yamaha r6 2003 workshop manual

EAS00010

YZF-R6R/YZF-R6SRYZF-R6RC/YZF-R6SRC

SERVICE MANUAL2002 by Yamaha Motor

Corporation, U.S.A.First edition, December 2002

All rights reserved. Any reproductionor unauthorized use without the writtenpermission of Yamaha Motor Corporation,

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

P/N LIT-11616-16-45

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

1413

11 12

10

GENINFO SPEC

ENG

FI ELEC

COOL

CHKADJ

TRBLSHTG

CHAS

EAS00008

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

EAS00012

TABLE OF CONTENTS

CHAPTER 1GENERAL INFORMATION

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

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

IMPORTANT INFORMATION 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL AND DISASSEMBLY 1-7. . . . . . . . . REPLACEMENT PARTS 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS 1-7. . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS 1-8. . . . . . . . . . . . . . BEARINGS AND OIL SEALS 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE CONNECTIONS 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 2-22. . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 2-24. . . . . . . . . . . . . . . ENGINE 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM DIAGRAMS 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OIL LUBRICATION CHART 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION DIAGRAMS 2-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 2-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 3PERIODIC CHECKS AND ADJUSTMENTS

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

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR FILTER CASE 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE VALVE CLEARANCE 3-10. . . . . . . . . . . . . . . . . . . . . . SYNCHRONIZING THE THROTTLE BODIES 3-16. . . . . . . . . . . . . . . . . ADJUSTING THE ENGINE IDLING SPEED 3-18. . . . . . . . . . . . . . . . . . . ADJUSTING THE THROTTLE CABLE FREE PLAY 3-19. . . . . . . . . . . . CHECKING THE SPARK PLUGS 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE COMPRESSION PRESSURE 3-22. . . . . . . . . . . . . . CHECKING THE ENGINE OIL LEVEL 3-24. . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE ENGINE OIL 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE ENGINE OIL PRESSURE 3-27. . . . . . . . . . . . . . . . . ADJUSTING THE CLUTCH CABLE FREE PLAY 3-29. . . . . . . . . . . . . . . CLEANING THE AIR FILTER ELEMENT 3-30. . . . . . . . . . . . . . . . . . . . . . CLEANING THE AIR INTAKE SYSTEM SURGE TANKS 3-31. . . . . . . . CHECKING THE THROTTLE BODY JOINTS 3-31. . . . . . . . . . . . . . . . . . CHECKING THE FUEL AND BREATHER HOSES 3-32. . . . . . . . . . . . . CHECKING THE CRANKCASE BREATHER HOSE 3-32. . . . . . . . . . . . CHECKING THE EXHAUST SYSTEM 3-33. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLANT LEVEL 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLING SYSTEM 3-34. . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE COOLANT 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE 3-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE FLUID LEVEL 3-41. . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-42. . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE PADS 3-43. . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE HOSES 3-43. . . . . . . . . BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-44. . . . . . . . . . . . . . . ADJUSTING THE SHIFT PEDAL 3-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE DRIVE CHAIN SLACK 3-46. . . . . . . . . . . . . . . . . . . . . LUBRICATING THE DRIVE CHAIN 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE STEERING HEAD 3-48. . . . . . . . . CHECKING THE FRONT FORK 3-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT FORK LEGS 3-51. . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-53. . . . . CHECKING THE TIRES 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WHEELS 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND LUBRICATING THE CABLES 3-58. . . . . . . . . . . . . . . LUBRICATING THE LEVERS AND PEDALS 3-58. . . . . . . . . . . . . . . . . . LUBRICATING THE SIDESTAND 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE REAR SUSPENSION 3-58. . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM 3-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY 3-59. . . . . . . . . . . . . . . . . CHECKING THE FUSES 3-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULBS 3-66. . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAMS 3-67. . . . . . . . . . . . . . . . . . . . . .

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 4-15. . . . . . . . . . .

FRONT AND REAR BRAKES 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE PADS 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FRONT BRAKE PADS 4-18. . . . . . . . . . . . . . . . . . . . . REPLACING THE REAR BRAKE PADS 4-21. . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER 4-23. . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE MASTER CYLINDER 4-26. . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4-28. . DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-28. . . . CHECKING THE FRONT AND REAR BRAKE MASTER

CYLINDERS 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER

CYLINDER 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-32. . . . . . . FRONT BRAKE CALIPERS 4-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE CALIPER 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE CALIPERS 4-38. . . . . . . . . . . DISASSEMBLING THE REAR BRAKE CALIPER 4-39. . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE CALIPERS 4-40. . . . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE

CALIPERS 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 4-43.

FRONT FORK 4-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK LEGS 4-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT FORK LEGS 4-48. . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT FORK LEGS 4-49. . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK LEGS 4-50. . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FRONT FORK LEGS 4-51. . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT FORK LEGS 4-56. . . . . . . . . . . . . . . . . . . . . .

HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE HANDLEBARS 4-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HANDLEBARS 4-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE HANDLEBARS 4-60. . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING HEAD 4-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDER BRACKET 4-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE UNDER BRACKET 4-65. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING HEAD 4-65. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STEERING HEAD 4-66. . . . . . . . . . . . . . . . . . . . . . . . .

REAR SHOCK ABSORBER ASSEMBLY 4-68. . . . . . . . . . . . . . . . . . . . . . . . HANDLING THE REAR SHOCK ABSORBER AND GAS

CYLINDER 4-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPOSING OF A REAR SHOCK ABSORBER AND GAS

CYLINDER 4-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4-71. . . . . CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND

GAS CYLINDER 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONNECTING ROD AND RELAY ARMS 4-72. . . . . . INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-72. . . . .

SWINGARM AND DRIVE CHAIN 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE SWINGARM 4-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE DRIVE CHAIN 4-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWINGARM 4-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE DRIVE CHAIN 4-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SWINGARM 4-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 5OVERHAULING THE ENGINE

ENGINE 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SPROCKET 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST PIPE 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEADS AND HOSES 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE ENGINE 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFTS 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD COVER 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFTS 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CAMSHAFTS 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CAMSHAFTS 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,

AND TIMING CHAIN GUIDES 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN TENSIONER 5-13. . . . . . . . . . . . . . . . INSTALLING THE CAMSHAFTS 5-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD 5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CYLINDER HEAD 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CYLINDER HEAD 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CYLINDER HEAD 5-20. . . . . . . . . . . . . . . . . . . . . . . . .

VALVES AND VALVE SPRINGS 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE VALVES 5-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVES AND VALVE GUIDES 5-24. . . . . . . . . . . . . . . CHECKING THE VALVE SEATS 5-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE SPRINGS 5-28. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE LIFTERS 5-29. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE VALVES 5-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER CLUTCH AND GENERATOR 5-31. . . . . . . . . . . . . . . . . . . . . . . . . STATOR COIL ASSEMBLY 5-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE GENERATOR 5-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE STARTER CLUTCH 5-34. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER CLUTCH 5-35. . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STARTER CLUTCH 5-35. . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE GENERATOR 5-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHIFT SHAFT 5-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT SHAFT AND STOPPER LEVER 5-38. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT SHAFT 5-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STOPPER LEVER 5-40. . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SHIFT SHAFT 5-40. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR 5-41. . . . . . . REMOVING THE PICKUP ROTOR 5-43. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE PICKUP ROTOR 5-43. . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH COVER 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CLUTCH 5-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRICTION PLATES 5-48. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PLATES 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH SPRINGS 5-49. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH HOUSING 5-50. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH BOSS 5-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRESSURE PLATE 5-50. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PULL LEVER SHAFT AND PULL ROD 5-51. . . . . . . INSTALLING THE CLUTCH 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PAN AND OIL PUMP 5-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE OIL PAN 5-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL PUMP 5-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RELIEF VALVE 5-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 5-58. . . . . . . . . CHECKING THE OIL STRAINER 5-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL NOZZLES 5-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE OIL PUMP 5-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PUMP 5-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL STRAINER 5-60. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PAN 5-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKCASE 5-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CRANKCASE 5-63. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKCASE 5-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BEARINGS AND OIL SEALS 5-64. . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN 5-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CRANKCASE 5-64. . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING RODS AND PISTONS 5-66. . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CONNECTING RODS AND PISTONS 5-67. . . . . . . . REMOVING THE CRANKSHAFT ASSEMBLY 5-68. . . . . . . . . . . . . . . . . CHECKING THE CYLINDER AND PISTON 5-68. . . . . . . . . . . . . . . . . . . CHECKING THE PISTON RINGS 5-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PISTON PINS 5-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BIG END BEARINGS 5-71. . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CONNECTING ROD AND PISTON 5-74. . . . . . . . . .

CRANKSHAFT 5-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT 5-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT JOURNAL BEARINGS 5-79. . . . . . . . INSTALLING THE CRANKSHAFT 5-82. . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION 5-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT

FORKS 5-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE TRANSMISSION 5-89. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT FORKS 5-89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT DRUM ASSEMBLY 5-90. . . . . . . . . . . . . . . . . . . CHECKING THE TRANSMISSION 5-90. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE TRANSMISSION 5-91. . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 6COOLING SYSTEM

RADIATOR 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RADIATOR 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE RADIATOR 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL COOLER 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL COOLER 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL COOLER 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THERMOSTAT 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE THERMOSTAT 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE THERMOSTAT 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE WATER PUMP 6-12. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WATER PUMP 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE WATER PUMP 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE WATER PUMP 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 7FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECU’S SELF-DIAGNOSTIC FUNCTION 7-3. . . . . . . . . . . . . . . . . . . . . . ALTERNATE INSTRUCTIONS OPERATION CONTROL

(FAIL-SAFE ACTION) 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAIL-SAFE ACTIONS TABLE 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING CHART 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSTIC MODE 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING DETAILS 7-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THROTTLE BODIES 7-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE INJECTOR 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE THROTTLE BODY 7-31. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRESSURE REGULATOR 7-32. . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP AND PRESSURE REGULATOR

OPERATION 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE THROTTLE POSITION

SENSOR 7-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INDUCTION SYSTEM 7-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INJECTION 7-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CUT-OFF VALVE 7-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM DIAGRAMS 7-36. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE AIR INDUCTION SYSTEM 7-37. . . . . . . . . . . . . . . . . .

CHAPTER 8ELECTRICAL

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 8-6. . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULB SOCKETS 8-7. . . . . . . CHECKING THE LEDs 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION SYSTEM 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC STARTING SYSTEM 8-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 8-15. . . . . . . . . TROUBLESHOOTING 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER MOTOR 8-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER MOTOR 8-21. . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE STARTER MOTOR 8-22. . . . . . . . . . . . . . . . . . . . . .

CHARGING SYSTEM 8-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 8-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE LIGHTING SYSTEM 8-30. . . . . . . . . . . . . . . . . . . . . . . .

SIGNALING SYSTEM 8-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SIGNALING SYSTEM 8-35. . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM 8-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL PUMP SYSTEM 8-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP SYSTEM 8-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP 8-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SELF-DIAGNOSIS 8-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

FEATURESGENINFO

8 Intake air pressuresensor

9 Throttle position sen-sor

10 Fuel injector11 Catalytic converter12 Crankshaft position

sensor13 Coolant temperature

sensor

14 Spark plug15 Cylinder identification

sensor16 Pressure regulator17 Battery18 ECU19 Atmospheric pressure

sensor20 Fuel injection system

relay

21 Engine trouble warn-ing light

22 Lean angle cut-offswitch

23 Air cut-off valve

1 Ignition coil2 Air filter case3 Intake temperature

sensor4 Fuel delivery hose5 Fuel tank6 Fuel pump7 Fuel return hose

EAS00896

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

1-3

FEATURESGENINFO

Illustration is for reference only.



8 ECU9 Atmospheric pressure

sensor

10 Coolant temperaturesensor

11 Cylinder identificationsensor

12 Crankshaft positionsensor

A Fuel systemB Air systemC Control system

1 Fuel pump2 Pressure regulator3 Fuel injector4 Throttle body5 Intake temperature

sensor

EAS00897

FI SYSTEMThe fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuelpressure that is applied to the injector at only 284 kPa (2.84 kg/cm2) higher than the intake manifoldpressure. Accordingly, when the energizing signal from the ECU energizes the injector, the fuel pas-sage opens, causing the fuel to be injected into the intake manifold only during the time the passageremains open. Therefore, the longer the length of time the injector is energized (injection duration), thegreater the volume of fuel that is supplied. Conversely, the shorter the length of time the injector is ener-gized (injection duration), the lesser the volume of fuel that is supplied.

The injection duration and the injection timing are controlled by the ECU. Signals that are input from thethrottle position sensor, crankshaft position sensor, intake air pressure sensor, atmospheric pressuresensor, intake temperature sensor and coolant temperature sensor enable the ECU to determine theinjection duration. The injection timing is determined through the signals from the crankshaft positionsensor and the cylinder identification sensor. As a result, the volume of fuel that is required by the en-gine can be supplied at all times in accordance with the driving conditions.

1-4

FEATURESGENINFO

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

NOTE:

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

an odometer (which shows the total distancetraveled)

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

a fuel reserve tripmeter (which shows thedistance traveled since the fuel level warninglight came on)

a clocka self-diagnosis devicea display brightness and engine speed warn-ing light control mode

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

Odometer and tripmeter modesPushing the “SELECT” button switches the display between the odometer mode “ODO” and the trip-meter modes “TRIP 1” and “TRIP 2” in the following order:ODO TRIP 1 TRIP 2 ODOIf the fuel level warning light comes on, the odometer display will automatically change to the fuel re-serve tripmeter mode “F-TRIP” and start counting the distance traveled from that point. In that case,pushing the “SELECT” button switches the display between the various tripmeter and odometermodes in the following order:F-TRIP TRIP 1 TRIP 2 ODO F-TRIPTo reset a tripmeter, select it by pushing the “SELECT” button, and then push the “RESET” button for atleast one second. If you do not reset the fuel reserve tripmeter manually, it will reset itself automaticallyand the display will return to the prior mode after refueling and traveling 5 km (3.1 mi).Clock modeTurn the key to “ON”.To change the display to the clock mode, push the “SELECT” button for at least one second.To change the display back to the prior mode, push the “SELECT” button.To set the clock:1. Push the “SELECT” button and “RESET” button together for at least two seconds.2. When the hour digits start flashing, push the “RESET” button to set the hours.3. Push the “SELECT” button, and the minute digits will start flashing.4. Push the “RESET” button to set the minutes.5. Push the “SELECT” button and then release it to start the clock.

1-5

FEATURESGENINFO

1 Shift timing indicator light2 “SELECT” button3 “RESET” button

NOTE:

Display brightness and shift timing indica-tor light control modeThis mode cycles through five control functions,allowing you to make the following settings inthe order listed below.1. Display brightness: This function allows you

to adjust the brightness of the multi-functiondisplay to suit the outside lighting conditions.

2. Shift timing indicator light activity: This func-tion allows you to choose whether or not theindicator light should be activated andwhether it should blink or stay on when acti-vated.

3. Shift timing indicator light activation: Thisfunction allows you to select the shift timingat which the indicator light will be activated.

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

5. Shift timing indicator light brightness: This function allows you to adjust the brightness of the indica-tor 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 engine is started before completing the procedure, only the settings made beforethe “SELECT” button was last pushed will be applied.

In this mode, the multi-function display shows the current setting for each function (except the shifttiming indicator light activity function).

To adjust the display brightness1. Turn the key to “OFF”.2. Push and hold the “SELECT” button.3. Turn the key to “ON”, and then, after five seconds, release the “SELECT” button.4. Push the “RESET” button to select the desired display brightness level.5. Push the “SELECT” button to confirm the selected display 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:a. The indicator light will stay on when activated. (This setting is selected when the indicator light stays

on.)b. The indicator light will flash when activated. (This setting is selected when the indicator light flashes

four times per second.)c. The indicator light is deactivated; in other words, it will not come on or flash. (This setting is selected

when the indicator light flashes once every two seconds.)2. Push the “SELECT” button to confirm the selected indicator light activity. The control mode changes

to the shift timing indicator light activation function.

1-6

FEATURESGENINFO

NOTE:

NOTE:

To set the shift timing indicator light activation function

The indicator light activation function can be set between 10,000 and 16,000 r/min.From 10,000 r/min to 12,000 r/min, the indicatar light can be set in increments of 500 r/min.From 12,000 r/min to 16,000 r/min, the indicatar light can be set in increments of 200 r/min.

1. Push the “RESET” button to select the desired engine speed for activating the indicator light.2. 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 indicator light deactivation function can be set between 7,000 and 12,000 r/min in increments of500 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 multi-function

display will return to the odometer, tripmeter or clock mode.

1-7

springlip

oilgrease

lip

IMPORTANT INFORMATIONGENINFO

EAS00020

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

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

equipment.Refer to the “SPECIAL TOOLS”.

3. When disassembling, always keep 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.

1-8

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

1-9

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.

1-10

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

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

Flywheel pullerAdapter

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

90890-01701YS-01880-A

Sheave holder

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

90890-01304YU-01304

Piston pin puller

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

Radiator cap testerAdapter

These tools are used to check the coolingsystem.

90890-01403YU-33975

Steering nut wrench

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

90890-01473

Damper rod holder

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

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

Pivot shaft wrenchPivot shaft wrench adapter

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

1-11



90890-01426YU-38411

Oil filter wrench

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

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

Rod pullerRod puller attachment

These tools are used to pull up the front forkdamper rod.

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

Fork seal driver weightFork seal driver attachment

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

Vacuum gauge90890-03094YU-08030

Vacuum gauge

This gauge is used to synchronize the carbu-retors.

Compressiongauge90890-03081YU-33223Adapter90890-04136

Compression gaugeAdapter

These tools are used to measure enginecompression.

90890-03112YU-3112

Pocket tester

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

Oil pressure gauge90890-03153YU-03153Adapter90890-03139

Oil pressure gaugeAdapter

These tools are used to measure engine oilpressure.

90890-03174

Digital circuit tester

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

90890-03176YM-03176

Fuel pressure adapter

This tool is needed to measure fuel pressure.

90890-03153YU-03153

Pressure gauge

This tool used is to measure fuel pressure.

1-12



90890-04044YM-04044

Piston ring compressor

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

90890-03158

Carburetor angle driver

This tool is used to turn the pilot screw whenadjusting the engine idling speed.

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

Valve spring compressorAttachment

These tools are used to remove or install thevalve 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 water pumpseal.

90890-04086YM-91042

Clutch holding tool

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

90890-04101

Valve lapper

This tool is needed to remove and installthe valve lifter.

90890-04111

Valve guide remover (φ4)

This tool is used to remove or install the valveguides.

90890-04112

Valve guide installer (φ4)

This tool is used to install the valve guides.

90890-04113YM-04113

Valve guide reamer (φ4)

This tool is used to rebore the new valveguides.

90890-06754YM-34487

Ignition checker

This tool is used to check the ignition systemcomponents.

1-13



90890-06756YB-35956

Vacuum/pressure pump gauge set

This tool used to measure the vacuum pres-sure.

90890-85505ACC-11001-05-01

Yamaha bond No. 1215

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

2-1

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code 5SL3 (USA except for CAL)5SL4 (CAL)5SL7 (USA except for CAL)5SL8 (CAL)

DimensionsOverall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

2,025 mm (79.7 in)690 mm (27.2 in)1,090 mm (42.9 in)820 mm (32.3 in)1,380 mm (54.3 in)135 mm (5.3 in)3,400 mm (133.9 in)

WeightWet (with oil and a full fuel tank)

Maximum load (except motorcycle)

182 kg (401 lb) (USA except for CAL)183 kg (404 lb) (CAL)193 kg (426 lb) (USA except for CAL)192 kg (423 lb) (CAL)

2-2

2

ENGINE SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

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

Liquid-cooled, 4-stroke, DOHC600 cm3 (36.61 cu.in)Forward-inclined parallel 4-cylinder65.5 44.5 mm (2.58 1.75 in)12.4 : 11,250 1,350 r/min24 kPa (180 mmHg, 7.0872inHg)

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

FuelRecommended fuelFuel tank capacityTotal (including reserve)Reserve only

Premium unleaded gasoline only

17 L (3.74 Imp gal, 4.49 US gal)3.5 L (0.77 Imp gal, 0.92 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) orSAE 20W40 type SE motor oil

At 15C (60F) or lowerYamalube 4 (10W30) orSAE 10W30 type SE motor oil

3.4 L (2.99 Imp qt, 3.59 US qt)2.4 L (2.11 Imp qt, 2.54 US qt)

2.6 L (2.29 Imp qt, 2.75 US qt)240 kPa at 6,600 r/min(2.4 kg/cm2 at 6,600 r/min)(2.4 bar at 6,600 r/min)(34.1 psi at 6,600 r/min)96C (205F)450 550 kPa (4.5 5.5 kg/cm2, 4.5 5.5 bar, 65.3 79.8 psi)

2-3


Item Standard Limit

Oil filterOil filter typeBypass valve opening pressure

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

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

Trochoid0.03 0.09 mm(0.0012 0.0035 in)0.03 0.08 mm(0.0012 0.0031 in)

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

Cooling systemRadiator capacityRadiator cap opening pressure

Radiator coreWidthHeightDepth

Coolant reservoirCapacity

Water pumpWater pump typeReduction ratioMax. impeller shaft tilt

2.15 L (1.89 Imp qt, 2.27 US qt)110 140 kPa (1.1 1.4 kg/cm2,1.1 1.4 bar, 16.0 20.3 psi)

320 mm (12.6 in)258 mm (10.2 in)24 mm (0.94 in)

0.44 L (0.39 Imp qt, 0.47 US qt)

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

0.15 mm(0.006 in)

Starting system type Electric starter

Electric fuel injectionTypeManufacturer

INP-250/4NIPPON INJECTOR

Spark plugsModel (manufacturer) quantitySpark plug gap

CR9EK or CR10EK (NGK) 40.6 0.7 mm (0.0236 0.0276 in)

Cylinder headVolumeMax. warpage

10.3 10.9 cm3 (0.63 0.67 cu.in)

0.05 mm(0.002 in)

2-4


Item Standard Limit

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

Measurement A

Measurement B

Exhaust camshaft lobe dimensions

Measurement A

Measurement B

Max. camshaft runout

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

33.45 33.55 mm (1.317 1.321 in)

25.12 25.22 mm (0.989 0.993 in)

32.55 32.65 mm (1.282 1.285 in)

25.07 25.17 mm (0.987 0.991 in)

0.08 mm(0.0031 in)

33.40 mm(1.315 in)25.07 mm(0.987 in)

32.50 mm(1.280 in)25.02 mm(0.985 in)0.06 mm(0.0024 in)

2-5


Head Diameter Face Width Seat Width Margin Thickness

Item Standard Limit

Timing chainModel/number of linksTensioning system

RH2015/120Automatic

Valves, valve seats, valve guidesValve clearance (cold)

IntakeExhaust

Valve dimensions

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

Valve head diameter AIntakeExhaust

Valve face width BIntakeExhaust

Valve seat width CIntakeExhaust

Valve margin thickness DIntakeExhaust

Valve stem diameterIntake

Exhaust

Valve guide inside diameterIntake

Exhaust

Valve-stem-to-valve-guide clearanceIntake

Exhaust

Valve stem runout

Valve seat widthIntakeExhaust

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

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

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

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

3.975 3.990 mm (0.1565 0.1571 in)

3.960 3.975 mm (0.1559 0.1565 in)

4.000 4.012 mm (0.1575 0.1580 in)

4.000 4.012 mm (0.1575 0.1580 in)

0.010 0.037 mm (0.0004 0.0015 in)

0.025 0.052 mm (0.0010 0.0020 in)

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

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

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

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

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

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

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

2-6


Item Standard Limit

Valve springsFree lengthIntake (inner)Intake (outer)Exhaust

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

Compressed spring force(installed)Intake (inner)

(outer)

Exhaust

Spring tilt

Intake (inner)

Intake (outer)

Exhaust

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

35.7 mm (1.41 in)40.3 mm (1.59 in)41.7 mm (1.64 in)

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

61.5 70.7 N (6.27 7.21 kg, 13.83 15.89 lb)139.1 160.1 N (14.18 16.33 kg,31.27 35.99 lb)160 184 N (16.32 18.76 kg, 35.97 41.36 lb)

Counter clockwiseClockwiseClockwise

33.9 mm (1.33 in)38.3 mm (1.50 in)39.6 mm (1.56 in)

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

CylindersCylinder arrangementBore strokeCompression ratioBoreMax. out-of-round

Forward-inclined, parallel 4-cylinder65.5 mm 44.5 mm (2.58 1.75 in)12.4 : 165.50 65.51 mm (2.5787 2.5791 in)

0.05 mm (0.002 in)

2-7


Item Standard Limit

PistonPiston-to-cylinder clearance

Diameter D

Height HPiston pin bore (in the piston)Diameter

OffsetOffset direction

Piston pinsOutside diameter

Piston-pin-to-piston-pin-boreclearance

Piston ringsTop ring

Ring typeDimensions (B T)End gap (installed)

Ring side clearance

2nd ring

Ring typeDimensions (B T)End gap (installed)

Ring side clearance

Oil ring

Dimensions (B T)End gap (installed)

0.010 0.035 mm (0.0004 0.0014 in)

65.475 65.490 mm (2.5778 2.5783 in)

4 mm (0.16 in)

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

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

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

0.030 0.065 mm (0.0012 0.0026 in)

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

0.030 0.065 mm (0.0012 0.0026 in)

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

0.055 mm(0.0022 in)

16.043 mm(0.6316 in)

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

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

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

2-8


Item Standard Limit

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

0.028 0.052 mm (0.0011 0.0020 in)

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

0.09 mm(0.0035 in)

Crankshaft

Width AWidth BMax. runout C

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

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

0.160 0.262 mm (0.0063 0.0103 in)0.028 0.052 mm (0.0011 0.0020 in)0.32 0.50 mm (0.01 0.02 in)0.034 0.058 mm (0.0013 0.0023 in)

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

0.03 mm(0.0012 in)

0.10 mm(0.0039 in)

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

Plate quantityColor codeThickness

Plate quantityClutch platesThicknessPlate quantityMax. warpage

ThicknessPlate quantityMax. warpage

Clutch springsFree length

Spring quantity

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

Brown2.9 3.1 mm (0.114 0.122 in)

6Purple2.9 3.1 mm (0.114 0.112 in)

2

1.9 2.1 mm (0.07 0.08 in)7

2.2 2.4 mm (0.086 0.095 in)1

50 mm (1.97 in)

6

2.8 mm(0.110 in)

2.8 mm(0.110 in)

0.1 mm(0.0039 in)

0.1 mm(0.0039 in)

49 mm(1.93 in)

2-9


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 gear86/44 (1.955)Chain drive48/16 (3.000)Left-foot operation

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

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

Shifting mechanismShift mechanism typeMax. shift fork guide bar bending

Shift drum/Guide bar

0.05 mm(0.002 in)

Air filter type Wet element

Fuel pumpPump typeModel (manufacturer)Output pressure

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

2-10


Item Standard Limit

Throttle position sensorResistanceOutput voltage (at idle)

4.85 5.15 kΩ at 20C (68F)0.63 0.73 V

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

38EIS (MIKUNI) 424 kPa (180 mmHg, 7.0872 inHg)6 8 mm (0 24 0 31 in)

Throttle cable free lay (at the flangeof the throttle grip)ID markThrottle valve size

6 8 mm (0.24 0.31 in)

5SL1 00 (5SL3/5SL7), 5SL4 10 (5SL4/5SL8)#100

2-11

CHASSIS SPECIFICATIONS SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

FrameFrame typeCaster angleTrail

Diamond2486 mm (3.39 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 MT5.50Aluminum120 mm (4.72 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)90 193 kg (198 426 lb)(USA except for CAL)90 192 kg (198 423 lb)(CAL)High-speed riding

Min. tire tread depth

Tubeless120/60 ZR17 M/C (55W)Pilot SPORT N (MICHELIN)D208FL (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)

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

1.6 mm (0.06 in)

2-12


Item Standard Limit

Rear tireTire typeSizeModel (manufacturer)

Tire pressure (cold)0 90 kg (0 198 lb)90 193 kg (198 426 lb)(USA except for CAL)90 192 kg (198 423 lb) (CAL)High-speed riding

Min. tire tread depth

Tubeless180/55 ZR17 M/C (73W)Pilot SPORT B (MICHELIN)D208L (DUNLOP)



1.6 mm(0.06 in)

Front brakesBrake typeOperationRecommended fluidBrake lever free playBrake discsDiameter thicknessMin. thickness

Max. deflection

Brake pad lining thickness

Master cylinder inside diameterCaliper cylinder inside diameter

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

298 5 mm (11.73 0.20 in)

4.5 mm (0.18 in)

14 mm (0.55 in)30.2 mm and 27 mm (1.19 in and 1.06 in)

4.5 mm(0.18 in)0.1 mm(0.004 in)0.5 mm(0.02 in)

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

Max. deflection

Brake pad lining thickness

Master cylinder inside diameterCaliper cylinder inside diameter

Single disc brakeRight foot operation7 11 mm (0.28 0.43 in)

DOT 44.3 9.3 mm (0.17 0.37 in)

220 5 mm (8.66 0.20 in)

6.0 mm (0.24 in)

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

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

2-13


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 innertube, with the inner 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)

249.3 mm (9.81 in)

100 mm (3.937 in)240.3 mm (9.46 in)8.3 N/mm (0.83 kg/mm, 46.49 lb/ in)0 120 mm (0 4.7244 in)43 mm (1.69 in)

No

Suspension oil “01”0.49 L (0.43 Imp qt, 0.52 US qt)106 mm (4.17 in)

871

1091

971

244.3 mm(9.62 in)

0.2 mm(0.01 in)

2-14


Item Standard Limit

SteeringSteering bearing type Angular bearing

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

Optional spring availableStandard spring preload gas/airpressureSpring preload adjusting positionsMinimumStandardMaximum

Rebound damping adjustingpositionsMinimum*Standard*Maximum*

Compression damping adjustingpositionsMinimum*Standard*Maximum*

*from the fully turned-in position

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

60 mm (2.36 in)

168.5 mm (6.63 in)157.5 mm (6.2 in)98 N/mm (9.80 kg/mm, 548.87 lb/ in)0 60 mm (0.00 2.36 in)No1,200 kPa (12 kg/cm2, 12 bar, 174 psi)

149

20105

20101

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

532ZLV KAI (DAIDO)11635 45 mm (1.38 1.77 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 timing

Crankshaft position sensorresistance/colorCDI unit model (manufacturer)

DC. CDI10 BTDC at 1,300 r/min(USA except for CAL)5 BTDC at 1,300 r/min (CAL)248 372 Ω at 20C (68F)/Gy-B

F8T926 (MITSUBISHI)

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

J0454 (DENSO)6 mm (0.24 in)0.17 0.23 Ω at 20C (68F)4.8 7.2 kΩ at 20C (68F)

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

A.C. magnetoLLZ68 (DENSO)14 V/300 W at 5,000 r/min0.18 0.26 Ω at 20C (68F)/W-W

Rectifier/regulatorRegulator typeModel (manufacture)

Semi conductor short circuitSH713AA (SHINDENGEN)

( )No-load regulated voltageRectifier capacityWithstand voltage

( )14.1 14.9 V35 A200 V

BatteryBattery typeBattery voltage/capacitySpecific gravityManufacturerTen hour rate amperage

GT9B-412 V/8 Ah1.320GS0.8A

Headlight type Halogen bulb

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

12 V 55 W 2LED 112 V 21 W/5W 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 indicator 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

SM-14 (MITSUBA)0.6 kW

10 mm (0.39 in)

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

0.7 mm (0.03 in)

3.5 mm(0.14 in)

27 mm(1.06 in)

Starter relayModel (manufacturer)AmperageCoil resistance

2768088-A (JIDECO)180 A4.18 4.62 Ω at 20C (68F)

HornHorn typeModel (manufacturer) quantityMax. amperagePerformanceCoil resistance

PlainYF-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 transistorFE246BH (DENSO)No75 95 cycles/min.21 W 2 + 3.4 W

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

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

40 A 115 A 120 A 115 A 115 A 115 A 110 A 140 A, 20 A, 15 A, 10 A 1

Fuel level senderModel (manufacture)Sender unit resistance-full

5PW (DENSO)750 1,100 Ω

Starting circuit at-off relayModel (manufacture)Coil resistance

G8R-30Y-R (OMRON)162 198 Ω

Headlight relay, Radiator fan motorrelayModel (manufacture)Coil resistance

ACA12115 (MATSUSHITA)72 88 Ω

Fuel injection system relayModel (manufacture)Coil resistance

G8R-30Y-R (OMRON)162 198 Ω

Water temperature sensorModel (manufacture)Resistance

K003T20191 (MITSUBISHI)0.2898 0.3542 Ω at 80C (176F)

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 in SI and METRIC UNITS.Use this table to convert METRIC unit data to IMPERIAL unit data.Ex.

