yamaha yzf r1 2004 service manual lit 11616 17 55 5 vy 28197 10

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YZF-R1S/YZF-R1SCSERVICE MANUAL

2003 by Yamaha MotorCorporation, U.S.A.

First edition, December 2003All rights reserved. Any reproduction

or unauthorized use without the writtenpermission of Yamaha Motor Corporation,

U.S.A. is expressly prohibited.Printed in U.S.A.

P/N LIT-11616-17-55

NOTE:

WARNING

CAUTION:

EAS00030

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.

This model has been designed and manufactured to perform within certain specifications in regard toperformance and emissions. Proper service with the correct tools is necessary to ensure that the ve-hicle will operate as designed. If there is any question about a service procedure, it is imperative thatyou contact a Yamaha dealer for any service information changes that apply to this model. This policyis intended to provide the customer with the most satisfaction from his vehicle and to conform to federalenvironmental quality objectives.

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.

This Service Manual contains information regarding periodic maintenance to the emission controlsystem. Please read this material carefully.

Designs and specifications are subject to change without notice.

EAS00040

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

2321

19 2018

16 1715

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11 12

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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 AND ADJUSTMENTS

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

CHAPTER 1GENERAL INFORMATION

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

FEATURES 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT FUNCTIONS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 2SPECIFICATIONS

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

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

CHASSIS SPECIFICATIONS 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONVERSION TABLE 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL TIGHTENING TORQUE SPECIFICATIONS 2-18. . . . . . . . . . . .

TIGHTENING TORQUES 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE TIGHTENING TORQUES 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS TIGHTENING TORQUES 2-23. . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 2-25. . . . . . . . . . . . . . . ENGINE 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM DIAGRAMS 2-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

CABLE ROUTING 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 3PERIODIC CHECKS AND ADJUSTMENTS

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

PERIODIC MAINTENANCE CHART FOR THE EMISSIONCONTROL SYSTEM 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL MAINTENANCE AND LUBRICATION CHART 3-1. . . . . . . . .

SEATS 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT COWLING AND SIDE COWLINGS 3-7. . . . . . . . . . . . . . . . . . . REAR COWLING 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR FILTER CASE 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE VALVE CLEARANCE 3-11. . . . . . . . . . . . . . . . . . . . . . SYNCHRONIZING THE THROTTLE BODIES 3-17. . . . . . . . . . . . . . . . . ADJUSTING THE EXHAUST GAS VOLUME 3-19. . . . . . . . . . . . . . . . . . ADJUSTING THE ENGINE IDLING SPEED 3-21. . . . . . . . . . . . . . . . . . . ADJUSTING THE THROTTLE CABLE FREE PLAY 3-22. . . . . . . . . . . . CHECKING THE SPARK PLUGS 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE COMPRESSION PRESSURE 3-24. . . . . . . . . . . . . . CHECKING THE ENGINE OIL LEVEL 3-26. . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE ENGINE OIL 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE ENGINE OIL PRESSURE 3-29. . . . . . . . . . . . . . . . . ADJUSTING THE CLUTCH CABLE FREE PLAY 3-31. . . . . . . . . . . . . . . REPLACING THE AIR FILTER ELEMENT 3-32. . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL AND BREATHER HOSES 3-33. . . . . . . . . . . . . CHECKING THE CRANKCASE BREATHER HOSE 3-34. . . . . . . . . . . . CHECKING THE EXHAUST SYSTEM 3-35. . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE EXUP CABLES 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLANT LEVEL 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLING SYSTEM 3-38. . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE COOLANT 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE FLUID LEVEL 3-44. . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-45. . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE PADS 3-45. . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE HOSES 3-46. . . . . . . . . BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-47. . . . . . . . . . . . . . . ADJUSTING THE SHIFT PEDAL 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE DRIVE CHAIN SLACK 3-49. . . . . . . . . . . . . . . . . . . . . LUBRICATING THE DRIVE CHAIN 3-50. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE STEERING HEAD 3-51. . . . . . . . . CHECKING THE FRONT FORK 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT FORK LEGS 3-54. . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-56. . . . . CHECKING THE TIRES 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WHEELS 3-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND LUBRICATING THE CABLES 3-61. . . . . . . . . . . . . . . LUBRICATING THE LEVERS AND PEDALS 3-61. . . . . . . . . . . . . . . . . . LUBRICATING THE SIDESTAND 3-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE REAR SUSPENSION 3-61. . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM 3-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY 3-62. . . . . . . . . . . . . . . . . CHECKING THE FUSES 3-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULBS 3-69. . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAMS 3-70. . . . . . . . . . . . . . . . . . . . . .

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 WHEEL SPROCKET 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE REAR WHEEL 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR WHEEL STATIC BALANCE 4-14. . . . . . . . . . .

FRONT AND REAR BRAKES 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE PADS 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FRONT BRAKE PADS 4-18. . . . . . . . . . . . . . . . . . . . . REPLACING THE REAR BRAKE PADS 4-20. . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER 4-22. . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE MASTER CYLINDER 4-25. . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-31. . . . . . . FRONT BRAKE CALIPERS 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE CALIPER 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE CALIPERS 4-37. . . . . . . . . . . DISASSEMBLING THE REAR BRAKE CALIPER 4-38. . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE CALIPERS 4-39. . . . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT FORK 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK LEGS 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT FORK LEGS 4-47. . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT FORK LEGS 4-48. . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK LEGS 4-49. . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FRONT FORK LEGS 4-50. . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT FORK LEGS 4-55. . . . . . . . . . . . . . . . . . . . . .

HANDLEBARS 4-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING DAMPER 4-60. . . . . . . . . . . . . . . . . . . . . . .

STEERING HEAD 4-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDER BRACKET 4-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE UNDER BRACKET 4-63. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING HEAD 4-63. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STEERING HEAD 4-64. . . . . . . . . . . . . . . . . . . . . . . . .

REAR SHOCK ABSORBER ASSEMBLY 4-65. . . . . . . . . . . . . . . . . . . . . . . . HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4-67. . . . . CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-68. . . . . . INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-68. . . . .

SWINGARM AND DRIVE CHAIN 4-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE SWINGARM 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE DRIVE CHAIN 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWINGARM 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE DRIVE CHAIN 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SWINGARM 4-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 5ENGINE

ENGINE 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SPROCKET 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST PIPE 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEADS AND HOSES 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE ENGINE 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFT 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD COVER 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFTS 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CAMSHAFTS 5-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CAMSHAFTS 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,AND TIMING CHAIN GUIDES 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN TENSIONER 5-17. . . . . . . . . . . . . . . . INSTALLING THE CAMSHAFTS 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD 5-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CYLINDER HEAD 5-23. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CYLINDER HEAD 5-23. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CYLINDER HEAD 5-24. . . . . . . . . . . . . . . . . . . . . . . . .

VALVES AND VALVE SPRINGS 5-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE VALVES 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVES AND VALVE GUIDES 5-28. . . . . . . . . . . . . . . CHECKING THE VALVE SEATS 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE SPRINGS 5-31. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE LIFTERS 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE VALVES 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER CLUTCH AND GENERATOR 5-35. . . . . . . . . . . . . . . . . . . . . . . . . STATOR COIL ASSEMBLY 5-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER CLUTCH 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE GENERATOR 5-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE STARTER CLUTCH 5-39. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE DAMPER 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER CLUTCH 5-40. . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STARTER CLUTCH 5-41. . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE GENERATOR 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT POSITION SENSOR 5-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CRANKSHAFT POSITION SENSOR 5-44. . . . . . . . . INSTALLING THE CRANKSHAFT POSITION SENSOR 5-44. . . . . . . .

CLUTCH 5-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH COVER 5-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PULL LEVER SHAFT 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH 5-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CLUTCH 5-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRICTION PLATES 5-52. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PLATES 5-52. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH SPRINGS 5-53. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH HOUSING 5-53. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH BOSS 5-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRESSURE PLATE 5-54. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PULL LEVER SHAFT AND PULL ROD 5-54. . . . . . . INSTALLING THE CLUTCH 5-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHIFT SHAFT 5-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT SHAFT AND STOPPER LEVER 5-58. . . . . . . . . . . . . . . . . . . . . . . REMOVING THE SHIFT SHAFT 5-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT SHAFT 5-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STOPPER LEVER 5-61. . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SHIFT SHAFT 5-61. . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PAN AND OIL PUMP 5-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE OIL PAN 5-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SPROCKET AND CHAIN 5-66. . . . . . . . . . . . . . . . . . . . CHECKING THE OIL PUMP 5-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RELIEF VALVE 5-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 5-68. . . . . . . . . CHECKING THE OIL STRAINER 5-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL NOZZLES 5-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE OIL PUMP 5-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL/WATER PUMP ASSEMBLY 5-69. . . . . . . . . . . . INSTALLING THE OIL PAN 5-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKCASE 5-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CRANKCASE 5-74. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKCASE 5-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BEARINGS AND OIL SEALS 5-75. . . . . . . . . . . . . . . . ASSEMBLING THE CRANKCASE 5-75. . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING RODS AND PISTONS 5-77. . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CONNECTING RODS AND PISTONS 5-78. . . . . . . . REMOVING THE CRANKSHAFT ASSEMBLY 5-79. . . . . . . . . . . . . . . . . CHECKING THE CYLINDER AND PISTON 5-79. . . . . . . . . . . . . . . . . . . CHECKING THE PISTON RINGS 5-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PISTON PINS 5-81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BIG END BEARINGS 5-82. . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CONNECTING ROD AND PISTON 5-86. . . . . . . . . .

CRANKSHAFT 5-92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT 5-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT DRIVE SPROCKET 5-93. . . . . . . . . . CHECKING THE CRANKSHAFT JOURNAL BEARINGS 5-93. . . . . . . . INSTALLING THE CRANKSHAFT 5-96. . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION 5-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION, SHIFT DRUM ASSEMBLY ANDSHIFT FORKS 5-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE TRANSMISSION 5-103. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT FORKS 5-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT DRUM ASSEMBLY 5-104. . . . . . . . . . . . . . . . . . . CHECKING THE TRANSMISSION 5-104. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE TRANSMISSION 5-105. . . . . . . . . . . . . . . . . . . . . . . . . .

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 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE THERMOSTAT ASSEMBLY 6-11. . . . . . . . . . . . . . . INSTALLING THE THERMOSTAT ASSEMBLY 6-11. . . . . . . . . . . . . . . .

WATER PUMP 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMPELLER SHAFT 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE WATER PUMP 6-14. . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE WATER PUMP 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE WATER PUMP 6-15. . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 7FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECU’S SELF-DIAGNOSTIC FUNCTION 7-4. . . . . . . . . . . . . . . . . . . . . . SUBSTITUTE CHARACTERISTICS OPERATION CONTROL(FAIL-SAFE ACTION) 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAIL-SAFE ACTIONS TABLE 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING CHART 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSTIC MODE 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING DETAILS 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THROTTLE BODIES 7-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INJECTORS 7-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE INJECTORS 7-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE THROTTLE BODIES 7-39. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE THROTTLE BODY JOINTS 7-39. . . . . . . . . . . . . . . . . . CHECKING THE PRESSURE REGULATOR 7-40. . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP AND PRESSURE REGULATOROPERATION 7-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE THROTTLE POSITIONSENSOR 7-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE SUB-THROTTLE POSITIONSENSOR 7-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE THERMO WAX 7-45. . . . . . . . . . . .

AIR INDUCTION SYSTEM 7-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INJECTION 7-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CUT-OFF VALVE 7-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM DIAGRAMS 7-47. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE AIR INDUCTION SYSTEM 7-48. . . . . . . . . . . . . . . . . .

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 LEDs 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION SYSTEM 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SIGNALING SYSTEM 8-36. . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM 8-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL PUMP SYSTEM 8-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP SYSTEM 8-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP 8-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SELF-DIAGNOSIS 8-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

MOTORCYCLE IDENTIFICATIONGENINFO

EAS00014

GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONEAS00017

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

EAS00018

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

1-2

11 Clock2 Speedometer3 “SELECT” button4 “RESET” button5 Tachometer6 Coolant temperature display/air intake

temperature display7 Odometer/tripmeters/fuel reserve tripme-

ter/stopwatch8 Shift timing indicator light

1 Clock2 Speedometer

FEATURESGENINFO

NOTE:

EAS00019

FEATURESINSTRUMENT FUNCTIONSMulti-function displayThe multi-function meter unit is equipped withthe following:a speedometer (which shows the ridingspeed)

a tachometer (witch shows engine speed)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 fuel level warninglight came on)

a stopwatcha clocka coolant temperature displayan air intake temperature displaya self-diagnosis devicea display brightness and shift timing indicatorlight control mode

Be sure to turn the key to “ON” before using the “SELECT” and “RESET” buttons.

Clock modeTurn the key to “ON”.To set the clock1. 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.

1-3

FEATURESGENINFO

1 Coolant temperature display/air intaketemperature display

2 Odometer/tripmeters/fuel reserve tripme-ter/stopwatch

3 Shift timing indicator light

NOTE:

NOTE:

Odometer, tripmeter, and stopwatch modesPush the “SELECT” button to switch the displaybetween the odometer mode “ODO”, the trip-meter modes “TRIP A” and “TRIP B” and thestopwatch mode in the following order:TRIP A TRIP B ODO Stopwatch TRIP AIf the fuel level warning light comes on, theodometer display will automatically change tothe fuel reserve tripmeter mode ”F-TRIP” andstart counting the distance traveled from thatpoint. In that case, push the ”SELECT” button toswitch the display between the various tripme-ter, odometer, and stopwatch modes in the fol-lowing order:F-TRIP Stopwatch TRIP A TRIP B ODO F-TRIPTo reset a tripmeter, select it by pushing the “SE-LECT” button, and then push the “RESET” buttonfor at least one second. If you do not reset the fuelreserve tripmeter manually, it will reset itself auto-matically and the display will return to the priormode after refueling and traveling 5 km (3 mi).

Stopwatch modeStandard measurement1. Push the “RESET” button to start the stopwatch.2. Push the “SELECT” button to stop the stopwatch.3. Push the “SELECT” button again to reset the stopwatch.

Split-time measurement1. Push the “RESET” button to start the stopwatch.2. Push the “RESET” button to measure split-times. (The colon “:” will start flashing.)3. Push the “RESET” button to display the final split-time or push the “SELECT” button to stop the stop-

watch and display total elapsed time.4. Push the “SELECT” button to reset the stopwatch.

Coolant temperature displayThe coolant temperature display indicates the temperature of the coolant. Push the “RESET” button toswitch the coolant temperature display to the air intake temperature display.

When the coolant temperature display is selected, “C” is displayed before the coolant temperature.

Air intake temperature displayThe air intake temperature display indicates the temperature of the air drawn into the air filter case. Pushthe “RESET” button to switch the coolant temperature display to the air intake temperature display.

Even if the air intake temperature is set to be displayed, the coolant temperature warning light comeson when the engine overheats.

When the key is turned to “ON”, the coolant temperature is automatically displayed, even if the airintake temperature was displayed prior to turning the key to “OFF”.

When the air intake temperature display is selected, “A” is displayed before thetemperature.

1-4

FEATURESGENINFO

NOTE:

Self-diagnosis devicesThe model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuitsare defective, the engine trouble warning light will come on, and then the right display will indicate atwo-digit error code (e.g.,11,12,13).

Display brightness and shift timing indicator light control modeThis mode cycles through five control functions, allowing you to make the following settings in the orderlisted below.Display brightness:This function allows you to adjust the brightness of the displays and tachometer to suit the outsidelighting conditions.

Shift timing indicator light activity:This function allows you to choose whether or not the indicator light should be activated and whetherit should flash or stay on when activated.

Shift timing indicator light activation:This function allows you to select the engine speed at which the indicator light will be activated.

Shift timing indicator light deactivation:This function allows you to select the engine speed at which the indicator light will be deactivated.

Shift timing indicator light brightness:This function allows you to adjust the brightness of the indicator light to suit your preference.

To make any settings in this mode, you have to cycle through all of its functions. However, if the key isturned to “OFF” or the engine is started before completing the procedure, only the settings made be-fore the “SELECT” button was last pushed will be applied.

In this mode, the right display shows the current setting for each function (except the shift timing indi-cator light activity function).

To adjust the brightness of the multifunction meter displays and tachometer1. Turn the key to “OFF”.2. Push and hold the “SELECT” button.3. Turn the key to “ON”, and then release the “SELECT” button after five seconds.4. Push the “RESET” button to select the desired brightness level.5. Push the “SELECT” button to confirm the selected brightness level. The control mode changes to

the shift timing indicator light activity function.

To set the shift timing indicator light activity function1. Push the “RESET” button to select one of the following indicator light activity settings:The indicator light will stay on when activated. (This setting is selected when the indicator light stayson.)

The indicator light will flash when activated. (This setting is selected when the indicator light flashesfour times per second.)

The indicator light is deactivated; in other words, it will not come on or flash. (This setting is selectedwhen the indicator light flashes once every two seconds.)

2. Push the ”SELECT” button to confirm the selected indicator light activity. The control mode changesto the shift timing indicator light activation function.

1-5

FEATURESGENINFO

NOTE:

NOTE:

To set the shift timing indicator light activation function

The shift timing indicator light activation function can be set between 7000 r/min and 15000 r/m. From7000 r/min to 12000 r/min, the indicator light can be set in increments of 500 r/min. From 12000 r/min to15000 r/min, the indicator light can be set in increments of 200 r/min.

1. Push the “RESET” button to select the desired engine speed for activating the indicator light.2. Push the “SELECT” button to confirm the selected engine speed. The control mode changes to the

shift timing indicator light deactivation function.

To set the shift timing indicator light deactivation function

The shift timing indicator light activation function can be set between 7000 r/min and 15000 r/min.From 7000 r/min to 12000 r/min, the indicator light can be set in increments of 500 r/min. From 12000r/min to 15000 r/min, the indicator light can be set in increments of 200 r/min.

Be sure to set the deactivation function to a higher engine speed than for the activation function,otherwise the shift timing indicator light will remain deactivated.

1. Push the “RESET” button to select the desired engine speed for deactivating the indicator light.2. Push the “SELECT” button to confirm the selected engine speed. The control mode changes to the

shift timing indicator light brightness function.

To adjust the shift timing indicator light brightness1. Push the “RESET” button to select the desired indicator light brightness level.2. Push the “SELECT” button to confirm the selected indicator light brightness level. The right display

will return to the odometer or tripmeter mode

1-6

springlip

oilgrease

lip

IMPORTANT INFORMATIONGENINFO

EAS00020

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.

EAS00021

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.

EAS00022

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:

EAS00023

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.

EAS00024

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

EAS00025

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:

EAS00026

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:

EAS00027

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

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 testerRadiator cap tester adapter

These tools are used to check the coolingsystem.

90890-01403YU-33975

Steering nut wrench

This tool is used to loosen or tighten thesteering stem ring nuts.

90890-01423YM-01423

Damper rod holder

This tool is used to hold the damper rod as-sembly when loosening or tightening thedamper rod assembly bolt.

90890-01426YU-38411

Oil filter wrench

This tool is needed to loosen or tighten theoil filter cartridge.

90890-01434YM-01434

Rod holder

This tool is used to support the damper ad-justing rod.

Rod puller90890-01437YM-01437Rod puller attachment90890-01436YM-01436

Rod pullerRod puller attachment

These tools are used to pull up the frontfork damper rod.

1-10



90890-01441YM-01441

Fork spring compressor

This tool is used to disassemble or assemble the front fork legs.

90890-01442YM-01442

Fork seal driver

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

90890-03094YU-08030

Vacuum gauge

This guide is used to synchronize the car-buretors.

Compressiongauge90890-03081YU-33223Adapter90890-04136

Compression gaugeCompression gauge adapter

These tools are used to measure enginecompression.

Valve spring compressor90890-04019YM-04019Attachment90890-04108YM-0125390890-04114YM-4114

Valve spring compressorValve spring compressor attachment

These tools are used to remove or installthe valve assemblies.

Middle driven shaftbearing driver90890-04058YM-4058Mechanical seal installer90890-04078YM-33221

Middle driven shaft bearing driverMechanical seal installer

These tools are used to install the waterpump seal.

90890-04086YM-91042

Clutch holding tool

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

90890-0411190890-04116YM-4116

Valve guide remover

This tool is used to remove or install thevalve guides.

90890-0411290890-04117YM-4117

Valve guide installer

This tool is used to install the valve guides.

1-11



90890-04113YM-0411390890-04118YM-4118

Valve guide reamer

This tool is used to rebore the new valveguides.

90890-06754YM-34487

Ignition checker

This tool is used to check the ignition sys-tem components.

90890-85505ACC-1109-0501

Yamaha bond No. 1215

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

90890-03174

Digital circuit tester

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

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

Pivot shaft wrenchPivot shaft wrench adapter

This tool is need to loosen or tighten thespacer bolt.

90890-03132YU-3112

Pocket tester

This instrument is needed for checking theengine oil temperature.

Oil pressure gauge90890-03153YU-03153Adapter90890-03139

Oil pressure gaugeAdapter

These tools are used to measure engine oilpressure.

90890-06756

Vacuum/pressure pump gauge set

This tool used to measure the vacuum pres-sure.

90793-80009

Engine tachometer

This tool is needed for observing enginerpm.

1-12



90890-04101

Valve lapper

This tool is needed to remove and installthe valve lifter.

90890-03176YM-03176

Fuel pressure adapter

This tool is needed to measure fuel pres-sure.

90890-03153YU-03153

Pressure gauge

This tool is used to measure fuel pressure.

90890-04143YM-04143

Camshaft wrench

This tool is used to hold and rotate the cam-shaft sprocket.

2-1

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code 5VY4 (USA), 5VY5 (CAL)

DimensionsOverall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

2,065 mm (8.13 in)720 mm (28.3 in)1,105 mm (43.5 in)835 mm (32.9 in)1,395 mm (54.9 in)135 mm (5.31 in)3,400 mm (133.9 in)

WeightWet (with oil and a full fuel tank)

Maximum load (except motorcycle)

193 kg (425 lb) (USA)194 kg (428 lb) (CAL)202 kg (445 lb) (USA)201 kg (443 lb) (CAL)

2-2

ENGINE SPECIFICATIONS SPEC

2

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, DOHC998 cm3 (60.90 cu.in)Forward-inclined parallel 4-cylinder77.0 53.6 mm (3.03 2.11 in)12.4 : 11,150 1,250 r/min22 kPa (165 mmHg, 6.5 inHg)

1,480 kPa (14.80 kg/cm2,14.80 bar,210.5 psi) at 350 r/min

FuelRecommended fuelFuel tank capacityTotal (including reserve)Reserve only

Premium unleaded gasoline only

18 L (3.96 Imp gal, 4.76 US gal)3.4 L (0.75 Imp gal, 0.90 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

At 5C (40F) or higherYamalube 4 (20W40) or SAE 20W40type SE motor oilAt 15C (60F) or lowerYamalube 4 (10W30) or SAE 10W30type SE motor oil

3.8 L (3.35 Imp qt, 4.02 US qt)2.9 L (2.55 Imp qt, 3.07 US qt)

3.1 L (2.73 Imp qt, 3.28 US qt)230 kPa at 5,000 r/min(2.3 kg/cm2 at 5,000 r/min)(2.3 bar at 5,000 r/min)(32.7 psi at 5,000 r/min)100C (212F)600 680 kPa (6.0 6.8 kg/cm2, 6.0 6.8 bar, 87.0 98.6 psi)

2-3


Item Standard Limit

Oil filterOil filter typeBypass valve opening pressure

Paper80 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

Trochoid0.01 0.10 mm(0.0004 0.0039 in)0.09 0.15 mm(0.00035 0.0059 in)

0.18 mm(0.0071 in)0.22 mm(0.0087 in)

Cooling systemRadiator capacityRadiator cap opening pressure

Radiator coreWidthHeightDepth

Coolant reservoirCapacity

Water pumpWater pump typeReduction ratioMax. impeller shaft tilt

2.51 L (2.21 Imp qt, 2.65 US qt)108 137 kPa (1.08 1.37 kg/cm2,1.0 1.3 bar, 15.6 19.9 psi)

380 mm (14.96 in)258 mm (10.2 in)24 mm (0.94 in)

0.25 L (0.22 Imp qt, 0.26 US qt)

Single suction centrifugal pump65/43 25/32 (1.181)

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

12.5 13.1 cm3 (0.76 0.80 cu.in)

0.10 mm(0.0039 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)22.500 22.521 mm (0.8858 0.8867 in)22.459 22.472 mm (0.8842 0.8847 in)0.028 0.062 mm (0.0011 0.0024 in)

32.85 32.95 mm (1.293 1.297 in)

25.14 25.24 mm (0.990 0.994 in)

30.75 30.85 mm (1.211 1.215 in)

23.09 23.19 mm (0.909 0.913 in)

32.75 mm(1.289 in)25.04 mm(0.986 in)

30.65 mm(1.207 in)22.99 mm(0.905 in)0.03 mm(0.0012 in)

2-5


Head Diameter Face Width Seat Width Margin Thickness

Item Standard Limit

Timing chainModel/number of linksTensioning system

RH2020/122Automatic

Valves, valve seats, valve guidesValve clearance (cold)

IntakeExhaust

Valve dimensions

0.11 0.20 mm (0.0043 0.0079 in)0.21 0.25 mm (0.0083 0.0098 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

23.4 23.6 mm (0.9213 0.9291 in)24.9 25.1 mm (0.9803 0.9882 in)

1.76 2.90 mm (0.0693 0.1142 in)1.76 2.90 mm (0.0693 0.1142 in)

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

0.5 0.9 mm (0.0197 0.0354 in)0.5 0.9 mm (0.0197 0.0354 in)

3.975 3.990 mm (0.1565 0.1571 in)

4.460 4.475 mm (0.1756 0.1762 in)

4.000 4.012 mm (0.1575 0.1580 in)

4.500 4.512 mm (0.1772 0.1776 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)

3.945 mm(0.1553 in)4.425 mm(0.1742 in)

4.050 mm(0.1594 in)4.550 mm(0.1791 in)

0.08 mm(0.0032 in)0.10 mm(0.0039 in)0.01 mm(0.0004 in)

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

2-6


Item Standard Limit

Valve springsFree lengthIntakeExhaust

Installed length (valve closed)IntakeExhaust

Compressed spring force(installed)Intake

Exhaust

Spring tilt

Intake

Exhaust

Winding direction (top view)IntakeExhaust

39.3 mm (1.55 in)39.3 mm (1.55 in)

32.7 mm (1.29 in)32.8 mm (1.29 in)

145.9 167.9 N (14.88 17.12 kg, 32.80 37.74 lb)164.1 188.9 N (16.73 19.26 kg, 36.89 42.46 lb)

ClockwiseClockwise

37.3 mm (1.47 in)37.3 mm (1.47 in)

2.5 /1.7 mm(0.07 in)2.5 /1.7 mm(0.07 in)

CylindersCylinder arrangementBore strokeCompression ratioBoreMax. out-of-round

Forward-inclined, parallel 4-cylinder77.0 mm 53.6 mm (3.03 2.11 in)12.4 : 177.00 77.01 mm (3.0315 3.0319 in)

0.005 mm (0.0002 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)

76.975 76.990 mm (3.0305 3.0311 in)

5 mm (0.20 in)

17.002 17.013 mm (0.6694 0.6698 in)0.5 mm (0.0197 in)Intake side

16.991 17.000 mm (0.6689 0.6693 in)0.002 0.022 mm (0.0001 0.0009 in)

Barrel0.90 2.75 mm (0.04 0.11 in)0.15 0.25 mm (0.0059 0.0098 in)

0.030 0.065 mm (0.0012 0.0026 in)

Taper0.80 2.75 mm (0.03 0.11 in)0.30 0.45 mm (0.0118 0.0177 in)

0.020 0.055 mm (0.0008 0.0022 in)

1.50 2.25 mm (0.06 0.09 in)0.10 0.40 mm (0.0039 0.0158 in)

0.120 mm(0.0047 in)

17.043 mm(0.6710 in)

16.971 mm(0.6682 in)0.072 mm(0.0028 in)

0.50 mm(0.0197 in)0.115 mm(0.0045 in)

0.80 mm(0.0315 in)0.115 mm(0.0045 in)

2-8


Item Standard Limit

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

0.034 0.058 mm (0.0013 0.0023 in)

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

0.09 mm(0.0035 in)

Crankshaft

Width AWidth BMax. runout C

Big end side clearance DCrankshaft-journal-to-crankshaft-journal-bearing clearanceBearing color code

55.20 56.60 mm (2.17 2.23 in)298.8 300.7 mm (11.76 11.84 in)

0.160 0.262 mm (0.0063 0.0103 in)0.014 0.037 mm (0.0006 0.0015 in)

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

0.03 mm(0.0012 in)

0.10 mm(0.0039 in)

2-9


Item Standard Limit

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

Plate quantityColor codeThickness

Plate quantityColor codeThickness

Plate quantityClutch platesThicknessPlate 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)

Purple2.9 3.1 mm (0.114 0.122 in)

7Green2.9 3.1 mm (0.114 0.112 in)

1–2.9 3.1 mm (0.114 0.112 in)

1

1.9 2.1 mm (0.07 0.08 in)8

52.5 mm (2.07 in)

6

2.8 mm(0.110 in)

2.8 mm(0.110 in)

2.8 mm(0.110 in)

0.1 mm(0.0039 in)

49.9 mm(1.96 in)

2-10


Item Standard Limit

TransmissionTransmission typePrimary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioOperationGear ratios1st gear2nd gear3rd gear4nd gear5th gear6th gear

Max. main axle runout

Max. drive axle runout

Constant mesh, 6-speedSpur gear65/43 (1.512)Chain drive45/17 (2.647)Left-foot operation

38/15 (2.533)33/16 (2.063)37/21 (1.762)35/23 (1.522)30/22 (1.364)33/26 (1.269)

0.08 mm(0.0032 in)0.08 mm(0.0032 in)

Shifting mechanismShift mechanism typeMax. shift fork guide bar bending

Shift drum/Guide bar

0.10 mm(0.0039 in)

Air filter type Oil coated paper element

Fuel pumpPump typeModel (manufacturer)Output pressure

Electrical5PW (DENSO)294 kPa (2.94 kg/cm2, 2.94 bar, 42.6 psi)

Throttle position sensorResistanceOutput voltage (at idle)

