B /G Black/Green. . . . B /L Black /Blue. . . . B /R Black/Red. . . . B /W Black/White. . . . B /Y Black/Yellow. . . . Br /B Brown/Black. . . . Br /G Brown/Green. . . . Br /L Brown/Blue. . . . Br /R Brown/Red. . . . Br /W Brown/White. . . .

G /B Green/Black. . . . G /L Green/Blue. . . . G /W Green/White. . . . G /Y Green/Yellow. . . . Gy /B Gray /Black. . . . L /B Blue/Black. . . . L /G Blue/Green. . . . L /R Blue/Red. . . . L /W Blue/White. . . . L /Y Blue/Yellow. . . . O /B Orange/Black. . . . O /R Orange/Red. . . . P /W Pink/White. . . . R /B Red/Black. . . . R /G Red/Green. . . . R /L Red/Blue. . . . R /W Red/White. . . . R /Y Red/Yellow. . . . W/L White /Blue. . . . W/Y White /Yellow. . . . Y /B Yellow/Black. . . . Y /G Yellow/Green. . . . Y /L Yellow/Blue. . . . Y /R Yellow/Red. . . .

FZ6-S(S) WIRING DIAGRAM

yamaha fz6-s 2004 (europe) service manual

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