METRIC MULTIPLIER IMPERIAL

** mm 0.03937 = ** in

2 mm 0.03937 = 0.08 in

CONVERSION TABLE

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

Tighten-ingtorque

mkgmkgcmkgcmkg

7.23386.7940.07230.8679

ftlbinlbftlbinlb

Weight kgg

2.2050.03527

lboz

Speed km/hr 0.6214 mph

Distance

kmmmcmmm

0.62143.2811.0940.39370.03937

miftydinin

Volume/Capacity

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

0.035270.061020.87990.2199

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

Misc.

kg/mmkg/cm2

Centigrade(C)

55.99714.22349/5+32

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

2-19

TIGHTENING TORQUES SPEC

TIGHTENING TORQUESENGINE TIGHTENING TORQUES

Item FastenerThread

Q’tyTightening torque

RemarksItem Fastener size Q tyNm mkg ftlb

Remarks

Spark plugsCylinder head

Camshaft capsCylinder head coverCamshaft cap oil check boltReed valve coverAir-cut valve stayCamshaft sprocketsConnecting rod capsGenerator rotorTiming chain tensionerTiming chain tensioner cap boltThermostat coverCoolant hose jointWater pump coverWater pumpRadiator and frameRadiator stay and crankcaseOil pump coverOil pumpOil panOil pan (center)Oil coolerEngine oil drain boltOil filter union boltOil filterOil pump chain guideOil pipeThrottle body jointAir filter case coverAir filter case and frameThrottle body and throttle bodyjointThrottle body and air filter caseExhaust pipe and cylinder headExhaust pipe and exhaust pipestayExhaust pipe and mufflerExhaust pipe stay and frameCrankcase (main journal)CrankcaseCrankcaseCrankcase

–Nut

BoltBoltBoltBoltBoltBoltBoltNutBoltBoltBoltBoltBoltBoltBoltBoltBoltBoltBoltBoltBoltBoltBoltBolt

–BoltBoltBolt

ScrewBolt

Clamp

ClampNutBolt

BoltBoltBoltBoltBoltBolt

M10M10

M6M6M6M8M6M6M7M7

M12M6M6M6M6M6M6M6M6M6M6M6M6

M20M14M20M20M6M6M6M5M6M4

M5M8M8

M8M8M8M6M6M8

410

22061414812122222133

1211111228614

481

11

102

132

131st 192nd 50

12101220101024

15 + 150

75127.0121010127.01012121212634370171212103.0103.0

3.02020

2034

141224

1.31.95.01.21.01.22.01.01.02.4

1.5 + 150

7.51.20.71.21.01.01.20.71.01.21.21.21.26.34.37.01.71.21.21.00.31.00.3

0.32.02.0

2.03.4

1.41.22.4

9.414368.77.28.7157.27.217

11 + 150

548.75.18.77.27.28.75.17.28.78.78.78.7463151128.78.77.22.27.22.2

2.21515

1525

1.08.717

Yamaha bondNo.1215

See NOTE 1

See NOTE 2

2-20

NOTE 1:


NOTE 2:

Item Fastener Thread Q’tyTightening torque

RemarksItem Fastenersize

Q tyNm mkg ftlb

Remarks

Generator rotor coverClutch coverClutch coverPickup coil rotor coverClutch cable holderPickup coil rotor coverShift shaft coverBreather plateStator coilPickup rotor cover and clampDrive sprocket coverOil gallery boltGenerator rotor cover and stator coil lead clampBreather hose coverOil pipeCrankshaft position sensorStarter clutchClutch pressure plateClutch boss

Drive sprocket

Transmission bearing housingShift drum retainerShift shaft spring stopperShift rodShift rodShift rod jointShift armPickup coil rotorStarter motorNeutral switchOil level switchSpeed sensorCylinder identification sensor

BoltBoltBoltBoltBoltBoltBolt

ScrewScrewScrew

Bolt–

Screw

BoltBoltBolt

ScrewBoltNut

Nut

ScrewBolt

ScrewNutNutBoltBoltBoltBolt

–BoltBoltBolt

M6M6M6M6M6M8M6M6M6M6

M6M16M6

M6M6M6M8M6

M20

M18

M6M6M8M8M6M6M6M8M6

M10M6M6M6

9915216331

321

422361

1

3211111121211

1212121212151212107.0

108

10

121210328.070

90

121022106.51010351020101010

1.21.21.21.21.21.51.21.21.00.7

1.00.81.0

1.21.21.03.20.87.0

9.0

1.21.02.21.0

0.651.01.03.51.02.01.01.01.0

8.78.78.78.78.7118.78.77.25.1

7.25.87.2

8.78.77.2235.851

65

8.77.2167.24.77.27.2257.2147.27.27.2

Use a lockwasherUse a lockwasher

Left thread

Retighten the bolt at 1000 km (600 ml).

1. First, tighten the bolts to approximately 12 Nm (1.2 mkg, 8.7 ftlb) with a torque wrench.2. Retighten the bolts 25 Nm (2.5 mkg, 18 ftlb) with a torque wrench.3. Loosen the all bolts one by one following the tightening order and then tighten them to 27 Nm (2.7

mkg, 20 ftlb) again.

Yamaha bondNo.1215

Yamaha bond No.1215

2-21


Cylinder head tightening sequence:

Crankcase tightening sequence.

2-22


CHASSIS TIGHTENING TORQUES

ItemThread Tightening

RemarksItem size Nm mkg ftlbRemarks

Upper bracket and front forkSteering stem nutHandlebar and front forkHandlebar and upper bracketLower ring nutUnder bracket pinch boltMain switch and upper bracketFront brake master cylinder cap stopperFront brake hose union boltsFront brake master cylinder and bracketWindshield and front cowlingFront cowling and headlight assemblyHeadlight and front cowling stayMeter assembly and front cowling stayFront cowling stay and frameFront cowling stay and ductDuct and jointSurge tank joint (front)Surge tank joint (rear)Rear view mirror and front cowlingCowling and inner panelCowlings and frameEngine mount bolts (front)Engine mount bolts (rear upper)Engine mount bolts (rear lower)Engine mount adjust boltFrame and rear frameInner panel and frameClutch cable lock nut (engine side)Throttle cable adjust nut (handlebar side)Pivot shaft and nutConnecting rod and frameRelay arm and connecting rodRelay arm and swingarmRear shockabsorber and relay armRear shockabsorber and bracketBracket and frameFuel pump and fuel tankFuel tank bracket and frameFuel tank bracket and fuel tankFuel tank and rear frameRider seat and frameCoolant reservoir tank and generator rotor coverFootrest bracket and frameRear footrest and frameRear footrest and mufflerRear brake master cylinder and footrest bracket

M8M28M8M6

M30M8M8M4

M10M6M5M5M5M5M8M5M5M4M5M6M5M6

M10M10M10M16M10M5M8M6

M18M10M10M10M10M10M14M5M6M6M6M6M6M8M8M8M8

2611333131423231.230130.41.72.51.3231.31.31.21.27

1.54.54545457

473.87

4.59544444444445247777

6.528282318

2.611.33.31.31.42.32.3

0.123.01.3

0.040.170.250.132.3

0.130.130.120.120.7

0.150.454.54.54.50.74.7

0.380.7

0.459.54.44.44.44.44.45.20.40.70.70.70.7

0.652.82.82.31.8

1982249.41017170.9229.40.3

1.231.810.9417

0.940.940.870.875.11.13.33333335.1342.75.13.3693232323232382.95.15.15.15.14.720201713

See NOTE 1

2-23

NOTE 1:


NOTE 2:

Item Thread TighteningRemarksItem

size Nm mkg ftlbRemarks

Rear brake hose union boltSidestand bracket and frameFront wheel axle shaft and boltRear wheel axle nutFront brake caliper and front forkFront brake disc and front wheelRear brake disc and rear wheelRear wheel sprocket and rear wheel drive hubBrake caliper bleed screwPinch bolt (front wheel axle)

M10M10M14M24M10M6M8

M10M8M8

306191110401830

1006

18

3.06.19.111.04.01.83.0

10.00.61.8

22446680291322724.313 See NOTE 2

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.

Tighten wheel axle pinch bolts 2 and 1 tospecified torque.

Retighten pinch bolt 2 to specified torque.Tap the outer side of the left fork leg with a rub-ber mallet to align it with the end of the wheelaxle.

Tighten wheel axle pinch bolts 4 and 3 tospecified torque.

Retighten pinch bolt 4 to specified torque.

2-24

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

Connecting rod bolts and nuts

Crankshaft journals

Camshaft lobes

Camshaft journals

Valve stems (intake and exhaust)

Valve stem ends (intake and exhaust)

Valve lifter surface

Piston cooler (O-ring)

Oil pump rotors (inner and outer)

Oil pump housing

Oil strainer

Clutch (pull rod)

Starter clutch idle gear inner surface

Starter clutch assembly

Primary driven gear

Transmission gears (wheel and pinion)

Main axle and drive axle

Shift drum bearing

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

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

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

2-25

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EAS00032

CHASSIS

Lubrication point Lubricant

Steering bearings and bearing races (upper and lower)

Front wheel oil seal (right and left)

Rear wheel oil seal

Front axle shaft

Rear wheel drive hub oil seal

Rear wheel drive hub mating surface

Rear axle shaft

Rear brake pedal shaft

Sidestand pivoting point and metal-to-metal moving parts

Link and sidestand switch contact point

Sidestand hook and spring

Throttle grip inner surface

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

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

Relay arm, connecting rod and rear shock absorber collar

Pivot shaft

Rear frame thread

Swingarm pivot bearing

Swingarm head pipe end, oil seal and bush

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

Engine mount bolts (rear upper and lower)

Seat lock assembly

Shift pedal shaft

Shift shaft joint

2-26

COOLING SYSTEM DIAGRAMS SPEC

1 Radiator2 Oil cooler

COOLING SYSTEM DIAGRAMS

2-27


1 Water pump2 Oil cooler3 Radiator

2-28


1 Oil cooler2 Water pump

2-29


1 Radiator2 Thermostat

2-30

ENGINE OIL LUBRICATION CHART SPEC

ENGINE OIL LUBRICATION CHART

2-31

LUBRICATION DIAGRAMS SPEC

1 Oil level switch2 Oil cooler3 Relief valve

LUBRICATION DIAGRAMS

2-32


1 Oil pump2 Exhaust camshaft3 Intake camshaft4 Oil strainer

2-33


1 Oil cooler2 Oil strainer3 Oil level switch4 Oil pump

2-34


1 Main axle2 Oil pump3 Relief valve

2-35


1 Cylinder head2 Intake camshaft3 Exhaust camshaft4 Crankshaft

2-36


1 Main axle2 Drive axle

2-37

CABLE ROUTING SPEC

A Pass the right handlebar switch lead inside the frontbrake hoses and over the throttle cables.

B Install the throttle cables to the hook so that the pull-ing side of the throttle cables is routed downward.

C Pass the clutch cable through the guide.D Plastic locking tie shall be positioned at 10 mm

(0.39 in.) below from the upper bracket.E Clamp the left handlebar switch lead to the front fork

with the plastic locking tie and cut the tip of the tie.Clamp it to the protector section.

1 Right handlebar switch lead2 Clutch cable3 Main switch lead and left handlebar switch lead4 Throttle cable (return side)5 Throttle cable (pull side)6 Front brake hoses7 Throttle cables8 Joint9 Under bracket

CABLE ROUTING

2-38

J Install the relay to the rib of the headlight.(Location for the left and right relays is alternative.)

K To the wire harnessL To the front turn signal /position light (right)M Set the sub wire harness in the joint.N Do not catch the sub wire harness when the duct is

assembled.O To the front turn signal /position light (left)P Point the tip of the plastic locking tie to the front side

of the vehicle. Cut the tip leaving 2 10 mm (0.08 0.39 in).

Q Point the tip of the plastic locking tie under the underbracket and rear side of the vehicle. Cut the tip leav-ing 2 10 mm (0.08 0.39 in).

CABLE ROUTING SPEC

F Pass the horn lead by the outside of the throttlecables and clamp it to the forefront of upper face ofthe under bracket. And then route it under the frontbrake hose and clamp it to the pawl of the undercover.

G Clamp it at the position of 40 60 mm (1.57 2.36in) from the upper face of the under bracket with theplastic locking tie. Cut the surplus part of the clamptip leaving 2 4 mm (0.08 0.16 in). Point the tipof the clamp to the outside of vehicle.

H Pass the throttle cables inside the front brakehoses.

I Set in the coupler between the head light’s hollowsection and the duct.

2-39

CABLE ROUTING SPEC

1 Throttle stop screw2 Coolant reservoir tank hose3 Crankshaft position sensor lead4 Rear brake light switch lead5 Water pump inlet hose6 Clutch cable7 Coolant hose protector8 Hose clamp assembly9 Hose clamp

A Pass the rear brake light switch lead outside of rearengine mount bolt.

B Pass the ignition coil lead outside of the radiatorhose.

C Pass the coolant reservoir tank hose under theframe and right side of the throttle body.

D Pass the clutch cable inside of the coolant reservoirtank hose and radiator return hoses.

E The punch mark starting point should be lower thanthe clamp’s top end.However, the aiming position of the punch markstarting point should be 5 mm (0.20 in) below theclamp’s bottom end.

F Pass the clutch cable inside of the radiator hose.G Assemble as “ ” shown below when clamping.H Tip of the plastic locking tie shall be pointed to the

inner side at the rear part of the vehicle.I Clamp the clutch cable so that it is positioned in this

range.J Clamp the clutch cable by routing the upper end of

the clamp along with the bottom end of the hoseclamp assembly.

a

2-40

CABLE ROUTING SPEC

K Put and apply the hose clamp to it.L Pass the crankshaft position sensor lead over the

throttle stop screw.

2-41

CABLE ROUTING SPEC

1 Throttle cable (return side)2 Throttle cable (pull side)3 Starter motor lead4 Canister hose (for CAL)5 Balance hose (for CAL)6 Canister (for CAL)7 Coolant reservoir tank breather hose8 Oil level switch lead9 Sidestand switch lead10 A.C. magneto lead11 Radiator fan motor lead12 Coolant reservoir tank13 Coolant reservoir tank cover14 Fuel tank drain hose15 Fuel tank breather hose16 Drive sprocket cover

A Pass the main switch lead under the left handlebarswitch lead and then to the right side of the vehicle.

B Pass the throttle stop cable by the left side of thesidestand switch lead, oil level switch lead, A.C.magneto lead, fuel tank drain hose and fuel tankbreather hose, and then to the right side of the ve-hicle.

C Pass the fuel tank drain hose and fuel tank breatherhose inside of the reservoir tank breather hose andreservoir tank hose, wire harness and throttle stopcable and then route it by the out side of the startermotor lead.

D To the throttle body.E Route the coolant reservoir tank hose by the out-

side of the fuel tank drain hose and the fuel tankbreather hose.

2-42

M Route it above the radiator hose.N Pass the throttle cable between the guide of the

cover 2 and the frame.O Pass the radiator fan motor lead through the hole of

the frame to the inner side of the vehicle.P To the horn.Q Route it below the coolant reservoir tank.R Pass the coolant reservoir tank breather hose

through the hole of the coolant reservoir tank cover.S Order of ups and downs means no object.

CABLE ROUTING SPEC

F Pass the fuel tank drain hose and fuel tank breatherhose through the clamp of the coolant reservoirtank.

G Projection allowance from the coolant reservoirtank cover shall be 30 50 mm (1.18 1.97 in).

H 10 50 mm (0.39 1.97 in).I Fasten the sidestand switch lead and oil level switch

lead with a clamp.J Pass the coolant reservoir tank breather hose, oil

level switch lead and sidestand switch lead throughthe clamp.

K Pass the sidestand switch lead, oil level switch leadand A.C. magneto lead between the engine stayand the engine.

L To the radiator fan motor relay and fuse box

2-43

CABLE ROUTING SPEC

1 Right handlebar switch lead2 Sub wire harness3 Cover 84 Ignition coil lead5 Throttle position sensor coupler6 Coolant reservoir tank hose7 Throttle stop cable8 Speed sensor lead coupler9 Crankshaft position sensor lead

coupler10 Fuel tank breather hose (except

for CAL)11 Fuel tank drain hose12 Fuel hose (return side)13 Fuel pump 2 coupler14 Fuel pump 1 coupler

15 Starter motor lead16 Fuel hose (feed side)17 Canister hose (for CAL)18 Crankcase breather hose19 Air vent hose20 Fuse box21 Cover 722 Radiator fan motor relay23 Radiator fan motor lead24 Left handlebar switch lead25 Main switch lead26 Wire harness27 Throttle cables28 Throttle sub-lead 1 (white 6

poles)

29 Throttle sub-lead 2 (black 6poles)

30 Oil level switch lead coupler(white 1 pole)

31 Sidestand switch lead coupler(blue 2 poles)

32 A.C. magneto lead coupler(white 3 poles)

33 Rear brake light switch lead cou-pler (brown 2 poles)

34 Neutral switch lead coupler(connector 1 pole)

2-44

CABLE ROUTING SPEC

A To the headlightB Make sure not to drop the headlight sub wire har-

ness beneath the projection of the duct. Check itwhen installing the side cowling.

C Clamp the plastic locking tie to the cover 8. Placethe coupler at the rear side of the vehicle against theplastic locking tie. Point the tip of the plastic lockingtie to the downward in the inner side of the vehicle.

D Route the head light and meter leads under theframe’s lower part from the hollow section of thecover 2.

E Pass the left and right handlebar switch leads out-side of the air filter case air vent hose.

F Connect the couplers (4 units) at the frame sidehole. Do not catch each lead and wire harness whenthe cover 8 is attached.

G From the radiatorH Pass the coolant reservoir tank hose through for-

ward the starter motor lead and speed sensor lead.I Pass the speed sensor lead coupler and crankshaft

position sensor lead coupler over the throttle stopcable.

J Pass the fuel tank breather hose and fuel tank drainhose under the fuel hose.

K To the rear brake light switch lead.L To the neutral switchM Insert the wire harness wrapping clamp to the frame

hole.N Pass the battery negative lead over the wire har-

ness.O There should be no interference between the wire

harness and the tip of the rear frame attaching bolts.

2-45

X Clamp the wire harness, left and right handlebarswitch leads and main switch lead. Align the tappingpositions of three leads except the wire harness.Point the tip of the clamp to the front side of the ve-hicle.

Y Sealing set of the cover can be either upper or loweragainst the frame lower end. However, it should notbe caught.

Z Clamp the wire harness, main switch lead branchsection and radiator fan motor lead.

AA Branching leads to the fuse box and radiator fanmotor relay shall pass through the guide sectionof the cover 2 under the wire harness and then tothe outside of the frame.

CABLE ROUTING SPEC

P To the coolant reservoir tankQ To the intake air temperature sensor (air filter case)R To the oil level switch, sidestand switch and A.C.

magnetoS Install the wire harness wrapping clamp to the stay

of the throttle body.T Pass the wire harness over the throttle air vent

hose.U Pass the wire harness between frame and coolant

hose.V Pass it through the frame hole.W Do not catch the coupler when the air filter case is

assembled.

2-46

CABLE ROUTING SPEC

AB To the fuse box and fan motor relayAC Pass the throttle cables over the cover 2.AD Point the tip of the plastic locking tie to the rear

side of the vehicle.AE To the main switch lead couplerAF Tip of the plastic locking tie should point to the

downward outside of the vehicle.AG Use the plastic locking tie to clamp the starter mo-

tor lead at the protector section.AH Branching harness from the wire harness.

2-47

1 Battery2 Battery positive lead3 Starter relay4 Turn signal relay5 Pressure sensor6 Tail /brake light7 Tool kit8 Starting circuit cut-off relay9 Battery box10 ECU11 Wire harness12 Battery negative lead13 Battery band

CABLE ROUTING SPEC

A Push the starter motor lead in the clamping sections(two points) or the battery box assembly and secureit.

B Fit the plastic cover in the starter relay after theflange bolts are installed.

C Make sure to clamp the wire harness. (Tighten it un-til the clamp latchet stops.)

D Install to the deepest position of the rib of the batterybox assembly.

E When installing the ECU, make sure to hook thepawls of the battery box assembly (at four points).

F Hook of the battery box assembly shall hook on theupper face of the fuse box. (It should not be put onthe side face.)

G Install the pin of the battery box assembly to itsbase.

2-48

H The knob section should be positioned in this area.I Pass the turn signal lead by the outside of the right

side attaching boss of the tail /brake light.J Pass the turn signal light and license light leads be-

tween the rear side ribs of the battery box assemblyand to the rear part of the vehicle.

K Connect the turn signal lead couplers.L Connect the license light leads.M Route the branching lead to the license light behind

the tail /brake light left side attaching boss.N Route the tail /brake light lead under the projection

part.O Route the tail /brake light lead above the projection

part.P There should be no significant difference between

right and left side of the tension rate on the band.

CABLE ROUTING SPEC

Q Point the opening to the rear side of the vehicle.R Connect the tail /brake light lead coupler.S Install the starting circuit cut-off relay to the deepest

position after placing the tail /brake light lead andturn signal lead in the guide.

T The hook of the battery box assembly should hookon the surface.

U Route the fuse box lead under the ECU connectioncoupler.

V Install the wrapping clamp of the wire harness to thehole of the battery box assembly.

W Connect the negative lead and the wire harness.

2-49

CABLE ROUTING SPEC

1 Fuel pump assembly2 Canister hose3 Canister4 Breather hose5 Blance hose6 Fuel tank drain hose

A Install the roll over valve until it contacts with the fueltank’s nipple.

B Install the O-ring with its lip pointed upward.C Install the clip with its tab pointed in the upward

direction.D Install the breather hose without projecting canister

nipple out of the breather hose.E Install the clip with its tab pointed in the downward

direction.

For California

3-1

3

INTRODUCTION/PERIODIC MAINTENANCE CHART FORTHE EMISSION CONTROL SYSTEM/GENERAL MAINTENANCE AND

LUBRICATION CHARTCHKADJ

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 SYSTEM

INITIAL ODOMETER READINGS

NO. ITEM REMARKS600 mi

(1,000 km)or

1 month

4,000mi(7,000 km)

or6 months

8,000 mi(13,000 km)

or12 months

12,000 mi(19,000 km)

or18 months

16,000 mi(25,000 km)

or24 months

20,000 mi(31,000 km)

or30 months

1 * Valve clearance(See page 3-10)

Check and adjust valve clearance whenengine is cold.

Every 26,600 mi (42,000 km)

2 * Spark plugs(See page 3-21)

Check condition. Adjust gap and clean. Replace at 8,000 mi (13,000 km) or 12

months.

Replace. Replace.

3 *Crankcase ventilationsystem(See page 3-32)

Check ventilation hose for cracks or dam-age.

Replace if necessary.

4 * Fuel line(See page 3-32)

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

5 * Exhaust system(See page 3-33)

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

6 *Electronic fuel injec-tion(See page 3-16, 18)

Check and adjust engine idle speed andsynchronization.

7 * Evaporative emissioncontrol system**

Check control system for damage. Replace if necessary.

8 * Air induction system(See page 7-35)

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

Replace any damaged parts.

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

** California only

GENERAL MAINTENANCE AND LUBRICATION CHARTINITIAL ODOMETER READINGS


(1,000 km)or

1 month

4,000mi(7,000 km)

or6 months

8,000 mi(13,000 km)

or12 months

12,000 mi(19,000 km)

or18 months

16,000 mi(25,000 km)

or24 months

20,000 mi(31,000 km)

or30 months

1 Engine oil(See page 3-24, 25)

Replace (warm engine before draining).

2 *Engine oil filter cartridge(See page 3-25)

Replace at initial 600 mi (1,000 km) or 1month, and thereafter every 8,000 mi(13,000 km) or 12 months.

3 * Air filter element(See page 3-30)

Check condition and damage. Replace if necessary.

4 * Cooling system

Check hoses for cracks or damage. Replace if necessary.

4 * Cooling system (See page 3-34, 35)

Replace with ethylene glycol antifreezecoolant every 24 months.

Replace.

5 *Brake system(See page 3-39, 40, 41,43)

Check operation, pad wear, and fluidleakage.

Correct if necessary.

6 * Clutch(See page 3-29)

Check operation. Adjust or replace cable.


3-2

GENERAL MAINTENANCE AND LUBRICATION CHARTCHKADJ

NOTE:

NOTE:

INITIAL ODOMETER READINGS


(1,000 km)or

1 month

4,000mi(7,000 km)

or6 months

8,000 mi(13,000 km)

or12 months

12,000 mi(19,000 km)

or18 months

16,000 mi(25,000 km)

or24 months

20,000 mi(31,000 km)

or30 months

7 * Control cables (See page 3-58)

Apply Yamaha chain and cable lube orengine oil 10W-30 thoroughly.

8 *Swingarm pivot bearing(See page 4-75)

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

based grease every 16,000 mi (25,000km) or 24 months.

Repack.

9 *Rear suspension linkpivots(See page 4-75)

Check operation. Correct if necessary.

10 *Shock absorber assembly (See page 4-71)

Check operation and for oil leakage. Replace if necessary.

11 * Front fork(See page 3-50)

Check operation and oil leakage. Replace if necessary.