4.9 5.1 kΩ at 20C (68F)0.63 0.73 V

Throttle bodiesModel (manufacturer) quantityIntake vacuum pressureThrottle cable free play (at the flange

45EIDW (MIKUNI) 222 kPa (165 mmHg, 6.4966 inHg)3 5 mm (0.12 0.20 in)

of the throttle grip)ID mark

Throttle valve size

5VY1 00 (USA)5VY5 10 (CAL)#100

2-11

CHASSIS SPECIFICATIONS SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

FrameFrame typeCaster angleTrail

Diamond2497 mm (3.82 in)

Front wheelWheel typeRimSizeMaterial

Wheel travelWheel runoutMax. radial wheel runoutMax. lateral wheel runout

Cast wheel

17 M/C MT3.50Aluminum120 mm (4.72 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 MT6.00Aluminum130 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)90 202 kg (198 445 lb)High-speed riding

Min. tire tread depth

Tubeless120/70 ZR17 M/C (58W)Pilot POWER C (MICHELIN)D218FL (DUNLOP)

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

1.6 mm (0.06 in)

Rear tireTire typeSizeModel (manufacturer)

Tire pressure (cold)0 90 kg (0 198 lb)90 202 kg (198 445 lb)High-speed riding

Min. tire tread depth

Tubeless190/50 ZR17 M/C (73W)Pilot POWER G (MICHELIN)D218L (DUNLOP)

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

1.6 mm (0.06 in)

2-12


Item Standard Limit

Front brakesBrake typeOperationRecommended fluidBrake lever free playBrake discsDiameter thicknessMin. thickness

Max. deflection

Brake pad lining thickness (inner)

Brake pad lining thickness (outer)

Master cylinder inside diameterCaliper cylinder inside diameter

Dual disc brakeRight hand operationDOT 42.3 11.5 mm (0.09 0.45 in)

320 4.5 mm (12.60 0.18 in)

4.5 mm (0.18 in)

4.5 mm (0.18 in)

14 mm (0.55 in)30.1 mm and 27 mm (1.19 in and 1.06 in)

4.0 mm(0.16 in)0.1 mm(0.004 in)0.5 mm(0.02 in)0.5 mm(0.02 in)

Rear brakeBrake typeOperationRecommended fluidBrake pedal freeplayBrake discsDiameter thicknessMin. thickness

Max. deflection

Brake pad lining thickness (inner)

Brake pad lining thickness (outer)

Master cylinder inside diameterCaliper cylinder inside diameter

Single disc brakeRight foot operationDOT 44.3 9.3 mm (0.17 0.37 in)

220 5 mm (8.66 0.20 in)

6.0 mm (0.24 in)

6.0 mm (0.24 in)

12.7 mm (0.5 in)31.8 mm (1.25 in)

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

2-13


Item Standard Limit

Front suspensionSuspension typeFront fork typeFront fork travelSpringFree length

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

Inner tube outer diameterInner tube bending limit

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

Spring preload adjusting positionsMinimumStandardMaximum

Rebound damping adjustingpositionsMinimum*Standard*Maximum*

Compression damping adjustingpositionsMinimum*Standard*Maximum*

*from the fully turned-in position

Telescopic forkCoil spring/oil damper120 mm (4.72 in)

236.5 mm (9.31 in)

100 mm (3.937 in)222.5 mm (8.76 in)8.83 N/mm (0.90 kg/mm, 50.42 lb/ in)0 120 mm (0 4.7244 in)43 mm (1.69 in)

No

Suspension oil “01”0.53 L (0.47 Imp qt, 0.56 US qt)76 mm (2.99 in)

84.51

26101

25101

231.8 mm(9.13 in)

0.2 mm(0.01 in)

2-14


Item Standard Limit

SteeringSteering bearing type Angular bearing

Lock to lock angle (left)Lock to lock angle (right)

2727

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

Rebound damping adjustingpositionsMinimum*Standard*Maximum*

Compression damping adjustingpositionsMinimum*Standard*Maximum*

*from the fully turned-in position

Swingarm (link suspension)Coil spring/gas-oil damper

65 mm (2.56 in)

173.5 mm (6.83 in)163.5 mm (6.44 in)83.4 N/mm (8.50 kg/mm, 476.21 lb/ in)0 65 mm (0.00 2.56 in)No1,200 kPa (12 kg/cm2, 12 bar, 171 psi)

149

20171

20121

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

50VA8 (DAIDO)11625 35 mm (0.98 1.38 in)

150.1 mm(5.91 in)

2-15

ELECTRICAL SPECIFICATIONS SPEC

ELECTRICAL SPECIFICATIONS

Item Standard Limit

System voltage 12 V

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

DC. T.C.I.5 BTDC at 1,050 r/min336 504 Ω at 20C (68F)/Gy-B

F8T822 (MITSUBISHI) (USA)F8T823 (MITSUBISHI) (CAL)

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

F6T558 (MITSUBISHI)6 mm (0.24 in)1.19 1.61 Ω at 20C (68F)8.5 11.5 kΩ at 20C (68F)

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

A.C. magnetoF4T850 (MITSUBISHI)14 V/560 W at 5,000 r/min0.14 0.18 Ω at 20C (68F)/W-W

Rectifier/regulatorRegulator typeModel (manufacture)

Semi conductor short circuitFH011AA (SHINDENGEN)

( )No-load regulated voltageRectifier capacityWithstand voltage

( )14.3 15.1 V50 A100 V

BatteryBattery typeBattery voltage/capacitySpecific gravityManufacturerTen hour rate amperage

YTZ10S12 V/8.6 Ah1.310YUASA0.8 A

Headlight type Halogen bulb

Bulbs (voltage/wattage quantity)HeadlightAuxiliary lightTail /brake lightFront turn signal light/position lightRear turn signal lightLicence plate lightMeter light

12 V 55 W 412 V 5 W 2LED 112 V 21 W/5 W 212 V 21 W 212 V 5 W 1LED 1

2-16


Item Standard Limit

Indicator light(voltage/wattage quantity)Neutral indicator lightHigh beam indicator lightOil level warning lightTurn signal indicator lightFuel level warning lightCoolant temparture indicator lightEngine trouble warning lightShift timing indicator light

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

Electric starting systemSystem typeStarter motorModel (manufacturer)Power outputBrushesOverall length

Spring force

Armature coil resistanceCommutator diameter

Mica undercut

Constant mesh

5VY (YAMAHA)0.9 kW

10.8 mm (0.43 in)

5.28 7.92 N (538 808 g, 18.99 28.48 oz)0.0090 0.0110 Ω at 20C (68F)24.5 mm (0.96 in)

1.5 mm (0.06 in)

3.6 mm(0.14 in)

23.5 mm(0.93 in)

Starter relayModel (manufacturer)AmperageCoil resistance

2768079-A (JIDECO)180 A4.18 4.62 Ω at 20C (68F)

HornHorn typeModel (manufacturer) quantityMax. amperagePerformanceCoil resistance

PlaneYF-12 (NIKKO) 13 A105 113 db/2 m1.15 1.25 Ω at 20C (68F)

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

Full transistorFE218BH (DENSO)No75 95 cycles/min.21 W 2 + 3.4 W

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

EXUP servo motorModel (manufacturer) 5VY (YAMAHA)

2-17


Item Standard Limit

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

50 A 115 A 125 A 110 A 115 A 115 A 210 A 125 A, 15 A, 10 A 1

2-18

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 inSI and METRIC UNITS.Use this table to convert METRIC unit data toIMPERIAL 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)

2-19

TIGHTENING TORQUES SPEC

Use a lock washer

TIGHTENING TORQUESENGINE TIGHTENING TORQUES

Item FastenerThread

Q’tyTightening torque

RemarksItem Fastener size Q tyNm mkg ftlb

Remarks

Spark plugs — M10 4 13 1.3 9.4Cylinder head Nut M10 10 See NOTE 1

Bolt M6 2 12 1.2 8.7Camshaft caps Bolt M6 28 10 1.0 7.2Cylinder head cover Bolt M6 6 12 1.2 8.7Cylinder head (exhaust pipe) Stud bolt M8 8 15 1.5 11Air indication system cap Bolt M6 4 10 1.0 7.2Camshaft sprockets Bolt M7 4 24 2.4 17Cylinder head and throttle body Clamp M5 4 3 0.3 2.2Connecting rod caps Bolt M8 8 20+150 2.0+150 14+150

Generator rotor Bolt M10 1 60 6.0 43Timing chain tensioner Bolt M6 2 10 1.0 7.2Water pump outlet pipe Bolt M6 1 10 1.0 7.2Water pump inlet pipe Bolt M6 1 10 1.0 7.2(water pump side)Water pump inlet pipe (front side) Bolt M6 1 10 1.0 7.2Oil /water pump assemblysprocket

Bolt M6 1 15 1.5 11

Water pump Bolt M6 2 12 1.2 8.7Thermostat cover Nut M6 2 10 1.0 7.2Thermostat inlet pipe Bolt M6 1 10 1.0 7.2Oil cooler Bolt M20 1 63 6.3 46Engine oil drain bolt Bolt M14 1 43 4.3 31Oil pipe Bolt M6 2 10 1.0 7.2Oil strainer Bolt M6 3 10 1.0 7.2Oil delivery pipe Bolt M6 3 10 1.0 7.2Oil filter union bolt Bolt M20 1 70 7.0 51Oil filter — M20 1 17 1.7 12Oil pan Bolt M6 14 12 1.2 8.7Oil pan Bolt M6 1 12 1.2 8.7Air filter case cover Screw M5 10 1.7 0.17 1.2Throttle body and throttle bodyjoint

Clamp M5 4 3 0.3 2.2

Throttle body and funnel Bolt M5 6 4.2 0.42 3.0Throttle cable Nut M6 1 4.5 0.45 3.3Throttle cable adjuster Bolt M6 1 4.5 0.45 3.3Stator coil Screw M6 3 14 1.4 10Generator rotor cover andbearing housing

Screw M6 3 10 1.0 7.2

Pull lever cover Bolt M6 2 10 1.0 7.2Thermostat assembly stay Bolt M6 2 10 1.0 7.2Starter clutch idler gear Bolt M6 1 10 1.0 7.2Clutch boss Nut M20 1 95 9.5 69 StakeClutch spring Bolt M6 6 10 1.0 7.2Drive sprocket Nut M22 1 85 8.5 61

2-20


Item Fastener Thread Q’tyTightening torque

RemarksItem Fastenersize

Q tyNm mkg ftlb

Remarks

Exhaust pipe and cylinder head Nut M8 8 20 2.0 14Catalyst pipe assembly andmuffler

Bolt M8 2 20 2.0 14

Exhaust pipe and exhaust valve Bolt M6 5 10 1.0 7.2pipe assemblyExhaust valve pipe and housing Bolt M6 1 10 1.0 7.2Pulley and shaft arm Nut M6 1 7 0.7 5.0EXUP pulley bracket Bolt M6 1 10 1.0 7.2EXUP pulley cover Bolt M6 2 10 1.0 7.2Exhaust valve pipe and bracket Bolt M8 1 20 2.0 14EXUP cable nut Nut M6 2 7 0.7 5.0Catalyst pipe bracket and frame Bolt M8 1 20 2.0 14Catalyst pipe and catalyst pipe Bolt M8 1 20 2.0 14bracketExhaust valve pipe and catalyst pipe

Bolt M8 1 20 2.0 14

EXUP servo motor Bolt M6 2 7 0.7 5.0Muffler and rear frame Bolt M8 2 23 2.3 17Muffler cover Bolt M6 2 10 1.0 7.2Crankcase Stud bolt M10 10 8 0.8 5.8Crankcase (main journal) Bolt M9 10 See NOTE 2Crankcase Bolt M6 10 12 1.2 8.7Crankcase Bolt M8 1 24 2.4 17Crankcase Bolt M8 5 24 2.4 17Generator rotor cover Bolt M6 4 12 1.2 8.7Generator rotor cover Bolt M8 3 22 2.2 16Drive sprocket cover Bolt M6 2 10 1.0 7.2Drive sprocket cover Bolt M6 1 10 1.0 7.2Crankcase cover (left) Screw M6 3 10 1.0 7.2Clutch cover Bolt M6 7 12 1.2 8.7Clutch cover Bolt M6 1 12 1.2 8.7Pickup rotor cover Bolt M6 6 12 1.2 8.7Breather cover Bolt M6 4 12 1.2 8.7Breather plate Bolt M6 3 10 1.0 7.2Plate Bolt M6 2 10 1.0 7.2Pickup rotor cover blind bolt Bolt M8 1 15 1.5 11Generator rotor cover plug Plug M20 1 8 0.8 5.8Main gallery plug (oil return) Plug M16 3 8 0.8 5.8Main gallery plug Plug M20 1 8 0.8 5.8Oil return pipe Bolt M6 2 10 1.0 7.2Oil return plug Screw M12 2 24 2.4 17Stator coil lead Bolt M6 1 10 1.0 7.2

2-21


NOTE 1:

NOTE 2:

Item Fastener Thread Q’tyTightening torque

RemarksItem Fastenersize

Q tyNm mkg ftlb

Remarks

Main axle bearing housing Bolt M6 3 12 1.2 8.7Shift fork shaft stopper Bolt M6 2 10 1.0 7.2Stopper screw Screw M8 1 22 2.2 16Shift rod lock nut (rear) Nut M6 1 7 0.7 5.0 Left thread

Shift rod lock nut (front) Nut M6 1 7 0.7 5.0Shift rod joint Bolt M6 1 10 1.0 7.2Shift arm Bolt M6 1 10 1.0 7.2E.C.U. Screw M6 2 7 0.7 5.0Neutral switch — M10 1 20 2.0 15EXUP servo motor cover Screw M5 2 2 0.2 1.5Coolant temperature sensor — M12 1 18 1.8 13Cylinder identification sensor Bolt M6 1 8 0.8 5.7Atmospheric pressure sensor Screw M5 2 7 0.7 5.0Crankshaft position sensor Bolt M6 1 10 1.0 7.2Oil level switch Bolt M6 2 10 1.0 7.2

1. First, tighten the bolts to approximately 19 Nm (1.9 mkg, 14 ftlb) with a torque wrench following thetightening order.

2. Retighten the bolts 67 Nm (6.7 mkg, 48 ftlb) with a torque wrench.

1. First, tighten the bolts to approximately 20 Nm (2.0 mkg, 15 ftlb) with a torque wrench following thetightening order.

2. Loosen the all bolts one by one following the tightening order and then tighten them to 20 Nm (2.7mkg, 15 ftlb) again.

3. Retighten the bolts further to reach the specified angle (60).

2-22


Cylinder head tightening sequence:

Crankcase tightening sequence.

2-23


See NOTE 2

CHASSIS TIGHTENING TORQUES

ItemThread Tightening

RemarksItem size Nm mkg ftlbRemarks

Upper bracket and outer tube M8 26 2.6 19Upper bracket and steering stem nut M28 113 11.3 82Handlebar and outer tube M8 17 1.7 12Handlebar and upper bracket M6 13 1.3 9Steering shaft and ring nut M30 18 1.8 13 See NOTE 1Outer tube and under bracket M8 23 2.3 17Main switch and upper bracket M8 26 2.6 19Front brake master cylinder cap stopper M4 1.2 0.12 0.9Front brake hose union bolts M10 30 3.0 22Front brake master cylinder and bracket M6 13 1.3 9Meter assembly and front cowling stay — 1.3 0.13 0.9Headlight and front cowling stay — 0.8 0.08 0.6Front cowling and headlight assembly — 1.5 0.15 1.1Cover 7, 8 and frame M6 5 0.5 3.6Under cowling and engine M6 5 0.5 3.6Windshield and front cowling M5 0.4 0.04 0.3Duct and console panel M5 1.3 0.13 0.9End grip and handlebar M6 4 0.4 2.9Horn bracket and under bracket M6 4 0.4 2.9Coolant reservoir tank and frame M6 5 0.5 3.6Engine mount front (left and right) M10 45 4.5 33Engine mount rear upper M10 51 5.1 37Engine mount rear under M10 51 5.1 37Engine mount rear adjust bolt M16 7 0.7 5.1Catalyst pipe stay and frame M10 44 4.4 32Clutch cable lock nut (engine side) M8 7 0.7 5.1Main frame and rear frame M10 41 4.1 30Throttle cable adjust nut (throttle body side) M6 5 0.5 3.6Cover 2 and plate — 0.8 0.08 0.6Pivot shaft and nut M18 105 10.5 76Connecting rod and frame M10 44 4.4 32Relay arm and connecting rod M10 44 4.4 32Relay arm and swingarm M10 44 4.4 32Rear shock absorber and relay arm M10 44 4.4 32Rear shock absorber and upper bracket M10 44 4.4 32Upper bracket and frame M14 92 9.2 67Seal guard M6 7 0.7 5.1Drive chain case M6 7 0.7 5.1Chain puller adjust nut M8 16 1.6 12Fuel tank and fuel pump assembly M5 4 0.4 2.9Fuel tank stay (front side) and frame M6 7 0.7 5.1Fuel tank and fuel tank stay (front side) M6 7 0.7 5.1Fuel tank stay (rear side) and rear frame M6 7 0.7 5.1Side cover and fuel tank M5 0.4 0.04 0.3Rider seat and frame M6 7 0.7 5.1Seat lock plate and rear frame M6 10 1.0 7Side cover (rear side) and frame M5 4 0.4 2.9

2-24


NOTE 1:

NOTE 2:

NOTE 3:

Item Thread TighteningRemarksItem

size Nm mkg ftlbRemarks

Battery box and frame M6 7 0.7 5.1Atmospheric pressure sensor and battery box — 0.7 0.07 0.5Lean angle cut-off switch and battery box — 2 0.2 1.4Foot rest bracket (front) and frame M8 28 2.8 20Foot rest bracket (rear) and frame M8 28 2.8 20Rear brake master cylinder and foot rest bracket M6 18 1.8 13Rear brake hose union bolt M10 30 3.0 22Sidestand bracket and frame M10 63 6.3 46Front wheel axle shaft and bolt M14 91 9.1 66Rear wheel axle nut M24 150 15.0 109Front brake caliper and front fork M10 35 3.5 25Front brake disc and front wheel M6 18 1.8 13Rear brake disc and rear wheel M6 30 3.0 22Rear wheel sprocket and drive hub M10 100 10.0 72Brake caliper bleed screw M8 6 0.6 4.3Front wheel axle pinch bolt M8 20 2.0 14 See NOTE 3

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.

1. Insert the front wheel axle from the right sideand tighten it with the flange bolt from the leftside to 91 Nm (9.1 mkg, 65.8 ftlb).

2. In the order from the pinch bolt 2 pinchbolt 1 pinch bolt 2 , tighten each bolt to20 Nm (2.0 mkg, 14 ftlb) without perform-ing temporary tightening.

3. Check that the end face of the axle head andthe end face of the fork side are flush-mounted. If they are out of alignment, makesure to fit them by adding the external forceby hand or with a plastic hammer, etc.If the end face of the axle is not parallel to theend face of the fork, align them so that onepoint of the axle circumference is positionedon the end face of the fork.At this stage, it can be accepted if the endface of the axle becomes partially concaveto the end face of the fork.

4. In the order from the pinch bolt 4 pinchbolt 3 pinch bolt 4 , tighten each bolt to20 Nm (2.0 mkg, 14 ftlb) without perform-ing temporary tightening.

2-25

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EAS00031

LUBRICATION POINTS AND LUBRICANT TYPESENGINE

Lubrication point Lubricant

Oil seal lips

O-rings

Bearings

Crankshaft pins

Piston surfaces

Piston pins

Crankshaft journals

Camshaft lobes

Camshaft journals

Valve stems (intake and exhaust)

Valve stem ends (intake and exhaust)

Water pump impeller shaft

Oil pump rotors (inner and outer)

Oil pump housing

Oil strainer

Clutch (pull rod)

Oil /water pump drive sprocket and washer

Clutch (thrust plate)

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

Crankcase mating surface Yamaha bondNo.1215

Clutch cover (crankcase mating surface) Yamaha bondNo.1215

Generator rotor cover (crankcase mating surface) Yamaha bondNo.1215

Pickup rotor cover Yamaha bondNo.1215

2-26

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EAS00032

CHASSIS

Lubrication point Lubricant

Steering bearings and bearing races (upper and lower)

Throttle grip inner surface

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

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

Engine mount bolts (rear upper and lower)

Relay arm, connecting rod and rear shock absorber collar

Pivot shaft

Swingarm pivot bearing

Swingarm head pipe end, oil seal and bush

Oil seal (relay arm, connecting arm and rear shock absorber)

Seat lock assembly moving parts

Sidestand pivoting pint and metal-to-metal moving parts

Link and sidestand switch contact point

Sidestand hook and spring

Shift shaft joint

Front wheel oil seal (right and left)

Front axle shaft

Rear wheel oil seal

Rear wheel drive hub oil seal

Rear wheel drive hub mating surface

2-27

1 Radiator fan2 Radiator3 Water pump

COOLING SYSTEM DIAGRAMS SPEC

EAS00033

COOLING SYSTEM DIAGRAMS

2-28

1 Thermostat2 Radiator cap3 Radiator4 Oil cooler

COOLING SYSTEM DIAGRAMS SPEC

2-29

ENGINE OIL LUBRICATION CHART SPEC

ENGINE OIL LUBRICATION CHART

2-30

LUBRICATION DIAGRAMS SPEC

1 Intake camshaft2 Exhaust camshaft3 Oil filter cartridge4 Oil level switch

EAS00034

LUBRICATION DIAGRAMS

2-31

1 Intake camshaft2 Exhaust camshaft3 Crankshaft4 Oil cooler5 Oil pipe6 Oil strainer7 Oil pump8 Relief valve


2-32

1 Oil cooler2 Oil filter cartridge3 Oil level switch4 Oil strainer5 Oil pump6 Oil pipe


2-33

1 Main axle2 Oil delivery pipe3 Drive axle


2-34

1 Cylinder head2 Crankshaft


2-35

CABLE ROUTING SPEC

G Clamp the head light lead bywrapping and insert it to the in-take air grill hole. (only at theright side.)

H Do not connect the wire to thecoupler with the plug for options.

I To the turn signal lightJ To the wire harnessK Cut the tip of the clamp.

A Insert to the rib of the head light.(Either location of the right andleft relays is acceptable.)

B The lead should not stretch toomuch.

C Make sure to insert the couplerand boot to the stay 1 hole.

D The speedometer lead shouldnot be strained.

E To the stay 1 holeF Connect after passing over the

upper side of the duct.

1 Ground lead2 Meter lead3 Stay 14 Auxiliary light lead (right)5 Headlight lead6 Auxiliary light lead (left)7 Console panel 18 Duct 19 Console panel 210 Duct 211 Headlight lead (right)12 Headlight lead (left)

EAS00035

CABLE ROUTING

2-36

CABLE ROUTING SPEC

L Clamp the head light lead to thestay 1 at the positioning whitetape section. There should be noslack when clamping. Point thetip of the clamp (excessive part)to the front side of the vehicle.Fasten the head light lead with aclamp.

M Feed a lead wire through the Ushape cutout of the console pan-el.

2-37

F Clamp the leads inside the frontfork of the vehicle. Point the exitof the horn lead to the left frontfork side.

G Two throttle cables should notcross with each other.Route two throttle cables behindthe brake hose, pass betweenthe inside of the under bracket’supper side front fork and guidewire assembly, and then pass itthrough the clamp that is in-serted to the cover 3 under theframe.

A Route the clutch cable so as toget along the front side of themain switch after passing itthrough the guide.

B Pass the main switch leadthrough the guide wire.

C Pass the left handlebar switchlead through the guide wire.

D Point the tip of the band (exces-sive part) to the rear side of thevehicle and cut the surplus sec-tion. Clamp it to the outer tube.

E Clamp the section between 0and 20 mm (0 and 0.79 in) fromthe split of the under bracket.

CABLE ROUTING SPEC

1 Right handlebar switch lead2 Clutch cable3 Main switch lead4 Left handlebar switch lead5 Horn lead6 Horn7 Throttle cables8 Brake hose9 Throttle cable (return side)10 Throttle cable (pull side)

2-38

CABLE ROUTING SPEC

H Clamp the assembly of theclamp and guide wire to the frontfork outer tube. Cut the tip of theclamp leaving 2 to 4 mm (0.08 0.16 in). Point the binding part tothe external part of the vehicle.Clamp it to the outer tube.

I Cut the tip leaving 2 to 4mm(0.08 0.16 in).

2-39

E Clamp the clamp upper endalong the line of lower end of thehose clamp assembly. Point thetip of the clamp (surplus section)to the front side of the vehicle.Clutch cable is what the clampfastens.

F The clutch cable doesn’t projectoutside the water hose and thecylinder head in the box part inthe figure.

G To the engineH Clamp behind the bracket 3.

17 Throttle body lead

A Clamp it after passing betweenthe frame and radiator stay.Point the tip of the clamp (exces-sive part) to the front side of thevehicle. Fasten the right handle-bar switch lead with a clamp.

B To the wire harnessC The clutch cable positioning

guide should be above the upperend of the clamp. Fasten theclutch cable with a clamp. (Referto )

D Position relation between theclamp and guide.

M

CABLE ROUTING SPEC

1 Wire harness2 Crankshaft position sensor lead3 Heat protector4 Right handlebar switch lead5 Positioning guide6 Rear brake light switch lead7 Coolant reservoir tank8 Speed sensor lead9 Clutch cable10 Radiator11 Oil cooler outlet hose12 Coolant reservoir tank drain

hose13 Breather pipe14 Fuel tank drain hose15 A.C. magneto lead16 Wire harness

2-40

P To the air filterQ Route the fuel tank drain hose

over the canister stay and be-tween the breather hose 2 andwire harness. On the front side ofthe canister stay, let though thebottom of the A.C.magneto leadand the wire harness.

R Route by the upside of vehicleaway from the canister stay.

CABLE ROUTING SPEC

I The coupler for the air inductionsolenoid lead and camshaft sen-sor lead should be connectedabove the ignition coil sub wireharness and it should not dropon the cylinder head cover be-hind the ignition coil.

J Pass the right handlebar switchlead between the frame and heatprotector.

K Coolant reservoir tank drainhose should cross with thespeed sensor lead under theswingarm bracket. Route thecoolant reservoir tank drain hoseover the up side of the vehicle.

L Pass the rear brake light switchlead between the swingarmbracket and coolant reservoirtank.

M Release the tip of the clamp andinstall it to the clutch cable.Insert the clamp to the hole lo-cated on the right back side ofthe radiator.Radiator fan motor lead shouldnot be caught while inserting theclamp.

N Push the clamp until it hits the ra-diator side stay. Radiator fan mo-tor lead should not be caught.

O Clamp the clutch cable so that itis within this specified clamp.

2-41

C Fold back the clamp and secureit after passing the lead throughthe clamp.

D To the EXUP servo motorE Pass the coolant reservoir tank

drain hose and fuel tank drainhose through the clamp from theouter side of the water pump inletpipe after routing it behind thewater pump breather hose. The lengths of two hose ends areallowed to be random. Any direc-tion of cut edges can be ac-cepted. (Only for the fuel tankdrain hose)

F Clamp the fuel tank drain hoseand fuel tank breather hose.

A Clamp the leads so that they arepositioned inner of the vehiclethan the washer position afterrouting them between the frameand radiator stay. Align the clampposition with the taping sectionsof leads. Point the tip of the clamp(surplus section) to the downfront side of the vehicle.What the clamp fastens at thisstage are the handlebar switchand main switch leads.

B Pass the main switch lead andleft handlebar switch lead be-tween the frame and the heatprotector.

CABLE ROUTING SPEC

1 Heat protector2 Main switch lead3 Left handlebar switch lead4 EXUP servo motor lead5 Coolant reservoir tank drain hose6 Fuel tank drain hose7 Coolant outlet pipe8 Sidestand switch lead9 Oil level switch lead10 A.C.magneto lead11 Fuse box stay12 Water hose13 Stay 114 Chain case cover

2-42

R Arrange so as not for each hoseto cross in the part between “BB”from the section “AA” which is inthe illustration.

G Route the lead by the inside ofthe water hose and water pipe.

H Route the lead by the inside ofthe water hose and water pipe.

I Route by the outside of vehicleaway from the water hose.

J Point the tip of the clamp (exces-sive part) to the down rear side ofthe vehicle. Fasten the wire har-ness with a clamp.

K Route the water hose so that it isplaced at the outermost positionfinally after routing other leadsand hoses in the guide.

L To the coolant reservoir tank

CABLE ROUTING SPEC

M There should be no exposure ofbared conductors due to the dis-placement of the tube.

N Route the coolant reservoir tankdrain hose so that it is routed atthe innermost position to eachhose and lead.

O Can be routed in any order.P Align the molded part of the fuel

tank drain hose with the stay 1.Q Routing of the fuel tank drain

hose.EXUP servo motor, oil levelswitch and sidestand switchleads are omitted in this drawing.

2-43

33 Throttle body side cap34 Mud guard35 Turn signal light lead36 License plate light lead37 Rear fender rib38 Speed sensor lead39 Rear brake light switch lead40 Rear frame41 Swingarm bracket42 Main fuse lead43 Starting circuit cut-off relay lead44 Turn signal light relay lead45 Starter relay lead46 Main fuse lead (To the battery

positive lead)47 Right handlebar switch lead

17 Battery negative lead18 Starter motor lead19 A.C.magneto lead20 Oil level switch lead21 Sidestand switch lead22 Throttle body lead23 Coolant reservoir tank drain hose24 Fuel tank drain hose25 Cover 726 Radiator fan motor lead (left)27 Radiator fan motor lead (right)28 Wire harness29 Pipe 330 Frame31 Coolant reservoir tank hose32 Thermo stat assembly breather

hose

CABLE ROUTING SPEC

1 Heat protector2 Crankshaft position sensor lead3 Neutral switch lead4 Ground lead5 Coolant reservoir tank6 Battery positive lead7 Starter relay8 Turn signal relay9 Main fuse10 Lean angle cut-off switch11 Atmospheric pressure sensor12 Tail /brake light lead13 Rear fender14 Seat lock cable15 Anti safety alarm coupler16 Starting circuit cut-off relay

2-44

K Pass the water hose lower sideof the thermostat, and betweenthe ground lead and the neutralswitch.

L Install the leads so that the en-gine ground lead is positionedlower and the battery negativelead to be upper. Install the pro-trusion of each lead to be abovethe vehicle.

M Route the crankshaft positionsensor lead under the wire har-ness.

N To the fuel pumpO Clamp the wire harness winding

in and insert it to the frame hole.

A Pass the wire harness throughthe clamp inserted to the radiatorstay.

B To the headlight leadC Clamp the lead between three

protrusions of the pipe (the firstand second parts from the ve-hicle front). Point the tip of theclamp (excessive part) to the in-side of the vehicle.

D To the vehicle right side diagramE To the engineF Clamp the lead between three

protrusions of the pipe (the in-side and outside of the vehicle).

G Point the tip of the clamp (exces-sive part) to the inside of the ve-hicle.

H All hoses and leads should berouted over the vehicle’s upperside above the heat protector.

I To the starter motorJ Fasten the wire harness, clank

shaft position sensor lead, rearbrake light switch lead andspeed sensor lead with a clamp.Then, point the tip of the clamp(cut the tip of the clamp leaving 2to 4 mm (0.08 to 0.16 in).) to theinside of the vehicle.

CABLE ROUTING SPEC

2-45

W Point the tip of the clamp (sur-plus section) to the rear side ofthe vehicle. Fasten the starterrelay lead, turn signal relay lead,main fuse lead, main fuse lead(from the battery positive lead)and starting circuit cut-off relaylead with a clamp.

X Route each lead under the wireharness.

Y Fasten the wire harness, batterynegative lead and starter motorlead with a clamp. Point the tip ofthe clamp (excessive part) to theinside of the vehicle.

P Pass the lead through inside ofthe battery band.

Q Press on the tip of the clamp af-ter passing the leads through it.

R Insert the tail /brake light lead tothe rear frame hole.

S Insert the clamp from the vehiclefront to the rear side and fasteneach lead, coupler and onion-head to the fender rib, and thenpoint the tip of the clamp (exces-sive part) to the upper side of thevehicle.

T Hold down the clamp tips afterpassing each lead.

U Make sure to position the cou-pler at the downmost position ofleads. However, the couplershould be set in the rear frame sothat it is not caught by the seatbottom, cover and other compo-nents.

V Point the tip of the clamp (exces-sive part) to the inside of the ve-hicle. Fasten the wire harnesswith a clamp.

CABLE ROUTING SPEC

2-46

DD Fasten the wire harness,A.C.magneto lead, andthrottle body lead with aclamp. Point the tip of theclamp (cut the tip of the clampleaving 2 to 4 mm (0.08 to 0.16in).) to the inside of the ve-hicle.

EE To the air filterFF To the throttle bodyGG To install the cover 7, install so

as to set each coupler in thecover. Make sure that eachlead is not caught by the cover7.

Z Point the tip of the clamp (exces-sive part) to the down side of thevehicle. Fasten the wire har-ness, battery negative lead, A.C.magneto lead and starter motorlead with a clamp.

AA To the speed sensorBB Insert the wire harness wrap-

ping clamp to the hole of theframe.

CC After passing the lead be-tween the wire harness andstarter motor leads, fasteningby the clamp should be can-celled and route the lead un-der the idle remote controller.

CABLE ROUTING SPEC

HH Insert the wire harness wrap-ping clamp to the hole of theframe.

II Make sure that the lead is fas-tened with the guide of the ra-diator stay.

JJ To the right handlebar switchKK Do not place it beyond pipe 3

in the direction to the externalpart of the vehicle.

LL Battery negative lead shouldnot run on the swingarmbracket.

2-47

PP Route the leads in random or-der.

MM Route each lead lower thanthe frame plate. Leads shouldbe routed in random order.Clamp can be inserted in anydirection.

NN Route each lead higher thanthe frame plate, pass it to theinside of the vehicle from thehole. Leads should be routedin random order.Clamp can be inserted in anydirection.

OO The hoses should not be lo-cated higher than the throttlebody side cap over the up sideof the vehicle.

CABLE ROUTING SPEC

2-48

a Fuel piping connector attach-ment directions. (fuel pump side)

1. Insert the connector until theclick sound is heard and checkthat the connector does notcome off. Make sure that no for-eign matter is caught in the seal-ing section. (It is prohibited towear the cotton work gloves orequivalent coverings.)

G This part works as a dropoutstopper.

2. After Item 1 mentioned above isfinished, check that the clamp isinserted from the down side, and

, and -sections are per-fectly equipped.A B C

A Install the lip of O-ring facing up-ward.

B Install the part pointing the whitepaint part of the hose to the leftside of the vehicle.

C Any direction of the clip grip canbe accepted.

D Install the clip grip as specified inthe drawing.

E Install the part pointing the whitepaint part of the hose to the leftside of the vehicle.

F Point the clip grip to the left sideof the vehicle.

CABLE ROUTING SPEC

1 Fuel tank2 O-ring3 Fuel tank drain hose4 Fuel tank breather hose5 Clip6 Air filter stay7 Fuel hose 28 3 way connector9 Pipe10 Fuel tank bracket11 Fuel hose clamp12 Fuel hose 113 Fuel pump assembly

2-49

F Point the clip grip to the upperside of the vehicle.

G Install the part pointing the yel-low paint mark to the front side ofthe vehicle.

H Install the part pointing the yel-low paint mark to the left side ofthe vehicle.

A Point the clip grip to the downside of the vehicle.

B Insert the hose so that its tip ofthe nipple does not protrude.

C Install the part pointing the whitepaint mark to the left side of thevehicle.

D Insert the hose until it reachesthe R-bottom of the pipe.

E To the throttle body

CABLE ROUTING SPEC

for CAL1 Clip2 Clamp3 Rivet4 Roll over valve assembly5 Balance pipe6 Pipe 47 Canister hose8 Canister assembly9 Canister bracket10 Frame11 Canister stay12 Pipe 213 Pipe 3

3-1

3

INTRODUCTION/PERIODIC MAINTENANCE CHART FOR THE EMISSIONCONTROL SYSTEM/GENERAL MAINTENANCE AND LUBRICATION CHART

CHKADJ

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.

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEMINITIAL ODOMETER READINGS

No. ITEM ROUTINE600 mi

(1000 km)or

1 month

4000 mi(7000 km)

or6 months

8000 mi(13000 km)

or12 months

12000 mi(19000 km)

or18 months

16000 mi(25000 km)

or24 months

20000 mi(31000 km)

or30 months

1 * Fuel line(See page 3-33)

Check fuel hoses for cracks or damage. Replace if necessary.

2 * Spark plugs(See page 3-23)

Check Condition. Adjust gap and clean. Replace every 8000 mi (13000 km) or 12

months.

Replace. Replace.

3 * Valve clearance(See page 3-11)

Check and adjust valve clearance when en-gine is cold.

Every 26600 mi (42000 km)

4 *Crankcase breathersystem(See page 3-34)

Check breather hose for cracks or damage. Replace if necessary.

5 * Electronic fuel injection(See page 3-17, 21)

Check and adjust engine idle speed and syn-chronization.

6 * Exhaust system(See page 3-35)

Check for leakage. Tighten if necessary. Replace gasket(s) if necessary.

7 *Evaporative emissioncontrol system(For California only)

Check control system for damage. Replace if necessary.

8 * Air induction system (See page 7-46)

Check the air cut-off valve, reed valve, andhose for damage.

Replace any damaged parts if necessary.

GENERAL MAINTENANCE AND LUBRICATION CHARTINITIAL ODOMETER READINGS


(1000 km)or

1 month

4000 mi(7000 km)

or6 months

8000 mi(13000 km)

or12 months

12000 mi(19000 km)

or18 months

16000 mi(25000 km)

or24 months

20000 mi(31000 km)

or30 months

1 * Air filter element(See page 3-32)

Check condition and damage. Replace if necessary.

2 * Clutch(See page 3-31)

Check operation. Adjust or replace cable.

3 * Front brake(See page 3-42, 44, 45)

Check operation, fluid level, and for fluid leak-age.

Replace brake pads if necessary.

4 * Rear brake(See page 3-43, 44, 45)

Check operation, fluid level, and for fluid leak-age.

Replace brake pads if necessary.

5 * Brake hoses Check for cracks or damage. 5 * Brake hoses

(See page 3-46) Replace. Every 4 years

6 * Wheels(See page 4-3)

Check runout and for damage. Replace if necessary.

7 * Tires(See page 3-58)

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

8 * Wheel bearings(See page 4-3)

Check bearings for smooth operation. Replace if necessary.

3-2

NOTE:

GENERAL MAINTENANCE AND LUBRICATION CHARTCHKADJ

NOTE:

INITIAL ODOMETER READINGS


(1000 km)or

1 month

4000 mi(7000 km)

or6 months

8000 mi(13000 km)

or12 months

12000 mi(19000 km)

or18 months

16000 mi(25000 km)

or24 months

20000 mi(31000 km)

or30 months

9 *Swingarm pivotbearings(See page 4-71)

Check bearing assemblies for looseness. Moderately repack with lithium-soap-based

grease. Repack.

10 Drive chain(See page 3-49, 50)

Check chain slack/alignment and condition. Adjust and lubricate chain with a special O-

ring chain lubricant thoroughly.Every 600 mi (800 km) and after washing the motorcycle or riding in the rain

11 * Steering bearings(See page 3-51)

Check bearing assembly for looseness. Moderately repack with lithium-soap-based

grease every 16000 mi (25000 km) or 24months.

Repack.

12 * Steering damper(See page 4-60)

Check operation and for oil leakage.

13 * Chassis fasteners(See page 2-23)

Check all chassis fitting and fasteners. Correct if necessary.

14Brake and clutchlever pivot shafts(See page 3-61)

Apply lithium-soap-based grease (all-purposegrease) lightly.

15 Sidestand pivot(See page 3-61)

Check operation. Apply lithium-soap-based grease (all-pur-

pose grease) lightly.

16 * Sidestand switch(See page 3-61, 8-4)

Check operation and replace if necessary.

17 * Front fork(See page 3-53)

Check operation and for oil leakage. Replace if necessary.

18 *Shock absorber assembly(See page 3-56, 4-67)

Check operation and for oil leakage. Replace if necessary.

19 *Rear suspensionlink pivots(See page 4-71)

Check operation. Correct if necessary.

20 Engine oil(See page 3-26, 28)

Change (warm engine before draining.)

21 * Engine oil filter cartridge(See page 3-28)

Replace.

22 * Cooling system

Check hoses for cracks or damage. Replace if necessary.

22 * Cooling system(See page 3-37, 38, 39)

Change with ethylene glycol antifreeze cool-ant every 24 months.

Change.

23 * EXUP system(See page 3-36)

Check operation, cable free play and pulleyposition.

Every 12000 mi (19000 km)

24 * Control cables(See page 3-61)

Apply Yamaha chain and cable lube or en-gine oil SAE 10W-30 thoroughly.

25 *Throttle grip housingand cable(See page 3-22)

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

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi(13000 km) or 12 months.

Air filterThis model’s air filter is equipped with a disposable oil-coated paper element, which must not becleaned with compressed air to avoid damaging it.

The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas. Hydraulic brake service

After disassembling the brake master cylinders and calipers, always change the fluid. Regularlycheck the brake fluid levels and fill the reservoirs as required.

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

Order Job/Part Q’ty Remarks

12

Removing the seatsRider seatPassenger seat

11

Remove the parts in the order listed.

For installation, reverse the removal procedure.

7 Nm (0.7 mkg, 5.1 ftlb)

SEATSCHKADJ

EAS00039

SEATS

3-4


123456789

1011

Removing the fuel tankRider searFuel tank side coverFuel hose connector coverFuel hoseFuel return hoseFuel sender couplerFuel pump couplerFuel tank over flow hoseFuel tank breather hoseFuel tankFuel tank coverFuel pump

21111111111

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

Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.

For installation, reverse the removalprocedure.

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

4 Nm (0.4 mkg, 2.9 ftlb)

4 Nm (0.4 mkg, 2.9 ftlb)

FUEL TANKCHKADJ

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 connector cover fuel return hose fuel hose fuel sender coupler fuel pump coupler fuel tank breather hose fuel tank over flow 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:

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 fuel return hose fuel hose connector cover

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

3-7


123456789

10111213

Removing the front cowling andside cowlingsRider seatSide cowlingFront turn signal light lead couplerSide cowling inner panelBottom cowlingBottom cowing front coverFrame side coverFrame side panelHeadlight panelFront cowlingRear view mirrorWindshieldAir intake ductAir intake duck mount

2222122212122


Refer to “SEATS”.

Disconnect.


7 Nm (0.7 mkg, 5.1 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

16 Nm (1.6 mkg, 12 ftlb)

COWLINGSCHKADJ

COWLINGSFRONT COWLING AND SIDE COWLINGS

3-8


123456

Removing the rear cowlingRider seat and passenger seatMufflerRear cowling (upper)Tail /brake light lead couplerRear turn signal light lead couplerTail /brake lightLicense plate bracket assemblyRear cowling (lower)

114111

Remove the parts in the order listed.Refer to “SEATS”.Refer to “EXHAUST PIPE” in chapter 5.

Disconnect.Disconnect.


4 Nm (0.4 mkg, 2.9 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb)

COWLINGSCHKADJ

REAR COWLING

3-9

COWLINGSCHKADJ

NOTE:

NOTE:

REMOVAL1. Remove: rear cowlingside cowlings

To remove the quick fastener, push its centerwith a screwdriver, then pull the fastener out.

INSTALLATION1. Install:side cowlings rear cowling

To install the quick fastener, push its pin so that itprotrudes from the fastener head, then insertthe fastener into the cowling and push the pin ain with a screwdriver. Make sure that the pin isflush with the fastener’s head.

3-10


123456789

10

Removing the air filter caseRider searFuel tankPlugAir temperature sensor lead couplerSpacerAir temperature sensorAir filter case coverAir filterFunnelAir filter caseAir induction system hoseCrankcase breather hose

1111112111

Remove the parts in the order listed.Refer to “SEATS”.Refer to “FUEL TANK”.

Disconnect.

Disconnect.Disconnect.For installation, reverse the removalprocedure.

2 Nm (0.2 mkg, 1.4 ftlb)

3.4 Nm (0.34 mkg, 2.5 ftlb)

AIR FILTER CASECHKADJ

AIR FILTER CASE

3-11

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. Remove rider seatRefer to “SEATS”.

fuel tankRefer to “FUEL TANK”.

air filter caseRefer to “AIR FILTER CASE”.

bottom cowlingsside cowlingsRefer to “COWLINGS”.

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 “CAMSHAFT” in chapter 5.

3. Removepickup rotor cover 1

3-12


NOTE:

NOTE:

4. Measure:valve clearanceOut of specification Adjust.

Valve clearance (cold)Intake valve0.11 0.20 mm (0.0043 0.0079 in)Exhaust valve0.21 0.25 mm (0.0083 0.0098 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

3-13


NOTE:

NOTE:

NOTE:

5. Remove:camshafts

Refer to “DISASSEMBLING THE ENGINE –CAMSHAFT AND CYLINDER HEAD” in chap-ter 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 lifter2 and valve pad 1 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.

3-14


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.

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

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

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

Camshaft cap bolt10 Nm (1.0 mkg, 7.2 ftlb)

3-15


NOTE:Refer to “ASSEMBLING AND ADJUSTINGTHE ENGINE – CYLINDER HEAD AND CAM-SHAFT” 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.

3-16


VALVE CLEARANCE (cold): 0.11 0.20 mm (0.0043 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): 0.21 0.25 mm (0.0083 0.0098 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 0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 2350.11 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 0.20 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 2350.21 0.250.26 0.30 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.31 0.35 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.36 0.40 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.41 0.45 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.46 0.50 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.51 0.55 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.56 0.60 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.61 0.65 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.66 0.70 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.71 0.75 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.76 0.80 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.81 0.85 180 185 190 195 200 205 210 215 220 225 230 235 2400.86 0.90 185 190 195 200 205 210 215 220 225 230 235 2400.91 0.95 190 195 200 205 210 215 220 225 230 235 2400.96 1.00 195 200 205 210 215 220 225 230 235 2401.01 1.05 200 205 210 215 220 225 230 235 2401.06 1.10 205 210 215 220 225 230 235 2401.11 1.15 210 215 220 225 230 235 2401.16 1.20 215 220 225 230 235 2401.21 1.25 220 225 230 235 2401.26 1.30 225 230 235 2401.31 1.35 230 235 2401.36 1.40 235 2401.41 1.45 240

3-17

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: rider seatRefer to “SEATS”.


3. Remove:synchronizing hoses 1

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

digital tachometer(near the spark plug)

Vacuum gauge90890-03094, YU-08030

3-18

SYNCHRONIZING THE THROTTLE BODIESCHKADJ

NOTE:

CAUTION:

NOTE:

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

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

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

Engine idling speed1,150 1,250 r/min

8. Adjust: throttle body synchronization

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

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

22 kPa(165 mmHg, 6.5 inHg)

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

3-19

SYNCHRONIZING THE THROTTLE BODIES/ADJUSTING THE EXHAUST GAS VOLUME

CHKADJ

NOTE:

NOTE:

9. Measure:engine idling speedOut of specification Adjust.Make sure that the vacuum pressure is withinspecification.

10. Stop the engine and remove the measuringequipment.

11. 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)

13. Install:synchronizing hoses fuel tankRefer to “FUEL TANK”.

rider seatRefer to “SEATS”.

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 clock LCD.

3-20

ADJUSTING THE EXHAUST GAS VOLUMECHKADJ

NOTE:

NOTE:

3. Using the “SELECT” button, select either theCo adjustment mode 1 (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” and “RESET” buttons toselect the cylinder 2 .

The adjustment cylinder appears on the clockLCD.“RESET” button = decrement“SELECT” button = increment

6. Excute the selection of the cylinder by simul-taneously pressing the “SELECT” and “RE-SET” buttons for approximately 2 seconds.

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

The Co adjustment volume appears on the tripLCD.“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.

3-21

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, and the engine should have ad-equate compression.

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

2. Install:digital tachometer(near the spark plug)

3. Check:engine idling speedOut of specification Adjust.

Engine idling speed1,150 1,250 r/min

4. 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 is increased.

Direction Engine idling speed isdecreased.

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

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

3 5 mm (0.12 0.20 in)

3-22

ADJUSTING THE THROTTLE CABLE FREE PLAYCHKADJ

NOTE:

a

b

WARNING

EAS00056

ADJUSTING THE THROTTLE CABLE FREE PLAY

Prior to adjusting the throttle cable free play, theengine idling speed should be adjusted proper-ly.

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. Adjust: throttle cable free play

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.

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

3-23

CHECKING THE SPARK PLUGSCHKADJ

CAUTION:

EAS00059

CHECKING THE SPARK PLUGSThe following procedure applies to all of thespark plugs.1. Remove:side cowlingsbottom cowlingsRefer to “COWLINGS”.

2. Remove: radiator upper bolts radiator lower boltRefer to “RADIATOR” in chapter 6.

3. Remove: ignition coilsspark plugs

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.

4. Check:spark plug typeIncorrect Change.

Spark plug type (manufacturer)CR9EK (NGK)

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

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

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

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

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

3-24

CHECKING THE SPARK PLUGS/MEASURING THE COMPRESSION PRESSURE

CHKADJ

13 Nm (1.3 mkg, 9.4 ftlb)

NOTE:

NOTE:

CAUTION:

8. Install:spark plugs ignition coils

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

9. Install: radiator upper bolts radiator lower boltRefer to “RADIATOR” in chapter 6.

10. Install:side cowlingsbottom cowlingsRefer to “COWLINGS”.

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: ignition coilsspark plugs

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.

3-25

MEASURING THE COMPRESSION PRESSURECHKADJ

WARNING

NOTE:

4. Install:compression gauge 1adapter

Compression gauge90890-03081, YU-33223

Adapter90890-04136

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

Compression pressure (at sea level)

Minimum1,290 kPa (12.90 kg/cm2,12.90 bar, 183.48 psi)

Standard1,480 kPa (14.80 kg/cm2,14.80 bar, 210.5 psi)

Maximum1,660 kPa (16.60 kg/cm2,16.60 bar, 236.11 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.

3-26

MEASURING THE COMPRESSION PRESSURE/CHECKING THE ENGINE OIL LEVEL

CHKADJ

13 Nm (1.3 mkg, 9.4 ftlb)

NOTE:

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.

6. Install:spark plug

7. Install: ignition coils

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.

3-27

CHECKING THE ENGINE OIL LEVELCHKADJ

NOTE:

NOTE:

Recommended oilAT 5C (40F) or higher A

Yamalube 4 (20W40) orSAE 20W40 type SE motoroil

AT 15C (60F) or lower BYamalube 4 (10W30) orSAE 10W30 type SE motoroil

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.

3-28

CHANGING THE ENGINE OILCHKADJ

NOTE:

CAUTION:

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:bottom cowlingsRefer to “COWLINGS”.

4. Remove:engine oil filler cap 1

Remove the engine oil filler cap 1 with the spe-cial wrench 2 and cover 3 .

5. Remove:engine oil drain bolt 1(along with the gasket)

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

7. 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.

3-29

CHANGING THE ENGINE OIL/MEASURING THE ENGINE OIL PRESSURE

CHKADJ

43 Nm (4.3 mkg, 31 ftlb)

CAUTION:

Oil filter cartridge17 Nm (1.7 mkg, 12 ftlb)

8. Replace:engine oil drain bolt gasket New

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

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

QuantityTotal amount

3.8 L (3.35 Imp qt, 4.02 US qt)Without oil filter cartridgereplacement

2.9 L (2.55 Imp qt, 3.07 US qt)With oil filter cartridgereplacement

3.1 L (2.73 Imp qt, 3.28 US qt)

11. Install:engine oil filler capbottom cowlingsRefer to “COWLINGS”.


EAS00077

MEASURING THE ENGINE OIL PRESSURE1. Check:engine oil levelBelow the minimum level mark a 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:bottom cowlingsRefer to “COWLINGS”.

3-30

MEASURING THE ENGINE OIL PRESSURECHKADJ

WARNING

NOTE:

4. Remove:oil gallery bolt 1

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

5. Install:oil pressure gauge 1adapter 2

Pressure gauge90890-03153, YU-03153

Oil pressure adapter90890-03139

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

Engine oil pressure230 kPa(2.3 kg/cm2, 2.3 bar, 32.71 psi)

Engine speedApprox. 5,000 r/min

Engine oil temperature100C (212F)

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.

3-31

MEASURING THE ENGINE OIL PRESSURE/ADJUSTING THE CLUTCH CABLE FREE PLAY

CHKADJ

8 Nm (0.8 mkg, 5.8 ftlb)

CAUTION:

c

b

NOTE:

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

7. Install:oil gallery bolt 1

Be carful to tighten too much.

8. Install:bottom cowlingsRefer to “COWLINGS”.

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.

3-32

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

CHKADJ

a

b

NOTE:

Engine sidea. Loosen the locknut 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.

c. Tighten the locknuts.

Lock nut7Nm (0.7 mkg, 5.1 ftlb)

EAS00086

REPLACING THE AIR FILTER ELEMENT1. Remove: rider seatRefer to “SEATS”.


2. Remove:air filter case cover 1

3. Check:air filter element 1Damage Replace.

Replace the air filter element at periodic inter-vals of 40,000 km travel.The air filter needs more frequent service if youare riding in unusuallu wet or dusty areas.

3-33

REPLACING THE AIR FILTER ELEMENT/CHECKING THE FUEL AND BREATHER HOSES

CHKADJ

CAUTION:

NOTE:

NOTE:

4. Install:air filter case cover

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.

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



EAS00096

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


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

Before removing the fuel hoses, place a fewrags in the area under where it will be removed.

3-34

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

CHKADJ

CAUTION:

CAUTION:

CAUTION:



To install the fuel tank, check that the breath-er hose is not folded or pinched by the fueltank.

EAS00098

CHECKING THE CRANKCASE BREATHERHOSE1. Remove: rider seatRefer to “SEATS”.


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

Make sure the crankcase breather hose isrouted correctly.



To install the fuel tank, check that the breath-er hose is not folded or pinched by the fueltank.

3-35

CHECKING THE EXHAUST SYSTEMCHKADJ

WARNING

NOTE:

EAS00099

CHECKING THE EXHAUST SYSTEMThe following procedure applies to all of the ex-haust pipes and gaskets.

Do not touch the muffler bracket until the ex-haust system has cooled.

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

gaskets 4Exhaust gas leaks Replace.

2. Check: tightening torque

Exhaust pipe nut 520 Nm (2.0 mkg, 14 ftlb)

Exhaust pipe and exhaust valve pipe bolt 6

10 Nm (1.0 mkg, 7.2 ftlb)Catalyst pipe assembly bolt 7

20 Nm (2.0mkg, 14 ftlb)Catalyst pipe assembly andmuffler bolt 8

20 Nm (2.0 mkg, 14 ftlb)Muffler cover 9

10 Nm (1.0 mkg, 7.2 ftlb)

Install the EXUP cable in parallel without twist-ing its upper 10 and lower sides 11 .black metal 10 is upper.white metal 11 is lower.

3-36

ADJUSTING THE EXUP CABLESCHKADJ

EAS00101

ADJUSTING THE EXUP CABLES1. Remove:bottom cowlingsRefer to “COWLINGS”.

2. Remove:EXUP valve pulley cover 1

3. Check:EXUP system operation

a. Turn the main switch ON.b. Check that the EXUP valve operates properly.

4. Check:EXUP cable free play (at the EXUP valvepulley) a + b

Maximum EXUP cable free play (at the EXUP valve pulley)

Less than 4 mm (0.16 in)

5. Adjust:EXUP cable free play

a. Turn the main switch to “ON”.b. Check the EXUP pulley position.c. Projection of the EXUP pulley position is be-

tween 1 and 2 .d. Loosen the both locknuts 3 .e. Turn the both adjusting nuts 4 in or out.f. Tighten the both locknuts.

6. Install:EXUP valve pulley cover

EXUP valve pulley cover bolt10 Nm (1.0 mkg, 7.2 ftlb)

3-37

ADJUSTING THE EXUP CABLES/CHECKING THE COOLANT LEVEL

CHKADJ

NOTE:

CAUTION:

NOTE:

7. Install:bottom cowlingsRefer to “COWLINGS”.

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.

3-38

CHECKING THE COOLING SYSTEMCHKADJ

EAS00104

CHECKING THE COOLING SYSTEM1. Remove:bottom cowlingsside cowlingsRefer to “COWLINGS”.

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

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

3. Install:side cowlingsbottom cowlingRefer to “COWLINGS”.

3-39

CHANGING THE COOLANTCHKADJ

CAUTION:

EAS00105

CHANGING THE COOLANT1. Remove:bottom cowlingsside cowlingsRefer to “COWLINGS”.


2. Remove:coolant reservoir tankcoolant reservoir hose

3. Disconnect:coolant reservoir cap 1

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

5. Remove: radiator cap 1

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 bolts 1(along with the copper washers)

3-40


10 Nm (1.0 mkg, 7.2 ftlb)

WARNING

7. Drain:coolant(water pump inlet pipe and outlet pipe)

8. Check:copper washers 1 New

9. Install:coolant drain bolts 2(with copper washers)

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

2.51 L(2.21 Imp qt, 2.65 US qt)

Coolant reservoir capacity0.25 L(0.22 Imp qt, 0.26 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.

3-41


CAUTION:

NOTE:

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.

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.

18. Install: rider seatRefer to “SEATS”.

bottom cowlingsside cowlingsRefer to “COWLINGS”.

3-42

ADJUSTING THE FRONT BRAKECHKADJ

NOTE:

a

ac

b

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 the de-sired position.

Direction Distance is the largest.

Direction 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.

3-43

ADJUSTING THE REAR BRAKECHKADJ

a

b

WARNING

WARNING

CAUTION:

EAS00110

ADJUSTING THE REAR BRAKE1. 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.

Locknut16 Nm (1.6 mkg, 12 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.

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

3-44

A

B

CHECKING THE BRAKE FLUID LEVELCHKADJ

NOTE:

WARNING

CAUTION:

NOTE:

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.

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.

3-45

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

CHKADJ

NOTE:

a

b

EAS00128

ADJUSTING THE REAR BRAKE LIGHT SWITCH

The rear brake light switch is operated by move-ment of the brake pedal.The rear brake light switch is properly adjustedwhen the brake light comes on just before thebraking 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.

EAS00122

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

3-46

B

A

B

A

CHECKING THE FRONT AND REAR BRAKE PADS/CHECKING THE FRONT AND REAR BRAKE HOSES

CHKADJ

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 7.

Brake pad wear limita 0.5 mm (0.02 in)b 1.0 mm (0.04 in)

A Front brakeB Rear brake

EAS00131

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

A FrontB Rear2. Check:brake hose clamp 2Loose 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.

3-47

B

C

A

BLEEDING THE HYDRAULIC BRAKE SYSTEMCHKADJ

WARNING

NOTE:

NOTE:

EAS00135

BLEEDING THE HYDRAULIC BRAKE SYSTEM

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 Front brake master cylinderB Front brake caliperC Rear brake caliper

Bleeding order of the front hydraulic brake sys-tem is the following order:1. front brake master cylinder.2. front brake calipers.3. front brake master cylinder.

d. 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.

3-48

BLEEDING THE HYDRAULIC BRAKE SYSTEM/ADJUSTING THE SHIFT PEDAL

CHKADJ

NOTE:

WARNING

NOTE:

a

b

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.

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.

After bleeding air, the brake fluid may oozearound the thread section of each bleed screw.This phenomenon does not show the leakagebut the brake fluid that has been accumulated inthe thread of screw while bleeding air. Pleasewipe off to make the parts clean.

EAS00136

ADJUSTING THE SHIFT PEDAL1. Adjust:shift pedal position

a. Loosen both locknuts 1 .b. Turn the shift rod 2 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.

3-49

ADJUSTING THE DRIVE CHAIN SLACKCHKADJ

NOTE:

CAUTION:

WARNING

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 slack25 35 mm (0.98 1.38 in)

4. Adjust:drive chain slack

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

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

3-50

a

b

ADJUSTING THE DRIVE CHAIN SLACK/LUBRICATING THE DRIVE CHAIN

CHKADJ

NOTE:

Direction Drive chain is tightened.

Direction Drive chain is loosened.

To maintain the proper wheel alignment, adjustboth sides evenly.

d. Tighten both locknuts to specification.

Locknut16 Nm (1.6 mkg, 12 ftlb)

e. Tighten the wheel axle nut to specification.

Wheel axle nut150 Nm (15 mkg, 108 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 quickly. 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 kero-sene to clean the drive chain. Wipe the drivechain dry and thoroughly lubricate it with engineoil or chain lubricant that is suitable for O-ringchains. Do not use any other lubricants on thedrive chain since they may contain solvents thatcould damage the O-rings.