12 * Steering bearings(See page 3-48)

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

based grease every 16,000 mi (25,000km) or 24 months.

Repack.

13Brake and clutch lever pivot shafts (See page 3-58)

Apply lithium-soap-based grease (all-pur-pose grease) lightly.

14Brake and shift pedalpivot shafts(See page 3-58)

Apply lithium-soap-based grease (all-pur-pose grease) lightly.

15 Drive chain(See page 3-46)

Check chain slack/alignment and condi-tion.

Adjust and lubricate chain with a specialO-ring chain lubricant thoroughly.

Every 500 mi (800 km) or after washing themotorcycle or riding in the rain.

16 * Wheel bearings(See page 4-3)

Check bearing for smooth operation.

17 Sidestand pivot(See page 3-58)

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

pose grease) lightly.

18 * Sidestand switch(See page 8-4)

Check operation and replace if neces-sary.

19 * Chassis fasteners(See page 2-22)

Check all chassis fitting and fasteners. Correct if necessary.

20 * Brake hoses Check for cracks or damage. 20 * Brake hoses

(See page 3-43) Replace. Every 4 years

21 * Wheels(See page 4-3)

Check runout and for damage. Replace if necessary.

22 * Tires(See page 3-55)

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


From 24,000 mi (37,000 km) 36 months, repeat the maintenance intervals starting from 4,000 mi(7,000 km) or 6 months.

The air filter needs more frequent service if you are 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 seatsPassenger seatRider 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

Removing the fuel tankRider seatFuel hose connector coverFuel hoseFuel return hoseFuel sender couplerFuel pump couplerFuel tank overflow hoseFuel tank breather hoseFuel tankFuel pump

111111111

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

Disconnect.Disconnect.


7 Nm (0.7 mkg, 5.1 ftlb)

7 Nm (0.7 mkg, 5.1 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 return hose fuel hose

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

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

3. Remove: fuel tank

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

REMOVING THE FUEL PUMP1. Remove: fuel pump

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

Do not touch the base section of the fuelsender.

3-6

FUEL TANKCHKADJ

4 Nm (0.4 mkg, 2.9 ftlb)

NOTE:

CAUTION:

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 holders are in the correct position,otherwise the fuel hose will not be properlyinstalled.

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

3-7


1234

56789

1011

Removing the cowlingsRider and passenger seatsFront cowling inner panel (left and right)Front turn signal light lead couplersSide cowlings (left and right)Side cowlings inner panels (left and right)Bottom cowlings (left and right)Bottom cowling front coverFront cowlingRear view mirrors (left and right)WindshieldRear cowlingFrame side cover

2222

2112112

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

Disconnect.


COWLINGSCHKADJ

COWLINGS

3-8

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.

3-9


1234567

Removing the air filter caseRider seatFuel tankAir intake ductIntake temperature sensor couplerThrottle body hoseAir induction system hoseClampAir filter caseCrankcase breather hose

2121411

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

Disconnect.Disconnect.Disconnect.Loosen.

Disconnect.For installation, reverse the removal procedure.

10 Nm (1.0 mkg, 7.2 ftlb)

AIR FILTER CASECHKADJ

AIR FILTER CASE

3-10

ADJUSTING THE VALVE CLEARANCECHKADJ

NOTE:

EAS00045

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

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

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

1. Remove rider seatRefer to “SEATS”.

fuel tankRefer to “FUEL TANK”.

air filter caseRefer to “AIR FILTER CASE”.

bottom cowlingside 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

3-11


NOTE:

NOTE:

4. Measure:valve clearanceOut of specification Adjust.

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

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

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

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

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

If the valve clearance is incorrect, record themeasured reading.

Measure the valve clearance in the followingsequence.

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

A Frontd. To measure the valve clearances of the other

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

B Degrees that the crankshaft is turned counter-clockwise

C CylinderD Combustion cycle

Cylinder #2 180

Cylinder #4 360

Cylinder #3 540

3-12


NOTE:

NOTE:

NOTE:

5. Remove:camshafts

Refer to “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 lifter1 and valve pad 2 so that they can beinstalled in the correct place.

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

Valve padthickness range

Available valvepads

Nos.120

240

1.20(0.0472) 2.40 mm

(0.0945 in)

25 thicknesses in0.05 mm (0.002 in)

increments

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

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

3-13


NOTE:

NOTE:

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

Last digit Rounded value

0 or 2 0

5 5

8 10

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

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

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

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

Lubricate the valve pad with molybdenum dis-ulfide grease.

Lubricate the valve lifter with molybdenum dis-ulfide oil.

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)

3-14


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.

3-15


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

MEASURED

CLEARANCE

INSTALLED PAD NUMBER

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

MEASURED

CLEARANCE

INSTALLED PAD NUMBER

STANDARD CLEARANCE

STANDARD CLEARANCE

INTAKE

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

EXHAUST

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

3-16

ADJUSTING THE VALVE CLEARANCE/SYNCHRONIZING THE THROTTLE BODIES

CHKADJ

NOTE:

NOTE:

NOTE:

7. Install:all removed parts


SYNCHRONIZING THE THROTTLE BODIES

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

1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

2. Remove: rider seatRefer to “SEATS”.



3. Remove:synchronizing hose 1

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

digital tachometer(near the spark plug)

Vacuum gauge90890-03094, YU-08030

3-17

SYNCHRONIZING THE THROTTLE BODIESCHKADJ

NOTE:

CAUTION:

NOTE:

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


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 speed1,250 1,350 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.

Carburetor angle driver90890-03158

Vacuum pressure at engine idling speed

24 kPa(180 mmHg, 7.0872 inHg)

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

3-18

SYNCHRONIZING THE THROTTLE BODIES/ADJUSTING THE ENGINE IDLING SPEED

CHKADJ

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)

6 8 mm (0.24 0.31 in)

12. Remove:digital tachometervacuum gauge



rider seatRefer to “SEATS”.

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(to the ignition of cylinder #1)

3. Check:engine idling speedOut of specification Adjust.

Engine idling speed1,250 1,350 r/min

3-19

ADJUSTING THE ENGINE IDLING SPEED/ADJUSTING THE THROTTLE CABLE FREE PLAY

CHKADJ

a

b

NOTE:

4. Adjust:engine idling speed

a. Turn the throttle stop screw 1 in direction aor b until the specified engine idling speed isobtained.

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)

6 8 mm (0.24 0.31 in)

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.


6 8 mm (0.24 0.31 in)




left frame side coverRefer to “COWLINGS”.

3-20

ADJUSTING THE THROTTLE CABLE FREE PLAYCHKADJ

NOTE:

a

b

NOTE:

a

b

WARNING

3. Adjust: throttle cable free play

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

Throttle body sidea. Loosen the locknut 2 on the decelerator

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

to take up any slack on the decelerator cable.

Direction Throttle cable free play isincreased.

Direction Throttle cable free play isdecreased.

c. Tighten the locknuts.

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

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.

3-21

ADJUSTING THE THROTTLE CABLE FREE PLAY/CHECKING THE SPARK PLUGS

CHKADJ

CAUTION:

4. Install: left frame side coverRefer to “COWLINGS”.




EAS00059

CHECKING THE SPARK PLUGSThe following procedure applies to all of thespark plugs.1. Remove: rider seatRefer to “SEATS”.



2. Remove:heat protector plate 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.

3. Check:spark plug typeIncorrect Change.

Spark plug type (manufacturer)CR9EK or CR10EK (NGK)

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

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

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

3-22

CHECKING THE SPARK PLUGS/MEASURING THE COMPRESSION PRESSURE

CHKADJ

13 Nm (1.3 mkg, 9.4 ftlb)

NOTE:

NOTE:

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

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

7. Install:spark plug

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




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.




4. Remove:cover ignition coilsspark plugs

3-23

MEASURING THE COMPRESSION PRESSURECHKADJ

CAUTION:

WARNING

NOTE:

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

5. Install:compression gauge 1adapter

Compression gauge90890-03081, YU-33223

Adapter90890-04136

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

Compression pressure (at sea level)

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

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

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

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

until the reading on the compression gaugestabilizes.

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

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

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

3-24

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.

7. Install:spark plug

8. Install: ignition coils

9. Install:heat protector plateair filter caseRefer to “AIR FILTER CASE”.



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.

3-25

CHECKING THE ENGINE OIL LEVEL/CHANGING THE ENGINE OIL

CHKADJ

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.

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 cowlingRefer to “COWLINGS”.

coolant reservoir tankRefer to “CHANGING THE COOLANT”.

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

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

3-26

CHANGING THE ENGINE OILCHKADJ

CAUTION:

43 Nm (4.3 mkg, 31 ftlb)

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

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

Oil filter wrench90890-01426, YU-38411

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

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

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

Oil filter cartridge17 Nm (1.7 mkg, 12 ftlb)

7. Replace:engine oil drain bolt gasket New

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

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

QuantityTotal amount

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

2.4 L (2.11 Imp qt, 2.54 US qt)With oil filter cartridgereplacement

2.6 L (2.29 Imp qt, 2.75 US qt)

3-27

CHANGING THE ENGINE OIL/MEASURING THE ENGINE OIL PRESSURE

CHKADJ

CAUTION:

WARNING

10. Install:engine oil filler capcoolant reservoir tankRefer to “CHANGING THE COOLANT”.

bottom cowlingRefer to “COWLINGS”.


EAS00077

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


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

3. Remove:bottom cowlingRefer to “COWLINGS”.

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

3-28

MEASURING THE ENGINE OIL PRESSURECHKADJ

NOTE:

8 Nm (0.8 mkg, 5.8 ftlb)

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

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

Engine speedApprox. 6,600 r/min

Engine oil temperature96C (205F)

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

Engine oil pressure Possible causes

Below ifi i

Faulty oil pumpspecification Clogged oil filter

Leaking oil passage

Broken or damaged oil seal

Above specification

Leaking oil passage

Faulty oil filter

Oil viscosity too high

7. Install:oil gallery bolt 1

8. Install:bottom cowlingRefer to “COWLINGS”.

3-29

ADJUSTING THE CLUTCH CABLE FREE PLAYCHKADJ

c

b

NOTE:

a

b

EAS00078

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

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

10 15 mm (0.39 0.59 in)

2. Adjust:clutch cable free play

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

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

Direction Clutch cable free play isincreased.

Direction Clutch cable free play isdecreased.

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

Engine sidea. Remove the bottom cowling. Refer to

“COWLINGS”.b. Loosen the locknuts 1 .c. Turn the adjusting nut 2 in direction a or b

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

Direction Clutch cable free play isincreased.

Direction Clutch cable free play isdecreased.

d. Tighten the locknuts.e. Install the bottom cowling. Refer to “COWL-

INGS”.

3-30

CLEANING THE AIR FILTER ELEMENTCHKADJ

CAUTION:

NOTE:

EAS00086

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


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

3. Clean:air filter element 1Use solvent to clean the air filter element. Af-ter cleaning the air filter element, remove thesolvent from the air filter element.

4. Apply the engine oil to the entire surface ofthe filter and remove the excess oil. The airfilter should be wet but not dripping.

5. Check:air filter elementDamage Replace.

6. Install:air filter elementair 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.

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


3-31

CLEANING THE AIR INTAKE SYSTEM SURGE TANKS/CHECKING THE THROTTLE BODY JOINTS

CHKADJ

EAS00092

CLEANING THE AIR INTAKE SYSTEM SURGE TANKSThe following procedure applies to both air in-take system surge tanks.1. Remove: front cowlingRefer to “COWLINGS”.

2. Remove:air intake system surge tank 1

3. Clean:air intake system surge tank

a. Thoroughly flush out the air intake systemsurge tank with clean water.

b. Hold the air intake system surge tank upsidedown to allow the water to drain out.

c. Repeat the flushing steps until the excesswater is clear and free of debris.

d. Place the air intake system surge tank in anupright position to allow any remaining waterto drain out of the lower drain tube.

e. Keep the air intake system surge tank uprightto allow it to dry sufficiently.

4. Install:air intake system surge tank

5. front cowlingRefer to “COWLINGS”.

EAS00095

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

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

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

3-32

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

CHKADJ

NOTE:

CAUTION:

EAS00096

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


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

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



EAS00098

CHECKING THE CRANKCASE BREATHER HOSE1. 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.



3-33

CHECKING THE EXHAUST SYSTEM/CHECKING THE COOLANT LEVEL

CHKADJ

NOTE:

EAS00099

CHECKING THE EXHAUST SYSTEMThe following procedure applies to all of the ex-haust pipes and gaskets.1. Remove:bottom cowlingRefer to “COWLINGS”.

radiatorRefer to “RADIATOR” in chapter 6.

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

gasket 3Exhaust gas leaks Replace.

3. Check: tightening torque

Exhaust pipe nut 420 Nm (2.0 mkg, 15 ftlb)

Exhaust pipe and muffler bolt 520 Nm (2.0 mkg, 15 ftlb)

Muffler and rear footrest nut 623 Nm (2.3 mkg, 17 ftlb)

Exhaust pipe and exhaust pipe stay 7

20 Nm (2.0 mkg, 15 ftlb)

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

bottom cowlingRefer to “COWLINGS”.

EAS00102

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


3-34

CHECKING THE COOLANT LEVEL/CHECKING THE COOLING SYSTEM

CHKADJ

CAUTION:

NOTE:

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.

EAS00104

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

3-35

CHECKING THE COOLING SYSTEM/CHANGING THE COOLANT

CHKADJ

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

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

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

EAS00105

CHANGING THE COOLANT1. Remove:bottom cowlings left side cowlingRefer to “COWLINGS”.

coolant reservoir tank cover2. Remove:coolant reservoir tank

3-36

CHANGING THE COOLANTCHKADJ

CAUTION:

10 Nm (1.0 mkg, 7.2 ftlb)

3. Disconnect:coolant reservoir cap 1

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

5. Remove: radiator cap 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 bolt (water pump) 1(along with the copper washer)

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

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

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

3-37


WARNING

CAUTION:

10. Install:coolant reservoir tank

11. Connect:coolant reservoir hose

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

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

Mixing ratio1:1 (antifreeze:water)

QuantityTotal amount

2.15 L (1.89 Imp qt, 2.27 US qt)

Coolant reservoir capacity0.44 L (0.39 Imp qt, 0.47 US qt)

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

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

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

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

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

3-38


NOTE:

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

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

Do not mix different types of antifreeze.

13. Install: radiator cap

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

15. Install:coolant reservoir cap

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

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

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

18. Install:coolant reservoir tank coverbottom cowling left side cowlingRefer to “COWLINGS”.

3-39

ADJUSTING THE FRONT BRAKECHKADJ

NOTE:

a

a

WARNING

CAUTION:

EAS00107

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

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

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

Position #1 Distance is the largest.

Position #5 Distance is the smallest.

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

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

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

3-40

ADJUSTING THE REAR BRAKECHKADJ

a

b

WARNING

WARNING

CAUTION:

EAS00110

ADJUSTING THE REAR BRAKE1. Check:brake pedal position(distance a bottom of the footrest bracket)Out of specification Adjust.

Brake pedal position (below the bottom of the footrest bracket)

7 11 mm (0.28 0.43 in)

2. Adjust:brake pedal position

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

until the specified brake pedal position is ob-tained.

Direction Brake pedal is raised.

Direction Brake pedal is lowered.

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

c. Tighten the locknut 1 to specification.

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.

3-41

A

B

ADJUSTING THE REAR BRAKE/CHECKING THE BRAKE FLUID LEVEL

CHKADJ

NOTE:

WARNING

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

EAS00115

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


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

Recommended brake fluidDOT 4

A Front brakeB Rear brake

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

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

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

3-42

CHECKING THE BRAKE FLUID LEVEL/ADJUSTING THE REAR BRAKE LIGHT SWITCH

CHKADJ

CAUTION:

NOTE:

NOTE:

a

b

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.

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.

3-43

B

A

B

A

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

CHKADJ

EAS00122

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

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

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

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

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

3-44

A

B

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 FrontB Reard. Place the other end of the hose into a con-

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

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

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

3-45

BLEEDING THE HYDRAULIC BRAKE SYSTEM/ADJUSTING THE SHIFT PEDAL

CHKADJ

WARNING

b

c

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

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

j. Tighten the bleed screw to specification.

Bleed screw6 Nm (0.6 mkg, 4.3 ftlb)

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

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

EAS00136

ADJUSTING THE SHIFT PEDAL1. Check:shift rod length aOut of specification Adjust.

Shift rod length290 mm (11.42 in)

2. Adjust:shift pedal position

a. Loosen both locknuts 1 .b. Turn the shift rod 2 in direction b or c to

obtain the correct shift pedal position.

Direction Shift pedal is raised.

Direction Shift pedal is lowered.

c. Tighten both locknuts.

3-46

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 slack35 45 mm (1.38 1.77 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.

3-47

ADJUSTING THE DRIVE CHAIN SLACK/LUBRICATING THE DRIVE CHAIN

CHKADJ

a

b

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 nut110 Nm (11 mkg, 80 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

3-48

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)

3-49

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)

14 Nm (1.4 mkg, 10 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.

3-50

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.

3-51

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: 7Maximum: 1

Rebound damping

Never go beyond the maximum or minimumadjustment positions.

3-52

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: 10 clicks in direction b *Standard: 9 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).



3-53

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


3-54

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).


*: with the adjusting knob fully turned-in direction a

Compression damping


1. Adjust:compression damping


DirectionCompression damping isincreased (suspension isharder).

DirectionCompression damping isdecreased (suspension is softer).



3-55

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)

182 kg (401 lb)(USA except for CAL)183 kg (404 lb) (CAL)

Maximumload*

193 kg (426 lb)(USA except for CAL)192 kg (423 lb) (CAL)

Cold tirepressure

Front Rear

Up to 90 kgload*

250 kPa (2.5 kgf/cm2,

2.5 bar,35.6 psi)

250 kPa (2.5 kgf/cm2,

2.5 bar,35.6 psi)

90 kg maximum load*

2.5 kPa (2.5 kgf/cm2,

2.5 bar,35.6 psi)

290 kPa (29 kgf/cm2,

2.9 bar,41.3 psi)

High-speed riding

2.5 kPa (2.5 kgf/cm2,

2.5 bar,35.6 psi)

2.5 kPa (2.5 kgf/cm2,

2.5 bar,35.6 psi)

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

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

3-56

A B

CHECKING THE TIRESCHKADJ

WARNING

WARNING

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

Minimum tire tread depth1.6 mm (0.06 in)

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

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

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

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

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

A TireB Wheel

Tube wheel Tube tire only

T beless wheelTube or tubeless

Tubeless wheel tire

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

3-57

CHECKING THE TIRES/CHECKING THE WHEELSCHKADJ

WARNING

NOTE:

WARNING

NOTE:

Front tire

Manufacturer Size Model

DUNLOP 120/60ZR 17M/C (55W)

D208FL

MICHELIN 120/60ZR 17M/C (55W)

PilotSPORTS N

Rear tire

Manufacturer Size Model

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

D208L

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

PilotSPORTS B

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.

3-58

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

3-59

CHECKING AND CHARGING THE BATTERYCHKADJ

WARNING

CAUTION:

EAS00178

ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERY

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

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

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTEOUT OF REACH OF CHILDREN.

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

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

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

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

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

3-60

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

Ope

n-ci

rcui

t vol

tage

(V

)

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

13.0

12.5

12.0

11.5

5 6.5 10Charging time (hours)

Ambienttemperature20C

Ope

n-ci

rcui

t vol

tage

(V

)

Charging condition of the battery (%)


NOTE:

CAUTION:

NOTE:

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


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

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

3. Remove:battery

4. Check:battery charge

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

Positive tester probe positive battery terminal

Negative tester probe negative battery terminal

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

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

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

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

3-61

ChargingAmbient temperature 20C

Ope

n-ci

rcui

t vol

tage

(V

)

Check the open-circuitvoltage.

Time (minutes)


WARNING

CAUTION:

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

Do not quick charge a battery.

Never remove the MF battery sealing caps.Do not use a high-rate battery chargersince it forces a high-amperage currentinto the battery quickly and can cause bat-tery overheating and battery plate damage.

If it is impossible to regulate the chargingcurrent on the battery charger, be carefulnot to overcharge the battery.

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

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

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

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

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

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

3-62


Measure the open-circuitvoltage prior to charging.

Connect a charged andAMP meter to the batteryand start charging.

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

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

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

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

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

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

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

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

YES NO

YES

NO

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

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

Charging method using a variable-current (voltage) charger

3-63


Measure the open-circuitvoltage prior to charging.

Connect a charger andAMP meter to the batteryand start charging.

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

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

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

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

Set the charging time at 20 hours(maximum).

YES NO

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

NOTE:

Charging method using a constant voltage charger

3-64

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”.

3-65

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 40 A 1

Fuel injectionsystem

15 A 1

Headlight 20 A 1

Signalingsystem

15 A 1

Ignition 15 A 1

Backup fuse(odometerand clock)

10 A 1

Radiatorfan motor

15 A 1

Reserve 40 A, 20 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”.


3-66

REPLACING THE HEADLIGHT BULBSCHKADJ

WARNING

CAUTION:

EAS00183

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

2. Disconnect:headlight bulb coverheadlight coupler 1

3. Remove:headlight bulb holder 1

4. Remove:headlight bulb

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

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

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

6. Install:headlight bulb holder

7. Install:headlight bulb cover

8. Connect:headlight coupler

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

3-67

ADJUSTING THE HEADLIGHT BEAMSCHKADJ

a

b

a

b

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


123456789

Removing the front wheel and brakediscs

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

224112222


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

Loosen.


NOTE:

7 Nm (0.7 mkg, 5.1 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

91 Nm (9.1 mkg, 66 ftlb)

18 Nm (1.8 mkg, 13 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

18 Nm (1.8 mkg, 13 ftlb)

FRONT WHEEL AND BRAKE DISCS CHAS

EAS00514

CHASSISFRONT WHEEL AND BRAKE DISCS

4-2

4


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

221


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. Remove: front wheel axle front wheel axle bolt 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 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 discsDamage/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 2 3 mm (0.08

0.12 in) below 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: 4.5 mm (0.18 in)Rear: 4.5 mm (0.18 in)

4. Adjust:brake disc deflection

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

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

4-6


NOTE:

NOTE:

Brake disc boltFront: 18 Nm (1.8 mkg, 13 ftlb)Rear: 30 Nm (3.0 mg, 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 with the mark 1 pointing in thedirection of wheel rotation.

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

5. Install the brake calipers by installing thebolts, and then tightening them to the speci-fied torque.

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

Brake caliper bolt:40 Nm (4.0 mkg, 29 ftlb)

6. Install the brake hose holders by installingthe bolts and nuts.

7. Secure the wheel axle by installing the axlebolt, and then tightening it to the specifiedtorque.

Axle bolt:91 Nm (9.1 mkg, 66 ftlb)

4-7


NOTE:

NOTE:

8. Tighten wheel axle pinch bolt 2 , and thenpinch bolt 1 to specified torque.

9. Retighten pinch bolt 2 to the specifiedtorque.

Wheel axle pinch bolt:18 Nm (1.8 mkg, 13 ftlb)

10. Tap the outer side of the left fork leg with arubber mallet to align it with the end of thewheel axle.

11. Tighten wheel axle pinch bolt 4 , and thenpinch bolt 3 to specified torque.

12. Retighten pinch bolt 4 to the specifiedtorque.

Wheel axle pinch bolt:18 Nm (1.8 mkg, 13 ftlb)

13. While applying the front brake, push downhard on the handlebar several times tocheck for proper fork operation.

EAS00549

ADJUSTING THE FRONT WHEEL STATICBALANCE

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

Adjust the front wheel static balance with thebrake discs installed.

1. Remove:balancing weight(s)

2. Find: front wheel’s heavy spot

Place the front wheel on a suitable balancingstand.

4-8


NOTE:

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

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

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

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

until all the marks come to rest at the samespot.

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

3. Adjust: front wheel static balance

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

Start with the lightest weight.

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

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

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

4. Check: front wheel static balance

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

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

4-9


123456789

10

Removing the rear wheel

Rear brake caliperLocknut (left and right)Adjusting bolt (left and right)Wheel axle nutWasherRear wheel axleLeft adjusting blockRight adjusting blockRear wheelRear brake caliper bracket

1221111111


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

Loosen.Loosen.


NOTE:

110 Nm (11 mkg, 80 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

28 Nm (2.8 mkg, 20 ftlb)

REAR WHEEL AND BRAKE DISC CHAS

EAS00551

REAR WHEEL AND BRAKE DISCREAR WHEEL

4-10


123456789

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

111121611



100 Nm (10 mkg, 72 ftlb)

30 Nm (3.0 mkg, 22 ftlb)


EAS00556

REAR BRAKE DISC AND REAR WHEEL SPROCKET

4-11


Disassembling the rear wheelCollarBearingSpacerOil sealCirclipBearing

111111

Disassemble the parts in the order listed.

For installation, reverse the disassemblyprocedure.

123456


EAS00560

4-12


WARNING

NOTE:

NOTE:

NOTE:

EAS00561

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



2. Remove:brake caliper 1

Do not depress the brake pedal when removingthe brake caliper.

3. Loosen: locknuts 1 (left and right)adjusting bolts 2 (left and right)

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

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

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

4-13


EAS00565

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

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

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

EAS00567

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

rear wheel drive hub dampers 2Damage/wear Replace.

EAS00568

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

b Correct1 Drive chain roller2 Rear wheel sprocket

4-14


NOTE:

110 Nm (11 mkg, 80 ftlb)

28 Nm (2.8 mkg, 20 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

2. Replace: rear wheel sprocket

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

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

c. Install the new rear wheel sprocket.

Rear wheel sprocket self-locking nut

100 Nm (10 mkg, 72 ftlb)

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

EAS00572

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


2. Install: rear brake caliper bracket rear wheeladjusting blocks rear wheel axle

3. Adjust:drive chain slack

Drive drain slack35 45 mm (1.38 1.77 in)

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

(rear)

4-15


NOTE:

EAS00575

ADJUSTING THE REAR WHEEL STATICBALANCE

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

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

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

4-16


123456

Removing the front brake pads

Front brake caliperBrake pad clipBrake pad pinBrake pad springBrake padBleed screw

121121


The following procedure applies to both ofthe front brake calipers.


NOTE:

40 Nm (4.0 mkg, 29 ftlb)

6 Nm (0.6 mkg, 4.3 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

FRONT AND REAR BRAKES CHAS

EAS00577

FRONT AND REAR BRAKESFRONT BRAKE PADS

4-17


123456

Removing the rear brake padsScrew plugBrake pad pinRear brake caliperBrake pad shimBrake padBleed screw

121421



6 Nm (0.6 mkg, 4.3 ftlb)

28 Nm (2.8 mkg, 20 ftlb)

2.5 Nm (0.25 mkg, 1.8 ftlb)

18 Nm (1.8 mkg, 13 ftlb)

23 Nm (2.3 mkg, 17 ftlb)


REAR BRAKE PADS

4-18


CAUTION:

WARNING

NOTE:

EAS00579

Disc brake components rarely require disas-sembly.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.

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

4-19


NOTE:

2. Remove:brake pad clips 1brake pad pin 2brake pad spring 3

3. Remove:brake pads 1

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

Brake pad wear limit0.5 mm (0.02 in)

5. Install:brake padsbrake pad spring

Always install new brake pads, and a brake padspring as a set.

4-20


NOTE:

40 Nm (4.0 mkg, 29 ftlb)

a. Connect a clear plastic hose 1 tightly to thebleed screw 2 . Put the other end of the hoseinto an open container.

b. Loosen the bleed screw and push the brakecaliper pistons into the brake caliper withyour finger.

c. Tighten the bleed screw.


The arrow mark a on the brake pad spring mustpoint in the direction of disc rotation.

d. 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.

4-21


NOTE:

NOTE:

EAS00583

REPLACING THE REAR BRAKE PADS

When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disas-semble the brake caliper.

1. Remove:screw plug 1brake pad pinbrake caliper 2

2. Remove:brake pad spring

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

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

Brake pad wear limit1.0 mm (0.04 in)

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.

4-22


28 Nm (2.8 mkg, 20 ftlb)

23 Nm (2.3 mkg, 17 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 .

6. Install: rear brake caliper (front)

rear brake caliper (rear)

brake pad pinscrew plug


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

4-23


123456789

1011121314

Removing the front brake master cylinderBrake fluid

StopperBrake fluid reservoir capBrake fluid reservoir diaphragm holderBrake fluid reservoir diaphragmBrake fluid reservoir tankBrake fluid reservoir hoseDust coverCirclipHose jointBrake leverFront brake switch connectorUnion boltCopper washerBrake hose

11111111112132

Remove the parts in the order listed.Drain.Refer to “CHANGING THE BRAKE FLUID” in chapter 3.

Disconnect.

30 Nm (3.0 mkg, 22 ftlb)

13 Nm (1.3 mkg, 9.4 ftlb)


EAS00584

FRONT BRAKE MASTER CYLINDER

4-24


151617

Brake master cylinder bracketBrake master cylinderFront brake switch

111


30 Nm (3.0 mkg, 22 ftlb)

13 Nm (1.3 mkg, 9.4 ftlb)


4-25


Disassembling the front brake master cylinderDust bootCirclipBrake master cylinder kitBrake master cylinder body

1111



1234


EAS00585

4-26


123456789

10

Removing the rear brake mastercylinderBrake fluid

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

1111111211


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

4-27


Disassembling the rear brake mastercylinderBrake master cylinder kitBrake master cylinder body

11



12


EAS00587

4-28


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 hoses 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

4-29

B

A

A

B

A B


EAS00593

CHECKING THE FRONT AND REAR BRAKEMASTER CYLINDERSThe following procedure applies to both of thebrake master cylinders.1. Check:brake master cylinder Damage/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 kit Damage/scratches/wear Replace.

A FrontB Rear

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

brake fluid reservoir diaphragm 2Cracks/damage Replace.

4. Check:brake hoses Cracks/damage/wear Replace.

4-30


WARNING

13 Nm (1.3 mkg, 9.4 ftlb)

NOTE:

30 Nm (3.0 mkg, 22 ftlb)

WARNING

EAS00607

ASSEMBLING AND INSTALLING THEFRONT 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 mating surfaces of the brake mastercylinder holder with the punch mark b on theright handlebar.

First, tighten the upper bolt, then the lower bolt.There should be 8.2 mm (0.32 in.) for clear-ance between the right handlebar switch andthe 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”.

4-31


NOTE:

WARNING

CAUTION:

While holding the brake hose, tighten theunion bolt as shown.

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.

4-32


30 Nm (3.0 mkg, 22 ftlb)

CAUTION:

WARNING



EAS00610

ASSEMBLING THE REAR BRAKE MASTERCYLINDER1. Install:brake master cylinder kitcirclipdust boot

2. Install:copper washers Newbrake hose

When installing the brake hose onto thebrake master cylinder, make sure that thebrake pipe touches the projection a on thebrake master cylinder.


3. Fill:brake fluid reservoir(to the maximum level mark)


4-33


WARNING

CAUTION:







6. Adjust:brake pedal position aRefer to “ADJUSTING THE REAR BRAKE”in chapter 3.

Brake pedal position Brake pedal position (below thebottom of the footrest bracket)7 11 mm (0.28 0.43 in)

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

4-34


1234

Removing the front brake calipers

Brake fluidUnion boltCopper washerBrake hoseBrake caliper

1211


The following procedure applies to bothof the front brake calipers.

Drain.


NOTE:

7 Nm (0.7 mkg, 5.1 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

30 Nm (3.0 mkg, 22 ftlb)


EAS00613

FRONT BRAKE CALIPERS

4-35


Disassembling the front brake calipers

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

2112481


The following procedure applies to bothof the front brake calipers.


NOTE:

1234567

6 Nm (0.6 mkg, 4.3 ftlb)


EAS00615

4-36


1234

Removing the rear brake caliperBrake fluidUnion boltCopper washerBrake hoseBrake caliper

1211

Remove the parts in the order listed.Drain.


30 Nm (3.0 mkg, 22 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

28 Nm (2.8 mkg, 20 ftlb)


EAS00616

REAR BRAKE CALIPER

4-37


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

11241121



123

6 Nm (0.6 mkg, 4.3 ftlb)

45678

2.5 Nm (0.25 mkg, 1.8 ftlb)

18 Nm (1.8 mkg, 13 ftlb)


EAS00617

4-38


NOTE:

NOTE:

WARNING

EAS00625

DISASSEMBLING THE FRONT BRAKE CALIPERSThe following procedure applies to both of thebrake calipers.

Before disassembling the brake caliper, drainthe brake fluid from the entire brake system.

1. Remove:union bolt 1copper washers 2brake hose 3

Put the end of the brake hose into a containerand pump out the brake fluid carefully.

2. Remove:brake caliper pistons 1brake caliper piston seals 2

a. Secure the right side brake caliper pistonswith a piece of wood a .

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

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.

4-39


NOTE:

NOTE:

WARNING

EAS00627

DISASSEMBLING THE REAR BRAKE CALIPER

Before disassembling the brake caliper, drainthe brake fluid from the entire brake system.

1. Remove:union bolt 1copper washers 2brake hose 3brake caliper 4

Put the end of the brake hose into a containerand pump out the brake fluid carefully.

2. Remove:brake caliper piston 1brake caliper piston seals 2

a. Blow compressed air into the brake hosejoint opening a to force out the pistons fromthe brake caliper.

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

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

b. Remove the brake caliper piston seals.

4-40

A

B


WARNING

EAS00633

CHECKING THE FRONT AND REAR BRAKECALIPERS

Recommended brake componentreplacement schedule

Brake pads If necessary

Piston seals Every two years

Brake hoses Every four years

Brake fluid Every two yearsand whenever thebrake is disas-sembled

1. Check:brake caliper pistons 1Rust/scratches/wear Replace the brakecaliper pistons.

brake caliper cylinders 2Scratches/wear Replace the brake cali-per assembly.

brake caliper body 3Cracks/damage Replace the brake cali-per assembly.

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

Whenever a brake caliper is disassembled,replace the brake caliper piston seals.

A FrontB Rear

2. Check: rear brake caliper bracket 1Cracks/damage Replace.

4-41


WARNING

40 Nm (4.0 mkg, 29 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

WARNING

CAUTION:

EAS00640

ASSEMBLING AND INSTALLING THEFRONT 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

Refer to “REPLACING THE BRAKE PADS”.


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

4-42


WARNING

CAUTION:










4-43


WARNING

28 Nm (2.8 mkg, 20 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

WARNING

CAUTION:

ASSEMBLING AND INSTALLING THEREAR 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, make sure that the brake pipea touches the projection b on the brakecaliper.



4-44


WARNING

CAUTION:







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

4-45


123456

Removing the front fork legsFront wheelFront brake calipersFront cowling inner panelsFront fenderCap boltHandlebar pinch boltUpper bracket pinch boltUnder bracket pinch boltFront fork leg

111121


Refer to “FRONT AND REAR BRAKES”.Refer to “COWLINGS” in chapter 3.

Loosen.Loosen.Loosen.Loosen.


33 Nm (3.3 mkg, 24 ftlb)

26 Nm (2.6 mkg, 19 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

6 Nm (0.6 mkg, 4.3 ftlb)

FRONT FORK CHAS

EAS00647

FRONT FORKFRONT FORK LEGS

4-46


Disassembling the front fork legs

Cap boltO-ringDamper adjusting rodNutWasherSpacerWasherFork springDust sealOil seal clipDamper rod assembly boltCopper washer

111111111111


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

NOTE:

123456789101112

23 Nm (2.3 mkg, 17 ftlb)

15 Nm (1.5 mkg, 11 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

FRONT FORK CHAS

EAS00648

4-47


Damper rod assemblyInner tubeOil sealWasherOuter tube bushingInner tube bushingOil lock piece

1111111

For assembly, reverse the disassemblyprocedure.

13141516171819

23 Nm (2.3 mkg, 17 ftlb)

15 Nm (1.5 mkg, 11 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

FRONT FORK CHAS

4-48

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: front cowling inner panelsRefer 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

4-49

FRONT FORK CHAS

NOTE:

CAUTION:

NOTE:

EAS00655

DISASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Loosen:nut 1

2. Remove:cap bolt 2(from the damper rod assembly)

3. Remove:damper adjusting rod 1washer 2spacer 3 fork spring

4. Drain: fork oil

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

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

Do not scratch the inner tube.

6. Remove:damper rod assembly boltcopper washer

While holding the damper rod with the damperrod holder 1 , loosen the damper rod assemblybolt.

4-50

FRONT FORK CHAS

WARNING

Damper rod holder90890-01473

7. Remove:damper rod assembly

8. Remove: inner tubeoil seal inner tube bushing

a. Hold the front fork leg horizontally.b. Slowly push A the inner tube into the outer

tube and just before it bottoms out, pull B theinner tube back quickly.

c. Repeat this step until the inner tube sepa-rates from the outer tube.

EAS00657

CHECKING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Check: inner tube 1outer tube 2Bends/damage/scratches Replace.

Do not attempt to straighten a bent innertube as this may dangerously weaken it.

2. Measure:spring free length aOut of specification Replace.

Spring free length249.3 mm (9.81 in)<Limit> : 244.3 mm (9.62 in)

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

oil lock piece 2damper rod adjusting rod 3Bends/damage Replace.

4-51

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-ringDamage/wear Replace.

EAS00661

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

Make sure the oil levels in both front forklegs are equal.

Uneven oil levels can result in poor han-dling and a loss of stability.

When assembling the front fork leg, be sure toreplace the following parts:– inner tube bushing– outer tube bushing– oil seal– dust seal

Before assembling the front fork leg, makesure all of the components are clean.

1. Install: inner tube bushingoil lock piece inner tube 1damper rod assembly 2damper rod assembly boltcopper washer New

4-52

FRONT FORK CHAS

WARNING

CAUTION:

40 Nm (4.0 mkg, 29 ftlb)

NOTE:

Always use new copper washers.

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 holder90890-01473

4. Install:outer tube bushing 1(with the fork seal driver weight 2 and forkseal driver attachment 3 )

Fork seal driver weight90890-01367, YM-33963

Fork seal driver attachment90890-01374, YM-8020-A

4-53

FRONT FORK CHAS

CAUTION:

NOTE:

NOTE:

5. Install:washeroil seal 1(with the fork seal driver weight and fork sealdriver attachment)

Make sure the numbered side of the oil sealfaces up.

Before installing the oil seal, lubricate its lipswith lithium-soap-based grease.

Lubricate the outer surface of the inner tubewith fork oil.

Before installing the oil seal, cover the top ofthe front fork leg with a plastic bag 2 to protectthe oil seal during installation.

6. Install:oil seal clip 1

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

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

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

Rod puller90890-01437, YM-01437

Rod puller attachment90890-01436

4-54

FRONT FORK CHAS

CAUTION:

NOTE:

NOTE:

NOTE:

9. Fully compress the front fork leg.10. Fill: front fork leg(with the specified amount of the recom-mended fork oil)

Quantity (each front fork leg)0.49 L (0.43 Imp qt, 0.52 US qt)

Recommended oilSuspension oil “01”

Be sure to use the recommended fork oil.Other oils may have an adverse effect onfront fork performance.

When disassembling and assembling thefront fork leg, do not allow any foreign ma-terial to enter the front fork.

11. After filling the front fork leg, slowly strokethe damper rod 1 up and down (at least tentimes) to distribute the fork oil.

Be sure to stroke the damper rod slowly be-cause the fork oil may spurt out.

12. Slowly stroke the inner tube 1 up and downto distribute the fork oil once more (1 stroke= about 100 mm (3.94 in)).

Be careful not to stroke the inner tube over 100mm (3.94 in) as this will cause air to enter. If theinner tube is stroked more than 100 mm (3.94in), repeat steps (12) and (13).

13. Before measuring the fork oil level, wait tenminutes until the oil has settled and the airbubbles have dispersed.

Be sure to bleed the front fork leg of any residualair.

4-55

FRONT FORK CHAS

NOTE:

14. Measure: front fork leg oil level aOut of specification Correct.

Front fork leg oil level (from the top of the inner tube, with the inner tube fully compressed, and withoutthe spring)

106 mm (4.17 in)

15. Install:nut 1 fork spring 2washer 3spacer 4washer 5damper adjusting rod 6cap bolt 7

a. Remove the rod puller and rod puller attach-ment.

b. Install the damper adjusting rod locknut 1and position it as specified a .

Damper adjusting rod nut position (from the top of the rod to the top of the nut) a

11 mm (0.43 in)

c. Set the cap bolt distance b to specification.

Distance b25 mm (0.98 in)

d. Install the damper adjusting rod, fork spring,washer (lower), spacer and washer (upper).

Install the fork spring with the smaller pinch afacing up.

b Larger pitch

4-56

FRONT FORK CHAS

WARNING

NOTE:

23 Nm (2.3 mkg, 17 ftlb)

26 Nm (2.6 mkg, 19 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

e. Install the cap bolt and finger tighten it.

Before installing the cap bolt, apply greaseonto the O-ring.

Always use a new cap bolt O-ring.

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

Nut15 Nm (1.5 mkg, 11 ftlb)

EAS00662

INSTALLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Install:handlebar (temporarily)

2. Install: front fork legTemporarily tighten the upper and underbracket pinch bolts.

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

3. Remove:handlebar

4. Tighten:under bracket pinch bolt

upper bracket pinch bolt 1

cap bolt 2

4-57

FRONT FORK CHAS

33 Nm (3.3 mkg, 24 ftlb)

13 Nm (1.3 mkg, 9.4 ftlb)

WARNING

5. Install:handlebarhandlebar pinch bolt 1

handlebar bolt 2

Make sure the brake hoses are routed prop-erly.

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

4-58


123456789

1011121314

Removing the handlebarsGrip endHandlebar gripClutch switch connectorLeft handlebar switchClutch cableClutch leverRight handlebar switchThrottle gripThrottle cablesFront brake light switch connectorFront brake master cylinder holderFront brake master cylinderReservoir tank bracketHandlebar

21111111221112


Disconnect.

Disconnect.


33 Nm (3.3 mkg, 24 ftlb)

13 Nm (1.3 mkg, 9.4 ftlb)

13 Nm (1.3 mkg, 9.4 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

11 Nm (1.1 mkg, 8.0 ftlb)

33 Nm (3.3 mkg, 24 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

13 Nm (1.3 mkg, 9.4 ftlb)

HANDLEBARS CHAS

EAS00665

HANDLEBARS

4-59

HANDLEBARS CHAS

WARNING

NOTE:

WARNING

EAS00667

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


2. Remove:grip endhandlebar grip

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

3. Remove: left handlebar switch 1clutch lever holder 2

4. Remove:grip end right handlebar switch 1 throttle grip 2 front brake master cylinder 3

EAS00669

CHECKING THE HANDLEBARS1. Check: left handlebar right handlebarBends/cracks/damage Replace.

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

4-60

HANDLEBARS CHAS

WARNING

NOTE:

33 Nm (3.3 mkg, 24 ftlb)

13 Nm (1.3 mkg, 9.4 ftlb)

13 Nm (1.3 mkg, 9.4 ftlb)

CAUTION:

NOTE:

EAS00674

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


2. Install: throttle cables throttle grip 1 right handlebar switch 2

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

3. Install: right handlebar 1 right handlebar pinch bolt 2

right handlebar bolt 3

4. Install: front brake master cylinder 1master cylinder holder 2

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

First, tighten the upper bolt, and then thelower bolt.

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

There should be 8.2 mm (0.32 in) of clearancebetween the right handlebar switch and thebrake master cylinder holder.

4-61

HANDLEBARS CHAS

11 Nm (1.1 mkg, 8.0 ftlb)

NOTE:

33 Nm (3.3 mkg, 24 ftlb)

13 Nm (1.3 mkg, 9.4 ftlb)

NOTE:

WARNING

23 Nm (2.3 mkg, 17 ftlb)

5. Install:clutch lever holder 1

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

6. Install: left handlebar left handlebar pinch bolt 1

left handlebar bolt 2

7. Install: left handlebar switch 1

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

8. 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.

9. Install:grip ends

4-62

HANDLEBARS CHAS

10. 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)

11. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY” in chapter 3.


6 8 mm (0.24 0.31 in)

4-63


1234567

Removing the under bracketFront wheelFront brake calipersFront fork legsFront fenderHandlebarsFuel tankAir filter case

Main switch couplerSteering stem nutWasherUpper bracketUnder bracket panelLock washerUpper ring nut

2111111


Refer to “HANDLEBARS”.Refer to “FUEL TANK” in chapter 3.Refer to “AIR FILTER CASE” in chapter3.Disconnect

Refer to “FRONT FORK”.

Refer to “FRONT WHEEL AND BRAKEDISCS”.

26 Nm (2.6 mkg, 19 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

113 Nm (11.3 mkg, 82 ftlb)

52 Nm (5.2 mkg, 38 ftlb)14 Nm (1.4 mkg, 10 ftlb)

1st2nd

STEERING HEAD CHAS

EAS00676

STEERING HEADUNDER BRACKET

4-64


89

10111213141516

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

111121112


26 Nm (2.6 mkg, 19 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

113 Nm (11.3 mkg, 82 ftlb)


1st2nd

STEERING HEAD CHAS

4-65

STEERING HEAD CHAS

WARNING

NOTE:

WARNING

EAS00679

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


2. Remove:steering stem nutwasherupper bracket lock washer rubber washer ring nut 1(with the steering nut wrench 2 )

Hold the lower ring nut with the exhaust andsteering nut wrench, and then remove the upperring nut with the ring nut wrench.

Steering nut wrench90890-01403, YU-33975

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

EAS00681

CHECKING THE STEERING HEAD1. Wash:bearingsbearing races

Recommended cleaning solventKerosene

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

4-66

STEERING HEAD CHAS

CAUTION:

NOTE:

3. Replace:bearingsbearing races

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

b. Remove the bearing race 3 from the underbracket 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 bracketunder 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.

4-67

STEERING HEAD CHAS

113 Nm (11.3 mkg, 82 ftlb)

NOTE:

NOTE:

3. Install:upper bracketwashersteering stem nut

Temporarily tighten the steering stem nut.

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

Temporarily tighten the upper and under brack-et pinch bolts.

5. Install: front wheelRefer to “FRONT WHEEL AND BRAKEDISCS”.

4-68


1

2

34

5

67

8

Removing the rear shock absorber assemblyRear wheel

Self-locking nut/bolt (Relay arm – rear shock absorber)Self-locking nut/bolt(Rear shock absorber upper)Rear shock absorberSelf-locking nut/bolt(Relay arm – swingarm)Self-locking nut/bolt(Relay arm – connecting rod)Relay armSelf-locking nut/nut(Connecting rod – frame)Connecting rod

1/1

1/1

11/1

1/1

21/1

1


Refer to “REAR WHEEL AND BRAKEDISC”.

52 Nm (5.2 mkg, 38 ftlb)

44 Nm (4.4 mkg, 32 ftlb)

44 Nm (4.4 mkg, 32 ftlb)

REAR SHOCK ABSORBER ASSEMBLY CHAS

EAS00685

REAR SHOCK ABSORBER ASSEMBLY

4-69



91011

Oil seal/bearing/collarOil seal/bearing/collarBracket

6/3/32/1/1

1For installation, reverse the removal procedure.

52 Nm (5.2 mkg, 38 ftlb)

44 Nm (4.4 mkg, 32 ftlb)

44 Nm (4.4 mkg, 32 ftlb)

4-70


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.

4-71


WARNING

NOTE:

NOTE:

EAS00694

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



2. Remove: rear wheelRefer to “REAR WHEEL AND BRAKEDISC”.

3. Remove: rear shock absorber assembly lower bolt 1

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

4. Remove: rear shock absorber assembly upper bolt 1 rear shock absorber assembly

EAS00696

CHECKING THE REAR SHOCK ABSORBERASSEMBLY AND GAS CYLINDER1. Check: rear shock absorber rodBends/damage Replace the rear shockabsorber assembly.

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

4-72


NOTE:

44 Nm (4.4 mkg, 32 ftlb)

44 Nm (4.4 mkg, 32 ftlb)

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

gas cylinderDamage/gas leaks Replace.

bushingsDamage/wear Replace.

dust sealsDamage/wear Replace.

boltsBends/damage/wear Replace.

CHECKING THE CONNECTING ROD ANDRELAY ARMS1. Check:connecting rod 1 relay arms 2Damage/wear Replace.

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

3. Check:collars 5Damage/scratches Replace.

EAS00698

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY1. Lubricate:spacersbearings


2. Install: rear shock absorber assembly

When installing the rear shock absorber assem-bly, lift up the swingarm.

3. Tighten: rear shock absorber assembly upper nut 1

rear shock absorber assembly lower nut 2

4-73


123456789

Removing the swingarm and drive chainRear wheel

Rear shock absorber assembly

Relay arms and connecting rod

Drive sprocket coverAdjusting boltLocknutRear fenderPivot shaft nut/washerPivot shaftSwingarmDrive chainDrive chain guideDust cover

221

1/111112


Refer to “REAR WHEEL AND BRAKEDISC”.Refer to “REAR SHOCK ABSORBERASSEMBLY”.Refer to “REAR SHOCK ABSORBERASSEMBLY”.Refer to “ENGINE” in chapter 5.

95 Nm (9.5 mkg, 69 ftlb) 6 Nm (0.6 mkg, 4.3 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

16 Nm (1.6 mkg, 12 ftlb)

SWINGARM AND DRIVE CHAIN CHAS

EAS00700

SWINGARM AND DRIVE CHAIN

4-74


10111213

BearingSpacerPivot shaft adjust boltDrive chain case

2111


95 Nm (9.5 mkg, 69 ftlb) 6 Nm (0.6 mkg, 4.3 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

16 Nm (1.6 mkg, 12 ftlb)


4-75


WARNING

NOTE:

EAS00703

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



2. Remove: rear wheelRefer to “REAR WHEEL AND BRAKEDISC”.

rear shock absorber assembly, relay armand connecting rodRefer to “REAR SHOCK ABSORBER AS-SEMBLY”.

3. Measure:swingarm side playswingarm vertical movement

a. Measure the tightening torque of the pivotshaft nut.

Pivot shaft nut95 Nm (9.5 mkg, 69 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.

4-76


WARNING

NOTE:

WARNING

EAS00704

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



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

EAS00707

CHECKING THE SWINGARM1. Check:swingarmBends/cracks/damage Replace.

2. Check:pivot shaftRoll the pivot shaft on a flat surface.Bends Replace.

Do not attempt to straighten a bent pivotshaft.

3. Wash:pivot shaftdust coversspacerwashersbearings

Recommended cleaning solventKerosene

4-77


NOTE:

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

bearingsDamage/pitting 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.

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.

4-78


CAUTION:

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 then 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 lubricant suitable for O-ring chains

6. Check:drive sprocket rear wheel sprocketMore than 1/4 tooth a wear Replace thedrive chain sprockets as a set.Bent teeth Replace the drive chain sprock-ets as a set.

b Correct1 Drive chain roller2 Drive chain sprocket

4-79


6 Nm (0.6 mkg, 4.3 ftlb)

95 Nm (9.5 mkg, 69 ftlb)

NOTE:

44 Nm (4.4 mkg, 32 ftlb)

44 Nm (4.4 mkg, 32 ftlb)

NOTE:

EAS00711

INSTALLING THE SWINGARM1. Lubricate:bearingsspacersdust coverspivot shaft


2. Install:pivot shaft adjust bolt 1

swingarmpivot shaft

Use the pivot shaft wrench 2 and adapter 3 totighten the pivot adjust bolt to specificationtorque.

Pivot shaft wrench:90890-01471, YM-01471

Pivot shaft wrench adapter90890-01476

3. Install: relay arms 1connecting rod 2

Install the connecting rod front bolt 3 from theleft.

4. Install: rear shock absorber assembly rear wheelRefer to “INSTALLING THE REAR SHOCKABSORBER ASSEMBLY” and “INSTAL-LING THE REAR WHEEL”.

5. Adjust:drive chain slackRefer to “ADJUSTING THE DRIVE CHAINSLACK” in chapter 3.

Drive chain slack35 45 mm (1.38 1.77 in)

5-1

5


12345678

Removing the drive sprocketBottom cowlingSide cowlingsDrive chain

Lock nutShift rodShift armDrive sprocket coverNutLock washerChain guideDrive sprocket

21111111


Loosen.Refer to “ADJUSTING THE DRIVE CHAIN” in chapter 3.Loosen.


Refer to “COWLINGS” in chapter 3.

10 Nm (1.0 mkg, 7.2 ftlb)

6.5 Nm (0.65 mkg, 4.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

90 Nm (9.0 mkg, 65 ftlb)

ENGINE ENG

OVERHAULING THE ENGINE

ENGINEDRIVE SPROCKET

5-2

ENGINE ENG

20 Nm (2.0 mkg, 15 ftlb)

20 Nm (2.0 mkg, 15 ftlb)

20 Nm (2.0 mkg, 15 ftlb)


123

Removing the exhaust pipeBottom cowlingSide cowlingsMufflerExhaust pipe assemblyExhaust pipe gasket

114




23 Nm (2.3 mkg, 17 ftlb)

EAS00189

EXHAUST PIPE

5-3


12

Disconnecting the leads and hosesAir filter caseThrottle body assembly

Engine oilOil filter cartridge

Oil coolerAir cut-off valve

Starter motor

Battery negative leadBattery positive lead

11

Disconnect the parts in the order listed.Refer to “AIR FILTER CASE” in chapter 3.Refer to “THROTTLE BODIES” in chapter 7.

Refer to “OIL COOLER” in chapter 6.Refer to “AIR INDUCTION SYSTEM” inchapter 7.Refer to “STARTING SYSTEM” in chapter8.

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

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

CAUTION:

20 Nm (2.0 mkg, 15 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

ENGINE ENG

EAS00188

LEADS AND HOSES

5-4

ENGINE ENG


3456789

10

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

11111111

Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.For connecting reverse the disconnectionprocedure.

20 Nm (2.0 mkg, 15 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

5-5


123456789

Removing the engine

Drive chain guideRight front engine mounting boltLeft front engine mounting boltSelf-locking nutRear engine mounting boltEngine bracket boltEngine bracketEngine mounting adjust boltEngine

122222121

Removing the parts in the order listed.

Place a suitable stand under the frame andengine.

Use the pivot shaft wrench and adapter toloosen the engine mounting adjust bolts.


NOTE:

Refer to “INSTALLING THE ENGINE”.

NOTE:

7 Nm (0.7 mkg, 5.1 ftlb)

45 Nm (4.5 mkg, 33 ftlb)

45 Nm (4.5 mkg, 33 ftlb)

45 Nm (4.5 mkg, 33 ftlb)

45 Nm (4.5 mkg, 33 ftlb)

ENGINE ENG

EAS00191

ENGINE

5-6

ENGINE ENG

45 Nm (4.5 mkg, 33 ftlb)

NOTE:

45 Nm (4.5 mkg, 33 ftlb)

NOTE:

7 Nm (0.7 mkg, 5.1 ftlb)

NOTE:

EAS00192

INSTALLING THE ENGINE1. Install:engine bracket 1 (to the engine)

engine mounting adjust bolts (temporary tighten)

2. Install: rear engine mounting bolts 1

Lubricate the rear engine mounting boltthreads with lithium-soap-based grease.

3. Install: right front engine mounting bolts 1(temporary tighten)

left front engine mounting bolts 2

First tighten the rear side engine mounting bolt.

4. Tighten:engine mounting adjust bolts

First tighten the lower engine mounting adjustbolt.

Use the pivot shaft wrench 1 and pivot shaftwrench adapter 2 to tighten the enginemounting adjust bolts.

5-7

ENGINE ENG

45 Nm (4.5 mkg, 33 ftlb)

NOTE:

45 Nm (4.5 mkg, 33 ftlb)

NOTE:

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

7 Nm (0.7 mkg, 5.1 ftlb)

Pivot shaft wrench90890-01471, YM-01471

Pivot shaft wrench adapter90890-01476

5. Tighten:nuts 1 (rear engine mounting bolts)

First tighten the lower self-locking nut.

6. Tighten: right front engine mounting bolts 1

First tighten the rear side engine mounting bolt.

7. Install:shift arm 1

Align the punch mark a in the shift shaft withthe slot in the shift arm.

Align the bottom edge of the shift pedal with themark on the frame-to-swingarm bracket.

8. Install:drive chain guide 1

5-8


123456

Removing the cylinder head coverThrottle body assembly

Radiator assemblyAir cut-off valve

Ignition coilSpark plugCylinder head coverCylinder head cover gasketTiming chain guide (top side)Cylinder identification sensor

441111

Remove the parts in the order listed.Refer to “THROTTLE BODIES” in chapter 7.Refer to “RADIATOR” in chapter 6.Refer to “AIR INDUCTION SYSTEM” inchapter 7.


13 Nm (1.3 mkg, 9.4 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

CAMSHAFTS ENG

EAS00194

CAMSHAFTSCYLINDER HEAD COVER

5-9


123456789

101112

Removing the camshaftsPickup rotor cover

Camshaft sprocket boltTiming chain tensionerTiming chain tensioner gasketTiming chain guide (exhaust side)Intake camshaft capDowel pinExhaust camshaft capDowel pinIntake camshaftExhaust camshaftPinTiming chain guide (intake side)

411136361111

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


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

NOTE:

10 Nm (1.0 mkg, 7.2 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

24 Nm (2.4 mkg, 17 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

CAMSHAFTS ENG

EAS00196

CAMSHAFTS

5-10

CAMSHAFTS ENG

NOTE:

CAUTION:

EAS00198

REMOVING THE CAMSHAFTS1. Remove:pickup rotor coverRefer to “CRANKSHAFT POSITION SEN-SOR AND PICKUP ROTOR”.

2. Align: “T” mark a on the pickup rotor(with the crankcase mating surface b )

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

sion stroke, align the “T” mark a on the pick-up rotor with the crankcase mating surfaceb .