Recommended lubricantEngine oil or chain lubricant suitable for O-ring chains

3-51

CHECKING AND ADJUSTING THE STEERING HEADCHKADJ

WARNING

NOTE:

NOTE:

EAS00146

CHECKING AND ADJUSTING THE STEERING 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)

3-52

CHECKING AND ADJUSTING THE STEERING HEADCHKADJ

WARNING

NOTE:

NOTE:

c. Loosen the lower ring nut 4 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 under bracket and check the upper andlower bearings.Refer to “STEERING HEAD” in chapter 4.

e. Install the rubber washer 3 .f. Install the upper ring nut 2 .g. Finger tighten the upper ring nut 2 , then

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

h. Install the lock washer 1 .

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.

3-53

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.

EAS00150

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 handlebars severaltimes and check if the front fork reboundssmoothly.Rough movement Repair.Refer to “FRONT FORK” in chapter 4.

3-54

ADJUSTING THE FRONT FORK LEGSCHKADJ

WARNING

CAUTION:

a

b

CAUTION:

EAS00155

ADJUSTING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.

Always adjust both front fork legs evenly.Uneven adjustment can result in poor han-dling and loss of stability.


Spring preload

Grooves are provided to indicate the ad-justment position.

Never go beyond the maximum or mini-mum adjustment positions.

1. Adjust:spring preload

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

DirectionSpring preload isincreased (suspension isharder).

DirectionSpring preload isdecreased (suspension is softer).

Adjusting positionsMinimum: 8Standard: 4.5Maximum: 1

Rebound damping

Never go beyond the maximum or minimumadjustment positions.

3-55

ADJUSTING THE FRONT FORK LEGSCHKADJ

a

b

CAUTION:

a

b

1. Adjust: rebound damping

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

DirectionRebound damping isincreased (suspension isharder).

DirectionRebound damping isdecreased (suspension is softer).

Adjusting positionsMinimum: 26 clicks in direction b *Standard: 10 clicks in direction b *Maximum: 1 clicks in direction b *

* with the adjusting screw fully turned-in direction a

Compression damping


1. Adjust:compression damping


DirectionCompression damping isincreased (suspension isharder).

DirectionCompression damping isdecreased (suspension is softer).



3-56

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLYCHKADJ

WARNING

CAUTION:

a

b

CAUTION:

EAS00158

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY


Spring preload


1. Adjust:spring preload

a. Adjust the spring preload with the specialwrench and extension bar included in theowner’s tool kit.

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: 4Maximum: 9

Rebound damping


3-57

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLYCHKADJ

a

b

CAUTION:

a

b

1. Adjust: rebound damping


DirectionRebound damping isincreased (suspension isharder).

DirectionRebound damping isdecreased (suspension is softer).



Compression damping


1. Adjust:compression damping


DirectionCompression damping isincreased (suspension isharder).

DirectionCompression damping isdecreased (suspension is softer).



3-58

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)

193 kg (425 lb)194 kg (428 lb) for CAL

Maximumload*

202 kg (445 lb)201 kg (443 lb) for CAL

Cold tirepressure

Front Rear

Up to 90 kgload*

250 kPa (2.5 kgf/cm2,

2.5 bar,35.6 psi)

290 kPa (2.9 kgf/cm2,

2.9 bar,41.3 psi)

90 kg maximum load*

250 kPa (2.5 kgf/cm2,

2.5 bar,35.6 psi)

290 kPa (2.9 kgf/cm2,

2.9 bar,41.3 psi)

High-speed riding

250 kPa (2.5 kgf/cm2,

2.5 bar,35.6 psi)

290 kPa (2.9 kgf/cm2,

2.9 bar,41.3 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.

3-59

A B

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 manufacturerand of the same design. No guarantee con-cerning handling characteristics can be giv-en if a tire combination other than one ap-proved by Yamaha is used on thismotorcycle.

3-60

CHECKING THE TIRES/CHECKING THE WHEELSCHKADJ

WARNING

NOTE:

WARNING

NOTE:

Front tire

Manufacturer Size Model

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

D218FL

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

PilotPOWER C

Rear tire

Manufacturer Size Model

DUNLOP 190/50ZR 17M/C (73W)

D218L

MICHELIN 190/50ZR 17M/C (73W)

PilotPOWER G

New tires have a relatively low grip on theroad surface until they have been slightlyworn. Therefore, approximately 100 kmshould be traveled at normal speed beforeany 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.

3-61

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

LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION

CHKADJ

WARNING

NOTE:

EAS00170

CHECKING AND LUBRICATING THE CABLESThe 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 cable lubricant

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.


EAS00174

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

Recommended lubricantMolybdenum-disulfide grease

3-62

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.

3-63

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 “SEATS”.

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%

3-64

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.

3-65


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

3-66


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

3-67

CHECKING AND CHARGING THE BATTERY/CHECKING THE FUSES

CHKADJ

CAUTION:

CAUTION:

NOTE:

6. 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 connection Connect properly.

9. Lubricate:battery terminals

Recommended lubricantDielectric grease

10. Install: rider seatRefer to “SEATS”.

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


2. Check: fuse

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

Set the pocket tester selector to “Ω 1”.

3-68

CHECKING THE FUSESCHKADJ

WARNING


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 50 A 1

Fuel injectionsystem

15 A 1

Headlight 25 A 1

Signalingsystem

10 A 1

Ignition 15 A 1

Backup fuse(odometerand clock)

10 A 1

Radiatorfan motor

15 A 2

Reserve 25 A, 15 A,10 A

1

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


3-69

A

A

B

B

B

REPLACING THE HEADLIGHT BULBSCHKADJ

WARNING

EAS00183

REPLACING THE HEADLIGHT BULBSThe following procedure applies to both of theheadlight bulbs.1. Disconnect:headlight bulb cover 1headlight coupler 2

A high beamB low beam

2. Remove:headlight bulb holder 1

A high beamB low beam3. Remove:headlight bulb

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

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

3-70

REPLACING THE HEADLIGHT BULBS/ADJUSTING THE HEADLIGHT BEAMS

CHKADJ

CAUTION:

a

b

a

b

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.

5. Install:headlight bulb holder

6. Install:headlight bulb cover (high beam)headlight bulb coupler (low beam)

7. Connect:headlight coupler (high beam)headlight cover (low beam)

EAS00185

ADJUSTING THE HEADLIGHT BEAMSThe following procedure applies to both of theheadlights.1. Remove: front cowling inner panelsRefer to “COWLINGS”.

2. Adjust:headlight beam (vertically)


Direction Headlight beam is raised.

Direction Headlight beam is lowered.

3. Adjust:headlight beam (horizontally)


Direction Headlight beam moves tothe left.

Direction Headlight beam moves tothe right.

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

4-1

4

FRONT WHEEL AND BRAKE DISCS CHAS


123456789

10

Removing the front wheel and brakediscs

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

2222411212


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


NOTE:

35 Nm (3.5 mkg, 25 ftlb)

6 Nm (0.6 mkg, 4.3 ftlb)

91 Nm (9.1 mkg, 66 ftlb)

20 Nm (2.0 mkg, 13 ftlb)

6 Nm (0.6 mkg, 4.3 ftlb)

18 Nm (1.8 mkg, 13 ftlb)

2 Nm (0.2 mkg, 1.4 ftlb)

2 Nm (0.2 mkg, 1.4 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 disassembly procedure.

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 caliperRefer to “FRONT BRAKE CALIPERS”.

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 bolt 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.

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

4-4


NOTE:

CAUTION:

NOTE:

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

Radial wheel runout limit1.0 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.

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.

4-5


NOTE:

EAS00533

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 handlebars 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 1.5 mm (0.06 in) be-

low the edge of the brake disc.

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

Brake disc thickness limit (minimum)

Front : 4.0 mm (0.16 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.

4-6


NOTE:

91 Nm (9.1 mkg, 66 ftlb)

20 Nm (2.0 mkg, 14 ftlb)

CAUTION:

Brake disc boltFront : 18 Nm (1.8 mkg, 13 ftlb)Rear : 30 Nm (3.0 mkg, 22 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.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 axle

wheel axle pinch bolt

Before tightening the wheel axle nut, pushdown hard on the handlebars several timesand check if the front fork rebounds smooth-ly.

4-7


35 Nm (3.5 mkg, 25 ftlb)

NOTE:

WARNING

NOTE:

NOTE:

6. Install:brake caliper (left and right)

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

Make sure the brake hose is routed properly.

EAS00549

ADJUSTING THE FRONT WHEEL STATIC BALANCE

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.

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”.

4-8


NOTE:

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


123456789

10

Removing the rear wheel

Rear brake caliperLock nut (left and right)Adjusting bolt (left and right)Wheel axle nutWasherRear wheel axleLeft adjusting blockRight adjusting blockRear wheelBrake caliper bracket

1221111111


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

Loosen.Loosen.


NOTE:

22 Nm (2.2 mkg, 16 ftlb)

27 Nm (2.7 mkg, 20 ftlb)

150 Nm (15 mkg, 108 ftlb)

REAR WHEEL AND BRAKE DISC CHAS

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

11211161


For installation, reverse the disassembly procedure.

100 Nm (10 mkg, 72 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

EAS00560

REAR BRAKE DISC AND REAR WHEEL SPROCKET

4-11



Disassembling the rear wheelCollarBearingSpacerOil sealCirclipBearing

111111


For assembly, reverse the disassemblyprocedure.

123456

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 bolt 2

4. Remove:wheel axle nut 1wheel axle 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 REAR WHEEL 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:

150 Nm (15 mkg, 108 ftlb)

27 Nm (2.7 mkg, 20 ftlb)

22 Nm (2.2 mkg, 16 ftlb)

NOTE:

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. Tighten:wheel axle nutbrake caliper bolts (front)

(rear)

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”.

4-15


1234567

Removing the front brake pads

Brake hose holderFront brake caliperBrake pad clipBrake pad pinBrake pad springBrake padBleed screw

1121121


The following procedure applies to both ofthe front brake calipers.


NOTE:

5 Nm (0.5 mkg, 3.6 ftlb)

35 Nm (3.5 mkg, 25 ftlb)

6 Nm (0.6 mkg, 4.3 ftlb)

FRONT AND REAR BRAKES CHAS

EAS00577

FRONT AND REAR BRAKESFRONT BRAKE PADS

4-16



1234567

Removing the rear brake padsScrew plugBrake pad pinRear brake caliperBrake pad shimBrake padBleed screwBrake pad spring

1114211



5 Nm (0.5 mkg, 3.6 ftlb)

27 Nm (2.7 mkg, 20 ftlb)

3 Nm (0.3 mkg, 2.2 ftlb)

17 Nm (1.7 mkg, 12 ftlb)

22 Nm (2.2 mkg, 16 ftlb)

REAR BRAKE PADS

4-17


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.

4-18


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 pad clips 1brake pad pin 2brake pad spring 3

3. Remove:brake pads 1(along with the brake pad shims)

4. Measure:brake pad wear limit aOut of specification Replace the brakepads as a set.

Brake pad wear limit0.5 mm (0.02 in)

4-19


NOTE:

NOTE:

35 Nm (3.5 mkg, 25 ftlb)

5. Install:brake pad shims(onto the brake pads)

brake padsbrake pad spring

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.

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.

Install the brake pad spring pointing a towardthe bleed screw.

e. Install new brake pads and a new brake padspring.

6. Install:brake pad pinsbrake pad clipsbrake caliper

7. 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.

8. Check:brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

4-20


NOTE:

NOTE:

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

2. Remove :brake pads 1(along with the brake pad shims 2 )

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 shims(onto the brake pads)

brake padsbrake pad spring

Always install new brake pads, brake padshims, and a brake pad spring as a set.

4-21


27 Nm (2.7 mkg, 20 ftlb)

22 Nm (2.2 mkg, 16 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 3 onto eachnew brake pad 4 .

5. Install: rear brake caliper (front)

rear brake caliper (rear)

brake pad pinscrew plug


7. Check:brake pedal operationSoft or spongy feeling Bleed the brake sys-tem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

4-22



123456789

Removing the front brake master cylinderBrake fluid

StopperBrake fluid reservoir capBrake fluid reservoir diaphragm holderBrake fluid reservoir diaphragmBrake fluid reservoir tankBrake fluid reservoir hoseBrake leverFront brake switch connectorUnion bolt

111111121


Drain.Refer to “CHANGING THE BRAKE FLUID” in chapter 3.

Disconnect.

3.8 Nm (0.38 mkg, 2.7 ftlb)

1.2 Nm (0.12 mkg, 0.9 ftlb)

13 Nm (1.3 mkg, 9.4 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

EAS00584

FRONT BRAKE MASTER CYLINDER

4-23



1011121314

Copper washerBrake hoseBrake master cylinder bracketBrake master cylinderFront brake light switch

21111


3.8 Nm (0.38 mkg, 2.7 ftlb)

1.2 Nm (0.12 mkg, 0.9 ftlb)

13 Nm (1.3 mkg, 9.4 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

4-24



Disassembling the front brake master cylinderBrake master cylinder kitBleed screwBrake master cylinder body

111



123

6 Nm (0.6 mkg, 4.3 ftlb)

EAS00585

4-25



123456789

1011

Removing the rear brake master cylinderBrake fluid

Brake fluid reservoir capBrake fluid reservoir diaphragm holderBrake fluid reservoir diaphragmBrake fluid reservoir tankBrake fluid reservoir hoseHose jointBushUnion boltCopper washerBrake hoseBrake master cylinder

11111111211


Drain.Refer to “CHANGING THE BRAKEFLUID” in chapter 3.


30 Nm (3.0 mkg, 22 ftlb) 18 Nm (1.8 mkg, 13 ftlb)

EAS00586

REAR BRAKE MASTER CYLINDER

4-26



Disassembling the rear brake mastercylinderBrake master cylinder kitHose jointBushBrake master cylinder body

1111



1234

4-27


NOTE:

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 connector 1(from the brake light switch)

2. Remove:union bolt 2copper washers 3brake hose 4

To collect any remaining brake fluid, place acontainer under the master cylinder and the endof the brake hose.

3. Remove :brake master cylinder bracketbrake master cylinder assembly

4. Remove :dust bootcirclip

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. Remove :brake master cylinder assembly

3. Remove :dust bootcirclip

4-28

A

B

A

B

BA


EAS00593

CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERSThe following procedure applies to both of thebrake master cylinders.1. Check:brake master cylinderDamage/scratches/wear Replace.

brake fluid delivery passages(brake master cylinder body)Obstruction Blow out with compressed air.

A FrontB Rear

2. Check:brake master cylinder kitDamage/scratches/wear Replace.

A FrontB Rear

3. Check:brake fluid reservoir 1Cracks/damage Replace.

brake fluid reservoir diaphragm 2Cracks/damage Replace.

A FrontB Rear4. Check:brake hosesCracks/damage/wear Replace.

4-29


WARNING

13 Nm (1.3 mkg, 9.4 ftlb)

NOTE:

30 Nm (3.0 mkg, 22 ftlb)

WARNING

EAS00607

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 :brake master cylinder kitcirclip Newdust boot

2. Install:brake master cylinder 1

Install the brake master cylinder holder withthe “UP” mark a facing up.

Align the end of the brake master cylinderholder with the punch mark b on the right han-dlebar.

First, tighten the upper bolt, then the lower bolt.There should be 2 2.5 mm (0.08 0.10 in)for clearance between the right handlebarswitch and the brake master cylinder holder.

3. Install:copper washers Newbrake hoseunion boltbrake light switch coupler

Proper brake hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING”.

4-30


NOTE:

WARNING

CAUTION:

While holding the brake hose, tighten theunion bolt.

Turn the handlebars to the left and right tomake sure the brake hose does not touch oth-er parts (e.g., wire harness, cables, leads).Correct if necessary.

4. Fill:brake fluid reservoir(with the specified amount of the recom-mended brake fluid)






5. Bleed:brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

4-31


30 Nm (3.0 mkg, 22 ftlb)

WARNING

CAUTION:


7. Check:brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

EAS00608

ASSEMBLING THE REAR BRAKE MASTER CYLINDER1. 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 b )


4-32


WARNING

CAUTION:







6. Adjust: rear brake light operation timingRefer to “ADJUSTING THE REAR BRAKELIGHT SWITCH” in chapter 3.

4-33



1234

Removing the front brake calipers

Brake fluid

Union boltCopper washerbrake hosebrake caliper

1211



Drain.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.


NOTE:

6 Nm (0.6 mkg, 4.3 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

35 Nm (3.5 mkg, 25 ftlb)

EAS00613

FRONT BRAKE CALIPERS

4-34



Disassembling the front brake calipers

Brake pad clipBrake pad pinBrake pad springBrake padBrake caliper pistonBrake caliper piston sealBleed screw

2112481




NOTE:

1234567

5 Nm (0.5 mkg, 3.6 ftlb)

EAS00615

4-35



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.


30 Nm (3.0 mkg, 22 ftlb)

27 Nm (2.7 mkg, 20 ftlb)22 Nm (2.2 mkg, 16 ftlb)

EAS00616

REAR BRAKE CALIPER

4-36



Disassembling the rear brake caliperScrew plugBrake pad pinBrake padBrake pad shimBrake pad springBrake caliper pistonBrake caliper piston sealBleed screw

11241121



12345678

5 Nm (0.5 mkg, 3.6 ftlb)

17 Nm (1.7 mkg, 12 ftlb)

3 Nm (0.3 mkg, 2.2 ftlb)

EAS00617

4-37


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 brake caliper pistons with a pieceof wood a .

b. Blow compressed air into the brake hosejoint opening b to force out the left side pis-tons from the brake caliper.

Never try to pry out the brake caliper pis-tons.

Do not loosen the bolts 3 .

c. Remove the brake caliper piston seals.d. Repeat the previous steps to force out the

right side pistons from the brake caliper.

4-38


NOTE:

NOTE:

WARNING

EAS00626

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. Secure the brake caliper piston with a pieceof wood a .

b. Blow compressed air into the brake hosejoint opening b to force out the piston fromthe brake caliper.

Cover the brake caliper piston with a rag.Be careful not to get injured when the pis-ton is expelled from the brake caliper.

Never try to pry out the brake caliper pis-ton.

c. Remove the brake caliper piston seals.

4-39

A

B


WARNING

EAS00633

CHECKING THE FRONT AND REAR BRAKE CALIPERS

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:brake caliper bracket 1Cracks/damage Replace.

4-40


WARNING

35 Nm (3.5 mkg, 25 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

6 Nm (0.6 mkg, 4.3 ftlb)

WARNING

CAUTION:

EAS00640

ASSEMBLING AND INSTALLING THE 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 padsbrake pad springbrake pad pin

2. Install:brake caliper 1

copper washers Newbrake hose 2union bolt 3brake hose holder


When installing the brake hose onto thebrake caliper 1 , make sure the brake pipe atouches the projection b on the brake cali-per.

4-41


WARNING

CAUTION:







4. Bleed:brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM“ in chapter 3.

5. 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.

6. Check:brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to ”BLEEDING THE HYDRAULICBRAKE SYSTEM“ in chapter 3.

4-42


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 REAR BRAKE 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


When installing the brake hose onto thebrake caliper 1 , make sure the brake pipe atouches the projection b on the brake cali-per.

4-43


WARNING

CAUTION:









5. Check:brake pedal operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

4-44


123456

Removing the front fork legsFront wheel

Front brake calipersSide cowlingsFront fenderCap boltHandlebar pinch boltUpper bracket pinch boltUnder bracket pinch boltFront fork leg

111121

Remove the parts in the order listed.Refer to “FRONT WHEEL AND BRAKEDISCS”.Refer to “FRONT AND REAR BRAKES”.Refer to “COWLINGS” in chapter3.

Loosen.Loosen.Loosen.Loosen.


6 Nm (0.6 mkg, 4.3 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

17 Nm (1.7 mkg, 12 ftlb)

26 Nm (2.6 mkg, 19 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

FRONT FORK CHAS

EAS00647

FRONT FORKFRONT FORK LEGS

4-45

FRONT FORK CHAS


Disassembling the front fork legs

Cap boltO-ringDamper adjusting rodNutWasherSpacerFork springDust sealOil seal clipOil seal

1111111111


The following the procedure applies toboth of the front fork legs.

NOTE:

12345678910

23 Nm (2.3 mkg, 17 ftlb)

15 Nm (1.5 mkg, 11 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

EAS00648

4-46

FRONT FORK CHAS


WasherDamper rod assembly boltCopper washerDamper rod assemblyInner tubeOuter tube

111111


111213141516

23 Nm (2.3 mkg, 17 ftlb)

15 Nm (1.5 mkg, 11 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

4-47

FRONT FORK CHAS

WARNING

NOTE:

WARNING

EAS00649

REMOVING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Stand the motorcycle on a level surface.



2. Remove front wheel front brake caliperRefer to “FRONT WHEEL AND BRAKEDISCS”.

3. Remove:Side CowlingsRefer to “COWLINGS” in chapter 3.

handlebar

4. Loosen:handlebar pinch bolt 1upper bracket pinch bolt 2cap bolt 3under bracket pinch bolt 4

Before loosening the upper and underbracket pinch bolts, support the front forkleg.

5. Remove: front fork leg

4-48

FRONT FORK CHAS

NOTE:

WARNING

NOTE:

CAUTION:

EAS00652

DISASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Remove:cap bolt 1(from the damper adjusting rod)

spacer 2nut 3

a. Press down on the spacer with the forkspring compressor 4 .

b. Install the rod holder 5 between the nut 3and the spacer 2 .

Fork spring compressor90890-01441, YM-01441

Rod holder90890-01434, YM-01434

Use the side of the rod holder that is marked “B”.

c. Loosen the nut.d. Remove the cap bolt.e. Remove the rod holder and fork spring com-

pressor.

The fork spring is compressed.

f. Remove the spacer and nut.

2. Drain: fork oil

Stroke the damper rod 1 several times whiledraining the fork oil.

3. Remove:dust sealoil seal clip 1oil sealwasher(with a flat-head screwdriver)

Do not scratch the inner tube.

4-49

FRONT FORK CHAS

NOTE:

WARNING

4. Remove:damper rod assembly boltdamper rod assembly

While holding the damper rod assembly with thedamper rod holder 1 , loosen the damper rodassembly bolt.

Damper rod holder90890-01423, YM-01423

EAS00656

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 length236.5 mm (9.31 in)<Limit> : 231.8 mm (9.13 in)

3. Check:damper rod 1Damage/wear Replace.Obstruction Blow out all of the oil pas-sages with compressed air.

damper rod adjusting rodBends/damage Replace.

4-50

FRONT FORK CHAS

CAUTION:

WARNING

NOTE:

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-ring 1Damage/wear Replace.

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:– 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 1damper rod assembly 2damper rod assembly boltcopper washer New

4-51

FRONT FORK CHAS

WARNING

CAUTION:

23 Nm (2.3 mkg, 17 ftlb)

NOTE:

Always use new copper washer.

Allow the damper rod assembly to slideslowly down the inner tube 1 until it pro-trudes from the bottom of the inner tube. Becareful not to damage the inner tube.

2. Lubricate: inner tube’s outer surface

Recommended lubricantSuspension oil “01” or equivalent

3. Tighten:damper rod assembly bolt 1

LOCTITE

While holding the damper rod assembly with thedamper rod holder 2 , tighten the damper rodassembly bolt.

Damper rod holder90890-01423, YM-01423

4. Install:dust seal 1oil seal clip 2oil seal 3washer 4

4-52

FRONT FORK CHAS

CAUTION:

NOTE:

NOTE:

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 to protectthe oil seal during installation.

5. Install :Oil seal 1(with the fork seal driver 2 )

Fork seal driver90890-01442, YM-01442

6. Install:oil seal clip 1

Adjust the oil seal clip so that it fits into the outertube’s groove.

7. Install:dust seal 1(with the fork seal driver weight 2 )

Fork seal driver90890-01442m YM-01442

4-53

FRONT FORK CHAS

NOTE:

NOTE:

8. Install: rod puller 1 rod puller attachment 2(onto the damper rod 3 )

Rod puller90890-01437, YM-01437

Rod puller attachment90890-01436, YM-01436

9. Fill: front fork leg(with the specified amount of the recom-mended fork oil)

Quantity (each front fork leg)0.53 L (0.47 Imp qt, 0.56 US qt)

Recommended oilSuspension oil “01” or equivalent

Front fork leg oil level (from the top of the outer tube, with the outer tube fully compressed and without the fork spring)

76 mm (2.99 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.

10. Install:nut 1 fork spring 2spacer 3damper adjusting rod 4cap bolt 5

a. Remove the rod puller and adapter.b. Install the nut.c. Install the fork spring, and spacer.

Install the spring with the smaller pitch a facingup A .

4-54

FRONT FORK CHAS

NOTE:

WARNING

d. Press down on the spacer with the forkspring compressor 1 .

e. Pull up the rod puller and install the rod hold-er 2 between the nut 3 and the spacer 4 .

Use the side of the rod holder that is marked “B”.

Fork spring compressor90890-01441, YM-01441

Rod holder90890-01434, YM-01434

f. Remove the rod puller and adapter.g. Install the nut 1 and position it as specified

b .

Distance b11 mm (0.43 in)

h. Set the cap bolt distance c to specification.

Distance c13 mm (0.51 in)

i. Install the damper adjusting rod and cap bolt,and then finger tighten the cap bolt.

j. Hold the cap bolt and tighten the nut to speci-fication.

Nut15 Nm (1.5 mkg, 11 ftlb)

k. Remove the rod holder and fork spring com-pressor.

The fork spring is compressed.Always use a new cap bolt O-ring.

4-55

FRONT FORK CHAS

NOTE:

23 Nm (2.3 mkg, 17 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

17 Nm (1.7 mkg, 12 ftlb)

26 Nm (2.6 mkg, 19 ftlb)

WARNING

EAS00662

INSTALLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Install: front fork legTemporarily tighten the upper and lowerbracket pinch bolts.

Make sure the inner fork tube is flush with thetop of the handlebar holder.

2. Tighten:under bracket pinch bolt 1

cap bolt 2handlebar pinch bolt 3

upper bracket pinch bolt 4

Make sure the brake hoses are routed prop-erly.

3. Adjust:spring preload rebound dampingcompression dampingRefer to “ADJUSTING THE FRONT FORKLEGS” in chapter 3.

4-56


123456789

101112131415

Removing the handlebarsFront cowling and side cowlingLeft grip endHandlebar gripClutch switch connectorLeft handlebar switchClutch cableClutch leverRight grip endThrottle cable housingThrottle cableThrottle gripFront brake light switch connectorRight handlebar switchClutch cable holderBrake fluid reservoir tankBrake master cylinder bracket

112111112121111

Remove the parts in the order listed.Refer to “COWLINGS” in chapter 3.

Disconnect.

Disconnect.

113 Nm (11.3 mkg, 82 ftlb)

17 Nm (1.7 mkg, 12 ftlb)

11 Nm (1.1 mkg, 8.0 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

13 Nm (1.3 mkg, 9.4 ftlb)

23 Nm (2.3 mkg, 17 ftlb)3.8 Nm (0.38 mkg, 2.7 ftlb)

3.8 Nm (0.38 mkg, 2.7 ftlb)

3.8 Nm (0.38 mkg, 2.7 ftlb)13 Nm (1.3 mkg, 9.4 ftlb)

26 Nm (2.6 mkg, 19 ftlb)

17 Nm (1.7 mkg, 12 ftlb)

HANDLEBARS CHAS

EAS00665

HANDLEBARS

4-57

HANDLEBARS CHAS


161718192021222324

Brake master cylinderSteering damperHandlebar pinch boltUpper bracket boltUpper bracket pinch boltSteering stem nutUpper bracketLeft handlebarRight handlebar

112221111


113 Nm (11.3 mkg, 82 ftlb)

17 Nm (1.7 mkg, 12 ftlb)

11 Nm (1.1 mkg, 8.0 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

13 Nm (1.3 mkg, 9.4 ftlb)

23 Nm (2.3 mkg, 17 ftlb)3.8 Nm (0.38 mkg, 2.7 ftlb)

3.8 Nm (0.38 mkg, 2.7 ftlb)

3.8 Nm (0.38 mkg, 2.7 ftlb)13 Nm (1.3 mkg, 9.4 ftlb)

26 Nm (2.6 mkg, 19 ftlb)

17 Nm (1.7 mkg, 12 ftlb)

4-58

HANDLEBARS CHAS

WARNING

NOTE:

NOTE:

WARNING

WARNING

EAS00667

REMOVING THE HANDLEBARS1. Stand the motorcycle on a level surface.


2. Remove:handlebar grip 1

Blow compressed air between the left handle-bar and the handlebar grip, and gradually pushthe grip off the handlebar.

3. Remove: throttle cable housing 1 throttle grip 2

While removing the throttle cable housing, pullback the rubber cover 3 .

EAS00669

CHECKING THE HANDLEBARS1. Check: left handlebar 1 right handlebar 2Bends/cracks/damage Replace.

Do not attempt to straighten bent handle-bars as this may dangerously weaken them.

EAS00674

INSTALLING THE HANDLEBARS1. Stand the motorcycle on a level surface.


4-59

HANDLEBARS CHAS

NOTE:

CAUTION:

NOTE:

NOTE:

NOTE:

2. Install: right handlebar switch 1

Align the projection a on the right handlebarswitch with the hole b in the right handlebar.

3. Install:brake master cylinder holder 1

Install the brake master cylinder holderwith the “UP” mark facing up.

First, tighten the upper bolt, then the lowerbolt.

Align the mating surfaces of the brake mastercylinder holder with the punch mark a in theright handlebar.

There should be 2 mm (0.08 in) of clearancebetween the right handlebar switch and thebrake master cylinder holder.

4. Install: throttle grip throttle cable housing 1 throttle cables

Align the projection a on the throttle cablehousing with the hole b in the right handlebar.

5. Install:clutch lever holder 1

Align the slit in the clutch lever holder with thepunch mark a in the left handlebar.

4-60

HANDLEBARS CHAS

NOTE:

WARNING

6. Install: left handlebar switch 1

Align the projection a on the left handlebarswitch with the hole b in the left handlebar.

7. Install:handlebar grip

a. Apply a thin coat of rubber adhesive onto theend of the left handlebar.

b. Slide the handlebar grip over the end of theleft handlebar.

c. Wipe off any excess rubber adhesive with aclean rag.

Do not touch the handlebar grip until therubber adhesive has fully dried.