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

3. Loosen:camshaft sprocket bolts 1

4. Loosen:cap bolt 1

5. Remove: timing chain tensioner 2gasket

6. Remove: timing chain guide (exhaust side)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.

5-11

CAMSHAFTS ENG

NOTE:

7. Remove: intake camshaft 1exhaust camshaft 2

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

8. Remove:camshaft sprockets

EAS00204

CHECKING THE CAMSHAFTS1. Check:camshaft lobesBlue discoloration/pitting/scratches Re-place the camshaft.

2. Measure:camshaft lobe dimensions a and bOut of specification Replace the cam-shaft.

Camshaft lobe dimension limitIntake camshaft

a 33.45 33.55 mm(1.317 1.321 in)<Limit>: 33.40 mm (1.315 in)b 25.12 25.22 mm (0.989 0.993 in)<Limit>: 25.07 mm (0.987 in)

Exhaust camshafta 32.55 32.65 mm (1.282 1.285 in)<Limit>: 32.50 mm (1.280 in)b 25.07 25.17 mm (0.987 0.991 in)<Limit>: 25.02 mm (0.985 in)

5-12

CAMSHAFTS ENG

NOTE:

3. Measure:camshaft runoutOut of specification Replace.

Camshaft runout limit0.06 mm (0.0024 in)

4. Measure:camshaft-journal-to-camshaft-cap clear-anceOut of specification Measure the camshaftjournal diameter.

Camshaft-journal-to-camshaft-cap clearance

0.028 0.062 mm (0.0011 0.0024 in)<Limit>: 0.08 mm (0.0031 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 diameter22.967 22.980 mm (0.9042 0.9047 in)

5-13

CAMSHAFTS ENG

NOTE:

EAS00208

CHECKING THE TIMING CHAIN, CAMSHAFTSPROCKETS, AND TIMING CHAIN GUIDESThe following procedure applies to all of thecamshaft sprockets and timing chain guides.1. Check: timing chain 1Damage/stiffness Replace the timingchain and camshaft sprockets as a set.

2. Check:camshaft sprocketMore than 1/4 tooth wear a Replace thecamshaft sprockets and the timing chain as aset.

a 1/4 toothb Correct1 Timing chain roller2 Camshaft sprocket

3. Check: timing chain guide (exhaust side) 1 timing chain guide (intake side) 2 timing chain guide (top side) 3Damage/wear Replace the defectivepart(s).

EAS00210

CHECKING THE TIMING CHAIN TENSIONER1. Check: timing chain tensionerCracks/damage Replace.

2. Check:one-way cam operationRough movement Replace the timingchain tensioner assembly.

a. Lightly press the timing chain tensioner rodinto the timing chain tensioner housing byhand.

While pressing the timing chain tensioner rod,wind it clockwise with a thin screwdriver 1 untilit stops.

5-14

CAMSHAFTS ENG

NOTE:

b. Remove the screwdriver and slowly releasethe timing chain tensioner rod.

c. Make sure that the timing chain tensioner rodcomes out of the timing chain tensionerhousing smoothly. If there is rough move-ment, replace the timing chain tensioner.

3. Check:cap boltcopper washer Newgasket NewDamage/wear Replace the defectivepart(s).

EAS00215

INSTALLING THE CAMSHAFTS1. Align: “T” mark a on the pickup rotor(with the crankcase mating surface b )

a. Turn the crankshaft clockwise.b. When piston #1 is at TDC, align the “T” mark

a with the crankcase mating surface b .

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

Make sure the match mark a on the camshaftsprocket is aligned with the cylinder head edgeb .

5-15

CAMSHAFTS ENG

NOTE:

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

CAUTION:

NOTE:

3. Install:dowel pinsexhaust camshaft caps intake cmashaft caps

Make sure each camshaft cap is installed in itsoriginal place.

Make sure the arrow mark a on each cam-shaft cap points towards the right side of theengine.

4. Install:camshaft cap bolts

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

I1, 12: Intake side camshaft cap markE1, E2: Exhaust side camshaft cap mark

Lubricate the camshaft cap bolts with theengine oil.

The camshaft cap bolts must be tightenedevenly or damage to the cylinder head,camshaft caps, and camshafts will result.

Do not turn the crankshaft when installingthe camshaft to avoid damage or impropervalve timing.

5. Install: timing chain guide (exhaust side)

When installing the timing chain guide, be sureto keep the timing chain as tight as possible onthe exhaust side.

5-16

CAMSHAFTS ENG

WARNING

24 Nm (2.4 mkg, 17 ftlb)

CAUTION:

6. Install: timing chain tensioner

a. While lightly pressing the timing chain ten-sioner rod by hand, turn the tensioner rod ful-ly clockwise with a thin screwdriver 1 .

b. With the timing chain tensioner rod turned allthe way into the timing chain tensioner hous-ing (with the thin screwdriver still installed),install the gasket and the timing chain ten-sioner 2 onto the cylinder block.

Always use a new gasket.

c. Tighten the timing chain tensioner bolts 3 tothe specified torque.

Timing chain tensioner bolt12 Nm (1.2 mkg, 8.7 ftlb)

d. Remove the screwdriver, make sure that thetiming chain tensioner rod releases, and thentighten the cap bolt to the specified torque.

Cap bolt7 Nm (0.7 mkg, 5.1 ftlb)

7. Turn:crankshaft(several full turns clockwise)

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

camshaft sprocket match mark cMake sure the match marks on the camshaftsprockets are aligned with the crankcasemating surface d .Out of alignment Adjust.Refer to the installation steps above.

9. Tighten:camshaft sprocket bolts 1

Be sure to tighten the camshaft sprocketbolts to the specified torque to avoid thepossibility of the bolts coming loose anddamaging the engine.

5-17

CAMSHAFTS ENG

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

5-18


123

Removing the cylinder headIntake and exhaust camshaftEngine bracketCylinder headCylinder head gasketDowel pin

112

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


12 Nm (1.2 mkg, 8.7 ftlb)


1st2nd

CYLINDER HEAD ENG

EAS00221

CYLINDER HEAD

5-19

CYLINDER HEAD ENG

NOTE:

NOTE:

NOTE:

EAS00222

REMOVING THE CYLINDER HEAD1. Remove:cylinder head bolts

Loosen the bolts in the proper sequence asshown.

Loosen each bolt 1/2 of a turn at a time. Afterall of the bolts are fully loosened, removethem.

EAS00229

CHECKING THE CYLINDER HEAD1. Eliminate:combustion chamber carbon deposits(with a rounded scraper)

Do not use a sharp instrument to avoid damag-ing or scratching:spark plug bore threadsvalve seats

2. Check:cylinder headDamage/scratches Replace.

cylinder head water jacketMineral deposits/rust Eliminate.

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

Maximum cylinder head warpage0.05 mm (0.002 in)

a. Place a straightedge 1 and a thicknessgauge 2 across the cylinder head.

b. Measure the warpage.c. If the limit is exceeded, resurface the cylinder

head as follows.d. Place a 400 600 grit wet sandpaper on the

surface plate and resurface the cylinderhead using a figure-eight sanding pattern.

To ensure an even surface, rotate the cylinderhead several times.

5-20

CYLINDER HEAD ENG

NOTE:

19 Nm (1.9 mkg, 14 ftlb)

50 Nm (5.0 mkg, 36 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

NOTE:

EAS00233

INSTALLING THE CYLINDER HEAD1. Install:gasket New 1dowel pins 2

2. Install:cylinder head

Pass the timing chain through the timing chain cavity.

3. Tighten:cylinder head bolts 1 10

1st2nd

cylinder head bolts 11 , 12

First, tighten the bolts 1 10 to approximate-ly 19 Nm (1.9 mkg, 14 ftlb) with a torquewrench and then tighten the 50 Nm (5.0 mkg,36 ftlb).

Lubricate the cylinder head bolts with engineoil.

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

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

5-21


123456789

10111213

Remove the valves and valve springsCylinder headIntake valve lifterIntake valve padIntake valve cotterIntake valve upper spring seatIntake valve spring outerIntake valve spring innerIntake valve oil sealIntake valve lower spring seatIntake valveIntake valve guideExhaust valve lifterExhaust valve padExhaust valve cotter

88

16888888888

16

Remove the parts in the order listed.Refer to “CYLINDER HEAD”.

Refer to “REMOVING/INSTALLINGTHE VALVES”.

VALVES AND VALVE SPRINGS ENG

EAS00236

VALVES AND VALVE SPRINGS

5-22



141516171819

Exhaust valve upper spring seatExhaust valve springExhaust valve oil sealExhaust valve lower spring seatExhaust valveExhaust valve guide

888888


Refer to “REMOVING/INSTALLINGTHE VALVES”.

5-23


NOTE:

NOTE:

NOTE:

NOTE:

EAS00238

REMOVING THE VALVESThe following procedure applies to all of thevalves and related components.

Before removing the internal parts of the cylin-der head (e.g., valves, valve springs, valveseats), make sure the valves properly seal.

1. Remove:valve lifter 1valve pad 2

Make a note of the position of each valve lifterand valve pad so that they can be reinstalled intheir original place.

2. Check:valve sealingLeakage at the valve seat Check the valveface, valve seat, and valve seat width.Refer to “CHECKING THE VALVE SEATS”.

a. Pour a clean solvent a into the intake andexhaust ports.

b. Check that the valves properly seal.

There should be no leakage at the valve seat 1 .

3. Remove:valve cotters 1

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

5-24


NOTE:

Valve spring compressor90890-04019, YM-04019

Valve spring compressor attachment

90890-04108, YM-01253

4. Remove:upper spring seat 1valve spring outer 2valve spring inner (intake only) 3valve 4oil seal 5 lower spring seat 6

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

EAS00239

CHECKING THE VALVES AND VALVEGUIDESThe following procedure applies to all of thevalves and valve guides.1. Measure:valve-stem-to-valve-guide clearance

Valve-stem-to-valve-guide clearance =Valve guide inside diameter a –Valve stem diameter b

Out of specification Replace the valveguide.

Valve-stem-to-valve-guide clearance

Intake0.010 0.037 mm (0.0004 0.0015 in)<Limit>: 0.08 mm (0.0031 in)

Exhaust0.025 0.052 mm (0.0010 0.0020 in)<Limit>: 0.10 mm (0.0039 in)

5-25


NOTE:

NOTE:

2. Replace:valve guide

To ease valve guide removal and installation,and to maintain the correct fit, heat the cylinderhead to 100C (212F) in an oven.

a. Remove the valve guide with the valve guideremover 1 .

b. Install the new valve guide with the valveguide installer 2 and valve guide remover1 .

c. After installing the valve guide, bore thevalve guide with the valve guide reamer 3 toobtain the proper valve-stem-to-valve-guideclearance.

After replacing the valve guide, reface the valveseat.

Valve guide remover (4 mm, 0.16 in)

90890-04111,Valve guide installer (4 mm, 0.16 in)

90890-04112,Valve guide reamer (4 mm, 0.16 in)

90890-04113, YM-04113

3. Eliminate:carbon deposits(from the valve face and valve seat)

4. Check:valve facePitting/wear Grind the valve face.

valve stem endMushroom shape or diameter larger than thebody of the valve stem Replace the valve.

5-26


NOTE:

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

Valve margin thickness0.6 0.8 mm (0.0236 0.0315 in)<Limit>: 0.5 mm (0.02 in)

6. Measure:valve stem runoutOut of specification Replace the valve.

When installing a new valve, always replacethe valve guide.

If the valve is removed or replaced, always re-place the oil seal.

Valve stem runout<Limit>: 0.04 mm (0.0016 in)

EAS00240

CHECKING THE VALVE SEATSThe following procedure applies to all of thevalves and valve seats.1. Eliminate:carbon deposits(from the valve face and valve seat)

2. Check:valve seatPitting/wear Replace the cylinder head.

3. Measure:valve seat width aOut of specification Replace the cylinderhead.

Valve seat width0.9 1.1 mm (0.0354 0.0433 in)<Limit>: 1.6 mm (0.06 in)

a. Apply Mechanic’s blueing dye (Dykem) bonto the valve face.

b. Install the valve into the cylinder head.c. Press the valve through the valve guide and

onto the valve seat to make a clear impres-sion.

d. Measure the valve seat width.

5-27


NOTE:

NOTE:

CAUTION:

NOTE:

Where the valve seat and valve face contactedone another, the blueing will have been re-moved.

4. Lap:valve facevalve seat

After replacing the cylinder head or replacingthe valve and valve guide, the valve seat andvalve face should be lapped.

a. Apply a coarse lapping compound a to thevalve face.

Do not let the lapping compound enter thegap between the valve stem and the valveguide.

b. Apply molybdenum disulfide oil onto thevalve stem.

c. Install the valve into the cylinder head.d. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all ofthe lapping compound.

For the best lapping results, lightly tap the valveseat while rotating the valve back and forth be-tween your hands.

e. Apply a fine lapping compound to the valveface and repeat the above steps.

f. After every lapping procedure, be sure toclean off all of the lapping compound fromthe valve face and valve seat.

g. Apply Mechanic’s blueing dye (Dykem) bonto the valve face.

h. Install the valve into the cylinder head.i. Press the valve through the valve guide and

onto the valve seat to make a clear impres-sion.

5-28


j. Measure the valve seat width c again. If thevalve seat width is out of specification, refaceand lap the valve seat.

EAS00241

CHECKING THE VALVE SPRINGSThe following procedure applies to all of thevalve springs.1. Measure:valve spring free length aOut of specification Replace the valvespring.

Valve spring free lengthIntake valve spring (inner)35.7 mm (1.41 in)<Limit>: 33.9 mm (1.33 in)Intake valve spring (outer)40.3 mm (1.59 in)<Limit>: 38.3 mm (1.50 in)Exhaust valve spring41.7 mm (1.64 in)<Limit>: 39.6 mm (1.56 in)

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

b Installed length

Compressed valve spring force (installed)

Intake valve spring (inner)61.5 70.7 N (6.27 7.21 kg,13.83 15.89 lb)

Intake valve spring (outer)139.1 160.1 N (14.18 16.33 kg, 31.27 35.99 lb)

Exhaust valve spring160 184 N (16.32 18.76 kg,35.97 41.36 lb)

5-29


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

Spring tilt limitIntake valve spring (inner)

2.5 /1.6 mm (0.06 in)(outer)2.5 /1.8 mm (0.07 in)Exhaust valve spring2.5 /1.8 mm (0.07 in)

EAS00242

CHECKING THE VALVE LIFTERSThe following procedure applies to all of thevalve lifters.1. Check:valve lifterDamage/scratches Replace the valve lift-ers and cylinder head.

EAS00246

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

2. Lubricate:valve stem 1valve stem seal 2(with the recommended lubricant)

Recommended lubricantMolybdenum disulfide oil

3. Install:valve 1 lower spring seat 2valve stem seal 3valve spring inner (intake only) 4valve spring outer 5upper spring seat 6(into the cylinder head)

5-30


NOTE:

NOTE:

CAUTION:

NOTE:

Make sure that each valve is installed in itsoriginal place.

Install the valve springs with the larger pitch afacing up.

b Smaller pitch

4. Install:valve cotters 1

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

Valve spring compressor90890-04019, YM-04019

Valve spring compressor attachment

90890-04108, YM-01253

5. To secure the valve cotters onto the valvestem, lightly tap the valve tip with a soft-facehammer.

Hitting the valve tip with excessive forcecould damage the valve.

6. Install:valve pad 1valve lifter 2

Lubricate the valve lifter and valve pad withmolybdenum disulfide oil.

The valve lifter must move smoothly when ro-tated with a finger.

Each valve lifter and valve pad must be rein-stalled in its original position.

5-31


12345

Removing the stator coil assemblyRider seat and fuel tank

Buttom cowlingLeft side cowlingCoolantCoolant reservoir tank

Engine oil

Stator coil assembly couplerGenerator rotor coverGenerator rotor cover gasketDowel pinStator coil assembly lead holder

11121

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

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


32 Nm (3.2 mkg, 23 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

75 Nm (7.5 mkg, 54 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

STARTER CLUTCH AND GENERATOR ENG

EAS00341

STARTER CLUTCH AND GENERATORSTATOR COIL ASSEMBLY

5-32



6789

10111213

Stator coil assemblyGenerator rotor boltWasherGenerator rotorStarter clutch assemblyIdler gear shaftIdler gearStarter clutch drive gear

11111111


Refer to “REMOVING/INSTALLINGTHE GENERATOR”.

32 Nm (3.2 mkg, 23 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

75 Nm (7.5 mkg, 54 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

5-33


NOTE:

NOTE:

EAS00347

REMOVING THE GENERATOR1. Remove: rider seat and fuel tankRefer to “SEATS” and “FUEL TANK” in chap-ter 3.

buttom cowling left side cowlingRefer to “COWLINGS” in chapter 3.

2. Drain:coolantRefer to “CHANGING THE COOLANT” inchapter 3.

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

3. Remove:generator rotor cover

Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern. After all ofthe bolts are fully loosened, remove them.

4. Remove:generator rotor bolt 1washer

While holding the generator rotor 2 with thesheave holder 3 , loosen the generator rotorbolt.

Do not allow the sheave holder to touch theprojection on the generator rotor.

Sheave holder90890-01701, YS-01880-A

5-34


CAUTION:

NOTE:

NOTE:

5. Remove:generator rotor 1(with the flywheel puller 2 and flywheel pull-er attachment)

woodruff key

To protect the end of the crankshaft, placean appropriate sized socket between the fly-wheel puller set’s center bolt and the crank-shaft.

Make sure the flywheel puller is centered overthe generator rotor.

Flywheel puller90890-01362, YU-33270

Flywheel puller attachment90890-04089, YM-33282

REMOVING THE STARTER CLUTCH1. Remove:starter clutch bolt 1

While holding the generator rotor with thesheave holder, remove the starter clutch bolt.



5-35


32 Nm (3.2 mkg, 23 ftlb)LOCTITIE

NOTE:

EAS00351

CHECKING THE STARTER CLUTCH1. Check:starter clutch rollers 1Damage/wear Replace.

2. Check:starter clutch idle gear 1starter clutch drive gear 2Burrs/chips/roughness/wear Replacethe defective part(s).

3. Check:starter clutch gear’s contacting surfaces aDamage/pitting/wear Replace the starterclutch gear.

4. Check:starter clutch operation

a. Install the starter clutch drive gear 1 ontothe starter clutch 2 and hold the starterclutch.

b. When turning the starter clutch drive gearclockwise A , the starter clutch and the start-er clutch drive gear should engage, other-wise the starter clutch is faulty and must bereplaced.

c. When turning the starter clutch drive gearcounterclockwise B , it should turn freely,otherwise the starter clutch is faulty and mustbe replaced.

EAS00355

INSTALLING THE STARTER CLUTCH1. Install:starter clutch

While holding the generator rotor 1 with thesheave holder 2 , tighten the starter clutchbolt.

5-36


NOTE:

75 Nm (7.5 mkg, 54 ftlb)

NOTE:

12 Nm (1.2 mkg, 8.7 ftlb)



EAS00354

INSTALLING THE GENERATOR1. Install:generator rotorwasher Newgenerator rotor bolt

Clean the tapered portion of the crankshaftand the generator rotor hub.

Replace the washer with new one.

2. Tighten:generator rotor bolt 1

While holding the generator rotor 2 with thesheave holder 3 , tighten the generator rotorbolt.



3. Apply:sealant(onto the stator coil assembly lead grommet)

Yamaha bond No.121590890-85505, ACC-11001-05-01

4. Install:stator coil

5. Install:generator rotor cover

5-37


NOTE:Tighten the generator rotor cover bolts in stagesand in a crisscross pattern.

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

coolantRefer to “CHANGING THE COOLANT” inchapter 3.

7. Install: left side cowlingbuttom cowlingRefer to “COWLINGS” in chapter 3.

rider seat and fuel tankRefer to “SEATS” and “FUEL TANK” in chap-ter 3.

5-38


123456789

10

Removing the shift shaft and stopperleverCoolant reservoir tankCoolant

Drive sprocket coverShift shaft coverShift shaft cover gasketDowel pinOil sealShift shaftShift shaft springCollarStopper lever springCirclipWasher

1111111111


Refer to “ENGINE”.

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

22 Nm (2.2 mkg, 16 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

SHIFT SHAFT ENG

EAS00327

SHIFT SHAFTSHIFT SHAFT AND STOPPER LEVER

5-39

SHIFT SHAFT ENG


11121314

Stopper leverCollarWasherShift shaft spring stopper

1111


22 Nm (2.2 mkg, 16 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

5-40

SHIFT SHAFT ENG

22 Nm (2.2 mkg, 16 ftlb)

NOTE:

NOTE:

EAS00328

CHECKING THE SHIFT SHAFT1. Check:shift shaft 1Bends/damage/wear Replace.

shift shaft spring 2Damage/wear Replace.

EAS00330

CHECKING THE STOPPER LEVER1. Check:stopper lever 1Bends/damage Replace.Roller turns roughly Replace the stopperlever.

EAS00332

INSTALLING THE SHIFT SHAFT1. Install:shift shaft spring stopper 1

washersshift shaft 2

Apply LOCTITE to the threads of the shiftshaft spring stopper.

Hook the ends 3 of the stopper lever springonto the stopper lever 4 and the crankcaseboss.

Mesh the stopper lever with the shift drum seg-ment assembly.

2. Install:shift shaft cover

Lubricate the oil seal lips with lithium-soap-based grease.

5-41


12345

Removing the crankshaft positionsensor and pickup rotorRider seatFuel tankRight side cowlingBottom cowlingEngine oil

Generator cover

Clutch cableCrankshaft position sensor lead couplerPickup rotor coverPickup rotor cover gasketDowel pin

11112


Refer to “SEATS” in chapter 3.Refer to “FUEL TANK” in chapter 3.

Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Refer to “STARTER CLUTCH AND GENERATOR”.Disconnect.Disconnect.


10 Nm (1.0 mkg, 7.2 ftlb)

15 Nm (1.5 mkg, 11 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

35 Nm (3.5 mkg, 25 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR ENG

CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR

5-42



678

Crankshaft position sensorPickup rotorPlug screw

111


10 Nm (1.0 mkg, 7.2 ftlb)

15 Nm (1.5 mkg, 11 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

35 Nm (3.5 mkg, 25 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

5-43


NOTE:

NOTE:

NOTE:

REMOVING THE PICKUP ROTOR1. Remove:clutch cable holder 1pickup rotor cover 2


2. Remove:pickup rotor bolt 1washer 2pickup rotor 3

While holding the generator rotor 4 with the ro-tor holding tool 5 , loosen the pickup rotor bolt.


INSTALLING THE PICKUP ROTOR1. Install:pickup rotor 1washerpickup rotor bolt

When installing the pickup rotor, align thegroove 2 in the crankshaft sprocket with thepoint a in the pickup rotor.

5-44


35 Nm (3.5 mkg, 25 ftlb)

NOTE:

NOTE:

2. Tighten:pickup rotor bolt 1

While holding the generator rotor 2 with thesheave holder 3 , tighten the pickup rotor bolt.


3. Apply:sealant(onto the crankshaft position sensor leadgrommet)

Yamaha bond No.121590890-85505, ACC-11001-5-01

4. Install:pickup rotor coverclutch cable holder

When installing the pickup rotor cover, alignthe timing chain guide (intake side) pin 1 ofthe with the hole 2 in the pickup rotor cover.

Tighten the pickup rotor cover bolts in stagesand in a crisscross pattern.

5-45


12345

Removing the clutch coverBottom cowlingRight side cowlingEngine oil

Coolant

Coolant hoseClutch cableClutch coverClutch cover gasketDowel pin

11112

Removing the parts in the order listed.

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



12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

CLUTCH ENG

EAS00273

CLUTCHCLUTCH COVER

5-46

CLUTCH ENG


Disassembling the clutch coverCirclipWasherPull leverPull lever springOil sealBearing

221112



123456

5-47


123456789

101112

Removing the clutchCompression springPressure platePull rodBearingFriction plate (Brown)Clutch plate (t=2.0 mm, 0.08 in)Friction plate (Purple)Clutch plate (t=2.3 mm, 0.09 in)Clutch boss nutLock plateClutch bossThrust plate

611167211111



70 Nm (7.0 mkg, 51 ftlb)

8 Nm (0.8 mkg, 5.8 ftlb)

CLUTCH ENG

EAS00274

CLUTCH

5-48

CLUTCH ENG

NOTE:

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 friction platesclutch plates

3. Straighten the lock washer tab.4. Loosen:clutch bass nut 1

While holding the clutch boss 2 with the univer-sal clutch holder, loosen the clutch boss nut.

Universal clutch holder90890-04086, YM-91042

5. Remove:clutch boss nut 1 lock washer 2clutch boss 3 thrust plate 4

EAS00280

CHECKING THE FRICTION PLATESThe following procedure applies to all of the fric-tion plates.1. Check: friction plateDamage/wear Replace the friction platesas a set.

5-49

CLUTCH ENG

NOTE:

2. Measure: friction plate thicknessOut of specification Replace the frictionplates as a set.

Measure the friction plate at four places.

Friction plate thickness2.9 3.1 mm (0.114 0.122 in)<Limit>: 2.8 mm (0.110 in)

EAS00281

CHECKING THE CLUTCH PLATESThe following procedure applies to all of theclutch plates.1. Check:clutch plateDamage Replace the clutch plates as aset.

2. Measure:clutch plate warpage(with a surface plate and thickness gauge 1 )Out of specification Replace the clutchplates as a set.

Clutch plate warpage limit0.1 mm (0.0039 in)

EAS00282

CHECKING THE CLUTCH SPRINGSThe following procedure applies to all of theclutch springs.1. Check:clutch springDamage Replace the clutch springs as aset.

5-50

CLUTCH ENG

NOTE:

NOTE:

2. Measure:clutch spring free length aOut of specification Replace the clutchsprings as a set.

Clutch spring free length50 mm (1.97 in)<Limit>: 49 mm (1.93 in)

EAS00284

CHECKING THE CLUTCH HOUSING1. Check:clutch housing dogs Damage/pitting/wear Deburr the clutchhousing dogs or replace the clutch housing.

Pitting on the clutch housing dogs will cause er-ratic clutch operation.

2. Check:bearing Damage/wear Replace the bearing andclutch housing.

EAS00285

CHECKING THE CLUTCH BOSS1. Check:clutch boss splinesDamage/pitting/wear Replace the clutchboss.

Pitting on the clutch boss splines will cause er-ratic clutch operation.

EAS00286

CHECKING THE PRESSURE PLATE1. Check:pressure plate 1Cracks/damage Replace.

bearing 2Damage/wear Replace.

5-51

CLUTCH ENG

70 Nm (7.0 mkg, 51 ftlb)

NOTE:

EAS00287

CHECKING THE PULL LEVER SHAFT ANDPULL ROD1. Check:pull lever shaft pinion gear teeth apull rod teeth bDamage/wear Replace the pull rod andpull lever shaft pinion gear as a set.

2. Check:pull rod bearing Damage/wear Replace.

EAS00299

INSTALLING THE CLUTCH1. Install: thrust plate 1clutch boss 2 lock washer 3 Newclutch boss nut 4

While holding the clutch boss 2 with the clutchholding tool 5 , tighten the clutch boss nut.

Universal clutch holder90890-04089, YM-91042

3. Bend the lock washer tab along a flat side ofthe nut.

4. Lubricate: friction platesclutch plates(with the recommended lubricant)

Recommended lubricantEngine oil

5-52

CLUTCH ENG

NOTE:

NOTE:

8 Nm (0.8 mkg, 5.8 ftlb)

NOTE:

NOTE:

5. Install: friction platesclutch plates

First, install a clutch plate and then alternate be-tween a friction plate and a friction plate.

a. Install the clutch plate and friction plate at fol-lowing the illustrated.Clutch plate 1 : t=2.3 mm (0.09 in)Clutch plate 2 : t=2.0 mm (0.08 in)Friction plate 3 : Color code/PurpleFriction plate 4 : Color code/Brown

6. Install:pressure plate 1

Align the punch mark b in the pressure platewith the punch mark a in the clutch boss.

7. Install:bearing 1pull rod 2pressure plate 3clutch springsclutch spring bolts

Tighten the clutch spring bolts in stages and in acrisscross pattern.

8. Install:pull lever

In stall the pull lever with the “UP” mark facingtoward lower side.

5-53

CLUTCH ENG

NOTE:

9. Install:clutch covergasket 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.

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

5-54


12345678

Removing the oil pan and oil pumpEngine oil

Coolant

Exhaust pipe assemblyWater pumpOil level switch couplerOil level switchOil level switch lead holderOil panOil pan gasketDowel pinOil strainerOil strainer gasket

11111211

Remove the parts in the order listed.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Refer to “CHANGING THE COOLANT” inchapter 3.Refer to “ENGINE”.Refer to “WATER PUMP” in chapter 6.Disconnect.

12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)43 Nm (4.3 mkg, 31 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb)

OIL PAN AND OIL PUMP ENG

EAS00356

OIL PAN AND OIL PUMP

5-55

12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)43 Nm (4.3 mkg, 31 ftlb)



910111213

Oil pipeOil delivery pipeOil pump assemblyDowel pinRelief valve assembly

11121



5-56



Disassembling the oil pump assemblyOil pump coverPinOil pump inner rotorOil pump outer rotorPinWasherOil pump rotor housingOil pump driver sprocket

12111111



12345678

12 Nm (1.2 mkg, 8.7 ftlb)

5-57


NOTE:

EAS00362

REMOVING THE OIL PAN1. Remove:oil level switch 1oil pan 2oil pan gasketdowel pins


EAS00364

CHECKING THE OIL PUMP1. Check:oil pump driven gear 1oil pump rotor housing 2oil pump cover Cracks/damage/wear Replace the de-fective part(s).

2. Measure: inner-rotor-to-outer-rotor-tip clearance aouter-rotor-to-oil-pump-housing clearance

b1 Inner rotor2 Outer rotor3 Oil pump housing

Inner-rotor-to-outer-rotor-tip clearance

0.03 0.09 mm (0.0012 0.0035 in)<Limit>: 0.15 mm (0.0059 in)

Outer-rotor-to-oil-pump-housing clearance

0.03 0.08 mm (0.0012 0.0031 in)<Limit>: 0.15 mm (0.0059 in)

5-58


3. Check:oil pump operationRough movement Repeat steps (1) and(2) or replace the defective part(s).

EAS00365

CHECKING THE RELIEF VALVE1. Check: relief valve body 1 relief valve 2spring 3O-ring 4Damage/wear Replace the defectivepart(s).

EAS00367

CHECKING THE OIL DELIVERY PIPE ANDOIL PIPE1. Check:oil delivery pipe 1oil pipe 2Damage Replace.Obstruction Wash and blow out with com-pressed air.

EAS00368

CHECKING THE OIL STRAINER1. Check:oil strainer 1Damage Replace.Contaminants Clean with solvent.

EAS00373

CHECKING THE OIL NOZZLESThe following procedure applies to all of the oilnozzles.1. Check:oil nozzle 1Damage/wear Replace the oil nozzle.

O-ring 2Damage/wear Replace.

oil nozzle passageObstruction Blow out with compressed air.

5-59


12 Nm (1.2 mkg, 8.7 ftlb)

NOTE:

12 Nm (1.2 mkg, 8.7 ftlb)

CAUTION:

EAS00374

ASSEMBLING THE OIL PUMP1. Lubricate: inner rotorouter rotoroil pump shaft(with the recommended lubricant)


2. Install:oil pump housing 1oil pump shaft 2washer 3pin 4 inner rotor 5outer rotor 6dowel pins 7oil pump cover 8

When installing the inner rotor, align the pin 4 inthe oil pump shaft with the groove in the inner ro-tor 5 .

3. Check:oil pump operationRefer to “CHECKING THE OIL PUMP”.

EAS00376

INSTALLING THE OIL PUMP1. Install:oil pump drive chaingear coveroil pump

After tightening the bolts, make sure the oilpump turns smoothly.

5-60


NOTE:

12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

43 Nm (4.3 mkg, 31 ftlb)

WARNING

NOTE:

EAS00378

INSTALLING THE OIL STRAINER1. Install:oil strainer 1 relief valve 2

Make sure to check the arrow mark a locatedon the oil strainer housing for the front and reardirection of the engine and then install the oilstrainer so that its arrow mark points to the frontside of the engine.

EAS00380

INSTALLING THE OIL PAN1. Install:oil pipeoil delivery pipe

2. Install:dowel pinsgasket Newoil pan 1oil level switch 2

engine oil drain bolt

Always use new copper washers.

Tighten the oil pan bolts in stages and in acrisscross pattern.

Lubricate the oil level switch O-ring with en-gine oil.

5-61


12345

Removing the crankcaseEngineCylinder headStarter clutch and generator

Shift shaftCrankshaft position sensor and pickuprotorClutchWater pump assemblyOil pan and oil pumpTiming chainOil pump drive chainOil pump drive chain guideLower crankcaseDowel pin

11113

Remove the parts in the order listed.Refer to “ENGINE”.Refer to “CYLINDER HEAD”.Refer to “STARTER CLUTCH AND GENERATOR”.Refer to “SHIFT SHAFT”.Refer to “CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR”.Refer to “CLUTCH”.Refer to “WATER PUMP” in chapter 6.Refer to “OIL PAN AND OIL PUMP”.

12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

CRANKCASE ENG

CRANKCASE

5-62


678

Thrust plateWasherPlate

111


12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

CRANKCASE ENG

5-63

CRANKCASE ENG

NOTE:

CAUTION:

NOTE:

EAS00384

DISASSEMBLING THE CRANKCASE1. Place the engine upside down.2. Remove:crankcase bolts


Loosen the bolts in decreasing numerical or-der (refer to the numbers in the illustration).

The numbers embossed on the crankcase in-dicate the crankcase tightening sequence.

M8 85 mm (3.3 in) bolts: 1 7 , 10

M8 115 mm (4.5 in) bolts: 8 , 9M8 65 mm (2.6 in) bolts: 11 , 12

M6 65 mm (2.6 in) bolts: 13 , 14

M6 55 mm (2.2 in) bolts: 15 , 22 26

M6 45 mm (1.8 in) bolts: 16 , 19 , 20

M6 65 mm (2.6 in) bolts: 17 , 27

M6 75 mm (3.0 in) bolt: 18

M6 100 mm (3.9 in) bolts: 21

3. Remove: lower crankcase

Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced por-tions of the crankcase, not on the crankcasemating surfaces. Work slowly and carefullyand make sure the crankcase halves sepa-rate evenly.

4. Remove:dowel pins

5. Remove:crankshaft journal lower bearing(from the lower crankcase)

Identify the position of each crankshaft journallower bearing so that it can be reinstalled in itsoriginal place.

5-64

CRANKCASE ENG

EAS00399

CHECKING THE CRANKCASE1. Thoroughly wash the crankcase halves in a

mild solvent.2. Thoroughly clean all the gasket surfaces and

crankcase mating surfaces.3. Check:crankcaseCracks/damage Replace.

oil delivery passagesObstruction Blow out with compressed air.

EAS00401

CHECKING THE BEARINGS AND OILSEALS1. Check:bearingsClean and lubricate the bearings, then rotatethe inner race with your finger.Rough movement Replace.

2. Check:oil sealsDamage/wear Replace.

CHECKING THE TIMING CHAIN1 Check: timing chain 2Damage/stiffness Replace the timingchain and crankshaft sprocket as a set.

oil /water pump assembly drive chain 1Damage/stiffness Replace the oil /waterpump assembly drive chain and oil /waterpump assembly drive sprocket as a set.

ASSEMBLING THE CRANKCASE1. Lubricate:crankshaft journal bearings(with the recommended lubricant)


2. Apply:sealant

Yamaha bond No. 121590890-85505, ACC-1109-05-01

5-65

CRANKCASE ENG

NOTE:

CAUTION:

NOTE:

Do not allow any sealant to come into contactwith the oil gallery or crankshaft journal bear-ings. Do not apply sealant to within 2 3 mm ofthe crankshaft journal bearings.

3. Install:dowel pin

4. Set the shift drum assembly and transmis-sion gears in the neutral position.

5. Install: lower crankcase 1(onto the upper crankcase 2 )

Before tightening the crankcase bolts, makesure that the transmission gears shift cor-rectly when the shift drum assembly isturned by hand.

6. Install:crankcase bolts

Lubricate the bolt threads with engine oil. Install a washer on bolts 1 10 .Seal bolt 18

Tighten the bolts in the tightening sequencecast on the crankcase.

M8 85 mm (3.3 in) bolts: 1 7 , 10M8 115 mm (4.5 in) bolts: 8 , 9M8 65 mm (2.6 in) bolts: 11 , 12M6 65 mm (2.6 in) bolts: 13 , 14M6 55 mm (2.2 in) bolts: 15 , 22 26M6 45 mm (1.8 in) bolts: 16 , 19 , 20M6 65 mm (2.6 in) bolts: 17 , 27M6 75 mm (3.0 in) bolt: 18 M6 100 mm (3.9 in) bolt: 21

Crankcase boltBolt 1 10

1st: 12 Nm (1.2 mkg, 8.7 ftlb)2nd: 25 Nm (2.5 mkg, 18 ftlb)*3rd: 27 Nm (2.7 mkg, 20 ftlb)Bolt 11 , 12

24 Nm (2.4 mkg, 17 ftlb)Bolt 13 27

12 Nm (1.2 mkg, 8.7 ftlb)

* Loosen the all bolts following the tightening or-der and then tighten to specification torque.

5-66


123456789

10

Removing the connecting rods andpistonsLower crankcaseConnecting rod capBig end lower bearingBig end upper bearingPiston pin clipPiston pinPistonConnecting rodTop ring2nd ringOil ring

4448444444


Refer to “CRANKCASE”.


15 Nm (1.5 mkg, 11 ftlb) +150

CONNECTING RODS AND PISTONS ENG

EAS00252

CONNECTING RODS AND PISTONS

5-67


NOTE:

CAUTION:

NOTE:

NOTE:

EAS00393

REMOVING THE CONNECTING RODS ANDPISTONSThe following procedure applies to all of theconnecting rods and pistons.1. Remove:connecting rod cap 1big end bearings

Identify the position of each big end bearing sothat it can be reinstalled in its original place.

2. Remove:piston pin clips 1piston pin 2piston 3

Do not use a hammer to drive the piston pinout.

For reference during installation, put identifica-tion marks on the piston crown.

Before removing the piston pin, deburr the pis-ton pin clip groove and the piston pin borearea. If both areas are debarred and the pistonpin is still difficult to remove, remove it with thepiston pin puller set 4 .

Piston pin puller set90890-01304, YU-01304

3. Remove: top ring2nd ringoil ring

When removing a piston ring, open the end gapwith your fingers and lift the other side of the ringover the piston crown.

5-68


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.

5-69


NOTE:

Cylinder bore “C” 65.50 65.51 mm(2.5787 2.5791 in)

Wear limit 65.56 mm(2.5811 in)

Taper limit “T” 0.05 mm (0.002 in)

Out of round “R” 0.05 mm (0.002 in)

“C” = maximum of D1 D6

“T” = maximum of D1 or D2 – maximumof D5 or D6

“R” = maximum of D1 D3 or D5 –minimum of D2 D4 or D6

b. If out of specification, replace the cylinder,and the pistons and piston rings as a set.

c. Measure piston skirt diameter “P” with themicrometer.

a 4 mm (0.16 in) from the bottom edge of the piston

Piston size “P”65.475 65.490 mm (2.5778 2.5783 in)

d. If out of specification, replace the piston andpiston rings as a set.

e. Calculate the piston-to-cylinder clearancewith the following formula.

Piston-to-cylinder clearance =Cylinder bore “C” –Piston skirt diameter “P”

Piston-to-cylinder clearance0.010 0.035 mm (0.0004 0.0014 in)<Limit>: 0.055 mm (0.0022 in)

f. If out of specification, replace the cylinder,and the piston and piston rings as a set.

EAS00263

CHECKING THE PISTON RINGS1. Measure:piston ring side clearanceOut of specification Replace the pistonand piston rings as a set.

Before measuring the piston ring side clear-ance, eliminate any carbon deposits from thepiston ring grooves and piston rings.

5-70


NOTE:

NOTE:

Piston ring side clearanceTop ring

0.030 0.065 mm (0.0012 0.0026 in)<Limit>: 0.115 mm (0.0045 in)

2nd ring0.030 0.065 mm (0.0012 0.0026 in)<Limit>: 0.125 mm (0.0049 in)

2. Install:piston ring(into the cylinder)

Level the piston ring into the cylinder with thepiston crown.

a 5 mm (0.20 in)3. Measure:piston ring end gapOut of specification Replace the pistonring.

The oil ring expander spacer’s end gap cannotbe measured. If the oil ring rail’s gap is exces-sive, replace all three piston rings.

Piston ring end gapTop ring

0.25 0.35 mm (0.0098 0.0138 in)<Limit>: 0.60 mm (0.0236 in)

2nd ring0.7 0.8 mm (0.0276 0.0315 in)<Limit>: 1.15 mm (0.0453 in)

Oil ring0.10 0.35 mm (0.0039 0.0138 in)

CHECKING THE PISTON PINSThe following procedure applies to all of the pis-ton pins.1. Check:piston pinBlue discoloration/grooves Replace thepiston pin and then check the lubrication sys-tem.

5-71


2. Measure:piston pin outside diameter aOut of specification Replace the pistonpin.

Piston pin outside diameter15.991 16.000 mm (0.6296 0.6299 in)<Limit>: 15.971 mm (0.6288 in)

3. Measure:piston pin bore inside diameter bOut of specification Replace the piston.

Piston pin bore inside diameter16.002 16.013 mm (0.6300 0.6304 in)<Limit>: 16.043 mm (0.6316 in)

4. Calculate:piston-pin-to-piston clearanceOut of specification Replace the piston pinand piston as a set.

Piston-pin-to-piston clearance =Piston pin bore size –Piston pin outside diameter

Piston-pin-to-piston clearance0.002 0.022 mm(0.0001 0.0009 in)<Limit>: 0.072 mm (0.0028 in)

CHECKING THE BIG END BEARINGS1. Measure:crankshaft-pin-to-big-end-bearing clear-anceOut of specification Replace the big endbearings.

Crankshaft-pin-to-big-end-bearingclearance

0.028 0.052 mm (0.0011 0.0020 in)

The following procedure applies to all of theconnecting rods.

5-72

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 and nut seats withmolybdenum disulfide grease.

Make sure that the “Y” mark c on the connect-ing rod faces towards the left side of the crank-shaft.

Make sure that the characters d on both theconnecting rod and connecting rod cap arealigned.

5-73


CAUTION:

WARNING

CAUTION:

NOTE:

e. Tighten the connecting rod nuts.

Connecting rod nut15 Nm (1.5 mkg, 11 ftlb) + 150

f. Replace the connecting rod bolts and nutswith new ones.

Tighten the connecting rod bolts using theplastic-region tightening angle method.Always install new bolts and nuts.

g. Clean the connecting rod bolts and nuts.h. Tighten the connecting rod nuts.i. Put a mark 1 on the corner of the connecting

rod nut 2 and the connecting rod 3 .

j. Tighten the nut further to reach the specifiedangle (150).

When the nut is tightened more than the spe-cified angle, do not loosen the nut and thenretighten it.Replace the bolt with a new one and performthe procedure again.

Do not use a torque wrench to tighten thenut to the specified angle.

Tighten the nut until it is at the specifiedangles.

When using a hexagonal nut, note that theangle from one corner to another is 60

k. Remove the connecting rod and big endbearings.Refer to “REMOVING THE CONNECTINGRODS”.

l. Measure the compressed Plastigauge

width on the crankshaft pin.If the crankshaft-pin-to-big-end-bearingclearance is out of specification, select re-placement big end bearings.

5-74


NOTE:

NOTE:

2. Select:big end bearings (P1 P4)

The numbers A stamped into the crankshaftweb and the numbers 1 on the connectingrods are used to determine the replacementbig end bearing sizes.

“P1” “P4” refer to the bearings shown in thecrankshaft illustration.

For example, if the connecting rod “P1” and thecrankshaft web “P1” numbers are “5” and “2” re-spectively, then the bearing size for “P1” is:

“P1” (connecting rod) – “P1”(crankshaft) =5 – 2 = 3 (brown)

BIG END BEARING COLOR CODE

1 Blue

2 Black

3 Brown

4 Green

INSTALLING THE CONNECTING ROD ANDPISTONThe following procedure applies to all of theconnecting rods and pistons.1. Install: top ring 12nd ring 2upper oil ring rail 3oil ring expander 4 lower oil ring rail 5

Be sure to install the piston rings so that themanufacturer’s marks or numbers a face up.

5-75


NOTE:

2. Install:piston 1(onto the respective connecting rod 2 )

piston pin 3piston pin clip New 4

Apply engine oil onto the piston pin.Make sure that the “Y” mark a on the connect-ing rod faces left when the arrow mark b onthe piston is pointing up. Refer to the illustra-tion.

Reinstall each piston into its original cylinder(numbering order starting from the left: #1 to#4).

3. Lubricate:pistonpiston ringscylinder(with the recommended lubricant)


4. Offset:piston ring end gaps

a Top ringb Lower oil ring railc Upper oil ring raild 2nd ringe Oil ring expander5. Lubricate:crankshaft pinsbig end bearingsconnecting rod big end inner surface(with the recommended lubricant)


5-76


NOTE:

15 Nm (1.5 mkg, 11 ftlb) + 150

CAUTION:

6. Install:big end bearingsconnecting rod assembly(into the cylinder and onto the crankshaft pin)

connecting rod cap(onto the connecting rod)

Align the projections on the big end bearingswith the notches in the connecting rods andconnecting rod caps.

Be sure to reinstall each big end bearing in itsoriginal place.

While compressing the piston rings with onehand, install the connecting rod assembly intothe cylinder with the other hand.

Make sure that the “Y” marks a on the con-necting rods face towards the left side of thecrankshaft.

Make sure that the characters b on both theconnecting rod and connecting rod cap arealigned.

7. Align:bolt heads(with the connecting rod caps)

8. Tighten:connecting rod nuts

a. Replace the connecting rod bolts and nutswith new ones.

Tighten the connecting rod bolts using theplastic-region tightening angle method.Always install new bolts and nuts.

b. Clean the connecting rod bolts and nuts.c. Tighten the connecting rod nuts.d. Put a mark 1 on the corner of the connecting

rod nut 2 and the connecting rod 3 .

5-77


WARNING

CAUTION:

NOTE:

e. Tighten the nut further to reach the specifiedangle (150).

When the nut is tightened more than the spe-cified angle, do not loosen the nut and thenretighten it.Replace the bolt with a new one and performthe procedure again.

Do not use a torque wrench to tighten thenut to the specified angle.

Tighten the nut until it is at the specifiedangles.

When using a hexagonal nut, note that theangle from one corner to another is 60.

5-78


123

Removing the crankshaftCrankcase

Connecting rod caps

CrankshaftCrankshaft journal lower bearingCrankshaft journal upper bearing

155

Remove the parts in the order listed.Separate.Refer to “CRANKCASE”.Refer to “CONNECTING RODS AND PISTONS”.


CRANKSHAFT ENG

EAS00381

CRANKSHAFT

5-79

CRANKSHAFT ENG

CAUTION:

EAS00395

CHECKING THE CRANKSHAFT1. Measure:crankshaft runoutOut of specification Replace the crank-shaft.

Crankshaft runoutLess than 0.03 mm (0.0012 in)

2. Check:crankshaft journal surfacescrankshaft pin surfacesbearing surfacesScratches/wear Replace the crankshaft.

CHECKING THE CRANKSHAFT JOURNALBEARINGS1. Measure:crankshaft-journal-to-crankshaft-journal-bearing clearanceOut of specification Replace the crank-shaft journal bearings.

Crankshaft-journal-to-crankshaft-journal-bearing clearance

0.034 0.058 mm (0.0013 0.0023 in)

Do not interchange the crankshaft journalbearings. To obtain the correct crankshaft-journal-to-crankshaft-journal-bearing clear-ance and prevent engine damage, the crank-shaft journal bearings must be installed intheir original positions.

a. Clean the crankshaft journal bearings,crankshaft journals, and bearing portions ofthe crankcase.

b. Place the upper crankcase upside down on abench.

5-80

CRANKSHAFT ENG

NOTE:

NOTE:

NOTE:

NOTE:

c. Install the crankshaft journal upper bearings1 and the crankshaft into the upper crank-case.

Align the projections a on the crankshaft jour-nal upper bearings with the notches b in the up-per crankcase.

d. Put a piece of Plastigauge 2 on eachcrankshaft journal.

Do not put the Plastigauge over the oil hole inthe crankshaft journal.

e. Install the crankshaft journal lower bearings1 into the lower crankcase and assemblethe crankcase halves.

Align the projections a of the crankshaft jour-nal lower bearings with the notches b in thelower crankcase.

Do not move the crankshaft until the clearancemeasurement has been completed.

f. Tighten the bolts to specification in the tight-ening sequence cast on the crankcase.

Crankcase boltBolt 1 10

1st: 12 Nm (1.2 mkg, 8.7 ftlb)2nd: 25 Nm (2.5 mkg, 18 ftlb)*3rd: 27 Nm (2.7 mkg, 20 ftlb)Bolt 11 , 12

24 Nm (2.4 mkg, 17 ftlb)Bolt 13 27

12 Nm (1.2 mkg, 8.7 ftlb)

* Loosen the all bolts following the tightening or-der and then tighten to specification torque.

Lubricate the crankcase bolt threads with en-gine oil.Refer to “CRANKCASE”.

5-81

CRANKSHAFT ENG

NOTE:

g. Remove the lower crankcase and the crank-shaft journal lower bearings.

h. Measure the compressed Plastigauge

width c on each crankshaft journal.If the crankshaft-journal-to-crankshaft-jour-nal-bearing clearance is out of specification,select replacement crankshaft journal bear-ings.

2. Select:crankshaft journal bearings (J1 J5)

The numbers A stamped into the crankshaftweb and the numbers 1 stamped into the low-er crankcase are used to determine the re-placement crankshaft journal bearing sizes.

“J1 J5” refer to the bearings shown in thecrankshaft illustration.

If “J1 J5” are the same, use the same sizefor all of the bearings.

If the size is the same for all “J1 to J5” one digitfor that size is indicated. (Crankcase side only)

For example, if the crankcase “J1” and crank-shaft web “J1” numbers are “6” and “2” respec-tively, then the bearing size for “J1” is:

“J1” (crankcase) – “J1”(crankshaft web) – 1 =6 – 2 – 1 = 3 (brown)

CRANKSHAFT JOURNAL BEARINGCOLOR CODE

0 White

1 Blue

2 Black

3 Brown

4 Green

5-82

CRANKSHAFT ENG

NOTE:

EAS00407

INSTALLING THE CRANKSHAFT1. Install:crankshaft journal upper bearings 1(into the upper crankcase)

Align the projections a on the crankshaft jour-nal upper bearings with the notches b in theupper crankcase.

Be sure to install each crankshaft journal up-per bearing in its original place.

2. Install:crankshaft

3. Install:crankcase (lower)Refer to “CRANKCASE”.

5-83


123456789

1011

Removing the transmission, shift drum assembly, and shift forksCrankcase lower

Drive axle assemblyCirclipOil sealBearingShift drum retainerShift fork guide barSpringShift fork “L”Shift fork “R”Shift drum assemblyShift fork “C”

11111241111

Remove the part in the order listed.

Separate.Refer to “CRANKCASE”.

12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

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

5-84

TRANSMISSION ENG


1213141516

Main axle assemblyOil pipeOil baffle plateThrust plateWasher

11111


12 Nm (1.2 mkg, 8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)10 Nm (1.0 mkg, 7.2 ftlb)

5-85


Disassembling the main axle assemblyBearing2nd pinion gearToothed lock washerToothed lock washer retainer6th pinion gearCollarWasherCirclip3rd pinion gearCirclipWasher5th pinion gearCollarMain axle

11111111111111


1234567891011121314

TRANSMISSION ENG

5-86


Bearing housingBearing

11


1516

TRANSMISSION ENG

5-87


Disassembling the drive axleassemblyWasher1st wheel gearCollar5th wheel gearCirclipWasherCollar3rd wheel gearToothed lock washerToothed lock washer retainer4th wheel gearCollarWasherCirclip

11111111111111


1234567891011121314

TRANSMISSION ENG

5-88

TRANSMISSION ENG


6th wheel gearCirclipWasher2nd wheel gearCollarCollarOil sealBearingCirclipDrive axle

1111111111


15161718192021222324

5-89

TRANSMISSION ENG

WARNING

EAS00420

REMOVING THE TRANSMISSION1. Remove:main axle assembly 1(with the Torx wrench T30)

a. Insert two bolts 2 of the proper size, asshown in the illustration, into the main axleassembly bearing housing.

b. Tighten the bolts until they contact the crank-case surface.

c. Continue tightening the bolts until the mainaxle assembly comes free from the uppercrankcase.

EAS00421

CHECKING THE SHIFT FORKSThe following procedure applies to all of the shiftforks.1. Check:shift fork cam follower 1shift fork pawl 2Bends/damage/scoring/wear Replacethe shift fork.

2. Check:shift fork guide barRoll the shift fork guide bar on a flat surface.Bends Replace.

Do not attempt to straighten a bent shift forkguide bar.

3. Check:shift fork movement(along the shift fork guide bar)Rough movement Replace the shift forksand shift fork guide bar as a set.

5-90

TRANSMISSION ENG

EAS00422

CHECKING THE SHIFT DRUM ASSEMBLY1. Check:shift drum groovesDamage/scratches/wear Replace theshift drum assembly.

shift drum segment 1Damage/wear Replace the shift drum as-sembly.

shift drum bearing 2Damage/pitting Replace the shift drumassembly.

EAS00425

CHECKING THE TRANSMISSION1. Measure:main axle runout(with a centering device and dial gauge 1 )Out of specification Replace the mainaxle.

Main axle runout limit0.02 mm (0.0008 in)

2. Measure:drive axle runout(with a centering device and dial gauge 1 )Out of specification Replace the driveaxle.

Drive axle runout limit0.02 mm (0.0008 in)

3. Check: transmission gearsBlue discoloration/pitting/wear Replacethe defective gear(s).

transmission gear dogsCracks/damage/rounded edges Replacethe defective gear(s).

5-91

TRANSMISSION ENG

NOTE:

NOTE:

4. Check: transmission gear engagement(each pinion gear to its respective wheelgear)Incorrect Reassemble the transmissionaxle assemblies.

5. Check: transmission gear movementRough movement Replace the defectivepart(s).

6. Check:circlipsBends/damage/looseness Replace.

EAS00430

INSTALLING THE TRANSMISSION1. Install:oil pipe 1main axle assembly 2(with the Torx wrench T30)

Make sure to caulk the bolts at three positionsafter installing the bearing housing.

2. Install:shift fork “C” 3shift drum assembly 4shift fork guide bar

The embossed marks on the shift forks shouldface towards the right side of the engine andbe in the following sequence: “R”, “C”, “L”.

Carefully position the shift forks so that theyare installed correctly into the transmissiongears.

Install shift fork “C” into the groove in the 3rdand 4th pinion gear on the main axle.

5-92

TRANSMISSION ENG

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

NOTE:

3. Install:shift fork “R” 1 and “L” 2drive axle 3shift fork guide barshift drum retainer

Install shift fork “L” into the groove in the 6thwheel gear and shift fork “R” into the groove inthe 5th wheel gear on the drive axle.

Make sure that the drive axle bearing circlip ais inserted into the grooves in the upper crank-case.

9. Check: transmissionRough movement Repair.

Oil each gear, shaft, and bearing thoroughly.

6-1

6Order Job/Part Q’ty Remarks

12345678

Removing the radiatorRider seatFuel tankAir filter caseSide cowlings and bottom cowlingCoolant

Coolant reservoir hoseThrottle body hoseRadiator outlet hoseCoolant pipeRadiator inlet hoseOil cooler outlet hoseRadiatorRadiator fan

12111111

Remove the parts in the order listed.Refer to “SEATS” in chapter 3.Refer to “FUEL TANK” in chapter 3.Refer to “AIR FILTER CASE” in chapter 3.Refer to “COWLINGS” in chapter 3.Drain.Refer to “CHANGING THE COOLANT” inchapter 3.


12 Nm (1.2 mkg, 8.7 ftlb)

RADIATOR COOL

EAS00454

COOLING SYSTEMRADIATOR

6-2


9 Radiator cap 1For installation, reverse the removal procedure.


12 Nm (1.2 mkg, 8.7 ftlb)

RADIATOR COOL

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 pressure110 140 kPa(1.1 1.4 kg/cm2, 1.1 1.4 bar,16.0 20.3 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

1011

Removing the oil coolerRadiator assemblyEngine oil

Oil cooler outlet hoseUnion boltWasherOil coolerOil cooler inlet hoseOil cooler inlet pipeWater jacket joint hoseWater jacket jointO-ringO-ringWater pump hose

11111111112

Remove the parts in the order listed.Refer to “RADIATOR”.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.


10 Nm (1.0 mkg, 7.2 ftlb)

63 Nm (6.3 mkg, 46 ftlb)

OIL COOLER COOL

EAS00457

OIL COOLER

6-6

OIL COOLER COOL

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.



6-7


123

Removing the thermostatRider seatAir filter caseThrottle body assembly

Coolant

Radiator inlet hoseThermostat coverThermostat

111

Remove the parts in the order listed.Refer to “SEATS” chapter 3.Refer to “AIR FILTER CASE” in chapter 3.Refer to “THROTTLE BODIES” in chapter7.Drain.Refer to “CHANGING THE COOLANT” inchapter 3.