8. Adjust:clutch cable free playRefer to “ADJUSTING THE CLUTCHCABLE FREE PLAY” in chapter 3.

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

10 15 mm (0.39 0.59 in)

9. 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)

CHECKING THE STEERING DAMPER1. Check:steering damper bodyDamage/oil leaks Replace.(It replace with the assembly.)

steering damper rodBends/scratch Replace.(It replace with the assembly.)

bearingDamage/pitting Replace.(It replace with the assembly.)

4-61


123456789

10

Removing the under bracketFront wheel

Front cowling and side cowlingFront fork legsMain switch connectorUpper bracket boltLeft handlebar assemblyRight handlebar assemblySteering stem nutUpper bracketUnder bracket panelBrake hose holder boltLock washerUpper ring nut

2211111111

Remove the parts in the order listed.Refer to “FRONT WHEEL AND BRAKE DISCS”.Refer to “COWLINGS” in chapter 3.Refer to “FRONT FORK”.Disconnect.


38 Nm (0.38 mkg, 2.75 ftlb) 113 Nm (11.3 mkg, 82 ftlb)


1st2nd

23 Nm (2.3 mkg, 17 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

17 Nm (1.7 mkg, 12 ftlb)

STEERING HEAD CHAS

EAS00676

STEERING HEADUNDER BRACKET

4-62

STEERING HEAD CHAS


111213141516171819

Rubber washerLower ring nutUnder bracketBearing coverBearing inner raceUpper bearingLower bearingDust sealBearing outer race

111121112


38 Nm (0.38 mkg, 2.75 ftlb) 113 Nm (11.3 mkg, 82 ftlb)


1st2nd

23 Nm (2.3 mkg, 17 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

17 Nm (1.7 mkg, 12 ftlb)

4-63

STEERING HEAD CHAS

WARNING

WARNING

EAS00677

REMOVING THE UNDER BRACKET1. Stand the motorcycle on a level surface.


2. Remove: ring nut 1(with the steering nut wrench 2 )

Steering nut wrench90890–01403, YU-33975

Securely support the lower bracket so thatthere is no danger of it falling.

EAS00681

CHECKING THE STEERING HEAD1. Wash:bearingsbearing races

Recommended cleaning solventKerosene

2. Check:bearings 1bearing races 2Damage/pitting Replace.

3. Replace:bearingsbearing races

a. Remove the bearing races 1 from the steer-ing head pipe with a long rod 2 and hammer.

4-64

STEERING HEAD CHAS

CAUTION:

NOTE:

NOTE:

NOTE:

b. Remove the bearing race 3 from the lowerbracket with a floor chisel 4 and hammer.

c. Install a new rubber seal and new bearingraces.

If the bearing race is not installed properly,the steering head pipe could be damaged.

Always replace the bearings and bearingraces as a set.

Whenever the steering head is disassembled,replace the rubber 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: lower ring nut 1 rubber washer 2upper ring nut 3 lock washer 4Refer to “CHECKING THE STEERINGHEAD” in chapter 3.

3. Install:upper bracketsteering stem nut

Temporarily tighten the steering stem nut.

4. Install: front fork legsRefer to “INSTALLING THE FRONT FORKLEGS”.

Temporarily tighten the upper and lower bracketpinch bolts.

4-65


123456789

10

Removing the rear shock absorber assemblyEXUP servo motorSelf-locking nut/boltSelf-locking nut/boltSelf-locking nut/boltSelf-locking nutRear shock absorber assemblyOil seal/bearing/collarCollar/self-locking nut/boltConnecting armOil seal/bearing/collarRelay arm

1/11/11/111

6/3/31/1/1

22/1/1

1


Refer to “EXHAUST PIPE” in chapter 5.



44 Nm (4.4 mkg, 32 ftlb) 44 Nm (4.4 mkg, 32 ftlb)

REAR SHOCK ABSORBER ASSEMBLY CHAS

EAS00685

REAR SHOCK ABSORBER ASSEMBLY

4-66


WARNING

WARNING

EAS00687

HANDLING THE REAR SHOCK ABSORBERAND GAS CYLINDER

This rear shock absorber and gas cylindercontain highly compressed nitrogen gas.Before handling the rear shock absorber orgas cylinder, read and make sure you under-stand the following information. Themanufacturer cannot be held responsiblefor property damage or personal injury thatmay result from improper handling of therear shock absorber and gas cylinder.Do not tamper or attempt to open the rearshock absorber or gas cylinder.

Do not subject the rear shock absorber orgas cylinder to an open flame or any othersource of high heat. High heat can cause anexplosion due to excessive gas pressure.

Do not deform or damage the rear shockabsorber or gas cylinder in any way. If therear shock absorber, gas cylinder or bothare damaged, damping performance willsuffer.

EAS00689

DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDERGas pressure must be released before dispos-ing of a rear shock absorber and gas cylinder. Torelease the gas pressure, drill a 2 3 mm (0.08 0.12 in) hole through the gas cylinder at apoint 15 20 mm (0.59 0.79 in) from its endas shown.

Wear eye protection to prevent eye damagefrom released gas or metal chips.

4-67


WARNING

NOTE:

NOTE:

NOTE:

EAS00690

REMOVING THE REAR SHOCK ABSORBERASSEMBLY1. Stand the motorcycle on a level surface.

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


2. Remove:bottom cowlingRefer to “COWLINGS” in chapter 3.

servo motorRefer to “EXHAUST PIPE” in chapter 5.

3. Remove: rear shock absorber assembly lower bolt 1 relay arm-to-swingarm bolt 2

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

Raise the swingarm and then remove the rearshock absorber assembly from between theswingarm.

4-68


NOTE:

44 Nm (4.4 mkg, 32 ftlb)

44 Nm (4.4 mkg, 32 ftlb)

44 Nm (4.4 mkg, 32 ftlb)

EAS00695

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY1. Check: rear shock absorber rodBends/damage Replace the rear shockabsorber assembly.

rear shock absorberGas leaks/oil leaks Replace the rearshock absorber assembly.

springDamage/wear Replace the rear shock ab-sorber assembly.

bushingsDamage/wear Replace.

dust sealsDamage/wear Replace.

boltsBends/damage/wear Replace.

EAS00698

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY1. Lubricate:spacersbearings

Recommended lubricantLithium – soap-based grease

2. Install: rear shock absorber assembly

When installing the rear shock absorber as-sembly, lift up the swingarm.

Install the connecting arm front bolt from theright.

3. Tighten: rear shock absorber assembly upper nut

rear shock absorber assembly lower nut

relay arm-to swingarm nut

4. Install :EXUP servo motorRefer to “EXHAUST PIPE” in chapter 5.

bottom cowlingRefer to “COWLINGS” in chapter 3.

4-69

SWINGARM AND DRIVE CHAIN CHAS


1234567

Removing the swingarm and drivechainRear wheel

Rear shock absorber

Drive sprocket

MufflerCatalyst pipe assemblyRight footrest bracketAdjusting bolt / locknutDrive chain guardRear fenderBrake hose holderPivot shaft nut/washerPivot shaft

12/2111

1/11


Refer to “REAR WHEEL AND BRAKEDISC”.Refer to “REAR SHOCK ABSORBERASSEMBLY”.Refer to “ENGINE REMOVAL” in chapter5.Refer to “EXHAUST PIPE” in chapter 5.Refer to “EXHAUST PIPE” in chapter 5.

28 Nm (2.8 mkg, 20 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

105 Nm (10.5 mkg, 76 ftlb)

2 Nm (0.2 mkg, 1.4 ftlb)

16 Nm (1.6 mkg, 12 ftlb)

EAS00700

SWINGARM AND DRIVE CHAIN

4-70



89

10111213

SwingarmDrive chainDust coverDrive chain guideSpacerBearing

112112


28 Nm (2.8 mkg, 20 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

105 Nm (10.5 mkg, 76 ftlb)

2 Nm (0.2 mkg, 1.4 ftlb)

16 Nm (1.6 mkg, 12 ftlb)

4-71


WARNING

NOTE:

NOTE:

EAS00703

REMOVING THE SWINGARM1. Stand the motorcycle on a level surface.



2. Remove: relay arm-to-swingarm bolt 1connecting arm bolt 2 rear shock absorber assembly lower bolt 3

When removing the rear shock absorber as-sembly lower bolt, hold the swingarm so that itdoes not drop down.

3. Measure:swingarm side playswingarm vertical movement

a. Measure the tightening torque of the pivotshaft nut.

Pivot shaft nut105 Nm (10.5 mkg, 76 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 spacers,bearings, washers, and dust covers.

4-72


WARNING

NOTE:

NOTE:

WARNING

EAS00704

REMOVING THE DRIVE CHAIN1. Stand the motorcycle on a level surface.



2. Remove:drive chain(with the drive chain cutter)

Only cut the drive chain if it or the swingarm is tobe replaced.

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.

4-73


NOTE:

3. Wash:pivot shaftdust coversspacerwashersbearings

Recommended cleaning solventKerosene

4. Check:dust covers 1spacer 2Damage/wear Replace.

bearings 3Damage/pitting Replace.

5. Check:connecting arms 1 relay arm 2Damage/wear Replace.

6. Check:bearings 3oil seals 4Damage/pitting Replace.

7. Check:collars 5Damage/scratches Replace.

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.

4-74


CAUTION:

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 kerosene toclean the drive chain. Don’t soak drive chainin kerosine more them ten minutes. O-ring isdamage by kerosine.

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 the battery breather hose is properlyrouted away from the drive chain and belowthe swingarm.

5. Lubricate:drive chain

Recommended lubricantEngine oil or chain lubricantsuitable for O-ring chains

4-75


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

EAS00711

INSTALLING THE SWINGARM1. Lubricate:bearingsspacersdust coverspivot shaft


2. Install:swingarmpivot shaft 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.

Drive chain slack25 35 mm (0.98 1.38 in)

5-1


12345678

Removing the drive sprocketBottom cowlingsLock nutShift rodSift armDrive sprocket coverDrive sprocket nutLock washerDrive sprocketPlate

21111111

Remove the parts in the order listed.Refer to “COWLINGS” in chapter 3.Loosen.


10 Nm (1.0 mkg, 7.2 ftlb)

85 Nm (8.5 mkg, 61 ftlb)

7 Nm (0.7 mkg, 5 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

ENGINE ENG

ENGINEENGINEDRIVE SPROCKET

5-2

5


123456789

10

Removing the exhaust pipeRider seat and passenger seatFuel tankSide cowlings and bottom cowlingsEXUP pulley coverEXUP cableExhaust pipe assemblyExhaust pipe gasketExhaust valve pipe gasketExhaust valve pipe assemblyCatalyst pipe assemblyGasketMufflerGasket

1214111122

Remove the parts in the order listed.Refer to “SEATS” in chapter 3.Refer to “FUEL TANK” in chapter 3.Refer to “COWLINGS” in chapter 3.

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

20 Nm (2.0 mkg, 14 ftlb)

20 Nm (2.0 mkg, 14 ftlb)

20 Nm (2.0 mkg, 14 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

ENGINE ENG

EXHAUST PIPE

5-3


11121314

Muffler coverEXUP servo motorEXUP servo motor bracketProtector

2111


10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

20 Nm (2.0 mkg, 14 ftlb)

20 Nm (2.0 mkg, 14 ftlb)

20 Nm (2.0 mkg, 14 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

ENGINE ENG

5-4

ENGINE ENG


Disassembling the exhaust valve pipeWasherPulleyCollarPlateSpringHousingGasketShaft armExhaust valve pipeEXUP pulley bracket

1111111111



12345678910

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

7 Nm (0.7 mkg, 5 ftlb)

5-5


12

Disconnecting the leads and hosesFuel tankAir filter caseThrottle body assembly

Engine oil

Oil coolerAir cut-off valve

Starter motor

Battery negative leadBattery positive lead

11

Disconnect the parts in the order listed.Refer to “FUEL TANK” in chapter 3.Refer to “AIR FILTER CASE” in chapter 3.Refer to “THROTTLE BODIES” in chapter 7.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Refer to “OIL COOLER” in chapter 6.Refer to “AIR INDUCTION SYSTEM” inchapter 7.Refer to “STARTING SYSTEM” in chapter 7.

ENGINE ENG

LEADS AND HOSES

5-6


3456789

10

Clutch cableGround leadStator coil assembly couplerCrankshaft position sensor lead couplerOil level switch connectorNeutral switch connectorSpeed sensor couplerCylinder identification sensor coupler

12111111

First, disconnect the negative batterylead, and then the positive battery lead.For connecting, reverse the disconnec-tion procedure.

Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.For installation, reverse the removal procedure.

CAUTION:

ENGINE ENG

5-7

ENGINE ENG


12345678

Removing the engine

Right front engine mounting boltEngine mount collar (inside)Engine mount collar (outside)Left front engine mounting boltLower self locking nutLower engine mounting boltUpper self locking nutUpper engine mounting bolt

11111111


Place a suitable stand under the frame andengine.

NOTE:

51 Nm (5.1 mkg, 37 ftlb)

51 Nm (5.1 mkg, 37 ftlb)

45 Nm (4.5 mkg, 33 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

45 Nm (4.5 mkg, 33 ftlb)

ENGINE

5-8

ENGINE ENG


910

Engine mounting adjust boltEngine

21 Use the pivot shaft wrench and adapter to

loosen the engine mounting adjust bolts.

For installation, reverse the removal pro-cedure.

NOTE:

51 Nm (5.1 mkg, 37 ftlb)

51 Nm (5.1 mkg, 37 ftlb)

45 Nm (4.5 mkg, 33 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

45 Nm (4.5 mkg, 33 ftlb)

5-9

ENGINE ENG

NOTE:

7 Nm (0.7 mkg, 5.1 ftlb)

NOTE:

INSTALLING THE ENGINE1. Install:engine mounting adjust bolts(temporary tighten)

2. Install:engine

3. Install: lower engine mounting bolt 1upper engine mounting bolt 2self locking nuts

Lubricate the lower and upper engine mountingbolts threads with lithium-soap-based grease.

4. Install: left front engine mount bolt 1(temporary tighten)

5. Install:engine mount collar (inside) 1engine mount collar (outside) 2 right front engine mount bolt 3(temporary tighten)

6. Tighten:engine mounting adjust bolts

Use the pivot shaft wrench 1 and pivot shaftwrench adapter 2 to tighten the engine mount-ing adjust bolts.

5-10

ENGINE ENG

51 Nm (5.1 mkg, 37 ftlb)

NOTE:

45 Nm (4.5 mkg, 33 ftlb)

45 Nm (4.5 mkg, 33 ftlb)

Pivot shaft wrench90890-01471, YM-01471

Pivot shaft wrench adapter90890-01476

7. Tighten:upper self-locking nut 1 lower self-locking nut 2

First tighten the lower self-locking nut, and thentighten the upper self-locking nut.

8. Tighten: left front engine mounting bolt 1

9. Tighten: right front engine mounting bolt 1

5-11


1234

Removing the cylinder head coverFuel tankSide and bottom cowlingsThrottle body assembly

Radiator assemblyAir cut-off valve

Ignition coilSpark plugCylinder head coverCylinder head cover gasket

4411

Remove the parts in the order listed.Refer to “FUEL TANK” in chapter 3.Refer to “COWLINGS” in chapter 3.Refer to “THROTTLE BODIES” inchapter 7.Refer to “RADIATOR” in chapter 3.Refer to “AIR INDUCTION SYSTEM” in chapter 7.

13 Nm (1.3 mkg, 9.4 ftlb)

8 Nm (0.8 mkg, 5.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

CAMSHAFT ENG

EAS00194

CAMSHAFTCYLINDER HEAD COVER

5-12

CAMSHAFT ENG


567

Timing chain guide (top side)Cylinder identification sensorO-ring

111


13 Nm (1.3 mkg, 9.4 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

8 Nm (0.8 mkg, 5.7 ftlb)

5-13


1234567

89

10

Removing the camshaftsPickup rotor cover

Camshaft sprocket boltTiming chain tensionerTiming chain tensioner O-ringIntake camshaft capDowel pinExhaust camshaft capDowel pin

Intake camshaftExhaust camshaftCamshaft sprocket

4113636

112

Remove the parts in the order listed.Refer to “CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR”.Loosen.

Refer to “REMOVING THE CAMSHAFTS”.


During removal, the dowel pins may stillbe connected to the camshaft caps.

NOTE:

10 Nm (1.0 mkg, 7.2 ftlb)

24 Nm (2.4 mkg, 17 ftlb)

24 Nm (2.4 mkg, 17 ftlb)


CAMSHAFT ENG

EAS00196

CAMSHAFTS

5-14

CAMSHAFT 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

Camshaft wrench90890-04143

4. Remove: timing chain tensioner 1O-ring

5. Remove:camshaft caps 1dowel 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.

5-15

CAMSHAFT ENG

NOTE:

6. Remove: intake camshaft 1exhaust camshaft 2

To prevent the timing chain from falling into thecrankcase, fasten it with a wire 3 .

7. 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 32.85 32.95 mm(1.293 1.297 in)<Limit>: 32.75 mm (1.289 in)b 25.14 25.24 mm(0.990 0.994 in)<Limit>: 25.04 mm (0.986 in)

Exhaust camshafta 30.75 30.85 mm(1.211 1.215 in)<Limit>: 30.65 mm (1.207 in)b 23.09 23.19 mm(0.909 0.913 in)<Limit>: 22.99 mm (0.905 in)

5-16

CAMSHAFT ENG

NOTE:

3. Measure:camshaft runoutOut of specification Replace.

Camshaft runout limit0.03 mm (0.0012 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)

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 1 .

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 diameter22.459 22.472 mm (0.8842 0.8847 in)

5-17

CAMSHAFT 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).

CHECKING THE TIMING CHAIN TENSIONER1. Remove: timing chain tensioner housing 1 timing chain tensioner rod 2 timing chain tensioner spring 3

Squeeze the timing chain tensioner clip, andthen remove the timing chain tensioner springand timing chain tensioner rod.

2. Check: timing chain tensioner housing timing chain tensioner rod timing chain tensioner springDamage/wear Replace.

5-18

CAMSHAFT ENG

NOTE:

NOTE:

NOTE:

3. Install: timing chain tensioner spring timing chain tension rod 1

Prior to installing the timing chain tensioner rod,drain the engine oil from the timing chain ten-sioner housing.

a. Install the timing chain tensioner spring andtiming chain tensioner rod 1 .

b. Squeeze the timing chain tensioner clip 2and push the timing chain tensioner rod 3 .

When the timing chain tensioner rod 3 ispushed while holding the grip of the timing chaintensioner clip 2 , make sure not to release thetiming chain tensioner rod 3 before releasingthe timing chain tensioner clip 2 . (Otherwise,the timing chain tensioner rod 3 may run off.)

c. Hook the clip 4 to the timing chain tensionerrod 3 .

Hook the timing chain tensioner rod pin 5 to thecenter of the clip 4 . After the installation, checkthat the clip 4 can come off by its own weight bypushing the timing chain tensioner rod 3 at theposition of installation.

5-19

CAMSHAFT ENG

NOTE:

NOTE:

NOTE:

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: intake camshaft sprocket 1exhaust camshaft sprocket 2(with the camshaft sprockets temporarilytightened)

Install the camshaft sprockets as a illustration.

3. Install:exhaust camshaft 1 intake camshaft 2(with the camshaft sprockets temporarilytightened)

Make sure the punch mark a faces up.

4. 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.

L: Left side camshaft cap markR: Right side camshaft cap markI: Intake side camshaft cap markE: Exhaust side camshaft cap mark

5-20

CAMSHAFT ENG

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

CAUTION:

24 Nm (2.4 mkg, 17 ftlb)

CAUTION:

5. Install:camshaft cap bolts

Tighten the camshaft cap bolts in stages and ina crisscross pattern, working from the innercaps out.

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.

6. 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.

7. Align:camshaft punch mark aAlign the camshaft punch mark a and thecamshaft cap arrow mark b .


5-21

CAMSHAFT ENG

10 Nm (1.0 mkg, 7.2 ftlb)

CAUTION:

WARNING

8. Install:O-ring New timing chain tensioner 1 timing chain tensioner bolts 2

The “arrow” mark a on the timing chain ten-sioner should face up.

Always use a new O-ring.

9. Turn:crankshaft(several full turns clockwise)

10. Check: “T” mark aMake sure the “T” mark on the pickup rotor isaligned with the crankcase mating sure faceb .

camshaft punch mark cMake sure the punch mark c on the cam-shaft is aligned with the camshaft cap arrowmark d .Out of alignment Adjust.Refer to the installation steps above.

11. Measure:valve clearanceOut of specification Adjust.Refer to “ADJUSTING THE VALVE CLEAR-ANCE” in chapter 3.

12. Install:pickup coil rotor coverRefer to “CRANKSHAFT POSITION SEN-SOR”.

5-22


123456

Removing the cylinder headEngineIntake camshaftExhaust camshaftCylinder headCylinder head gasketDowel pinCoolant pipeO-ringThermo wax out let hose

112111

Remove the parts in the order listed.Refer to “ENGINE”.Refer to “CAMSHAFTS”.


18 Nm (1.8 mkg, 13 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)


1st2nd

10 Nm (1.0 mkg, 7.2 ftlb)

CYLINDER HEAD ENG

EAS00221

CYLINDER HEAD

5-23

CYLINDER HEAD ENG

NOTE:

NOTE:

NOTE:

EAS00222

REMOVING THE CYLINDER HEAD1. Remove: intake camshaftexhaust camshaftRefer to “REMOVING THE CAMSHAFTS”.

2. Remove:cylinder head nutscylinder head bolts

Loosen the nuts in the proper sequence asshown.

Loosen each nut 1/2 of a turn at a time. After allof the nuts are fully loosened, remove them.

EAS00227

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.

3. Measure:cylinder head warpageOut of specification Resurface the cylin-der head.

Maximum cylinder head warpage0.10 mm (0.0039 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.

5-24

CYLINDER HEAD ENG

8 Nm (0.8 mkg, 5.8 ftlb)

NOTE:

NOTE:

19 Nm (1.9 mkg, 14 ftlb)

67 Nm (6.7 mkg, 48 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

NOTE:

EAS00233

INSTALLING THE CYLINDER HEAD1. Check:cylinder head bolts 1

Retighten the cylinder head bolts to specifica-tion, before installing the cylinder head.

2. Install:gasket New 1

dowel pins3. Install:cylinder head

Pass the timing chain through the timing chaincavity.

4. Tighten:cylinder head nuts 1 10

1st2nd

cylinder head bolts 11 12

First, tighten the nuts 1 10 to approximate-ly 19 Nm (1.9 mkg, 14 ftlb) with a torquewrench, and then tighten the 67 Nm (6.7 mkg,48 ftlb).

Lubricate the cylinder head nuts with engineoil.

Tighten the cylinder head nuts in the propertightening sequence as shown and torquethem in two stages.

5. Install:exhaust camshaft intake camshaftRefer to “INSTALLING THE CAMSHAFTS”.

5-25

VALVES AND VALVE SPRINGS ENG


123456789

Removing the valves and valvespringsCylinder headIntake valve lifterIntake valve padIntake valve cotterIntake valve upper spring seatIntake valve springIntake valve oil sealIntake valve lower spring seatIntake valveIntake valve guide

121224121212121212


Refer to “CYLINDER HEAD”.

EAS00236

VALVES AND VALVE SPRINGS

5-26


101112131415161718

Exhaust valve lifterExhaust valve padExhaust valve cotterExhaust valve upper spring seatExhaust valve springExhaust valve oil sealExhaust valve lower spring seatExhaust valveExhaust valve guide

88

16888888



5-27


NOTE:

NOTE:

NOTE:

NOTE:

EAS00237

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 spring with the valve spring compressor2 and the valve spring compressor attachment3 .

Valve spring compressor90890-04019, YM-04019

Valve spring compressor attachment

Intake valve90890-04114, YM-4114

Exhaust valve90890-04108, YM-4108

5-28


NOTE:

NOTE:

4. Remove:upper spring seat 1valve spring 2valve stem seal 3 lower spring seat 4valve 5

Identify the position of each part very carefullyso that it can be reinstalled in its original place.

EAS00239

CHECKING THE VALVES AND VALVE GUIDESThe 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-guideclearance

Intake0.0010 0.0037 mm(0.0004 0.0015 in)<Limit>: 0.08 mm (0.0032 in)

Exhaust0.025 0.052 mm (0.0010 0.0020 in)

<Limit>: 0.10 mm (0.0039 in)

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.

5-29


NOTE:

NOTE:

After replacing the valve guide, reface the valveseat.

Valve guide removerIntake (4.0 mm, 0.16 in)

90890-04111Exhaust (4.5 mm, 0.18 in)

90890-04116, YM-4116Valve guide installer

Intake (4.0 mm, 0.16 in)90890-04112

Exhaust (4.5 mm, 0.18 in)90890-04117, YM-4117

Valve guide reamerIntake (4.0 mm, 0.16 in)

90890-04113Exhaust (4.5 mm, 0.18 in)

90890-04118, YM-4118

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. Measure:valve margin thickness aOut of specification Replace the valve.

Valve margin thickness0.5 0.9 mm (0.0197 0.0354 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 runout0.01 mm (0.0004 in)

5-30


NOTE:

NOTE:

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 widthIntake: 0.9 1.1 mmIntake: (0.0354 0.0433 in)Exhaust: 0.9 1.1 mmExhaust: (0.0354 0.0433 in)<Limit>: 1.6 mm (0.06 in)

a. Apply Mechanic’s blueing dye (Dykem) 1onto 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.

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.

5-31


CAUTION:

NOTE:

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) ontothe 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.

j. Measure the valve seat width a 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

39.3 mm (1.55 in) <Limit>: 37.3 mm (1.47 in)

Exhaust valve spring39.3 mm (1.55 in)<Limit>: 37.3 mm (1.47 in)

5-32


2. Measure:compressed valve spring force aOut of specification Replace the valvespring.

b Installed length

Compressed valve spring force(installed)

Intake valve spring145.9 167.9 N (14.88 17.12 kg, 32.80 37.74 lb) at 32.65 mm (1.285 in)

Exhaust valve spring164.1 188.9 N (16.73 19.26 kg, 36.89 42.46 lb) at 32.82 mm (12.92 in)

3. Measure:valve spring tilt aOut of specification Replace the valvespring.

Spring tilt limitIntake valve spring

1.7 mm (0.07 in)Exhaust valve spring

1.7 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.

EAS00245

INSTALLING THE VALVESThe following procedure applies to all of thevalves and related components.1. Deburr:valve stem end(with an oil stone)

5-33


NOTE:

NOTE:

NOTE:

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 4upper spring seat 5(into the cylinder head)

Install the valve spring with the larger pitch afacing up.

b Smaller pitch

Make sure that each valve is installed in its origi-nal place. Refer to the following embossedmarks.Right and left intake valve(-s): “5VY :”Middle intake valve(-s): “5VY .”Exhaust valve(-s): “5VY”

4. Install:valve cotters 1

Install the valve cotters by compressing thevalve spring with the valve spring compressor2 and the valve spring compressor attachment3 .

Valve spring compressor90890-04019, YM-04019

Valve spring compressorattachment

Intake valve90890-04114, YM-4114

Exhaust valve90890-04108, YM-4108

5-34


CAUTION:

NOTE:

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.

5-35


123456789

Removing the stator coil assemblyRider seatFuel tankLeft side cowlingBottom cowlingsEngine oil

Stator coil assembly lead couplerPlugGenerator rotor coverGasketDowel pinGenerator rotor assemblyDowel pinBearing housingCollar

111121211

Remove the parts in the order listed.Refer to “SEATS” in chapter 3.Refer to “FUEL TANK” in chapter 3.Refer to “COWLINGS” in chapter 3.

Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Disconnect.

10 Nm (1.0 mkg, 7.2 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)

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

14 Nm (1.4 mkg, 10 ftlb)

22 Nm (2.2 mkg, 16 ftlb)

22 Nm (2.2 mkg, 16 ftlb)

STARTER CLUTCH AND GENERATOR ENG

STARTER CLUTCH AND GENERATORSTATOR COIL ASSEMBLY

5-36



101112131415

BearingStator coil assembly lead holderIdler gearIdler gear shaftWasherBearing

111111


10 Nm (1.0 mkg, 7.2 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)

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

14 Nm (1.4 mkg, 10 ftlb)

22 Nm (2.2 mkg, 16 ftlb)

22 Nm (2.2 mkg, 16 ftlb)

5-37


123456789

Removing the starter clutchGenerator rotorDamperDriven gearWasherStarter clutch drive gearCollarWasherSpacerO-ring

131111111




STARTER CLUTCH

5-38


NOTE:

REMOVING THE GENERATOR1. Remove: rider seat fuel tank

Refer to “SEATS” and “FUEL TANK” in chapter3.2. Remove: left side cowlingbottom cowlings

Refer to “COWLINGS” in chapter 3.3. Drain:engine oil

Refer to “CHANGING THE ENGINE OIL” inchapter 3.

4. Remove:pluggenerator rotor cover 1

While pushing generator rotor, remove thegenerator rotor cover.

Loosen each bolt 1/4 of a turn a time, in stagesand in a crisscross pattern.

After all of the bolts are fully loosened, removethem.

5. Remove:generator rotor and starter clutch assembly

1 .

6. Remove: idler gear shaft bolt 1 idler shaft idler gear 2

5-39


REMOVING THE STARTER CLUTCH1. Remove:spacer 1O-ring 2washer 3

2. Remove:Starter clutch drive gear 1collar 2washer 3

3. Remove:driven gear 1dampers 2generator rotor 3

CHECKING THE DAMPER1. Check:dampers 1Damage/wear Replace.

5-40


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 gearcounterclockwise A , the starter clutch andthe starter clutch drive gear should engage,otherwise the starter clutch is faulty and mustbe replaced.

c. When turning the starter clutch drive gearclockwise B , it should turn freely, otherwisethe starter clutch is faulty and must be re-placed.

5-41


NOTE:

NOTE:

10 Nm (1.0 mkg, 7.2 ftlb)

INSTALLING THE STARTER CLUTCH1. Install:generator rotor 1damper 2driven gear 3

The hole side of the damper is installed to thegenerator side.

Lubricate the engine oil 4 .

2. Install:starter clutch drive gear 1collar 2washer 3Refer to “CHECKING THE STARTERCLUTCH”.

3. Install:washer 1O-ring 2 Newspacer 3

Lubricate the engine oil to O-ring.