12 Nm (1.2 mkg, 8.7 ftlb)

THERMOSTAT COOL

EAS00461

THERMOSTAT

6-8

1

THERMOSTAT COOL

NOTE:

NOTE:

12 Nm (1.2 mkg, 8.7 ftlb)

NOTE:

EAS00462

CHECKING THE THERMOSTAT1. Check: thermostat 1Does not open at 71 85C (160 185F) Replace.

a. Suspend the thermostat in a container filledwith water.

b. Slowly heat the water.c. Place a thermometer in the water.d. While stirring the water, observe the thermo-

stat and thermometer’s indicated tempera-ture.

1 Thermostat2 Thermometer3 Water4 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 coverCracks/damage Replace.

INSTALLING THE THERMOSTAT1. Install: thermostat

Install the thermostat with its breather hole afacing up.

2. Install thermostat cover

Before installing the thermostat cover to the cyl-inder head, lubricate the O-ring with a thin coatof lithium soap based grease.

6-9

THERMOSTAT COOL

3. Fill:cooling system(with the specified amount of the recom-mended coolant)Refer to “CHANGING THE COOLANT” inchapter 3.



6-10

Remove the parts in the order listed.Refer to “COWLINGS” in chapter 3.Drain.Refer to “CHANGING THE COOLANT” inchapter 3.

It is not necessary to remove the waterpump unless the coolant level is extremelylow or the coolant contains engine oil.


NOTE:


12345

Removing the water pumpBottom cowlingCoolant

Water pump inlet hoseWater pump outlet hoseWater pump hoseClutch cable/holderWater pump

111

1/11

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)

WATER PUMP COOL

EAS00408

WATER PUMP

6-11


Disassembling the water pumpWater pump coverO-ringImpeller shaftCirclipWater pump sealOil sealBearingWater pump housing

11111111



1234567

10 Nm (1.0 mkg, 7.2 ftlb)

8

WATER PUMP COOL

6-12

WATER PUMP COOL

NOTE:

NOTE:

NOTE:

NOTE:

EAS00471

DISASSEMBLING THE WATER PUMP1. Remove:circlip impeller shaft

2. Remove:water pump seal 1

Remove the water pump seal from the outsideof the water pump housing.

2 Water pump housing

3. Remove:oil seal 1(with a thin, flat-head screwdriver)

Remove the oil seal from the outside of the wa-ter pump housing.

4. Remove:bearing 1

Remove the bearing from inside of the waterpump housing.

5. Remove: rubber damper holder 1 rubber damper 2(from the impeller, with a thin, flat-headscrewdriver)

Do not scratch the impeller shaft.

6-13

WATER PUMP COOL

NOTE:

CAUTION:

NOTE:

EAS00473

CHECKING THE WATER PUMP1. Check:water pump housing 1water pump cover 2 impeller 3 rubber damper 4 rubber damper holder 5water pump sealsoil seal Cracks/damage/wear Replace.

2. Check:bearing Rough movement Replace.

3. Check:water pump outlet pipe radiator outlet hoseCracks/damage/wear Replace.

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 .

6-14

WATER PUMP COOL

NOTE:

CAUTION:

Mechanical seal installer90890-04078, YM-33221 4

Middle driven shaft bearing driver90890-04058, YM-04058 5

Quick GasketACC-11001-05-01

Yamaha bond #121590890-85505

A Push down.

3. Install: rubber damper New 1 rubber damper holder New 2

Before installing the rubber damper, apply tapwater or coolant onto its outer surface.

4. Measure: impeller shaft tiltOut of specification Repeat steps (3) and(4).

Make sure the rubber damper and rubberdamper holder are flush with the impeller.

Impeller shaft tilt limit0.15 mm (0.006 in)

1 Straightedge2 Impeller

6-15

WATER PUMP COOL

12 Nm (1.2 mkg, 8.7 ftlb)

NOTE:

NOTE:

INSTALLING THE WATER PUMP1. Install:water pump assembly

Align the projection a at the oil pump shaft andwater pump shaft groove b .

2. Install:water pump outlet hose 1water pump inlet hose 2

Install the inlet hose with yellow a mark posi-tioned outside.

Install the hose clamp with its screw headpointed to the inner side not to contact with thecowling.

3. Fill:coolantRefer to “CHANGING THE COOLANT” inchapter 3.

7-1

FUEL INJECTION SYSTEM FI

19 Atmospheric pressuresensor

20 Fuel injection systemrelay

21 Engine trouble warninglight

22 Lean angle cut-offswitch


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



10 Fuel injector11 Catalytic converter12 Crankshaft position

sensor

FUEL INJECTION SYSTEMFUEL INJECTION SYSTEM

7-2

7


1 Main switch5 Battery6 Fuse (main)9 Fuse (fuel injection)10 Fuse (ignition)11 Starting circuit cut-off relay12 Sidestand switch13 Fuel pump14 ECU15 Ignition coil16 Spark plug17 Fuel injector19 Neutral switch20 Crankshaft position sensor21 Intake air temperature sensor22 Coolant temperature sensor23 Throttle position sensor24 Intake air pressure sensor25 Atmospheric pressure sensor26 Cylinder identification sensor27 Speed sensor28 Lean angle cut-off switch35 Multi-function meter44 Engine stop switch

WIRING DIAGRAM

7-3

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 a engine trouble warning light.

After the engine has been stopped, the lowest fault code number appears on the clock LCD. Once afault code has been displayed, it remains stored in the memory of the ECU until it is deleted.

EAS00900

Engine trouble warning light indication and FI system operating condition

Warning light indication

ECU’s operation FI operation Vehicle operation

Flashing* Warning providedwhen unable to startengine

Operation stopped Can not be operated

Remains ON Malfunction detected Operated with substitute characteristics in accordance with thedescription of the malfunction.

Can or cannot be op-erated depending onthe 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 detective 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 detective.

7-4


EAS00902

ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION)If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-nates the engine trouble warning light and provides the engine with alternate operating instructionsthat are appropriate for the type of malfunction.When an abnormal signal is received from a sensor, the ECU processes the specified values that areprogrammed for each sensor in order to provide the engine with alternate operating instructions thatenable the engine to continue to operate or stop operating, depending on the conditions.The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value,and the other in which the ECU directly operates an actuator. Details on the fail-safe actions are givenin the table below.FAIL-SAFE ACTIONS TABLE

FaultCode No. Item Symptom Fail-safe action Engine

startabilityVehicle

drivability

11

Cylinder identificationsensor

No normal signals from the cylinderidentification sensor are received whenthe engine is started or while the motorcycle travels.

Continues to operate the engine basedon the results of the cylinderidentification that existed up to thatpoint.

Unable Able

12 Crankshaft positionsensor

No normal signals are received fromthe crankshaft position sensor.

Stops the engine (by stopping theinjection and ignition). Unable Unable

1314

Intake air pressuresensor (open or shortcircuit) (pipe system)

Intake air pressure sensor-open orshort circuit detected.Faulty intake air pressure sensor system.

Fixes the intake air pressure to760 mmHg. 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

19Sidestand switch (opencircuit in wire to ECU)

Open circuit is detected in the inputline from the sidestand switch to theECU.

-- (No start)Unable Unable

20

Intake air pressure sen-sor or Atmospheric pres-sure sensor

When the main switch is turned to ON,the atmospheric sensor voltage and in-take air pressure sensor voltage differgreatly.

Fixes the intake air pressure andatmospheric pressure to 760 mmHg. Able Able


Coolant temperature sensor-open orshort circuit detected.

Fixes the coolant temperature to60C. Able Able

22 Intake temperaturesensor

Intake temperature sensor-open orshort circuit detected.

Fixes the intake temperature to 20C. Able Able

23 Atmospheric pressuresensor

Atmospheric pressure sensor-open orshort circuit detected.

Fixes the atmospheric pressure to760 mmHg. 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: whenthe #1 cylinder is defective cut the in-jection of #1 and #4 cylinders)

Turn on the power to the air inductionsolenoid to always cut-off the air.

Able(dependingon the num-ber of faultycylinders)

Able(dependingon the num-ber of faultycylinders)

3041

Lean angle cut-offswitch (latch updetected) (open or shortcircuit)

The motorcycle has over turned.Lean angle cut-off switch-open or shortcircuit detected.

Turns OFF the fuel injection systemrelay of the fuel system. Unable Unable

42Speed sensor, neutralswitch

No normal signals are received from thespeed sensor; or, an open or shortcircuit is detected in the neutral switch.

Fixes the gear to the top gear.Able Able

43

Fuel system voltage(monitor voltage)

Supply power to the injector and fuelpump is not normal.

Fixes the battery voltage to 12 V. Dependingon the mal-

functioncase.

Dependingon the mal-

functioncase.

44

Error in writing theamount of COadjustment onEEPROM

An error is detected while reading orwriting on EEPROM (CO adjustmentvalue).

--

Able Able

46 Vehicle system powersupply (Monitor voltage)

Power supply to the FI system relay isnot normal

-- Unable Able

50ECU internalmalfunction (memorycheck error)

Faulty ECU memory. When thismalfunction is detected, the codenumber might not appear on the meter.

Shut down all functions except thecommunication with the meter. Unable Unable

—

Start unable warning Relay is not turned ON even if the cranksignal is input while the start switch isturned ON. When the start switch isturned ON while an error is detectedwith the fault code of No.11, 12, 19, 30,33, 43, 41 or 50.

Engine trouble warning light flasheswhen the start switch is turned ON.

Unable Unable

7-5

Engine operation is not normal or the engine trouble warning light is on.* Engine trouble warning light may not come on even if the engine operation is not normal.

The engine trouble warning light comes on.

Check the fault code number displayed on the me-ter.

Identify the system with the malfunction. (Refer tothe “FAIL-SAFE ACTION TABLE”.)

Identify the probable cause of malfunction. (Referto the “Fault code table”.)

Checking and repair the probable case of malfunc-tion.

Fault code No. YES Fault code No. NO

Check and repair.(Refer to “TROU-BLESHOOTING DE-TAILS”.)Monitor the operationof the sensors andactuators in the diag-nostic mode. (Referto “Diagnostic modetable” in chapter 7)

Check and repair.(Refer to “TROU-BLESHOOTING DE-TAILS”.)

Perform ECU reinstatement action. (Refer to “Re-instatement method” in “TROUBLESHOOTINGDETAILS”.)

Turn the main switch to “OFF”, turn the main switchback to “ON”, and then check if the fault code num-ber is still displayed.

Erasing the malfunction history:*The Malfunction history is stored even if the mainswitch is turned OFF.The malfunction history must be erased in thediagnostic mode. (Refer to the “Diagnostic modetable (Diagnostic code No.62)”)

Repairs completed

The engine trouble warning light does not comeon.

Check the operation of following sensors and ac-tuators in the Diagnostic mode (Refer to “Diagnos-tic mode table” in chapter 7.)01: Throttle position sensor (throttle angle)30: Ignition coil #131: Ignition coil #232: Ignition coil #333: Ignition coil #436: Injector #137: Injector #238: Injector #339: Injector #448: Al system solenoid

Malfunction of en-gine

Defective sensoror actuator

Check and repairthe inner parts ofengine. (Refer toChapter 5)

Check and repairthe correspondingsensor or actua-tor.

* Operated when the engine trouble warning light is on.

Fault code number displayed

Not fault code number displayed

OK NG

OK OK

Check the engine condition.

OK

NG


EAS00904

TROUBLESHOOTING CHART

7-6


NOTE:

NOTE:

EAS00905

DIAGNOSTIC MODESetting the diagnostic mode1. Turn the main switch to “OFF” and set the en-

gine stop switch to “ON”.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 clock LCD.

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. Set the engine stop switch to “OFF”.7. 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 theclock LCD (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.

8. 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.

9. Turn the main switch to “OFF” to cancel thethe diagnostic mode.

7-7


NOTE:This code appears if no normal sig-nals from the start switch is turnedON.

Fault code table

Faultcode No. Symptom Probable cause of malfunction

Diagnosticcode

11

No normal signals are received fromthe cylinder identification sensor whenthe engine is started or while the mo-tor cycle travels.

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

19

Open circuit in the input line from thesidestand switch to the ECU isdetected when the start switch ispressed.

Open circuit in wiring harness. Malfunction in ECU. 20

20

When the main switch is turned to “ON”, the atmospheric sensor voltage and intake 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

21

Coolant temperature sensor-open orshort circuit detected.

Open or short circuit in wiring harness. Defective coolant temperature sensor. Malfunction in ECU. Improperly installed sensor.

06

22

Intake temperature sensor-open orshort circuit detected.

Open or short circuit in wiring harness. Defective intake temperature sensor. Malfunction in ECU. Improperly installed sensor.

05

23

Atmospheric pressure sensor-open orshort circuit detected.

Open or short circuit in wiring sub lead. Defective atmospheric pressure sensor. Improperly installed sensor. Malfunction in ECU.

02

30The motorcycle has overturned. Overturned.

Malfunction in ECU. 08

7-8


Faultcode No. Symptom Probable cause of malfunction

Diagnosticcode

33

Open circuit is detected in the primarylead of the ignition coil (#1).

Open circuit in wiring harness. Malfunction in ignition coil. Malfunction in ECU. Malfunction in a component of ignition cut-off circuit system.

30

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

43Supply power to the injector and fuelpump is not normal

Open circuit in wiring harness. (red /blue line) 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

46Powr supply to the FI system relay isnot normal.

Open circuit in wiring harness. (red /white line) Malfunction in “CHARGING SYSTEM”. —

50

Faulty ECU memory. When thismalfunction is detected, the codenumber might not appear on themeter.

Malfunction in ECU. (The program and data are notproperly written on or read from the internal memory.) —

Er-1No signal are received from the ECU. Open or short circuit in wiring sub lead.

Malfunction in meter. Malfunction in ECU.

—

Er-2No signal are received from the ECUwithin the specified duration.

Improper connection in wiring sub lead. Malfunction in meter. Malfunction in ECU.

—

Er-3Data from the ECU cannot bereceived correctly.


—

Er-4Non-registered data has beenreceived from the meter.


—

7-9


NOTE:

EAS00907

Diagnostic mode tableSwitch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to“DIAGNOSTIC MODE”.

Check the intake temperature and coolant temperature as close as possible to the intake temperaturesensor and the coolant temperature sensor respectively.

If it is not possible to check the atmospheric pressure with an atmospheric pressure gauge, determinethe atmospheric pressure by using 760 mmHg as the standard.

If it is not possible to check the intake temperature, use the ambient temperature as reference.

Diagnosticcode

Item Description of actionData displayed on meter

(reference value)

01Throttle angle Displays the throttle angle.

Check with throttle fully closed. Check with throttle fully open.

0 125 degrees Fully closed position (15 17) Fully open position (97 100)

02Atmosphericpressure

Displays the atmospheric pressure.* Use an atmospheric pressure gauge to check the

atmospheric pressure.

Compare it to the valuedisplayed on the meter.

03

Pressure difference(atmosphericpressure-intake airpressure)

Displays the pressure difference (atmospheric pressure-intake air pressure).Engine stop switch is on.* Generate the pressure difference by cranking the engine

with the starter, without actually starting the engine.

10 200 mmHg

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: 3.8 4.2 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 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates ignitioncoil #1 for five times every second and illuminates theengine 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 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates ignitioncoil #2 for five times every second and illuminates theengine trouble warning light.* Connect an ignition checker.* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.


7-10


Diagnosticcode


(reference value)

32


turn it back ON.


33


turn it back ON.


36

Injector #1 After 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates theinjector five times every second and illuminates the enginetrouble 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 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates the AIsystem solenoid five times every second and illuminates theengine trouble warning light.* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the operating sound ofthe AI system solenoid 5 timeswith the engine stopswitch ON.

50

Fuel injection systemrelay

After 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates the fuelinjection system relay five times every second andilluminates the engine trouble warning light (the light is OFFwhen the relay is ON, and the light is ON when the relay isOFF).* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the fuel injection systemrelay operating sound 5 timeswith the engine stopswitch ON.

51

Radiator fan motorrelay

After 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates theradiator fan motor relay five times every 5 seconds andilluminates the engine trouble warning light. (ON 2 seconds,OFF 3 seconds)* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the radiator fan motorrelay operating sound 5 timeswith the engine stopswitch ON.(At that time, the fan motorrotates.)

7-11


Diagnosticcode


(reference value)

52

Headlight relay 1 After 1 second has elapsed from the time the engine stopswitch has been turned from OFF to ON, it actuates theheadlight relay five times every 5 seconds and illuminatesthe engine trouble warning light. (ON 2 seconds, OFF 3seconds)* If the engine stop switch is ON, turn it OFF once, and then

turn it back ON.

Check the headlight relayoperating sound 5 times with theengine stop switch ON.(At that time, the headlight turnsON.)

60

E2PROM fault codedisplay

Transmits the abnormal portion of the data in the E2PROMthat has been detected as a fault code 44.

If multiple malfunctions have been detected, differentcodes are displayed at 2-second intervals, and thisprocess is repeated.

(01 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 21(00) Displays when there is nomalfunction.

70 Control number Displays the program control number. 00 255

7-12


Cylinder identification sensoroutput voltage

When sensor is on4.8 V or more

When sensor is off0.8 V or less

Tester positive probe white Tester negative probe black/blue

12

EAS00908

TROUBLESHOOTING DETAILSThis section describes the countermeasures per fault code number displayed on the meter. Check andservice the items or components that are the probable cause of the malfunction following the order inthe “TROUBLESHOOTING CHART”.After the check and service of the malfunctioned part has been completed, reset the meter display ac-cording to the “Reinstatement method”.Fault code No.:

Fault code number displayed on the meter when the engine failed to work normally. (Refer to the“Fault code table”.)

Diagnostic code No.:Diagnostic code number to be used when the diagnostic mode is operated. (Refer to “DIAGNOSTICMODE”.)

Fault code No. 11 Symptom No normal signals are received from the cylinder identification sensor when theengine is started or while the motorcycle travels.

Used diagnostic code No. – –

Inspection operation item Operation item and countermeasure Reinstatementmethod

Installed condition of sensor Check the installed area for looseness orpinching.

Reinstated bystarting the engine

Defective cylinder identification sensor. Replace if defective.1. Connect the pocket tester (DC 20 V) to the

cylinder identification sensor coupler terminalas shown.

2. Turn the main switch to “ON”.3. Measure the cylinder identification sensor out-

put voltage.

4. Is the cylinder identification sensor OK?

and operating it atidle.

Open or short circuit in wiring harness and/orsub 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

Reinstated bystarting the engineand operating it atidle.

Connected condition of connectorInspect the coupler for any pins that mayhave pulled out.Check the locking condition of the coupler.

If there is a malfunction, repair it and connect itsecurely.

Cylinder identification sensor couplerMain wiring harness ECU couplerSub-wire harness coupler

7-13

Crankshaft position sensorresistance

248 372 Ω at 20C (68 F)(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.


Inspection operation item and probablecause

Operation item and countermeasure Reinstatementmethod


Reinstated bycranking the

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?

engine.

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

Connected condition of connectorInspect the coupler for any pins that mayhave pulled cut.Check the locking condition of the coupler.


Crankshaft position sensor couplerMain wiring harness ECU coupler

7-14

Intake air pressure sensor outputvoltage

3.75 4.25 V

Tester positive probe pink/white Tester negative probe black/blue

12

12


Fault code No. 13 Symptom Intake air pressure sensor - open or short circuit detected.

Used diagnostic code No. 03 (intake air pressure sensor)



Defective intake air pressure sensor 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?

Reinstated byturning the mainswitch ON.


Repair or replace if there is an open or shortcircuit.Between sensor coupler and ECU coupler

Black /Blue - Black/BluePink/White - Pink/WhiteBlue - Blue



Intake air pressure sensor couplerMain wiring harness ECU couplerSub-wire harness coupler

7-15


Fault code No. 14 Symptom Intake air pressure sensor - hose system malfunction (clogged or detached hose).

Used diagnostic code No. 03 (intake air pressure sensor)


Operation item and countermeasuer Reinstatementmethod

Intake air pressure sensor hose detached,clogged, kinked, or pinched.Intake air pressure sensor malfunction atintermediate electrical potential.Atmospheric pressure sensor malfunction atintermediate electrical potential.

Repair or replace the sensor hose.Inspect and repair the connection.

Reinstated bystarting the engineand operating it atidle.

Defective intake air pressure sensor. Replace if defective.Refer to “Fault code No. 13”.

Fault code No. 15 Symptom Throttle position sensor - open or short circuit detected.

Used diagnostic code No. 01 (throttle position sensor)



Defective throttle position sensor. Replace if defective.Refer to “THROTTLE BODIES” section.

Reinstated byturning the main



Black /Blue - Black/BlueYellow - YellowBlue - Blue

switch ON.

Installed condition of throttle position sensor. 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

Fault code No. 16 Symptom Stuck throttle position sensor detected.

Used diagnostic code No.01 (throttle position sensor)



Defective throttle position sensor Replace if defective.Refer to “THROTTLE BODIES” section.

Reinstated bystarting the engine,

Installed condition of throttle position sensor. Check the installed area for looseness or pinching.Check that it is installed in the specified position.Refer to “THROTTLE BODIES” section.

operating it at idle,and then racing it.

7-16


Fault code No. 19 Symptom Open circuit is detected in the input line from the sidestand switch to the ECU.

Used diagnostic code No. 20 (sidestand switch)



Defective sidestand switch Replace if defective.Refer to “CHECKING THE SWITCHES” inchapter 8.

If the transmissionis in gear, it isreinstated by


Repair or replace if there is an open or shortcircuit.Between sidestand switch coupler and startingcircuit cut-off relay coupler, starting circuit cut-offrelay coupler and ECU coupler

Blue/Black – Blue/Black, Blue/Yellow – Blue/Yellow

retracting thesidestand.If the transmissionis in neutral, it isreinstated byreconnecting thewiring.

Fault code No. 20 Symptom Faulty atmospheric pressure sensor or intake air pressure sensor.

Used diagnostic code No. 03 (intake air pressure sensor)02 (atmospheric pressure sensor)



Intake air pressure sensor hose detached,clogged, kinked, or pinched.Atmospheric pressure sensor hose isclogged.

Repair or replace the sensor hose. Reinstated byturning the mainswitch ON.

Defective intake air pressure sensor oratmospheric pressure sensor.

Replace if defective.Refer to “Fault code No.13 or No.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)



Installed condition of sensor Check the installed area for looseness or pinching.


Defective coolant temperature sensor. Replace if defective.Refer to “COOLING SYSTEM” in chapter 8.

switch ON.



Black /Blue - Black/BlueGreen/White - Green/White



Coolant temperature sensor couplerMain wiring harness ECU couplerSub-wire harness coupler

7-17


Intake air temperature sensorresistance

2.2 2.7 Ω at 20C (68 F)

Tester positive probe brown/white Tester negative probe black/blue

12

Handle the intake air temperature sensorwith special care.

Never subject the intake air temperature sen-sor to strong shocks. If the intake air temper-ature sensor is dropped, replace it.

WARNING

Fault code No. 22 Symptom Open or short circuit detected from the intake temperature sensor.

Used diagnostic code No. 05 (intake temperature sensor)





Defective intake temperature sensor. 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?

switch ON.



Black /Blue - Black/BlueBrown/White - Brown/White



Intake temperature sensor couplerMain wiring harness ECU couplerSub-wire harness coupler

7-18


Atmospheric pressure sensoroutput voltage

3.75 4.25 V

Tester positive probe blue Tester negative probe black/blue

12

1 2

Fault code No. 23 Symptom Open or short circuit detected from the atmospheric pressure sensor.

Used diagnostic code No. 02 (atmospheric pressure sensor)



Defective atmospheric pressure sensor. 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?


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

Installed condition of atmospheric pressuresensor

Check the installed area for looseness orpinching.



Atmospheric pressure sensor couplerMain wiring harness ECU coupler

7-19


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)



Defective lean angle cut-off switch Replace if defective.1. Remove the lean angle cut-off switch from the

motorcycle.2. Connect the lean angle cut-off switch coupler

to the wireharness.3. Connect the pocket tester (DC 20 V) to the

lean angle cut-off switch coupler as shown.

4. When turn the lean angle cut-off switchapprox. 65, the voltage reading is 1.0 V to 4.0V.

5. Is the lean angle cut-off switch OK?

Reinstated byturning the mainswitch ON(however, theengine cannot berestarted unlessthe main switch isfirst turned OFF).

The motorcycle has overturned. Raise the motorcycle upright.

Installed condition of the lean angle cut-offswitch

Check the installed area for looseness orpinching.



Lean angle cut-off switch couplerMain wiring harness ECU coupler

7-20


Fault code No. 33 Symptom Malfunction detected in the primary lead of the ignition coil (#1).

Used diagnostic code No. 30 (ignition coil #1)



Defective ignition coil (test the primary and Replace if defective. Reinstated bysecondary coils for continuity). Refer to “IGNITION SYSTEM” in chapter 8. starting the engine

d ti it tOpen 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 – OrangeBlack – Black

and operating it at idle.In case of multiplecylinder open orshort circuit inlead, make sure toturn ON and OFF



Ignition coil primary side coupler - OrangeMain wiring harness ECU couplerSub-wire harness coupler

turn ON and OFFthe main switchafter each time ofcranking.





Defective ignition coil (test the primary andsecondary coils for continuity).

Replace if defective.Refer to “IGNITION SYSTEM” in chapter 8.


Open or short circuit in lead wire. Repair or replace if there is an open or shortcircuit.Between ignition coil coupler (#2) and ECU coupler /main harness

Gray /Red – Gray/RedBlack – Black

and operating it atidle.In case of multiplecylinder open orshort circuit inlead, make sure toturn ON and OFF



Ignition coil primary side coupler - Gray/RedMain wiring harness ECU couplerSub-wire harness coupler









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/GreenBlack – Black




Ignition coil primary side coupler - Orange/GreenMain wiring harness ECU couplerSub-wire harness coupler


7-21









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/GreenBlack – Black


Connected state of connectorInspect the coupler for any pins that mayhave pulled out.Check the locking condition of the coupler.


Ignition coil primary side coupler - Gray/GreenMain wiring harness ECU couplerSub-wire harness coupler


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)



Defective lean angle cut-off switch Replace if defective.Refer to Fault code No. 30.


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

switch ON.



Lean angle cut-off switch couplerMain wiring harness ECU coupler

7-22


Speed sensor output voltageWhen sensor is on

DC 4.8 V or moreWhen sensor is off

DC 0.6 V or less

Tester positive probe pinkTester negative probe black/white

12

Fault code No. 42 Symptom 1 No normal signals are received from the speed sensor.2 Open or short circuit is detected in the neutral switch.

Used diagnostic code No. 07 (speed sensor)No. 21 (neutral switch)



Defective speed sensor Replace if defective.1. Measure the speed sensor output voltage.2. Connect the pocket tester (DC 20 V) to the

speed sensor coupler terminal as shown.

3. Measure the speed sensor output voltage.

4. Is the speed sensor OK?

Reinstated bystarting the engine, and inputting thevehicle speedsignals by operating the motorcycle at alow speed of 20 to30 km/h.

Open or short circuit in speed sensor lead. Repair or replace if there is an open or shortcircuit.Between sensor coupler and ECU coupler.

Blue - BlueWhite/Yellow - White /YellowBlack /Blue - Black/Blue

Gear for detecting vehicle speed has broken. Replace if defective.Refer to “TRANSMISSION” in chapter 5.

Connected condition of speed sensorconnectorInspect the coupler for any pins that mayhave pulled out.Check the locking condition of the coupler.

If there is a malfunction, repair it and connect itsecurely.Speed sensor coupler

Main wiring harness ECU coupler

Defective neutral switch Replace if defective.Refer to “CHECKING THE SWITCHES” inchapter 8.

Faulty shift drum(neutral detection area)

Replace if defective.Refer to “TRANSMISSION” in chapter 5.

Open or short circuit in neutral switch lead. Repair or replace if there is an open or shortcircuit.Between switch connector and ECU coupler

Sky blue - Black/Yellow



Neutral switch connectorMain wiring harness ECU coupler

7-23


Battery positive terminal red/black Battery positive terminal light green

12

Tester positive probe red Tester negative probe red/blue

34

Fault code No. 43 Symptom The ECU is unable to monitor the battery voltage.

Used diagnostic code No. 09 (fuel system voltage)



Malfunction in ECU Fuel injection system relay is on. Reinstated by

Open or short circuit in the wiring harness. Repair or replace if there is an open or shortcircuit.Between starting circuit cut-off relay (fuel injectionsystem relay), fuel pump, injector (#1 #4)

Red/Blue – Red /Blue

starting the engineand operating it atidle.

Malfunction or open circuit in fuel injectionsystem relay

Replace if defective.1. Disconnect the starting circuit cut-off relay

from the wire harness.2. Connect the pocket tester (Ω 1) and battery

(12 V) to the starting circuit cut-off relay termi-nals as shown.

3. Does the starting circuit cut-off relay have con-tinuity between red and red/blue?



Starting circuit cut-off relay coupler(fuel injection system relay)Fuel pump couplerInjector couplerECU coupler

7-24


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)



Malfunction in ECU Execute diagnostic code 60* Check the faulty cylinder. (If there are multiple

cylinders, the number of the faulty cylindersappear alternately at 2-second intervals.)