INSTALLING THE GENERATOR1. Install: idle gear shaft idle gear 1washer idle gear shaft bolt 2

LOCTITE

2. Install:generator rotor and starter clutch assembly

1

5-42


12 Nm (1.2 mkg, 8.7 ftlb)

22 Nm (2.2 mkg, 16 ftlb)

NOTE:

3. Install:generator cover gasketgenerator cover 1

(M6 bolts)(M8 bolts)

First tighten the M8 bolts and then tighten theM6 bolts.

Tighten the generator rotor cover bolts instages and in a crisscross pattern.

4. Fill:engine oilRefer to “CHANGING THE ENGINE OIL” inchapter 3.

5. Install:bottom cowling left side cowlingRefer to “COWLINGS” in chapter 3.

6. Install: fuel tank rider seatRefer to “SEATS” and “FUEL TANK” in chap-ter 3.

5-43


123456

Removing the crankshaft position sensorRider seatFuel tankSide cowlingsBottom cowlingsEngine oil

Crankshaft position sensor lead couplerCrankshaft position sensorO-ringPickup rotor coverGasketCover

111111


Refer to “SEATS” in chapter 3.Refer to “FUEL TANK” in chapter 3.Refer to “COWLINGS” in chapter 3.

Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Disconnect.


10 Nm (1.0 mkg, 7.2 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)

CRANKSHAFT POSITION SENSOR ENG

CRANKSHAFT POSITION SENSOR

5-44


NOTE:

12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

REMOVING THE CRANKSHAFT POSITION SENSOR1. Remove: rider seat fuel tankRefer to “SEATS” and “FUEL TANK” in chap-ter 3.

2. Remove: right side cowlingbottom cowlings

Refer to “COWLINGS” in chapter 3.3. Drain:engine oilRefer to “CHANGING THE ENGINE OIL” inchapter 3.

4. Disconnect:crankshaft position sensor lead coupler

5. Remove:crankshaft position sensorO-ringpickup rotor cover 1

Loosen each bolt 1/4 of a turn a time, in stagesand in a crisscross pattern.After all of the bolts are fully loosened, removethem.

INSTALLING THE CRANKSHAFT POSITION SENSOR1. Install:gasket Newpickup rotor cover 1

O-ring Newcrankshaft position sensor

LOCTITE

2. Connect:crankshaft position sensor lead coupler

3. Fill:engine oilRefer to “CHANGING THE ENGINE OIL” inchapter 3.

4. Install: right side cowlingbottom cowlingsRefer to “COWLINGS” in chapter 3.

5-45


5. Install: rider seat fuel tankRefer to “SEATS” and “FUEL TANK” in chap-ter 3.

5-46


123456

Removing the clutch coverRight side cowlingBottom cowlingEngine oil

CoverClutch cableClutch coverClutch cover gasketDowel pinOil filler cap

111121


Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.

Disconnect.


Refer to “COWLINGS” in chapter 3.

12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

CLUTCH ENG

CLUTCHCLUTCH COVER

5-47

CLUTCH ENG


123456

Removing the pull lever shaftCirclipPull leverPull lever springPull lever shaftOil sealBearing

211112



PULL LEVER SHAFT

5-48


123456789

101112

Removing the clutchCompression springPressure platePull rodBearingFriction plate 1Clutch plate 1Friction plate 2Wire clipClutch plate 2Friction plate 3Clutch damper springClutch damper spring seat

611117711111


10 Nm (1.0 mkg, 7.2 ftlb)

95 Nm (9.5 mkg, 69 ftlb)

CLUTCH ENG

CLUTCH

5-49

CLUTCH ENG


131415161718

Clutch boss nutWasherClutch bossThrust plateClutch housingBearing

111111


10 Nm (1.0 mkg, 7.2 ftlb)

95 Nm (9.5 mkg, 69 ftlb)

5-50

CLUTCH ENG

NOTE:

EAS00276

REMOVING THE CLUTCH1. Remove:clutch cover 1gasket

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

3. Remove: friction plate 1

4. Remove:clutch plate 1 1 friction plate 2

5. Straighten the clutch boss nut rib 1 .

5-51

CLUTCH ENG

NOTE:

NOTE:

6. Loosen:clutch boss nut 1

While holding the clutch boss 2 with the univer-sal clutch holder 3 , loosen the clutch boss nut.

Universal clutch holder90890-04086, YM-91042

7. Remove:clutch boss nutwasherclutch boss assembly thrust plate

8. Remove:wire clip 1

There is a built-in damper between the clutchboss and the clutch plate. It is not necessary toremove the wire circlip 1 and disassemble thebuilt-in damper unless there is serious clutchchattering.

9. Remove:clutch plate 2 1 friction plate 3 2

10. Remove:clutch damper spring 1clutch damper spring seat 2

5-52

CLUTCH ENG

NOTE:

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.

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)

5-53

CLUTCH ENG

NOTE:

NOTE:

EAS00282

CHECKING THE CLUTCH SPRINGSThe following procedure applies to all of theclutch springs.1. Check:clutch springDamage Replace the clutch springs as aset.

2. Measure:clutch spring free length aOut of specification Replace the clutchsprings as a set.

Clutch spring free length52.5 mm (2.07 in)<Limit>: 49.9 mm (1.96 in)

EAS00284

CHECKING THE CLUTCH HOUSING1. Check:clutch housing dogsDamage/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:bearingDamage/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.

5-54

CLUTCH ENG

NOTE:

EAS00286

CHECKING THE PRESSURE PLATE1. Check:pressure plate 1Cracks/damage Replace.

bearing 2Damage/wear Replace.

EAS00287

CHECKING THE PULL LEVER SHAFT ANDPULL ROD1. Check:pull lever shaft pinion gear teeth 1pull rod teeth 2Damage/wear Replace the pull rod andpull lever shaft pinion gear as a set.

2. Check:pull rod bearingDamage/wear Replace.

INSTALLING THE CLUTCH1. Install:clutch damper spring seat 1clutch damper spring 2

2. Install: friction plate 3 1clutch plate 2 2

Lubricate the engine oil.

5-55

CLUTCH ENG

NOTE:

95 Nm(9.5 mkg, 69 ftlb)

NOTE:

3. Install:wire clip 1

4. Install:clutch housing 1

Align the projection of clutch housing a andhollow of the oil pump drive gear b .

5. Install: thrust plateclutch boss assembly 1washerclutch boss nut 2 New

Install the washer on the main axle with the“OUT” mark facing away from the motorcycle.

Lock the threads on the clutch boss nut bystaking them with a drift punch at the pointaligned with the groove in the axle.

While holding the clutch boss assembly 1with the clutch holding tool 3 , tighten theclutch boss nut.

Universal clutch holder90890-04089, YM-91042

5-56

CLUTCH ENG

NOTE:

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

NOTE:

6. Lubricate: friction platesclutch plates(with the recommended lubricant)

Recommended lubricantEngine oil

7. Install: friction plate 2clutch plate 1 1

8. Install: friction plate 1 1

Install the last friction plate shifting half phase.

9. Install:bearingpull rod 1pressure plate 2clutch springsclutch spring bolts 3

Tighten the clutch spring bolts in stages and in acrisscross pattern.

10. Install:pull lever

In stall the pull lever with the “” mark facing to-ward upper side.

5-57

CLUTCH ENG

NOTE:

12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

NOTE:

11. Install:clutch coverclutch cover gasket New

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.

12. Tighten:clutch cover bolts 1

clutch cover bolt 2

LOCTITE

Tighten the clutch cover bolts in a stages and ina crisscross pattern.

13. Adjust:clutch cable free playRefer to “ADJUSTING THE CLUTCHCABLE FREE PLAY” in chapter 3.

5-58


123456789

Removing the shift shaft and stopperleverSide cowlingsBottom cowlingsClutch assemblySift arm and shift rodCirclipWasherShift shaftCollarShift shaft springWasherStopper screwStopper leverWasher

111111111


Refer to “CLUTCH”.Refer to “ENGINE”.


22 Nm (2.2 mkg, 16 ftlb)

SHIFT SHAFT ENG

EAS00327

SHIFT SHAFTSHIFT SHAFT AND STOPPER LEVER

5-59

SHIFT SHAFT ENG


10111213

Oil sealBearingBearingStopper lever spring

1111


22 Nm (2.2 mkg, 16 ftlb)

5-60

SHIFT SHAFT ENG

REMOVING THE SHIFT SHAFT1. Remove: left and right side cowlingsbottom cowlingsRefer to “COWLINGS” in chapter 3.

2. Remove:clutch assemblyRefer to “CLUTCH”.

3. Remove:shift armshift rodRefer to “ENGINE”.

4. Remove:circlip 1Washer 2(left side of the engine)

5. Remove:shift shaft 1shift shaft spring 2collarwasher

6. Remove:stopper lever spring 1stopper screw 2stopper lever 3washer

5-61

SHIFT SHAFT ENG

22 Nm (2.2 mkg, 16 ftlb)

NOTE:

CHECKING THE SHIFT SHAFT1. Check:shift shaft 1Bends/damage/wear replace.

shift shaft spring 2collar 3Damage/wear Replace.

CHECKING THE STOPPER LEVER1. Check:stopper lever 1Bends/damage Replace.Roller turns roughly Replace the stopperlever.

INSTALLING THE SHIFT SHAFT1. Install:washerstopper lever 1stopper screw 2

LOCTITE

stopper lever spring 3

2. Install:washercollarshift shaft spring 1shift shaft 2

Mesh the stopper lever with the shift drum seg-ment assembly.

Lubricate the oil seal lips with lithium soapbase grease.

Install the end of the shift shaft spring onto theshift shaft spring stopper.

3. Install:Washer 1circlip 2 New

5-62

SHIFT SHAFT ENG

4. Install:shift rodshift armRefer to “ENGINE”.

5. Install:clutch assemblyRefer to “CLUTCH”.

6. Install: left and side cowlingbottom cowlingsRefer to “COWLING” in chapter 3.

5-63


12345678

Removing the oil pan and oil pumpSide cowlingsBottom cowlingsEngine oil

Exhaust pipe and exhaust valve pipeClutch assemblyWater pump inlet pipeWater pump outlet pipeOil level switch lead couplerOil level switchOil level switch lead holderOil panOil pan gasketDowel pinDrain pipeOil strainer

11111211


Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Refer to “EXHAUST PIPE”.Refer to “CLUTCH”.Refer to “OIL COOLER” in chapter 6.

Disconnect.


10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)


12 Nm (1.2 mkg, 8.7 ftlb)43 Nm (4.3 mkg, 31 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

OIL PAN AND OIL PUMP ENG

EAS00356

OIL PAN AND OIL PUMP

5-64



9101112

1314

15161718

Oil pipeOil delivery pipeRelief valve assemblyOil /water pump assembly drive chain guideCollarOil /water pump assembly drive sprocketWasherOil /water pump assembly drive chainDowel pinOil /water pump assembly

1111

11

1111


10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)


12 Nm (1.2 mkg, 8.7 ftlb)43 Nm (4.3 mkg, 31 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

5-65


Disassembling the oil pumpOil/water pump driven sprocketCollarOil pump housingBearingPinOil pump outer rotorOil pump inner rotorPin

11112111



12345678

15 Nm (1.5 mkg, 11 ftlb)


EAS00360

5-66


NOTE:

EAS00362

REMOVING THE OIL PAN1. Remove:oil level switch 1oil pan 2oil pan gasketdowel pins

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.

CHECKING THE SPROCKET AND CHAIN1. Check:oil /water pump assembly drive sprocket 1Cracks/damage/wear Replace the de-fective part(-s).

2. Check:oil /water pump assembly drive chain 1Damage/stiffness Replace the oil /waterpump assembly drive chain and oil /waterpump assembly drive sprocket as a set.

5-67


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

0.01 0.10 mm(0.0004 0.0039 in)<Limit>: 0.18 mm (0.0071 in)

Outer-rotor-to-oil-pump-housing clearance

0.09 0.15 mm(0.0035 0.0059 in)<Limit>: 0.22 mm (0.0087 in)

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).

5-68


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.

EAS00374

ASSEMBLING THE OIL PUMP1. Lubricate: inner rotorouter rotoroil pump shaft(with the recommended lubricant)


5-69


NOTE:

15 Nm (1.5 mkg, 11 ftlb)

NOTE:

12 Nm (1.2 mkg, 8.7 ftlb)

2. Install:pin 1 inner rotor 2outer rotor 3oil pump housing 4

When installing the inner rotor, align the pin 1 inthe oil pump shaft with the groove a in the innerrotor 2 .

3. Install:oil /water pump driven sprocket 1

LOCTITE

5VY mark of the oil /water pump driven gear isinstalled at oil pump side.

4. Check:oil pump operationRefer to “CHECKING THE OIL PUMP”.

INSTALLING THE OIL/WATER PUMPASSEMBLY1. Install:O-ring Newoil /water pump assembly 1dowel pinbolts 2

LOCTITE

5-70


NOTE:

CAUTION:

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

2. Install:washeroil /water pump assembly drive chain 1oil /water pump assembly drive sprocket 2collar

Install the oil /water pump assembly drive chain1 onto the oil /water pump assembly drivesprocket 2 .

After installing the oil /water pump assem-bly drive chain and drive sprocket, makesure the oil /water pump turns smoothly.

3. Install:oil /water pump assembly drive chain guide

1LOCTITE

“UP” mark of the oil /water pump assembly drivechain guide is upward.

4. Install:oil delivery pipe 1

LOCTITE

5. Install: relief valve 1O-ring New

oil strainer 2LOCTITE

O-ring Newoil pipe 3O-ring New

drain pipe 4O-ring New

5-71


12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

43Nm (4.3 mkg, 31 ftlb)

WARNING

NOTE:

EAS00380

INSTALLING THE OIL PAN1. Install:dowel pinsgasket Newoil pan 1oil level switch 2

engine oil drain bolt 3

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.

5-72


Removing the crankcaseAir filter caseThrottle body assembly

EngineCylinder headStarter clutch and generator

Shift shaftCrankshaft position sensor

ClutchOil pan and oil pumpStarter motor

Remove the parts in the order listed.Refer to “AIR FILTER CASE” in chapter 3.Refer to “THROTTLE BODIES” in chapter 7.Refer to “ENGINE”.Refer to “CYLINDER HEAD”.Refer to “STARTER CLUTCH AND GENERATOR”.Refer to “SHIFT SHAFT”.Refer to “CRANKSHAFT POSITION SENSOR”.Refer to “CLUTCH”.Refer to “OIL PAN AND OIL PUMP”.Refer to “STARTING SYSTEM” in chapter 8.


24 Nm (2.4 mkg, 17 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

24 Nm (2.4 mkg, 17 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

20 Nm (2.0 mkg, 14 ftlb) +60

CRANKCASE ENG

CRANKCASE

5-73

CRANKCASE ENG


123456789

Timing chainTiming chain guide (intake side)PinTiming chain guide (exhaust side)Left side coverO-ringLower crankcaseDowel pinDamper

112111131



24 Nm (2.4 mkg, 17 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

24 Nm (2.4 mkg, 17 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

20 Nm (2.0 mkg, 14 ftlb) +60

5-74

CRANKCASE ENG

NOTE:

CAUTION:

NOTE:

EAS00384

DISASSEMBLING THE CRANKCASE1. Place the engine upside down.2. Remove:crankcase bolts

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.

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.

M9 105 mm (4.1 in) bolts: 1 10

M8 60 mm (2.4 in) bolt: 11 LOCTITE

M8 60 mm (2.4 in) bolts: 12 , 16

M6 70 mm (2.8 in) bolts: 19 , 21 , 23

M6 65 mm (2.5 in) bolts: 17 , 18

M6 60 mm (2.4 in) bolts: 22 , 24 , 25

M6 50 mm (2.0 in) bolts: 20 , 26

M8 50 mm (2.0 in) bolts: 13 15

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.

5-75

CRANKCASE ENG

NOTE:

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.

ASSEMBLING THE CRANKCASE1. Lubricate:crankshaft journal bearings(with the recommended lubricant)


2. Apply:sealant

Yamaha bond No. 121590890-85505, ACC-1109-05-01

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(0.08 0.12 in) of the crankshaft journal bear-ings.

5-76

CRANKCASE ENG

CAUTION:

NOTE:

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 and 22 .Seal bolt 18

Tighten the bolts in the tightening sequencecast on the crankcase.

M9 105 mm (4.1 in) bolts: 1 10


M8 60 mm (2.4 in) bolts: 12 , 16

M6 70 mm (2.8 in) bolts: 19 , 21 , 23

M6 65 mm (2.5 in) bolts: 17 , 18

M6 60 mm (2.4 in) bolts: 22 , 24 , 25

M6 50 mm (2.0 in) bolts: 20 , 26

M8 50 mm (2.0 in) bolts: 13 15

Crankcase boltBolt 1 10

1st: 20 Nm (2.0 mkg, 14 ftlb)2nd*: 20 Nm (2.0 mkg, 14 ftlb)3rd: +60Bolt 11 16

24 Nm (2.4 mkg, 17 ftlb)Bolt 17 26

12 Nm (1.2 mkg, 8.7 ftlb)

* Following the tightening order, loosen the boltone by one and then retighten it to the specifictorque.

5-77


123456789

101112

Removing the connecting rods andpistonsLower crankcaseConnecting rod capBig end lower bearingBig end upper bearingPiston pin clipPiston pinPistonConnecting rodTop ring2nd ringOil ringCylinderCylinder gasket

444844444411


Refer to “CRANKCASE”.


20 Nm (2.0 mkg, 14 ftlb) +150

8 Nm (0.8 mkg, 5.8 ftlb)

CONNECTING RODS AND PISTONS ENG

EAS00252

CONNECTING RODS AND PISTONS

5-78


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.

After removing the connecting rods and con-necting rod caps, care should be taken not todamage the mating surfaces of the connectingrods and connecting rod caps.

2. Remove:CylinderCylinder gasketCylinder stud bolts

3. 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 debarred and the pistonpin is still difficult to remove, remove it with thepiston pin puller set 4 .

Piston pin puller set90890-01304, YU-01304

4. 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.

5-79


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.

5-80


NOTE:

Cylinder bore “C” 77.00 77.01 mm(3.0315 3.0319 in)

Wear limit 77.06 mm (3.03 in)

Taper limit “T” 0.005 mm (0.0002 in)

Out of round “R” 0.005 mm (0.0002 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”76.975 76.990 mm (3.0305 3.0311 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>: 0.120 mm (0.0047 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.

5-81


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 ring0.020 0.055 mm(0.0008 0.002 in)<Limit>: 0.115 mm (0.0045 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

0.15 0.25 mm(0.0059 0.0098 in)<Limit>: 0.50 mm (0.0197 in)

2nd ring0.30 0.45 mm(0.0118 0.0177 in)<Limit>: 0.80 mm (0.0315 in)

Oil ring0.10 0.40 mm(0.0039 0.0158 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.

5-82


2. Measure:piston pin outside diameter aOut of specification Replace the pistonpin.

Piston pin outside diameter16.991 17.000 mm(0.6689 0.6693 in)<Limit>: 16.971 mm (0.6682 in)

3. Measure:piston pin bore inside diameter bOut of specification Replace the piston.

Piston pin bore inside diameter17.002 17.013 mm(0.6694 0.6698 in)<Limit>: 17.043 mm (0.6710 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

0.034 0.058 mm(0.0013 0.0023 in)<Limit>: 0.09 mm (0.0035 in)

The following procedure applies to all of theconnecting rods.

5-83

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 rods 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 with molybdenumdisulfide 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.

5-84


NOTE:

NOTE:

NOTE:

CAUTION:

e. Tighten the connecting rod bolts.

Install by carrying out the following proceduresin order to assemble in the most suitable condi-tion.

Connecting rod bolt29.4 Nm (3.0 mkg, 21 ftlb)

First, tighten the bolts to 15 Nm (1.5 mkg, 11ftlb).

Retighten the bolts to 29.4 Nm (3.0 mkg, 21ftlb).

f. Replace the connecting rod bolts with newones.

g. Clean the connecting rod bolts.h. After installing the big end bearing, assemble

the connecting rod and connecting rod caponce using a single unit of the connectingrod.

i. Tighten the connecting rod bolt while check-ing that the sections shown a and b areflush with each other by touching the surface.

Side machined face aThrusting faces (4 places at front and rear)

b

To install the big end bearing, care should betaken not to install it at an angle and the positionshould not be out of alignment.

j. Loosen the connecting rod bolt, remove theconnecting rod and connecting rod cap andinstall these parts to the crankshaft with thebig end bearing kept in the current condition.

k. Tighten the connecting rod bolts.

Connecting rod bolt20 Nm (2.0 mkg, 14 ftlb) + 150

Tighten the connecting rod bolts using theplastic-region tightening angle method.

5-85


WARNING

CAUTION:

l. Clean the connecting rod bolts.m. Tighten the connecting rod bolts.n. Put a mark 1 on the corner of the connecting

rod bolt 2 and the connecting rod 3 .o. Tighten the bolt further to reach the specified

angle (150).

p. After the installation, check that the sectionshown a is flush with each other by touchingthe surface.

Side machined face a

When the bolt is tightened more than thespecified angle, do not loosen the bolt andthen retighten it.Replace the bolt with a new one and per-form the procedure again.

If they are not flush with each other, removethe connecting rod bolt and big end bear-ing and restart from step “e”. In this case,make sure to replace the connecting rodbolt.

Do not use a torque wrench to tighten thenut to the specified angle.

Tighten the bolt until it is at the specifiedangles.

q. Remove the connecting rod and big endbearings.Refer to “REMOVING THE CONNECTINGRODS”.

5-86


NOTE:

r. 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.

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

5-87


NOTE:

NOTE:

Be sure to install the piston rings so that themanufacturer’s marks or numbers a face up.

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)


5-88


8 Nm (0.8 mkg, 5.8 ftlb)

NOTE:

NOTE:

29.4 Nm (3.0 mkg, 21 ftlb)

NOTE:

6. Check:cylinder stud bolts 1

7. Install:cylinder gasket 2 New

8. Install:big end bearings(onto the connecting rods and connectingrod caps)

Align the projection a on the big end bearingswith the notches b in the connecting rods andconnecting rod caps.

Be sure to reinstall each big end bearing in itsoriginal place.

Make sure that the characters c on both theconnecting rod and connecting rod cap arealigned.

9. Tighten:

Install by carrying out the following proceduresin order to assemble in the most suitable condi-tion.

connecting rod bolts

First, tighten the bolts to 15 Nm (1.5 mkg, 11ftlb).

Retighten the bolts to 29.4 Nm (3.0 mkg, 21ftlb).

a. Replace the connecting rod bolts with newones.

5-89


NOTE:

NOTE:

b. Clean the connecting rod bolts.c. After installing the big end bearing, assemble

the connecting rod and connecting rod caponce using a single unit of the connectingrod.

d. Tighten the connecting rod bolt while check-ing that the sections shown a and b areflush with each other by touching the surface.

Side machined face aThrusting faces (4 places at front and rear)

b

To install the big end bearing, care should betaken not to install it at an angle and the positionshould not be out of alignment.

e. Loosen the connecting rod bolt, remove theconnecting rod and connecting rod cap andinstall these parts to the crankshaft with thebig end bearing kept in the current condition.

10. Install:piston assemblies 1(into the cylinder)

While compressing the piston rings with onehand, install the connecting rod assembly intothe cylinder with the other hand.

5-90


NOTE:

20 Nm (2.0 mkg, 14 ftlb) + 150

CAUTION:

11. Install:cylinder assembly 1connecting rod caps 2

Make sure that the “Y” marks a on the con-necting rods face towards the left side of thecrankshaft.

Make sure that the characters on both the con-necting rod and connecting rod cap arealigned.

12. Tighten:connecting rod bolts

Tighten the connecting rod bolts using theplastic-region tightening angle method.

a. Clean the connecting rod bolts.b. Tighten the connecting rod bolts.c. Put a mark 1 on the connecting rod bolts 2

and the connecting rod cap 3 .d. Tighten the bolt further to reach the specified

angle (150).e. After the installation, check that the section

show a is flush with each other by touchingthe surface.

Side machined face a

5-91


WARNING

CAUTION:

When the bolt is tightened more than thespecified angle, do not loosen the bolt andthen retighten it.Replace the bolt with a new one and per-form the procedure again.

If they are not flush with each other, removethe connecting rod bolt and big end bear-ing and restart from step “9”.In this case, make sure to replace the con-necting rod bolt.

Do not use a torque wrench to tighten thebolt to the specified angle.

Tighten the bolt until it is at the specifiedangles.

5-92


1234567

Removing the crankshaftCrankcase

Connecting rod and connecting rod capsCrankshaftCrankshaft journal lower bearingCrankshaft journal upper bearingWasherCrankshaft drive gearPinPickup rotor

1551111

Remove the parts in the order listed.Separate.Refer to “CRANKCASE”.Refer to “CONNECTING RODS AND PISTONS”.


60 Nm (6.0 mkg, 43 ftlb)

CRANKSHAFT ENG

EAS00381

CRANKSHAFT

5-93

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 DRIVESPROCKET1. Check:crankshaft drive sprocket 1Cracks/damage/wear Replace the de-fective part(s).

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

0.014 0.037 mm(0.0006 0.0015 in)<Limit>: 0.10 mm (0.0039 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.

5-94

CRANKSHAFT ENG

NOTE:

NOTE:

NOTE:

a. Clean the crankshaft journal bearings,crankshaft journals, and bearing portions ofthe crankcase.

b. Place the upper crankcase upside down on abench.

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: 20 Nm (2.0 mkg, 14 ftlb)2nd: 20 Nm (2.0 mkg, 14 ftlb)3rd: +60Bolt 11 16

24 Nm (2.4 mkg, 17 ftlb)Bolt 17 26

12 Nm (1.2 mkg, 8.7 ftlb)

M9 105 mm (4.1 in) bolts: 1 10


M8 60 mm (2.4 in) bolts: 12 , 16

M6 70 mm (2.8 in) bolts: 19 , 21 , 23

M6 65 mm (2.5 in) bolts: 17 , 18

M6 60 mm (2.4 in) bolts: 22 , 24 , 25

M6 50 mm (2.0 in) bolts: 20 , 26

M8 50 mm (2.0 in) bolts: 13 15

5-95

CRANKSHAFT ENG

NOTE:

NOTE:

* Following the tightening order, loosen the boltone by one and then retighten it to the specifictorque.

Lubricate the crankcase bolt threads with en-gine oil.Refer to “CRANKCASE”.

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 Blue

2 Black

3 Brown

4 Green

5-96

CRANKSHAFT ENG

NOTE:

60 Nm (6.0 mkg, 43 ftlb)

EAS00407

INSTALLING THE CRANKSHAFT1. Install:crankshaft journal upper bearings 1(into the upper crankcase)

2. Lubricate:crankshaft journal upper bearings(with the recommended lubricant)


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.

3. Install:crankshaft

4. Install:crankcase (lower)Refer to “CRANKCASE”.

5. Install:pinpickup rotor 1drive sprocket 2

5-97


123456789

101112

Removing the transmission, shift drum assembly, and shift forksCrankcase lower

Drive axle assemblyCirclipOil sealBearingWasherShift drum retainerSpringShift fork guide barShift fork “L”Shift fork “R”Shift drum assemblyShift fork “C”

111112221111

Remove the part in the order listed.

Separate.Refer to “CRANKCASE”.

12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

TRANSMISSION ENG

EAS00419

TRANSMISSIONTRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS

5-98

TRANSMISSION ENG


1314151617

Main axle retainerMain axle assemblyOil pipeO-ringOil baffle plate

11121


12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

5-99


Disassembling the main axle assembly2nd pinion gearToothed lock washerToothed lock washer retainer6th pinion gearCollarWasherCirclip3rd pinion gearCirclipWasher5th pinion gearCollarMain axle

1111111111111


12345678910111213

TRANSMISSION ENG

5-100


Bearing housingBearing

11


1415

TRANSMISSION ENG

5-101


Disassembling the drive axleassemblyWasher1st wheel gearCollar5th wheel gearCirclipWasher3rd wheel gearCollarToothed lock washerToothed lock washer retainer4th wheel gearCollarWasherCirclip

11111111111111


1234567891011121314

TRANSMISSION ENG

5-102

TRANSMISSION ENG


6th wheel gearCirclipWasherCollar2nd wheel gearCollarOil sealBearingDrive axle

111111111


151617181920212223

5-103

TRANSMISSION ENG

REMOVING THE TRANSMISSION1. Remove:drive axle assembly 1shift drum retainers 2shift fork guide barsshift fork “L” and “R”shift drum assemblyshift fork “C”

2. Remove:bearing housing 1main axle assembly 2

a. Insert two bolts 3 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.

3. Remove:oil pipe 1bearing 2

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.

5-104

TRANSMISSION ENG

WARNING

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.

EAS00422

CHECKING THE SHIFT DRUM ASSEMBLY1. Check:shift drum grooves 1Damage/scratches/wear Replace theshift drum assembly.

shift drum segment 2Damage/wear Replace the shift drum as-sembly.

shift drum bearing 3Damage/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 limit0.08 mm (0.0032 in)

5-105

TRANSMISSION ENG

NOTE:

12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

2. Measure:drive axle runout(with a centering device and dial gauge 1 )Out of specification Replace the driveaxle.

Drive axle runout limit0.08 mm (0.0032 in)

3. Check: transmission gearsBlue discoloration/pitting/wear Replacethe defective gear(s).

transmission gear dogsCracks/damage/rounded edges Replacethe defective gear(s).

INSTALLING THE TRANSMISSION1. Install:bearing 1

Make the seal side of bearing face to the outsideand install it close to the right end face of thecrankcase.

oil pipe 2

2. Install:main axle assembly 1bearing housing 2

LOCTITE

shift fork “C”shift drum assemblyshift fork guide barshift fork guide bar retainer

LOCTITE

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.

5-106

TRANSMISSION ENG

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

NOTE:

3. Install:shift fork “L” 1 and “R” 2drive axle assembly 3shift fork guide barshift fork guide bar retainer 4

LOCTITE

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.

6-1


12345

Removing the radiatorRider seatFuel tankAir filter caseSide cowlingsBottom cowlingCoolant

Fuse box stayCoolant reservoir hoseRadiatorRadiator fan motorRadiator inlet hose

11121


Refer to “AIR FILTER CASE” in chapter 3.

Drain.Refer to “CHANGING THE COOLANT” inchapter 3.Disconnect.


Refer to “SEATS” in chapter 3.

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

5 Nm (0.5 mkg, 3.6 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

RADIATOR COOL

EAS00454

COOLING SYSTEMRADIATOR

6-2

6

RADIATOR COOL


6789

1011

Radiator inlet pipeOil cooler outlet hoseWater pump breather hoseRadiator outlet hoseWater pump inlet pipeO-ring

111111


10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

5 Nm (0.5 mkg, 3.6 ftlb)

10 Nm (1.0 mkg, 7.2 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 pressure108 137 kPa(1.08 1.37 kg/cm2, 1.0 1.3 bar, 15.6 19.9 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. Fill:cooling system(with the specified amount of the recom-mended coolant)Refer to “CHANGING THE COOLANT” inchapter 3.

2. Check:cooling systemLeaks Repair or replace any faulty part.

3. Measure: radiator cap opening pressureBelow the specified pressure Replace theradiator cap.Refer to “CHECKING THE RADIATOR”.

6-5


123456789

Removing the oil coolerEngine oil

Oil cooler inlet hoseBoltWasherOil coolerO-ringWater pump outlet pipeO-ringWater jacket joint inlet hoseO-ring

111111111

Remove the parts in the order listed.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.

10 Nm (1.0 mkg, 7.2 ftlb)

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

Water jacket jointStayO-ring

111


10 Nm (1.0 mkg, 7.2 ftlb)

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 Newbolt 3

Before installing the oil cooler, lubricate the oilcooler bolt and O-ring with a thin coat of engineoil.

Make sure that the O-ring is positioned proper-ly.

Align the projection a on the oil cooler with theslot b in the crankcase.

3. Fill:cooling system(with the specified amount of the recom-mended coolant)Refer to “CHANGING THE COOLANT” inchapter 3.

crankcase(with the specified amount of the recom-mended engine oil)Refer to “CHANGING THE ENGINE OIL” inchapter 3.



6-8


12345

Removing the thermostat assemblyRider seatFuel tankAir filter caseCoolant

Thermostat assembly outlet hoseThermostat assembly breather hoseThermostat assemblyThermostat assembly inlet hoseBand

11112

Remove the parts in the order listed.Refer to “SEATS” in chapter 3.Refer to “FUEL TANK” in chapter 3.Refer to “AIR FILTER CASE” in chapter 3.Drain.Refer to “CHANGING THE COOLANT” inchapter3.


THERMOSTAT COOL

EAS00460

THERMOSTAT

6-9

THERMOSTAT COOL


Disassembling the thermostat housingThermostat housing coverThermostatThermostat housingO-ring

1111



1234

10 Nm (1.0 mkg, 7.2 ftlb)

6-10

THERMOSTAT COOL

NOTE:

EAS00462

CHECKING THE THERMOSTAT1. Check: thermostatDoes 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 housing cover 1 thermostat housing 2Cracks/damage Replace.

6-11

THERMOSTAT COOL

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

EAS00464

ASSEMBLING THE THERMOSTAT ASSEMBLY1. Install: thermostat housing 1 thermostat 2O-ring New 3 thermostat housing cover 4

Install the thermostat with its breather hole afacing up.

EAS00466

INSTALLING THE THERMOSTAT ASSEMBLY1. Fill:cooling system(with the specified amount of the recom-mended coolant)Refer to “CHANGING THE COOLANT” inchapter 3.



6-12

WATER PUMP COOL


1234

Removing the impeller shaft

Oil/water pump assembly and oilpump rotorWater pump coverO-ringPinImpeller shaft (along with the impeller)

1121


The water pump and oil pump are com-bined into one unit (oil /water pump as-sembly).

It is not necessary to remove the impellershaft unless the coolant level is extreme-ly low or coolant leaks from the oil pan.

Refer to “OIL PAN AND OIL PUMP” inchapter 5.

12 Nm (1.2 mkg, 8.7 ftlb)

NOTE:

EAS00468

WATER PUMPIMPELLER SHAFT

6-13

WATER PUMP COOL


5678

Water pump sealOil sealBearingO-ring

1111


12 Nm (1.2 mkg, 8.7 ftlb)

6-14

WATER PUMP COOL

NOTE:

NOTE:

NOTE:

EAS00471

DISASSEMBLING THE WATER PUMP1. Remove:water pump seal 1

Tap out the water pump seal from the inside ofthe water pump housing.

2 Water pump housing

2. Remove:oil seal 1bearing 2

Tap out the bearing and oil seal from the outsideof the water pump housing.

3 Water pump housing

3. Remove: rubber damper holder 1 rubber damper 2(from the impeller, with a thin, flat-headscrewdriver)

Do not scratch the impeller shaft.

EAS00473

CHECKING THE WATER PUMP1. Check:water pump housing cover 1water pump housing 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 pipeCracks/damage/wear Replace.

6-15

WATER PUMP COOL

NOTE:

CAUTION:

NOTE:

NOTE:

EAS00475

ASSEMBLING THE WATER PUMP1. Install:oil 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 .

Mechanical seal installer 490890-04078, YM-33221

Middle driven shaft bearingdriver 5

90890-04058, YM-04058Yamaha bond #1215

90890-85505Quick gasket

ACC-11001-05-01

A Push down.

3. Install: rubber damper New 2 rubber damper holder New 1

Before installing the rubber damper, apply tapwater or coolant onto its outer surface.

6-16

WATER PUMP COOL

CAUTION:

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

7-1

FUEL INJECTION SYSTEM FI

19 Atmospheric pressuresensor

20 Fuel injection systemrelay

21 Engine trouble warninglight

22 Lean angle cut-offswitch

23 Air cut-off valve

13 Coolant temperaturesensor

14 Spark plug15 Cylinder identification

sensor16 Pressure regulator17 Battery18 ECU

1 Ignition coil2 Air filter case3 Intake temperature

sensor4 Fuel delivery hose5 Fuel tank6 Fuel pump7 Fuel return hose

8 Intake air presure sen-sor

9 Throttle position sen-sor

10 Fuel injector11 Catalytic converter12 Crankshaft position

sensor

FUEL INJECTION SYSTEMFUEL INJECTION SYSTEM

7-2


7

WIRING DIAGRAM

7-3


1 Main switch4 Fuse (main)5 Fuse (backup)6 Battery7 Fuse (fuel injection)10 Starting circuit cut-off relay11 Neutral switch12 Sidestand switch13 Fuel pump14 E.C.U.15 Ignition coil #116 Ignition coil #217 Ignition coil #318 Ignition coil #419 Spark plug20 Injector #121 Injector #222 Injector #323 Injector #425 Sub-throttle position sensor26 EXUP servo motor27 Speed sensor28 Coolant temperature sensor29 Intake air temperature sensor31 Crankshaft position sensor32 Throttle position sensor33 Intake air pressure sensor34 Atmospheric pressure sensor35 Cylinder identification sensor36 Lean angle cut-off switch43 Multi function meter53 Engine stop switch73 Fuse (ignition)

7-4

30: Lean angle cut-off switch(latch up detected)

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 fault code number appears from the lowest value in order ofprecedence on the LCD meter. Once a fault code has been displayed, it remains stored in the memoryof 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.

11: Cylinder identification sensor

12: Crankshaft position sensor

19: Sidestand switch(open circuit in wire to ECU)

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.

7-5


SUBSTITUTE CHARACTERISTICS 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

Able / unableto start

Able / unableto drive

11

Cylinder identificationsensor

No normal signals are received fromthe cylinder identification sensor.

Continues to operate the engine basedon the results of the cylinderidentification that existed up to thatpoint.

Unable Able

12Crankshaft 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 system.

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.

Fixes the throttle position sensor tofully open. Able Able

17EXUP servo motorpotention(open or short circuit)

EXUP servo motor potention-open orshort circuit detected.

Turn the EXUP servo motor towardthe open side for 3 seconds and thenstop it.

Able Able

18

EXUP servo motor (lock) A lock of the EXUP servo motor isdetected.

Perform the preventive controlagainst motor locking.Perform the lock release operationtwice every 100 seconds.

Able Able

19Sidestand switch (opencircuit in wire to ECU)

Open circuit in the input line of ECUNo.15 terminal is detected when thestart switch is pressed.

-- (No start)Unable Unable

20Intake air pressureAtmospheric pressure

Defective values are detected due tothe internal malfunction

Fixes the intake air pressure andatmospheric pressure to 101.3 kpa. Able Able

21Coolant temperaturesensor

Coolant temperature sensor-open orshort circuit detected.

Fixes the coolant temperature to60C. Able Able

22Intake temperaturesensor

Intake temperature sensor-open orshort circuit detected.

Fixes the intake temperature to 20C.Able Able

23Atmospheric pressuresensor

Atmospheric pressure sensor-open orshort circuit detected.

Fixes the atmospheric pressure to101.3 kpa. Able Able

33343536

Faulty ignition Open circuit detected in the primarylead of the ignition coil.

Cut the injection of other cylinder inthe same group with the cylinder thatthe error is detected.(Example: when the #1 cylinder isdetective, cut the injection of #1 and#4 cylinders, when the #2 cylinder isdetective, cut the injection of #2 and#3 cylinders).Turn on the power to the air inductionsolenoid to always cut-off the air.

Able(dependingon the num-ber of faultycylinders)

Able(dependingon the num-ber of faultycylinders)

3041

Lean angle cut-offswitch (latch updetected) (open or shortcircuit)

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

43Fuel system voltage(monitor voltage)

The ECU is unable to monitor thebattery voltage (an open circuit in theline to the ECU).

Fixes the battery voltage to 12 V.Able Able

44

Error in writing theamount of COadjustment onEEPROM

An error is detected while reading orwriting on EEPROM (CO adjustmentvalue).

--

Able Able

7-6





46Vehicle system powersupply (Monitor voltage)

Power supply to the FI system is notnormal.

--Able Able

47Sub-throttle servo motorpotention (open or shortcircuit)

sub-throttle servo motor potention-open or short circuit detected.

Turn the sub-throttle servo motortoward the close side for 4 secondsand then stop it.

Able Able

48

Sub-throttle servo motor(lock)

A lock of the sub-throttle servo motor isdetected.

Perform the preventative controlagainst motor locking.(Perform the lock release operationtwice every 100 seconds.)

Able Able

50ECU internalmalfunction (memorycheck error)

Faulty ECU memory. When thismalfunction is detected, the codenumber might not appear on 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 is turned ONwhile an error is detected with the faultcode of No.11, 12, 19, 30, 41 or 50.

Engine trouble warning light flasheswhen the start switch is turned ON.

Unable Unable

Communication error with the meter




Er-1ECU internal malfunction(output signal error)

No signals are received from the ECU. – Unable Unable


No signals are received from the ECUwithin the specified duration.

– Unable Unable


Data from the ECU cannot be receivedcorrectly.

– Unable Unable

Er-4ECU internal malfunction(input signal error)

Non-registered data has been receivedfrom the meter.

– Unable Unable

7-7

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 probable cause of malfunction. (Referto the “Diagnostic fault code table”.)

Check and repair the probable case of malfunc-tion.

Fault code No.appear

Fault code No.disappear

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 “FAIL-SAFEACTIONS TABLE”.)

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.)

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

01: Throttle positionsensor (throttleangle)

03: Intake air pressure07: Vehicle speed pulse09: Fuel system volt-

age (battery bolt)21: Neutral switch30: Ignition coil #131: Ignition coil #2

32: Ignition coil #333: Ignition coil #436: Injector #137: Injector #238: Injector #339: Injector #448: Al system solenoid53: EXUP servo motor56: Sub-throttle servo

motor


EAS00904

TROUBLESHOOTING CHART

7-8


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.

7-9


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.

7-10


Diagnostic fault code table

Faultcode No. Symptom Probable cause of malfunction

Diagnosticcode

11

No normal signals are received fromthe cylinder identification sensor.

Open or short circuit in wiring sub lead. Open or short circuit in wiring harness. Defective cylinder identification sensor. Malfunction in ECU. Improperly installed sensor.

—

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 hosesystem; a hose is detached, causingconstant application of theatmospheric pressure to the sensor;or, the hose is clogged.

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

17EXUP servo motor potentioncircuit-open or short circuit detected.

Open or short circuit in wiring sub lead. Detective EXUP servo motor (potention circuit). 53

18EXUP servo motor is stuck. Open or short circuit in wiring sub lead.

Stuck EXUP servo motor (mechanism). Stuck EXUP servo motor (motor).

53

19Open circuit in the input line of ECUNo.15 terminal is detected when thestart switch is pressed.

Open circuit in wiring harness (ECU Coupler). Malfunction in ECU. 20

20

When the main switch is turned to ON,the atmospheric sensor voltage andintake air pressure sensor voltagediffer greatly.

Atmospheric pressure sensor hose is clogged. Intake air pressure sensor hose is clogged, kinked, or pinched. Malfunction of the atmospheric pressure sensor in the

intermediate electrical potential. Malfunction of the intake air pressure sensor in the

intermediate electrical potential. Malfunction in ECU.

0302

21Coolant temperature sensor-open orshort circuit detected.

Open or short circuit in wiring harness. Defective coolant temperature sensor. Malfunction in ECU.

06

22Intake temperature sensor-open orshort circuit detected.

Open or short circuit in wiring harness. Defective intake temperature sensor. Malfunction in ECU.

05

23Atmospheric pressure sensor-open orshort circuit detected.

Open or short circuit in wiring sub lead. Defective atmospheric pressure sensor. Malfunction in ECU.

02

30The motorcycle has overturned. Overturned.

Malfunction in ECU. 08

33

Open circuit is detected in the primarylead of the ignition coil (#1).

Open or short circuit in wiring harness. Malfunction in ignition coil. Malfunction in ECU. Malfunction in a component of ignition cut-off circuit system.

30

7-11


Faultcode No. Symptom Probable cause of malfunction

Diagnosticcode

34



31

35



32

36



33

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

43The ECU is unable to monitor thebattery voltage (an open circuit in themonitor line to the ECU).

Open circuit in wiring harness. 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”.—

47Sub-throttle servo motor potention cir-cuit-open or short circuit detected.

Open or short circuit in wiring harness. Detective Sub-throttle servo motor (potention circuit). 56

48Sub-throttle servo motor is stuck. Open or short circuit in wiring harness.

Stuck Sub-throttle servo motor (mechanism). Stuck Sub-throttle servo motor (motor).

56

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-1

No signal are received from the ECU. Open or short circuit in wiring harness. Malfunction in meter. Malfunction in ECU. Defective wire connection of the ECU coupler.

—

Er-2No signal are received from the ECUwithin the specified duration.

Improper connection in wiring harness. Malfunction in meter. Malfunction in ECU.

—

Er-3Data from the ECU can not bereceived correctly.


—

Er-4Non-registered data has beenreceived from the meter.


—

7-12


NOTE:

Diagnostic mode tableSwitch the meter display from the regular mode to the diagnosis 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 it with an atmospheric pressure gauge, judge it by using 101.3 kPa as thestandard.

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 18) Fully open position (95 100)

02Atmosphericpressure

Displays the atmospheric pressure.* Use an atmospheric pressure gauge to check the

atmospheric pressure.

Compare it to the valuedisplayed on the meter.

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 temperature 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 After the engine stop switch has been turned from OFF toON, it actuates ignition coil #1 for five times every secondand illuminates the engine trouble warning light.* Connect an ignition checker.* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check that spark is generated,5 times with the engine stopswitch ON.

31

Ignition coils #2 After the engine stop switch has been turned from OFF toON, it actuates ignition coil #2 for five times every secondand illuminates the engine trouble warning light.* Connect an ignition checker.* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.


7-13


Diagnosticcode


(reference value)

32


turn it back ON.


33


turn it back ON.


36

Injector #1 After the engine stop switch has been turned from OFF toON, it actuates the injector #1 five times every second andilluminates the engine trouble warning light.* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the operating sound ofthe injector five times withengine stop switch ON.

37


turn it back ON.


38


turn it back ON.


39


turn it back ON.


48

AI system solenoid After the engine stop switch has been turned from OFF toON, it actuates the AI system solenoid five times everysecond and illuminates the engine trouble warning light.* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the operating sound ofthe AI system solenoid 5 timeswith the engine stopswitch ON.

50

Fuel injection systemrelay

After the engine stop switch has been turned from OFF toON, it actuates the fuel injection system relay five timesevery second and illuminates the engine trouble warninglight (the light is OFF when the relay is ON, and the light isON when the relay is OFF).* 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 the engine stop switch has been turned from OFF toON, it actuates the radiator fan motor relay five times every5 seconds and illuminates the engine trouble warning light.(ON 2 seconds, OFF 3 seconds)* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the radiator fan motorrelay operating sound 5 timeswith the engine stopswitch ON.(At that time, the fan motorrotates.)

7-14


Diagnosticcode


(reference value)

52

Headlight relay 1 After the engine stop switch has been turned from OFF toON, it actuates the headlight relay five times every5 seconds and illuminates the engine trouble warning light.(ON 2 seconds, OFF 3 seconds)* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the headlight relayoperating sound 5 times with theengine stop switch ON.(At that time, the headlight turnsON.)

53

EXUP servo motor After the engine stop switch has been turned from OFF toON, it actuates the servo motor turns to open side and toclose side.* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Turn on the engine troublewarning light while servo motoris operated. (Operating angle isdisplayed on the LCD meter)

56

Sub-throttle servomotor

After the engine stop switch has been turned from OFF toON, it actuates the servo motor turns to open side and toclose side.* If the engine stop switch is ON, turn it OFF once, and then

turn it back on.

Turn on the engine trouble warn-ing light while servo motor is op-erated (Operating angle is dis-played on the LCD meter).

60

EEPROM fault codedisplay

Transmits the abnormal portion of the data in the E2PROMthat has been detected as a self-diagnostic fault code 44.

If multiple malfunctions have been detected, differentcodes are displayed at 2-second intervals, and thisprocess is repeated.

(01 04) Displays the cylindernumber.(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.

11 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 25(00) Displays when there is nomalfunction.

70 Control number Displays the program control number. 00 255

7-15


Cylinder identification sensoroutput voltage

When sensor is on4.8 V or more

When sensor is off0.8 V or less

Tester positive probe white /blackTester negative probe black/blue

12

TROUBLESHOOTING DETAILSThis section describes the measures per fault code number displayed on the meter. Carry out checkand maintenance on items or components that could be a cause of malfunction in accordance with theorder.When the check and maintenance of malfunctioned part is completed, restore the meter display ac-cording to the “Restore method”.Fault code No.:

Fault code number displayed on the meter when the engine failed to work normally. (Refer to “Diag-nostic fault code table”.)

Diagnostic code No.:Code number to be used when the diagnostic monitoring mode is operated. (Refer to “DIAGNOS-TIC MODE”.)

Fault code No. 11 Symptom No normal signals are received from the cylinder identification 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 bystarting the

2 Connected condition of connectorInspect 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.

Cylinder identification sensor couplerMain wiring harness ECU couplerSub-wire harness coupler

engine andoperating it atidle.

3 Open or short circuit in wiring harnessand/or sub lead.

Repair or replace if there is an open or short circuit.Between sensor coupler and ECU coupler

Blue – BlueWhite/Black – White /BlackBlack /Blue – Black/Blue

4 Defective cylinder identification sensor. Replace if defective.1. Connect the pocket tester (DC 20 V) to the

cylinder identification sensor coupler terminalas shown.

2. Set the main switch to “ON”.3. Measure the cylinder identification sensor out-

put voltage.

4. Is the cylinder identification sensor OK?

7-16

Crankshaft position sensorresistance

336 504 Ω at 20C (68F)(between gray and black)

Tester positive probe gray Tester negative probe black

12

12


Fault code No. 12 Symptom No normal signals are received from the crankshaft position sensor.




1 Installed condition of sensor Check the installed area for looseness orpinching.

Reinstated bycranking the



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?

7-17

Intake air pressure sensor outputvoltage

3.75 4.25 V

Tester positive probe pink/white Tester negative probe black/blue

12


Fault code No. 13 Symptom Intake air pressure sensor – open or short circuit detected.

Used diagnostic code No. 03 (intake air pressure sensor)





Intake air pressure sensor couplerMain wiring harness ECU couplerSub-wire harness coupler

Reinstated byturning themain switchON.


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 monitoring mode (CodeNo.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?

7-18


Fault code No. 14 Symptom Intake air pressure sensor – hose system malfunction (clogged or detachedhose).

Used diagnostic code No. 03 (intake air pressure sensor)


Operation item and countermeasuer Reinstatementmethod

1 Intake air pressure sensor hose detached,clogged, kinked, or pinched.Intake air pressure sensor malfunction atintermediate electrical potential.

Repair or replace the sensor hose.Inspect and repair the connection.

Reinstated bystarting theengine andoperating it at

2 Connected condition 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.If there is a malfunction, repair it and connect itsecurely.

idle.

3 Defective intake air pressure sensor. Execute the diagnostic mode (Code No.03).Replace if defective.Refer to “Fault code No. 13”.

7-19


Fault code No. 15 Symptom Throttle position sensor – open or shrt 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.




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.

Fault code No. 16 Symptom Stuck throttle position sensor detected.

Used diagnostic code No.01 (throttle position sensor)



1 When detecting fault code No.15. Refer to “Fault code No.15”. Reinstated by

2 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.

starting theengine,operating it atidle and then

3 Defective throttle position sensor Execute the diagnostic mode (Code No.01).Replace if defective.Refer to “THROTTLE BODIES” section.

idle, and thenracing it.

7-20


EXUP servomotor resistance(when the pulley is turned once)

5.25 9.75 kΩ at 20C (68F)

Positive tester terminal blueNegative tester probe white /red

12

Fault code No. 17 Symptom EXUP servo motor potention circuit – open or short circuit detected.

Used diagnostic code 53





EXUP servo motor couplerMain wireharness ECU coupler


2 Open or short circuit in wire harness. Repair or replace if there is an open or shortcircuit.Between motor coupler and ECU coupler

Blue – BlueWhite/Red – White /RedBlack /Blue – Black/Blue

3 Defective EXUP servo motor potentioncircuit.

Execute the diagnostic mode (Code No.53).Replace if defective.1. Disconnect the EXUP servomotor coupler from

the wire harness.2. Connect the pocket tester (Ω 1k) to the

EXUP servomotor coupler.

3. While slowly turning the EXUP servomotorpulley, measure the EXUP servomotor resis-tance.

4. Is the EXUP servomotor OK?

7-21


To prevent damaging the EXUP servomo-tor, perform this test within a few secondsof connecting the battery.

Positive battery terminal black/greenNegative battery lead black/red

12

CAUTION:

Fault code No. 18 Symptom EXUP servo motor is stuck.


Order Inspection operation item and probablecouse


1 Connected condition of connectorInspect the coupler for any pins thatmay have pulled out.Check the locking condition of thecoupler

If there is a malfunction repair it andconnect it securely.

EXUP servo motor couplerMain wire harness ECU coupler.

Reinstated byturning themain switchON.It takes 120

2 Open or short circuit in wire harness. Repair or replace if there is an openor short circuit.Between motor coupler and ECU coupler.

Black /Green – Black/GreenBlack /Red – Black/Red

seconds at themaximumbefore theoriginal statereturns.

3 Defective EXUP servo motor. Execute the diagnostic mode (Code No.53).Replace if defective.1. Disconnect the EXUP cables from the EXUP

servomotor pulley.2. Disconnect the EXUP servomotor coupler from

the wire harness.3. Connect the battery leads to the EXUP servo-

motor coupler as shown.

4. Check that the EXUP servomotor pulley ro-tates several times.

5. Does the EXUP servomotor pulley turn?

4 Defective EXUP valve, pulley, cable. Replace if defective

7-22


Fault code No. 19 Symptom Open circuit in the input line of ECU No.15 terminal is detected.

Used diagnostic code No. 20 (sidestand switch)



1 Connected condition of connectorMain wiring harness ECU coupler(No.15 pin)<pin location>

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 connected itsecurely.

If thetransmission isin gear, it isreinstated byretracting thesidestand.If the


Repair or replace if there is an open or shortcircuit.Between sidestand switch coupler and ECUcoupler

Blue/Black – Black

transmission isin neutral, it isreinstated byreconnectingthe wiring.

3 The malfunction of the sidestand switch. Replace if defective.Refer to “CHECKING THE SWITCHES” inchapter 8.

Fault code No. 20 Symptom Defective values are detected due to the internal malfunction of the intake airpressure sensor or the atmospheric pressure sensor.

Used diagnostic code No. 02 (atmospheric pressure sensor) 103 (intake air pressure sensor) 2



1 Defective atmospheric pressure sensor Execute the diagnostic mode (Code No.02).Replace if defective.Refer to “Fault code No.23”.

Reinstated byturning themain switch

2 Defective intake air pressure sensor Execute the diagnostic mode (Code No.03).Replace if defective.Refer to “Fault code No.13”.

ON.

7-23


Fault code No. 21 Symptom Open or short circuit is detected from the coolant temperature sensor.

Used diagnostic code No. 06 (coolant temperature sensor)





Coolant temperature sensor couplerMain wiring harness ECU couplerSub-wire harness coupler




Black /Blue – Black/BlueGreen/White – Green/White

3 Defective coolant temperature sensor. Execute the diagnostic mode (Code No.06).Replace if defective.Refer to “COOLING SYSTEM” in chapter 8.

7-24


Intake air temperature sensorresistance

2.21 2.69 kΩ at 20C (68F)

Tester positive probe brown/white Tester negative probe black/blue

12

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 temperature sensor.

Used diagnostic code No. 05 (intake temperature sensor)





Intake temperature sensor couplerMain wiring harness ECU couplerSub-wire harness coupler




Black /Blue – Black/BlueBrown/White – Brown/White

3 Defective intake 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?

7-25


Atmospheric pressure sensoroutput voltage

3.75 4.25 V

Tester positive probe pink Tester negative probe black/blue

12

Fault code No. 23 Symptom Open or short circuit detected from the atmospheric pressure sensor.

Used diagnostic code No. 02 (atmospheric pressure sensor)





Atmospheric pressure sensor couplerMain wiring harness ECU coupler


2 Open or short circuit in wiring harness. Repair or replace if there is an open or shortcircuit.Between sensor coupler and ECU coupler

Blue – BlueBlack /Blue – Black/BluePink – Pink

3 Defective atmospheric pressure sensor. Execute the diagnostic mode (Code No.02).Replace if defective.1. Connect the pocket tester (DC 20 V) to the

atmospheric pressure sensor coupler terminalas shown.

2. Set the main switch to “ON”.3. Measure the atmospheric pressure sensor out-

put voltage.

4. Is the atmospheric pressure sensor OK?

7-26


Tester positive prove blue Tester negative prove yellow/green

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 anglecut-off switch

Check the installed area for looseness orpinching.

turning themain switchON



Lean angle cut-off switch couplerMain wiring harness ECU coupler

ON(however, theengine cannotbe restartedunless themain switch is

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

emergency stop switch coupler as shown.

4. When turn the lean angle cut-off switchapprox. 65, the voltage reading is 0.4 V to 4.4V.

5. Is the emergency stop switch OK?

main switch isfirst turnedOFF).

7-27

FUEL INJECTION SYSTEM FIFUEL INJECTION SYSTEM FI

Fault code No. 33 Symptom Malfunction detected in the primary lead of the ignition coil (#1).

Used diagnostic code No. 30 (ignition coil #1)





Ignition coil primary side coupler – OrangeMain wiring harness ECU coupler

Reinstated bystarting the en-gine and oper-ating it at idle.

2 Open or short circuit in lead. Repair or replace if there is an open or shortcircuit.Between ignition coil coupler (#1) and ECU coupler /main harness

Orange – OrangeRed/Black – Red/Black

3 Detective 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.







Ignition coil primary side coupler – Gray/RedMain wiring harness ECU coupler


2 Open or short circuit in lead wire. Repair or replace if there is an open or shortcircuit.Between ignition coil coupler (#2) and ECU coupler /main harness

Gray /Red – Gray/RedRed/Black – Red/Black

3 Defective ignition coil (test the primaryand secondary coils for continuity).








Ignition coil primary side coupler – Orange/GreenMain wiring harness ECU coupler


2 Open or short circuit in lead wire. Repair or replace if there is an open or shortcircuit.Between ignition coil coupler (#3) and ECUcoupler /main harness

Orange/Green – Orange/GreenRed/Black – Red/Black



7-28






1 Connected state of connectorInspect the coupler for any pins thatmay have pulled out.Check the locking condition of thecoupler.


Ignition coil primary side coupler – Gray/GreenMain wiring harness ECU coupler


2 Open or short circuit in lead wire. Repair or replace if there is an open or shortcircuit.Between ignition coil coupler (#4) and ECUcoupler /main harness

Gray /Green – Gray/GreenRed/Black – Red/Black



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


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.

7-29


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 whiteTester negative probe black/blue

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 sensorconnector

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.Speed sensor coupler

Main wiring harness ECU coupler

Reinstated bystarting theengine, andinputting thevehicle speedsignals by

ti thA2 Open or short circuit in speed sensorlead.

Repair or replace if there is an open or short circuit.Between sensor coupler and ECU coupler.

Blue – BlueWhite/Yellow – White /YellowBlack /Blue – Black/Blue

operating themotorcycle at alow speed of20 to 30 km/h.

A3 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?

A4 Gear for detecting vehicle speed hasbroken.

Replace if defective.Refer to “TRANSMISSION” in chapter 5.


Operation item and countermeasure Reinstatementmethod.

B1 Connected condition of connectorInspect the coupler for any pins thatmay have pulled out.Check the locking condition of thecoupler.


Neutral switch connectorMain wiring harness ECU coupler

Reinstated bystarting theengine, andinputting thevehicle speedi l bB2 Open or short circuit in neutral switch

lead.Repair or replace if there is an open or short circuit.Between switch connector and ECU coupler

Sky blue – Black/Yellow

signals byoperating themotorcycle at alow speed of

B3 Defective neutral switch Execute the diagnostic mode (Code No.21).Replace if defective.Refer to “CHECKING THE SWITCHES” inchapter 8.

low s eed of20 to 30 km/h.

B4 Faulty shift drum(neutral detection area)

Replace if defective.Refer to “TRANSMISSION” in chapter 5.

7-30


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)ECU 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 harness. Repair or replace if there is an open or shortcircuit.Between battery terminal and ECU coupler

Red/white – Red/whiteRed – Blue/Yellow (Main switch and enginestop switch are on.)Red – Red/Blue (Fuel injection systemrelay is on.)

4 Malfunction or open circuit in fuel injectionsystem relay

Execute the diagnostic mode (Code No.09).Replace if defective.

1. Disconnect the starting circuit cut-off relayfrom 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 blue/white and black?

7-31


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 cylindersappear alternately at 2-second intervals.)

2. Readjust the CO of the displayed cylinder.Refer to “ADJUSTING THE EXHAUST GASVALUME” 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 theengine andoperating it atidle.

2 Faulty battery Replace or change the battery Refer to “CHECKING AND CHARGING THEBATTERY” in chapter 3.

3 The malfunction of the rectifier / regula-tor.

Replace if defective.Refer to “CHARGING SYSTEM” in chapter 8.

4 Open or short circuit in wiring harness. Repair or replace if there is an open or shortcircuit. 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

7-32


Fault code No. 47 Symptom Sub-throttle position sensor – open or short circuit detected.




1 Installed condition of sub-throttle positionsensor.

Check the installed area for looseness or pinch-ing.Check that it is installed in the specified position.Refer to “THROTTLE BODIES” section.




Throttle position sensor couplerMain wiring harness ECU couplerSub-wire harness coupler


Repair or replace if there is an open or short cir-cuit.Between sensor coupler and ECU coupler

Black /Blue – Black/BlueGreen/yellow – Green/yellowBlue – Blue

4 Defective sub-throttle position sensor. Replace if defective.Refer to “THROTTLE BODIES” section.

7-33


To prevent damaging the sub-throttle ser-vomotor, perform this test within a few se-conds of connecting the battery.

Positive battery terminal yellow/red Negative battery terminal yellow/white

12

CAUTION:

Fault code No. 48 Symptom Sub-throttle servo motor is stuck.


Order Inspection operation item and probablecouse


1 Connected condition of connectorInspect the coupler for any pins thatmay have pulled out.Check the locking condition of thecoupler

If there is a malfunction repair it andconnect it securely.

Sub-throttle servo motor couplerMain wire harness ECU coupler.

Reinstated byturning themain switchON.It takes 120

2 Open or short circuit in wire harness. Repair or replace if there is an openor short circuit.Between motor coupler and ECU coupler.

Yellow/Red – Yellow/RedYellow/White – Yellow/White

seconds at themaximumbefore theoriginal statereturns.

3 Defective sub-throttle servo motor. Execute the diagnostic mode (Code No.56).Replace if defective.1. Disconnect the sub-throttle cables from the

Sub-throttle servomotor pulley.2. Disconnect the sub-throttle servomotor coupler

from the wire harness.3. Connect the battery leads to the sub-throttle

servomotor coupler as shown.

4. Check that the sub-throttle servomotor pulleyrotates several times.

5. Does the sub-throttle servomotor pulley turn?

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.

7-34


Fault code No. Er-1 Symptom No signal are received from the ECU.

Er-2 Symptom No signal are received from the ECU within the specified duration.

Er-3 Symptom Data from the ECU cannot be received correctly.

Er-4 Symptom Non-registered data has been received from the meter.






Cylinder identification sensor couplerMain wiring harness ECU couplerSub-wire harness coupler




Yellow/Blue – Yellow/BlueBlack /White – Black/White

3 Malfunction in meter Replace the meter.

4 Malfunction in ECU Replace the ECU.

7-35


123456

78

Removing the throttle bodiesSeatFuel tankAir filter caseSub-wire harness couplerCoolant temperature sensor couplerThermo wax inlet hoseThermo wax outlet hoseIdle adjust screw wireThrottle body joint clamp

Throttle bodiesThrottle cables

211114

12

Remove the parts in the order listed.Refer to “SEAT” in chapter 3.Refer to “FUEL TANK” in chapter 3.Refer to “AIR FILTER CASE” in chapter 3.Disconnect.Disconnect.

Loosen.

If it loosens too much, the nut will sepa-rate.

Disconnect.

NOTE:

THROTTLE BODIES FI

THROTTLE BODIES

7-36


9

1011

Throttle body joint

Heat protectorFuel hose

4

11

To install the throttle body joint, makesure to install it to the cylinder with thesame figures corresponding to the fig-ures stated on the throttle body joint.


NOTE:

THROTTLE BODIES FI

7-37


123456789

101112131415

Removing the injectorsThrottle position sensor couplerSub-throttle position sensor couplerSub-throttle motor assembly couplerIntake air pressure sensor couplerCylinder #1-injector couplerCylinder #2-injector couplerCylinder #3-injector couplerCylinder #4-injector couplerSub wire harnessNegative pressure hoseIntake air pressure sensorFuel distributorInjectorSpringThermo wax assembly

111111111111411

Remove the parts in the order listed.Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.

THROTTLE BODIES FI

INJECTORS

7-38

THROTTLE BODIES FI


1617181920212223

Idle adjust screw wireCotter pinWasherLinkSub-throttle servo motor assemblyThrottle position sensorFuel pressure regulatorThrottle body assembly

12211111


7-39

THROTTLE BODIES FI

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.

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”.

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

3. Install: throttle bodiesRefer to “THROTTLE BODIES”.

7-40

THROTTLE BODIES FI

NOTE:

CHECKING THE PRESSURE REGULATOR1. Check:pressure regulatorDamage Replace.

CHECKING THE FUEL PUMP ANDPRESSURE REGULATOR OPERATION1. Check:pressure regulator operation

a. Remove the fuel tank.Refer to “FUEL TANK” in chapter 3.

b. Disconnect the negative pressure hose 1from the pressure regulator at the joint.

c. Connect the vacuum/pressure pump gaugeset 2 onto the negative pressure hose fromthe pressure regulator.

d. Connect the pressure gauge 3 and adapter4 onto the fuel injection pipe.

Vacuum/pressure pump gauge set90890-06756, YB-35956

Pressure gauge90890-03153, YU-03153

Adapter90890-03176, YM-03176

e. Install the fuel tank.Refer to “FUEL TANK” in chapter 3.

f. Start the engine.g. Measure the fuel pressure.

Fuel pressure294 kPa (2.94 kg/cm2, 42.6 psi)

h. Use the vacuum pressure pump gauge set toadjust the fuel pressure in relation to the vac-uum pressure as described below.

The vacuum pressure should not exceed 100kPa (760 mmHg, 29.9 inHg).

7-41

THROTTLE BODIES FI

NOTE:

Increase the vacuum pressure Fuel pressure is decreasedDecrease the vacuum pressure Fuel pressure is increased

Faulty Replace the pressure regulator.

EAS00916

CHECKING AND ADJUSTING THETHROTTLE 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

4 6 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


7-42

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 6 kΩ at 20C (68F)(yellow – black)

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)

e. After adjusting the throttle position sensorangle, tighten the throttle position sensorscrews.

7-43

THROTTLE BODIES FI

NOTE:

CHECKING AND ADJUSTING THESUB-THROTTLE POSITION SENSOR1. Check:sub-throttle position sensor

a. Disconnect the sub-throttle position sensorcoupler.

b. Remove the sub-throttle position sensorfrom the sub-throttle servo motor.

c. Connect the pocket tester (Ω 1k) to thesub-throttle position sensor.

Positive tester probe blue terminal 1Negative tester probe


d. Measure the maximum sub-throttle positionsensor resistance.Out of specification Replace the sub-throttle position sensor.

Maximum sub-throttle positionsensor resistance

4 6 kΩ at 20C (68F)(blue – black/blue)

e. Connect the pocket tester (Ω 1k) to thesub-throttle position sensor.

Positive tester probe green/yellow terminal 3

Negative tester probe black/blue terminal 2

f. While slowly opening the sub-throttle wormnut, check that the sub-throttle position sen-sor resistance is within the specified range.The resistance does not change or it changesabruptly Replace the sub-throttle positionsensor.

Check mainly that the resistance changes grad-ually when turning the sub-throttle worm nut,since the readings (from closed to wide-opensub-throttle) may differ slightly from those spe-cified.

Sub-throttle position sensorresistance

0 6 kΩ at 20C (68F)(black/blue – green/yellow)

7-44

THROTTLE BODIES FI

2. Adjust:sub-throttle position sensor full open angle

a. Turn the nut 1 of the worm shaft of the sub-throttle counterclockwise until it contactswith the full open stopper.

b. When the dimension of a sections of thethrottle bodies #3 and #4 is measured with amicrometer caliper, adjust with the adjuster2 of the output shaft section of the sub-throttle servo motor so that the dimension isin a range from 24.2 to 24.6 mm (0.95 to 0.97in).

A Front sideB Rear side

Sub-throttle dimension a24.2 24.6 mm (0.95 0.97 in)

c. After adjusting the dimension of a sectionsof the throttle bodies #3 and #4, measure thedimension of a sections of #1 and #2.

d. If the dimension of a sections of the throttlebodies #1 and #2 is different from the dimen-sion of a sections of the throttle bodies #3and #4, adjust it to the same dimension asthe measurement value adjusted for thethrottle bodies #3 and #4, using the tuningscrew 3 located between the throttle bodies#2 and #3.

3. Adjust:primary opening

a. After performing the full open angle of thesub-throttle position sensor, turn the nut ofthe worm shaft clockwise, measure the di-mension of b section with a micrometer cali-per or other device and adjust so that the di-mension is in a range from 8.1 to 8.5 mm(0.32 to 0.33 in).

A Front sideB Rear side

Sub-throttle dimension b8.1 8.5 mm (0.32 0.33 in)

7-45

A

THROTTLE BODIES FI

NOTE:

NOTE:

b. After performing the step a, move the sub-throttle position sensor to adjust to be in arange from 0.97 to 1.07 V

Sub-throttle position sensorvoltage

0.97 1.07 V(green/yellow – blue)

After setting up the sub-throttle position sen-sor, check that the sub-throttle position sensoroutput voltage is 0.4 V or more with the nut ofworm shaft turned to the full close side until itstops.

When the sub-throttle position sensor outputvoltage is 0.4 V or more, check that the sub-throttle position sensor output voltage is 4.6 Vor less with the nut of worm shaft turned to thefull open side until it stops.

CHECKING AND ADJUSTING THE THERMOWAX1. Check: thermo wax 1Damege Replace the thermo wax.

2. Adjust: thermo wax the end face distance a

a. Before adjusting the distance, push the rodb in order to be fitted in several times byhand.

b. Measure the outside air temperature, andadjust the distance a by turning the adjust-ing screw 2 . Refer to the thermo wax toler-ance table based on the measured outsideair temperature for correct adjustment.

Setup tolerance of the longitudinal axis shouldbe 0.2 mm ( 0.008 in).

After adjusting the thermo wax, check that thefirst idling is released at the coolant tempera-ture around 60C (140F) by idling.

If the first idling is not released around 60C(140F), make sure to set it again. (When thecoolant temperature is low, adjust the distancebetween the end faces longer or adjust it short-er when the coolant temperature is high.)

In case of turning the adjusting bolt two-thirdturn, the temperature varies about 10C(50F).

7-46

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

7-47


A To cylinder #1 and #2B To cylinder #3 and #4

1 Air cut-off valve2 Plate3 Reed valve assembly4 Reed valve cap5 To air filter case

EAS00509

AIR INDUCTION SYSTEM DIAGRAMS

7-48


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.

7-49


5. Check:Air induction system solenoid

a. Remove the Air induction system solenoidcoupler from the wire harness.

b. Connect the pocket tester (Ω 1) to the Airinduction system solenoid terminal asshown.

Tester positive probe orange 1Tester negative probe green 2

c. Measure the Air induction system solenoidresistance.

Air induction system solenoidresistance

18 22 Ω at 20C (68F)

d. Out of specification Replace.

8-1

8

ELECTRICAL COMPONENTS ELEC

9 Oil level switch10 Radiator fan motor11 Horn12 Ignition coil

1 Main switch2 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 sensor13 Sub-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 Headlight relay (dimmer)

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 Neutral switch12 Rear brake light switch13 Fuse box

1 Main switch2 Horn switch3 Dimmer switch4 Turn signal switch5 Clutch switch

6 Sidestand switch7 Engine stop switch8 Front brake light switch9 Start switch10 Oil level 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,confirm 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

IGNITION SYSTEM ELEC

EAS00735

IGNITION SYSTEMCIRCUIT DIAGRAM

8-9


1 Main switch4 Fuse (main)6 Battery10 Starting circuit cut-off relay11 Neutral switch12 Sidestand switch14 E.C.U.15 Ignition coil #116 Ignition coil #217 Ignition coil #318 Ignition coil #419 Spark plug31 Crankshaft position sensor35 Cylinder identification sensor36 Lean angle cut-off switch53 Engine stop switch59 Clutch switch73 Fuse (ignition)

8-10

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. ignition coil resistance6. crankshaft position sensor7. main switch8. engine stop switch9. neutral switch

10. sidestand switch11. clutch switch12. starting circuit cut-off relay (diode)13. lean angle cut-off switch14. 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).

Ignition checker90890-06754

Dynamic spark testerYM-34487


EAS00738

8-11


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.

5. 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.

EAS00747

Positive tester probe ignition coil terminal

Negative tester probe ignition coil terminal

Connect the pocket tester (Ω 1k) to theignition coil as shown.

Measure the primary coil resistance.

Primary coil resistance1.19 1.61 Ω at 20C

Negative tester probe ignition coil terminal

Positive tester probe spark plug terminal

1

2

Measure the secondary coil resistance.

Secondary coil resistance8.5 11.5 kΩ at 20C

Is the ignition coil OK?

YES NO

Replace the ignitioncoil.

EAS00743

8-12


6. 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 sensorresistance.

Crankshaft position sensorresistance

336 504 Ω at 20C(between gray and black)

Is the crankshaft position sensor OK?

YES NO

Replace thecrankshaft positionsensor.

EAS00749

7. Main switch

Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the main switch OK?

YES NO

Replace the mainswitch.

EAS00748 EAS00750

8. 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

9. Neutral switch

Check the neutral switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the neutral switch OK?

YES NO

Replace the neutralswitch.

EAS00752

10. 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

11. Clutch switch

Check the clutch switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the clutch switch OK?

YES NO

Replace the clutchswitch.

8-13


12. 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 blue/yellow

Negative tester probe sky blue

1

2

EAS00753


Negative tester probe blue/black

Continuity

1

3

Positive tester probe sky blue

Negative tester probe blue/yellow

2

1

Positive tester probe blue/black


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:

13. 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.

EAS00754

14. 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 switch4 Fuse (main)6 Battery8 Starter relay9 Starter motor10 Starting circuit cut-off relay11 Neutral switch12 Sidestand switch53 Engine stop switch54 Start switch73 Fuse (ignition)

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. fuel tank3. side cowlings4. throttle body assemblyTroubleshoot 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 blue/white Negative tester probe blue/white

Does the starting circuit cut-off relay havecontinuity between blue/white 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 blue/white Negative battery terminal red/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


34


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 motorSeatFuel tankThrottle body assembly

Starter motor leadStarter motor

11

Remove the parts in the order listed.Refer to “SEAT” in chapter 3.Refer to “FUEL TANK” in chapter 3.Refer to “THROTTLE BODIES” in chapter 7.



5 Nm (0.5 mkg, 3.6 ftlb)

EAS00767

STARTER MOTOR

8-20

STARTER MOTOR ELEC


Disassembling the starter motorO-ringFront coverLock washerWasherStarter motor yokeArmature assemblyO-ringStarter motor leadBrush holderRear cover

1111112211



12345678910

5 Nm (0.5 mkg, 3.6 ftlb)

5 Nm (0.5 mkg, 3.6 ftlb)

5 Nm (0.5 mkg, 3.6 ftlb)

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 limit24.5 mm (0.96 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 undercut1.5 mm (0.06 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

0.0090 0.0110 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 limit3.6 mm (0.14 in)

6. Measure:brush spring forceOut of specification Replace the brushsprings as a set.

Brush spring force5.28 7.92 N(538 808 gf, 18.99 28.48 oz)

7. Check:gear teethDamage/wear Replace the gear.

EAS00772

ASSEMBLING THE STARTER MOTOR1. Install:brush seat 1

Align the slot a on the brush seat with the tab bin the starter motor rear cover.

2. Install:armature 1

8-23

STARTER MOTOR ELEC

5 Nm (0.5 mkg, 3.6 ftlb)

NOTE:

3. Install:starter motor yoke 1O-rings 2 Newstarter motor rear cover 3bolts

Align the match marks a on the starter motoryoke with the match marks b on the front andrear covers.

8-24

2 A.C. magneto3 Rectifier / regulator4 Fuse (main)6 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. 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 resistance0.14 0.18 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

LIGHTING SYSTEM ELEC

EAS00780

LIGHTING SYSTEMCIRCUIT DIAGRAM

8-28


1 Main switch4 Fuse (main)6 Battery14 E.C.U.46 Hi beam indicator light49 Meter light57 Dimmer switch62 Front turn signal/position light (left)63 Front turn signal/position light (right)66 Headlight67 Auxiliary light68 License plate light69 Rear brake light switch70 Tail/brake light71 Headlight relay (on/off)72 Headlight relay (dimmer)74 Fuse (signal)75 Fuse (headlight)

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?


NOTE:

YES NO

1. Main, turn and headlight fuses

Check the main, turn and headlight fuses forcontinuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main, turn and headlight fuses 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, turn and headlight fuses2. battery3. main switch4. dimmer switch5. pass switch6. headlight relay (on/off)7. headlight relay (dimmer)8. wiring connections

(of the entire lighting system)




EAS00738

8-30

Does the Headlight relay (dimmer) havecontinuity between red/yellow andblack/green ?

NOYES

Replace the dimmerrelay.

Positive tester probe red/yellow Negative tester probe black/green

12

34

5. Headlight relay (on/off)

Disconnect the headlight relay (on/off) fromthe coupler.

Connect the pocket tester (Ω 1) and bat-tery (12 V) to the headlight relay (on/off) asshown.

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”.

Does the headlight relay (dimmer) havecontinuity between black/green andblack/yellow ?

Positive tester probe black/green Negative tester probe black/yellow

12

34

6. Headlight relay (dimmer)

Disconnect the headlight relay (dimmer)from the coupler.

Connect the pocket tester (Ω 1) and bat-tery (12 V) to the headlight relay (dimmer) asshown.

Positive battery lead black Negative battery lead yellow

34

34

YES NO

Replace the head-light relay (dimmer).


8-31

High beam indicator light (LEDs)Positive tester probe black/ 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

6

5

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/red Negative tester probe black

12

Turn the main switch to “ON”.Measure the voltage (DC 12 V) of blue/red

on the license plate light coupler (wireharness side).


1

This circuit is OK.

EAS00790

3. The tail /brake light fails to come on.

YES NO

1. 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 blue/redNegative tester probe black

12


on the tail /brake light coupler (wire har-ness side).


1

This circuit is OK.

8-33


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 blue/redNegative tester probe black 1


on the auxiliary light coupler (auxiliarylight side).


2

This circuit is OK.

2

5. The turn signal/position light fails to come on.

YES NO

1. Turn signal/position light and socket

Check the turn signal/position light bulb andsocket for continuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the turn signal/position light bulb andsocket OK?

Replace the turn sig-nal/position lightbulb, socket or both.

YES NO

2. Voltage

Connect the pocket tester (DC 20 V) to theturn signal/position light coupler (wire har-ness side) as shown.

The wiring circuit fromthe main switch to theturn signal/positionlight coupler is faultyand must be repaired.

Turn the main switch to “ON”.Measure the voltage (DC 12 V) of blue orblue on the turn signal/position light cou-pler (wire harness side).


3

This circuit is OK.

Left turn signal/position lightPositive tester probe blue Negative tester probe black

Right turn signal/position lightPositive tester probe blueNegative tester probe black

12

A

Left turn signal/position lightRight turn signal/position light

B

AB

34

1

8-34

SIGNALING SYSTEM ELEC

EAS00793

SIGNALING SYSTEMCIRCUIT DIAGRAM

8-35


1 Main switch4 Fuse (main)6 Battery10 Starting circuit cut-off relay11 Neutral switch13 Fuel pump14 E.C.U.27 Speed sensor38 Fuel level warning light39 Oil level warning light40 Neutral indicator light41 Tachometer42 Shift timing indicator light43 Multi function meter45 Coolant temperature indicator light47 Turn signal indicator light (left)48 Turn signal indicator light (light)55 Turn signal relay58 Horn switch60 Turn signal switch61 Horn62 Front turn signal /position light (left)63 Front turn signal /position light (right)64 Rear turn signal light (left)65 Rear turn signal light (right)73 Fuse (ignition)74 Fuse (signal)

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.

Positive tester probe yellow Negative tester probe black

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).


1

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.

Positive tester probe black/whiteNegative tester probe ground

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/position light, turn signal in-dicator light 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.

Positive tester probe brownNegative tester probe ground

1

Turn the main switch to “ON”.Measure the voltage (DC 12 V) on brown at the turn signal relay coupler (wire harnessside).


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 brown/whiteNegative tester probe ground

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

NO

8-39


C

YES NO

The wiring circuitfrom the turn signalswitch to the turn sig-nal light connector isfaulty and must berepaired.

Left turn signal/position lightPositive tester probe chocolateNegative tester probe ground

Right turn signal/position lightPositive tester probe dark greenNegative tester probe ground

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

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




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

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

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.

Positive tester probe brown Negative tester probe ground

1

Turn the main switch to “ON”.Measure the voltage (DC 12 V) of brown at 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

When you switch the positive and negativetester probes, the readings in the abovechart will be reversed.

NOTE:

1

8-41


3. Voltage


Positive tester probe black/redNegative tester probe black/white

12

Turn the main switch to “ON”.Measure the voltage (DC 12V) of black/red and black/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.

Positive tester probe green/whiteNegative tester 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

Replace the multi-function meter.

NO

1. Multi-function meter bulb socket

Check the multi-function meter bulb socketfor continuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Is the multi-function meter bulb socket OK?

YES

EAS00806

7. The speedometer fails to come on.

2. Speed sensor

Connect the pocket tester (DC 20 V) to thespeed sensor coupler (wire harness side)as shown.

Replace the speedsensor.

NOYES

Positive tester probe white/yellow Negative tester probe black/blue

12

Set the main switch to “ON”.Elevate the rear wheel and slowly rotate it.Measure the voltage (DC 5 V) of white/yel-low and blue. With each full rotation of therear wheel, the voltage reading should cyclefrom 0.6 V to 4.8 V to 0.6 V to 4.8 V.

Does the voltage reading cycle correctly?

This circuit is OK.

8-43

COOLING SYSTEM ELEC

EAS00807

COOLING SYSTEMCIRCUIT DIAGRAM

8-44

1 Main switch4 Fuse (main)6 Battery14 E.C.U.28 Coolant temperature sensor73 Fuse (ignition)76 Radiator fan motor relay77 Fuse (radiator fan motor left)78 Fuse (radiator fan motor right)79 Radiator fan motor 280 Radiator fan motor 1

COOLING SYSTEM ELEC

8-45

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

8-46

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 relay.

NOYES

Battery positive terminal red/white Battery negative terminal

green/yellow

1

2

Does the radiator fan motor relay have conti-nuity between red and brown/green?

Tester positive probe red Tester negative probe brown/green

34

COOLING SYSTEM ELEC

EAS00809

8-47

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

8-48

1 Main switch4 Fuse (main)6 Battery7 Fuse (fuel injection)10 Starting circuit cut-off relay13 Fuel pump14 E.C.U.53 Engine stop switch

FUEL PUMP SYSTEM ELEC

EAS00814

FUEL PUMP SYSTEMCIRCUIT DIAGRAM

8-49


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.

8-50


YES NO

2. Battery



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)




EAS00738

8-51


YES NO

5. Starting circuit cut-off relay (fuel injectionsystem relay)


Connect the pocket tester (Ω 1) and bat-tery (12 V) 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

8-52


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. Insert the plug 1 to fuel return hose end.b. Fill the fuel tank.c. Put the end of the fuel hose into an open con-

tainer.d. Connect the battery (DC 12 V) to the fuel

pump coupler as shown.

Positive battery lead red/blue 2Negative battery lead black 3

e. If fuel flows out of the fuel hose, the fuel pumpis OK. If fuel does not flow, replace the fuelpump.

8-53

SELF-DIAGNOSIS ELEC

SELF-DIAGNOSISThe YZF-R1(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 level warning light indi-cate the condition code.

Refer to *1

Oil level switch Open-circuitShort-circuit

The oil level warning light indicatethe condition code.

Refer to *2

*1 Condition codeFuel level warning light

*2 Condition codeOil level warning light

8-54

SELF-DIAGNOSIS ELEC

L/B B

Lg

B

BG/W

BR/L

Y/L

Y/B

R/G

Sb/

W

W

G/W

G/W

R/L

B

R/W

Lg

LgB

Sb/W

Sb/

WA

BrBrA

R/GR/GB

B/RB/RB Y/B Y/B B

Y/L Y/L BG/WG/WA

G

Y

14

3839

40

41

42

43

44

45

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 warning light fails tocome on”.

Is the fuel pump thermistor OK?

YES



NOTE:

14 Fuel pump45 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. fuel tankTroubleshoot with the following specialtool(-s).


1. Fuel pump thermistorCIRCUIT DIAGRAM

8-55

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


B/WWW

Y/L

Y/B

R/G

Sb/

W

W

W

G/W

R/W Sb/W

Sb/

WA

BrBrA

R/GR/GB

B/RB/RB Y/B Y/B B

Y/L Y/L

Dg

Ch

BG/WG/WA

B/W B/W

G

Y

B

40

41

42

43

44

45

46

47

48

49

50

51

52

45 Multi-function meter52 Oil level switch

2. Oil level switchCIRCUIT DIAGRAM

9-1

STARTING FAILURESTRBLSHTG

NOTE:

FUEL SYSTEMFuel tankEmpty fuel tankClogged fuel filterClogged fuel strainerClogged 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

Ignition 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 gasketDamaged cylinder 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

Air filter Improperly installed air filterClogged air filter element

Crankcase and crankshaft Improperly assembled crankcaseSeized crankshaft

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 insulator

9-2

9

Starting systemFaulty starter motorFaulty starter relayFaulty starting circuit cut-off relayFaulty starter clutch

STARTING FAILURES/INCORRECT ENGINE IDLING SPEED/POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

TRBLSHTG

ELECTRICAL SYSTEMSBatteryDischarged batteryFaulty battery

Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat rangeFouled spark plugWorn or damaged electrodeWorn or damaged insulator

Ignition coil(s)Broken or shorted primary or secondarycoils

Cracked or broken ignition coilIgnition 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 (idleadjusting screw)

Improper throttle cable free playFlooded throttle bodyFaulty air induction system

EAS00848

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 pull rodBroken 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

EAS00851

FAULTY CLUTCHCLUTCH SLIPSClutch Improperly assembled clutch Improperly adjusted clutch cableLoose or fatigued clutch springWorn friction plateWorn clutch plate

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 throttle body 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 E.C.U.

Loose union boltDamaged brake hoseOil or grease on the brake discOil or grease on the brake pad Incorrect brake fluid level

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 seal

9-5

FAULTY FRONT FORK LEGS/UNSTABLE HANDLINGTRBLSHTG

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

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 washer

Cracked or damaged cap bolt O-ring

EAS00863

UNSTABLE HANDLINGHandlebarsBent or improperly installed right handlebarBent or improperly installed left handlebar

Steering head components Improperly installed upper bracket Improperly installed under 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 ONToo many electrical accessories Incorrect connection

TAIL/BRAKE LIGHT BULB BURNT OUTFaulty battery Incorrectly adjusted rear brake light switch

59 Clutch switch60 Turn signal switch61 Horn62 Front turn signal /position light (left)63 Front turn signal /position light (right)64 Rear turn signal light (left)65 Rear turn signal light (right)66 Headlight67 Auxiliary light68 License plate light69 Rear brake light switch70 Tail /brake light71 Headlight relay (on/off)72 Headlight relay (dimmer)73 Fuse (ignition)74 Fuse (signal)75 Fuse (headlight)76 Radiator fan motor relay77 Fuse (radiator fan motor left)78 Fuse (radiator fan motor light)79 Radiator fan motor 280 Radiator fan motor 181 Ground

COLOR CODE

B Black. . . . . Br Brown. . . . Ch Chocolate. . . Dg Dark green. . . G Green. . . . Gy Gray. . . L Blue. . . . . Lg Light green. . . . O Orange. . . . 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/G Brown/Green. Br/L Brown/Blue. . Br/R Brown/Red. . Br/W Brown/White. G/B Green/Black. . G/R Green/Red. . G/W Green/White. .

G/Y Green/Yellow. . Gy/B Gray/Black. Gy/G Gray/Green. Gy/R Gray/Red. L/B Blue/Black. . . L/R Blue/Red. . L/W Blue/White. . L/Y Blue/Yellow. . . O/B Orange/Black. . O/G Orange/Green. . P/W Pink/White. . R/B Red/Black. . R/G Red/Green. . R/L Red/Blue. . R/W Red/White. . R/Y Red/Yellow. . Sb/W Sky blue/White. W/B White/Black. . W/R White/Red. . W/Y White/Yellow. . Y/B Yellow/Black. . Y/G Yellow/Green. . Y/L Yellow/Blue. . . Y/R Yellow/Red. . Y/W Yellow/White. .

YZF-R1S/YZF-R1SC WIRING DIAGRAM1 Main switch2 A.C. magneto3 Rectifier / regulator4 Fuse (main)5 Fuse (backup)6 Battery7 Fuse (fuel injection)8 Starter relay9 Starter motor10 Starting circuit cut-off relay11 Neutral switch12 Sidestand switch13 Fuel pump14 E.C.U15 Ignition coil #116 Ignition coil #217 Ignition coil #318 Ignition coil #419 Spark plug20 Injector #121 Injector #222 Injector #323 Injector #424 Air induction system solenoid25 Sub-throttle position sensor26 EXUP servo motor27 Speed sensor28 Coolant temperature sensor29 Intake air temperature sensor30 Option switch31 Crankshaft position sensor32 Throttle position sensor33 Intake air pressure sensor34 Atmospheric pressure sensor35 Cylinder identification sensor36 Lean angle cut-off switch37 Meter assembly38 Fuel level warning light39 Oil level warning light40 Neutral indicator light41 Tacho meter42 Shift timing indicator light43 Multi function meter44 Engine trouble warning light45 Coolant temperature indicator light46 Hi beam indicator light47 Turn signal indicator light (left)48 Turn signal indicator light (light)49 Meter light50 Oil level switch51 Right handlebar switch52 Front brake light switch53 Engine stop switch54 Start switch55 Turn signal relay56 Left handlebar switch57 Dimmer switch58 Horn switch

yamaha yzf r1 2004 service manual lit 11616 17 55 5 vy 28197 10

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