* 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.




Faulty battery Replace or change the battery Refer to “CHECKING AND CHARGING THE BAT-TERY” in chapter 3.

Reinstated bystarting the engineand operating it at

Open or short circuit in wiring hanress. Repair or replace if there is an open or short cir-cuit. Between battery and main switch

Red – Red Between main switch and Fuse (ignition)

Brown/blue – Brown/blue Between Fuse (ignition) and ECU

Red/white – Red/white

idle.


If there is a malfunction, repair it and connect itsecurely.ECU coupler.

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.)




Malfunction in ECU Replace the ECU. Reinstated byturning the mainswitch ON.

7-25


Fault code No. Er-1 Symptom No signal are received from the ECU.






Yellow/Blue - Yellow/BlueBlack /White - Black/White





Malfunction in meter Replace the meter.

Malfunction in ECU Replace the ECU.

Fault code No. Er-2 Symptom No signal are received from the ECU within the specified duration.



Operation item and contermeasure Reinstatementmethod










Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly.













7-26


Fault code No. Er-4 Symptom Non-registered data has been received from the meter.













7-27


12345

Removing the throttle bodiesSeats/fuel tank/rubber sheet

Air filter caseCoolant

Sub-wire harness couplerCoolant temp sensor couplerThrottle stop screwThrottle body joint clamp screwThrottle bodies

21141

Remove the parts in the order listed.Refer to “SEATS” and “FUEL TANK” inchapter 3.Refer to “AIR FILTER CASE” in chapter 3.Drain.Refer to “CHANGING THE COOLANT” inchapter 3.Disconnect.

Loosen.

THROTTLE BODIES FI

THROTTLE BODIES

7-28

THROTTLE BODIES FI


6789

Throttle cablePlunger control unit hoseThrottle body jointHeat protector

2241

Disconnect.Disconnect.

For installation, reverse the removalprocedure.

7-29

THROTTLE BODIES FI


123456789

Removing the injectorThrottle position sensor couplerIntake air pressure sensorCylinder #1-injector couplerCylinder #2-injector couplerCylinder #3-injector couplerCylinder #4-injector couplerSub wire harness 2Negative pressure hosePressure regulator

111111111

Remove the parts in the order listed.Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.Disconnect.

Disconnect.

7-30

THROTTLE BODIES FI


1011121314

Intake air pressure sensorFuel distributorInjectorThrottle position sensorThrottle body assembly

11411

For installation, reverse the removalprocedure.

7-31

THROTTLE BODIES FI

CAUTION:

EAS00911

The throttle bodies should not be disas-sembled.

EAS00912

CHECKING THE INJECTOR1. Check: injectorDamage Replace.

EAS00913

CHECKING THE THROTTLE BODY1. Check: throttle bodyCracks/damage Replace the throttle bo-dies.

2. Check: fuel passagesObstruction Clean.

a. Wash the throttle body in a petroleumbasedsolvent.Do not use any caustic carburetor cleaningsolution.

b. Blow out all of passages with compressedair.

7-32

THROTTLE BODIES FI

NOTE:

CHECKING THE PRESSURE REGULATOR1. Check:pressure regulatorDamage Replace.

CHECKING THE FUEL PUMP AND PRES-SURE 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 pressure284 kPa (2.84 kg/cm2, 40.4 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).

7-33

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 terminal 2

d. Measure the maximum throttle position sen-sor resistance.Out of specification Replace the throttleposition sensor.

Maximum throttle positionsensor resistance

3.5 6.5 kΩ at 20C (68F)(blue - black)

e. Connect the pocket tester (Ω 1k) to thethrottle position sensor.

Positive tester probe yellow terminal 3Negative tester probe black terminal 2

7-34

THROTTLE BODIES FI

NOTE:

Tester positive probe blue terminal Tester negative probe

yellow terminal

1

2

f. While slowly opening the throttle, check thatthe throttle position sensor resistance is with-in the specified range.The resistance does not change or itchanges abruptly Replace the throttleposition sensor.The slot is worn or broken Replace thethrottle position sensor.

Check mainly that the resistance changes grad-ually when turning the throttle, since the read-ings (from closed to wide-open throttle) may dif-fer slightly from those specified.

Throttle position sensorresistance

0 5 1.5 kΩ at 20C (68F)(yellow - black)

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 – blue)

g. After adjusting the throttle position sensorangle, tighten the throttle position sensorscrews.

7-35

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

7-36


A To cylinder #1 and #2B To cylinder #3 and #4

1 Air cut-off valve2 Reed valve3 To air filter case

EAS00509

AIR INDUCTION SYSTEM DIAGRAMS

7-37


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.

7-38


5. Checkair 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 solenoid resistance

18 22 Ω at 20C (68F)

d. Out of specification Replace.

8-1

ELECTRICAL COMPONENTS ELEC

9 Sidestand switch10 Oil level switch11 Radiator fan motor12 Horn13 Ignition coil14 Fuse box

1 Main switch2 Front brake light switch3 Clutch switch4 Battery5 Starter relay6 Fuse (main)7 Neutral switch8 Rear brake light switch

EAS00729

ELECTRICALELECTRICAL COMPONENTS

8-2

8

9 Speed sensor10 Crankshaft position sensor11 Cylinder identification sensor12 Radiator fan motor relay13 Headlight relay (on/off)14 Headlight relay (dimmer)

1 Coolant temperature sensor2 Intake air temperature sensor3 Intake air pressure sensor4 Lean angle cut-off switch5 Atmospheric pressure sensor6 ECU7 Starting circuit cut-off relay8 Turn signal relay

ELECTRICAL COMPONENTS ELEC

8-3

CHECKING SWITCH CONTINUITY ELEC

CAUTION:

NOTE:

NOTE:

EAS00730

CHECKING SWITCH CONTINUITYCheck each switch for continuity with the pockettester. If the continuity reading is incorrect,check the wiring connections and if necessary,replace the switch.

Never insert the tester probes into the cou-pler terminal slots. Always insert the probesfrom the opposite end of the coupler 1 tak-ing care not to loosen or damage the leads.


Before checking for continuity, set the pockettester to “0” and to the “Ω 1” range.

When checking for continuity, switch back andforth between the switch positions a few times.

The terminal connections for switches (e.g.,main switch, engine stop switch) are shown inan illustration similar to the one on the left.The switch positions a are shown in the far leftcolumn and the switch lead colors b are shownin the top row in the switch illustration.

“ ” indicates a continuity of electricitybetween switch terminals (i.e., a closed circuitat the respective switch position).

The example illustration on the left showsthat:There is continuity between red and brown/bluewhen 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

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 is used for turn signal and tail /brakelights and can be removed from the socket bypushing and turning the bulb counterclock-wise.

Bulbs D and E are used for meter and indi-cator lights and can be removed from theirrespective socket by carefully pulling themout.

8-6


WARNING

CAUTION:

NOTE:

CHECKING THE CONDITION OF THEBULBSThe following procedure applies to all of thebulbs.1. Remove:bulb

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

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.

8-7


NOTE:

WARNING

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.


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 shown.

A wire that is used as a jumper lead musthave at least the same capacity of the bat-tery lead, otherwise the jumper lead mayburn.

This check is likely to produce sparks,therefore, make sure no flammable gas orfluid is in the vicinity.

c. When the jumper leads are connected to theterminals the respective LED should illumi-nate.Does not light Replace the meter assem-bly.

8-8

1 Main switch5 Battery6 Fuse (main)10 Fuse (ignition)11 Starting circuit cut-off relay12 Sidestand switch14 ECU15 Ignition coil16 Spark plug19 Neutral switch20 Crankshaft position sensor28 Lean angle cut-off switch44 Engine stop switch55 Clutch switch

IGNITION SYSTEM ELEC

EAS00735

IGNITION SYSTEMCIRCUIT DIAGRAM

8-9

YES NO

2. Battery

Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.

Minimum open-circuit voltage12.8 V or more at 20C (68F)

Is the battery OK?

Clean the batteryterminals.

Recharge or re-place the battery.

EAS00739

YES NO

EAS00741

3. Spark plugs

The following procedure applies to all of thespark plugs.Check the condition of the spark plug.Check the spark plug type.Measure the spark plug gap.Refer to “CHECKING THE SPARK PLUGS”in chapter 3.

Standard spark plugCR9EK or CR10EK (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 switch10. sidestand switch11. clutch switch12. starting circuit cut-off relay13. lean angle cut-off switch14. wiring connections

(of the entire ignition system)

Before troubleshooting, remove the followingpart(s):

1. seat2. fuel tank3. air filter case4. bottom cowling5. side cowlingsTroubleshoot with the following special tool(s).

Dynamic spark testerYM-34487


EAS00738

8-10


NO YES

1

a

2

4. Ignition spark gap

The following procedure applies to all of thespark plugs.Disconnect the ignition coil from the sparkplug.

Connect the dynamic spark tester andignition coil as shown.

Turn 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.

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 resistance0.17 0.23 Ω at 20C (68F)

Negative tester probe ignition coil terminal

Positive tester probe spark plug terminal

1

2

Measure the secondary coil resistance.

Secondary coil resistance4.8 7.2 kΩ at 20C (68F)

Is the ignition coil OK?

YES NO

Replace the ignitioncoil.

EAS00747EAS00743

8-11


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

248 372Ω at 20C (68F)(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.

8-12


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:12. Starting circuit cut-off relay

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 sky blue

Negative tester probe black/yellow

Positive tester probe blue/yellow

Negative tester probe blue/black

1

2

3

4

EAS00753

Positive tester probe sky blue

Negative tester probe blue/yellow

Continuity1

3

Positive tester probe blue/black

Negative tester probe blue/yellow

4

3

Positive tester probe black/yellow

Negative tester probe sky blue

2

1

Positive tester probe blue/yellow

Negative tester probe sky blue

No continuity

3

1

13. Lean angle cut-off switch voltage

Remove the lean angle cut-off switch.Connect the pocket tester (Ω 1) to thelean angle cut-off switch terminals asshown.

Positive tester probe blueNegative tester probe yellow/green

Lean angle cut-off switch voltageLess than 65

Approximately 1 VMore than 65

Approximately 4 V

Is the lean angle cut-off switch OK?

a

b

8-13


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 ignitorunit.

8-14

1 Main switch5 Battery6 Fuse (main)7 Starter relay8 Starter motor10 Fuse (ignition)11 Starting circuit cut-off relay12 Sidestand switch19 Neutral switch44 Engine stop switch45 Start switch55 Clutch switch

ELECTRIC STARTING SYSTEM ELEC

EAS00755

ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM

8-15


EAS00756

STARTING CIRCUIT CUT-OFF SYSTEM OPERATIONIf the engine stop switch is set to “ ” and themain switch is set to “ON” (both switches areclosed), the starter motor can only operate if atleast one of the following conditions is met:The transmission is in neutral (the neutralswitch is closed).

The clutch lever is pulled to the handlebar (theclutch switch is closed) and the sidestand is up(the sidestand switch is closed).

The starting circuit cut-off relay prevents thestarter motor from operating when neither ofthese conditions has been met. In this instance,the starting circuit cut-off relay is open so cur-rent cannot reach the starter motor. When atleast one of the above conditions has been metthe starting circuit cut-off relay is closed and theengine can be started by pressing the starterswitch.

WHEN THE TRANSMISSION IS INNEUTRAL

WHEN THE SIDESTAND IS UP ANDTHE CLUTCH LEVER IS PULLED TOTHE HANDLEBAR

1 Battery2 Main fuse3 Main switch4 Ignition fuse5 Engine stop switch6 Starting circuit cut-off relay7 Diode8 Clutch switch9 Sidestand switch10 Neutral switch11 Start switch12 Starter relay13 Starter motor

8-16

YES NO

3. Starter motor

Connect the positive battery terminal andstarter motor lead with a jumper lead .

Repair or replace thestarter motor.

A wire that is used as a jumper leadmust have at least the same capacity ormore as that of the battery lead, other-wise the jumper lead may burn.

This check is likely to produce sparks,therefore make sure nothing flammableis in the vicinity.

Does the starter motor turn?

WARNING

12 3

EAS00758

YES NO

2. Battery



Is the battery OK?



EAS00739


NOTE:

YES NO

1. Main and ignition fuses

Check the main and ignition fuses for conti-nuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main and ignition fuses OK?


EAS00757

TROUBLESHOOTING

The starter motor fails to turn.

Check:1. main and ignition fuses2. Battery3. starter motor4. starting circuit cut-off relay5. starter relay6. main switch7. engine stop switch8. neutral switch9. sidestand switch

10. clutch switch11. start switch12. wiring connections

(of the entire starting system)


1. seat2. fuel tank3. left side cowlingTroubleshoot 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 red/white Negative battery terminal blue/white

Positive tester probe red Negative tester probe black

12

34

Does the starter relay have continuity be-tween red and black?

EAS00749

6. Main switch



YES NO


EAS00750




YES NO


EAS00751

8. Neutral switch



YES NO



8-18

Check the entire starting system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the starting system’s wiring properly con-nected and without defects?

EAS00766

12. Wiring

YES NO

Properly connect orrepair the startingsystem’s wiring.

The starting systemcircuit is OK.

11. Start switch

Check the start switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the start switch OK?

YES NO


EAS00764

10. Clutch switch

Check the clutch switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the clutch switch OK?

YES NO

Replace the clutchswitch.

EAS00763

EAS00752

9. Sidestand switch

Check the sidestand switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the sidestand switch OK?

YES NO

Replace the side-stand switch.


8-19

STARTER MOTOR ELEC


12

Removing the starter motorRider seatFuel tankLeft side cowlingStarter motor leadStarter motor

11

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)

5 Nm (0.5 mkg, 3.6 ftlb)

EAS00767

STARTER MOTOR

8-20

STARTER MOTOR ELEC


Disassembling the starter motorO-ringFront coverLock washerOil sealBearingWasher setRear coverWasher setO-ringBrush holderArmature assemblyStarter motor yoke

111111112111

Disassembly the parts in the order listed.


123456789101112

3.4 Nm (0.34 mkg, 2.5 ftlb)

7 Nm (0.7 mkg, 5.1 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 limit27 mm (1.06 in)

3. Measure:mica undercut aOut of specification Scrape the mica to theproper measurement with a hacksaw bladethat has been grounded to fit the commuta-tor.

Mica undercut0.7 mm (0.03 in)

The mica of the commutator must be undercutto ensure proper operation of the commutator.

4. Measure:armature assembly resistances (commuta-tor and insulation)Out of specification Replace the startermotor.

a. Measure the armature assembly resistanceswith the pocket tester.


Armature coilCommutator resistance 1

0.0012 0.0022 Ω at 20C (68F)

Insulation resistance 2Above 1 MΩ at 20C (68F)

b. If any resistance is out of specification, re-place the starter motor.

8-22

STARTER MOTOR ELEC

NOTE:

NOTE:

5. Measure:brush length a .Out of specification Replace the brushesas a set.

Brush length wear limit3.5 mm (0.14 in)

6. Measure:brush spring forceOut of specification Replace the brushsprings as a set.

Brush spring force7.16 9.52 N(730 971 gf, 25.77 34.27 oz)

7. Check:gear teethDamage/wear Replace the gear.

8. Check:bearingoil sealDamage/wear Replace the defectivepart(s).

EAS00772

ASSEMBLING THE STARTER MOTOR1. Install:brush seat 1

Align the tab a on the brush seat with the slot bin the starter motor rear cover.

2. Install:starter motor yoke 1O-ring 2 New front cover 3rear cover 4

Align the match marks a on the starter motoryoke with the match marks b on the front andstarter motor rear covers.

8-23

2 A.C. magneto3 Rectifier / regulator5 Battery6 Fuse (main)

CHARGING SYSTEM ELEC

EAS00773

CHARGING SYSTEMCIRCUIT DIAGRAM

8-24

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.

Are 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 resistance 15. stator coil resistance 26. wiring connections

(of the entire charging system)


1. seat2. fuel tank3. bottom cowlingTroubleshoot with the following special tool(s).


EAS00738

8-25


YES NO

5. Stator coil resistance 2

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 resistance0.18 0.26 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 resistance 1

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 assembly.

Are the tester readings correct?

8-26

LIGHTING SYSTEM ELEC

EAS00780

LIGHTING SYSTEMCIRCUIT DIAGRAM

8-27


1 Main switch5 Battery6 Fuse (main)10 Fuse (ignition)14 ECU38 High beam indicator light40 Meter light47 Fuse (headlight)51 Headlight relay (on/off)52 Headlight relay (dimmer)56 Dimmer switch63 Front turn signal/position light (right)64 Front turn signal/position light (left)65 Headlight66 License light67 Tail /brake light

8-28

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 handlebarswitch.


Is the battery OK?


NOTE:

YES NO

1. Main, ignition and headlight fuses

Check the main, ignition and headlight fusesfor continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main, ignition and headlight fusesOK?


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, ignition and headlight fuses2. battery3. main switch4. dimmer switch5. headlight relay (on/off)6. headlight relay (dimmer)7. wiring connections

(of the entire lighting system)


1. seat2. fuel tank3. side cowlings4. rear cowlingTroubleshoot with the following special tool(s).


EAS00738

8-29

Does the headlight relay (on/off) have conti-nuity between red/yellow and black/blue?

NOYES

Replace the head-light relay (on/off).

Positive tester probe red/yellow Negative tester probe black/blue

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)coupler as shown.

Positive battery lead blue/black Negative battery lead yellow/white

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)coupler as shown.

Does the headlight relay (dimmer) havecontinuity?

NOYES

Replace the head-light relay (dimmer).

12

High beamPositive battery lead yellow Negative battery lead black

Positive tester probe black/blue Negative tester probe black/yellow

34

EAS00787

YES NO

7. Wiring

Check the entire lighting system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the lighting system’s wiring properly con-nected and without defects?

Properly connect orrepair the lightingsystem’s wiring.

Check the conditionof each of the lightingsystem’s circuits.Refer to “CHECK-ING THE LIGHTINGSYSTEM”.


8-30

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/blue Negative tester probe black

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) of black/blue

or black/yellow on the headlight cou-pler (wire harness side).

Is the voltage within specification?

1

This circuit is OK.

AB

HeadlightPositive tester probe black/yellow Negative tester probe black

A

High beamB

5

6

34

3


EAS00788

CHECKING THE LIGHTING SYSTEM1. The headlight and the high beam indicator

light fail to come on.

8-31


YES NO

1. Meter light (LEDs)

Check the meter light for continuity.Refer to “CHECKING THE LEDs”

Are the meter light OK?

Replace the meterassembly.

EAS00789

2. The meter light fails to come on.

YES NO

2. 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 blue Negative tester probe black/white

12

Turn the main switch to “ON”.Measure the voltage (DC 12 V) of blue onthe meter assembly coupler (wire harnessside).


1

This circuit is OK.

EAS00790

3. The tail /brake light fails to come on.

YES NO

1. Tail /brake light (LEDs)

Check the tail /brake light for continuity.Refer to “CHECKING THE LEDs”

Are the tail /brake light OK?

Replace thetail /brake light as-sembly.

YES NO

2. Voltage

Connect the pocket tester (DC 20 V) to thetail /brake light coupler (wire harness side)as shown.

Wiring circuit fromthe main switch tothe tail /brake lightcoupler is faulty andmust be repaired.

Positive tester probe blue/red Negative tester probe black

12

Turn the main switch to “ON”.Measure the voltage (DC 12 V) of blue/red

on the tail /brake light coupler (wire har-ness side).


1

This circuit is OK.

8-32


YES NO

1. License light bulb and socket

Check the license light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”

Are the license light bulb and socket OK?

Replace the licenselight bulb, socket orboth.

EAS00792

4. The license light fails to come on.

YES NO

2. Voltage

Connect the pocket tester (DC 20 V) to thelicense light coupler (wire harness light side)as shown.

The wiring circuitfrom the main switchto the license lightcoupler is faulty andmust be repaired.

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 light coupler (wire harnessside).


1

This circuit is OK.

YES NO

1. Turn signal/position light bulb 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 light bulb,socket or both.

5. The turn signal/position light fails to comeon.

YES NO

2. Voltage

Connect the pocket tester (DC 20 V) to theturn signal/position light couplers (wire har-ness side) as shown.

The wiring circuitfrom the main switchto the turn signal/position light con-nectors is faulty andmust be repaired.

Tester positive probe blueTester negative probe black

12

Turn the main switch to “ON”.Measure the voltage (12 V) of blue on theturn signal/position light couplers (wire har-ness side).


1

This circuit is OK.

8-33

SIGNALING SYSTEM ELEC

EAS00793

SIGNALING SYSTEMCIRCUIT DIAGRAM

8-34


1 Main switch5 Battery6 Fuse (main)10 Fuse (ignition)11 Starting circuit cut-off relay13 Fuel pump14 ECU19 Neutral switch27 Speed sensor30 Fuel level warning light31 Oil level warning light32 Neutral indicator light33 Tachometer34 Shift timing indicator light35 Multi-function meter37 Coolant temperature indicator light39 Turn signal indicator light41 Oil level switch43 Front brake light switch46 Fuse (signal)53 Rear brake light switch57 Horn switch58 Turn signal switch59 Horn60 Turn signal relay61 Rear turn signal light (right)62 Rear turn signal light (left)63 Front turn signal /position light (right)64 Front turn signal /position light (left)67 Tail /brake light

8-35

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.

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. Main, ignition and signaling fuses

Check the main, ignition and signaling fusesfor continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main, ignition and signaling fusesOK?


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. main, ignition and signaling fuses2. battery3. main switch4. wiring connections

(of the entire signaling system)


1. seat2. fuel tank3. bottom cowling4. side cowlings5. rear cowlingTroubleshoot with the following special tool(s).


EAS00738

8-36


YES NO

1. Tail /brake light (LEDs)

Check the tail /brake light for continuity.Refer to “CHECKING THE LEDs”

Are the tail /brake light OK?

Replace thetail /brake light as-sembly.

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.

8-37


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?


EAS00799

3. The turn signal/position light, turn signalindicator 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

5. Voltage

Connect the pocket tester (DC 20 V) to theturn signal/position light connector or meterassembly coupler (wire harness side) asshown.

Front turn signal/position lightRear turn signal lightTurn signal indicator light

ABC

NO

8-38


YES NO

The wiring circuitfrom the turn signalswitch to the turn sig-nal light connector isfaulty and must berepaired.

Left turn signal lightPositive tester probe chocolate Negative tester probe ground

Right turn signal lightPositive tester probe dark green Negative 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

C

1. Neutral indicator light (LEDs)

Check the neutral indicator light for continu-ity.Refer to “CHECKING THE LEDs”

Are the neutral indicator light OK?

EAS00801

4. The neutral indicator light fails to come on.

YES NO


YES NO

2. Neutral switch




YES NO

3. Voltage



Positive tester probe brownNegative tester probe ground

1

Turn the main switch to “ON”.Measure the voltage (DC 12 V) of brown atthe meter assembly coupler (wire harnessside).


This circuit is OK.

8-39


YES NO

1. Oil level warning light (LEDs)

Check the oil level warning light for continu-ity.Refer to “CHECKING THE LEDs”

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 earth1

1 2

Measure the oil level switch resistance.

Oil level switch resistance484 536 Ω at 20C (68F)114 126 Ω at 20C (68F)

12

Is the oil level switch OK?

3. Voltage


Positive tester probe black/redNegative tester probe black/white

12

Turn the main switch to “ON”.Measure the voltage (DC 12 V) of black/red

and black/white at the meter assem-bly coupler.


1 2

YES NO

The wiring circuitfrom the main switchto the meter assem-bly is faulty and mustbe repaired.

This circuit is OK.

YES NO

1. Fuel level warning light (LEDs)

Check the fuel level warning light for conti-nuity.Refer to “CHECKING THE LEDs”

Are the fuel level warning light OK?


EAS00803

6. The fuel level warning light fails to come on.

2

8-40


YES NO

2. 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 1) to the fuelsender as shown.

Replace the fuelpump assembly.

Positive tester probe green/whiteNegative tester probe black

12

Check the fuel sender for continuity. Is the fuel sender OK?

YES NO

3. Voltage



Positive tester probe green/whiteNegative 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

YES NO

1. Multi-function meter LEDs

Check the multi-function meter LEDs forcontinuity.Refer to “CHECKING THE LEDs”.

Is the multi-function meter LEDs OK?


EAS00806

7. The speedometer fails to operate.

8-41


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 blue

12

Turn the main switch to “ON”.Elevate the rear wheel and slowly rotate it.Measure the voltage (DC 5 V) of blue andwhite/yellow. 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?

3. Voltage

Connect the pocket tester (DC 20 V) to themeter assembly coupler (wire harnessside) as shown.


YESNO

Positive tester probe yellow/blue Negative tester probe black/white

12

Turn the main switch to “ON”.Elevate the rear wheel and slowly rotate it.Measure the voltage (DC 5 V) of yellow/blue

on the meter assembly coupler (wire har-ness side).


1

This circuit is OK.

8-42

1 Main switch5 Battery6 Fuse (main)10 Fuse (ignition)14 ECU

22 Coolant temperature sensor48 Fuse (radiator fan motor)49 Radiator fan motor relay50 Radiator fan motor

COOLING SYSTEM ELEC

EAS00807

COOLING SYSTEMCIRCUIT DIAGRAM

8-43

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)


1. seat2. fuel tank3. bottom cowling4. side cowlingsTroubleshoot with the following special tool(s).


EAS00738

8-44

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 of 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 brown/green and blue?

Tester positive probe brown/green Tester negative probe blue

34

COOLING SYSTEM ELEC

EAS00809

8-45

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 (132F): 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

8-46

1 Main switch5 Battery6 Fuse (main)9 Fuse (fuel injection)10 Fuse (ignition)11 Starting circuit cut-off relay13 Fuel pump14 ECU44 Engine stop switch

FUEL PUMP SYSTEM ELEC

EAS00814

FUEL PUMP SYSTEMCIRCUIT DIAGRAM

8-47


1 Battery2 Fuse (main)3 Main switch4 Fuse (ignition)5 Engine stop switch6 ECU7 Fuse (fuel injection)8 Starting circuit cut-off relay

(fuel pump injection system relay)9 Fuel pump

EAS00815

FUEL PUMP SYSTEMThe ECU includes the control unit for thefuel pump.

8-48


YES NO

2. Battery

Check the condition of the batteryRefer to “CHECKING THE BATTERY” inchapter 3.


Is the battery OK?



EAS00739

EAS00749

3. Main switch


YES NO



EAS00750



YES NO



NOTE:

YES NO

1. Main, ignition and fuel injection fuses

Check the main, ignition and fuel injectionfuses for continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.


Are the main ignition and fuel injection fusesOK?

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 pump injection system relay)6. Fuel pump7. Wiring connections

(the entire fuel system)


1. Seat2. Fuel tankTroubleshoot with the following special tool(s).


EAS00738

8-49


YES NO

5. Starting circuit cut-off relay


Connect the pocket tester (Ω 1) and bat-tery (12V) to the starting circuit cut-off relaycoupler as shown.


Positive battery lead red/black Negative battery lead light green

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?

Replace the fuelpump.

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

8-50


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.

8-51

SELF-DIAGNOSIS ELEC

SELF-DIAGNOSISThe YZF-R6 features a self-diagnosing system for the following circuit(-s):Fuel senderOil level switch

If any of these circuits are defective, their respective condition codes will be displayed on the warninglight when the main switch is turn to “ON” (irrespective of whether the engine is running or not)

Circuit Defect(-s) System response Condition code

Fuel sender Open-circuitShort-circuit

The fuel warning light indicate thecondition code.

Refer to *1

Oil level switch Open-circuitShort-circuit

The oil level warning light indicatethe condition code.

Refer to *2

*1 Condition codeFuel warning light

*2 Condition codeOil level warning light

8-52

SELF-DIAGNOSIS ELEC

Repair or replace thewire harness.

NO

1. Wire harness

Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.

Is the wire harness OK?

YES

NO

2. Fuel sender

Check the fuel sender for continuity.Refer to “The fuel level indicator light fails tocome on”.

Is the fuel sender OK?

YES

Replace the fuelpump.

Replace the multi-function meter.

NOTE:

13 Fuel pump35 Multi-function meter

TROUBLESHOOTING

The warning light starts to indicate theself-diagnosis sequence.

Check:1. Fuel sender2. Oil level switch

Before troubleshooting, remove the followingpart(-s):

1) Seats2) Fuel tank3) Lower cowlingTroubleshoot with the following specialtool(-s).


1. Fuel senderCIRCUIT DIAGRAM

8-53

SELF-DIAGNOSIS ELEC

Replace the oil levelswitch.

NO

2. Oil level switch

Check the oil level switch for continuity.Refer to “The oil level warning light fails tocome on”.

Is the oil level switch OK?

YES

Repair or replace thewire harness.

NO

1. Wire harness

Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.

Is the wire harness OK?

YES

Replace the multi-function meter.

35 Multi-function meter41 Oil level switch

2. Oil level switchCIRCUIT DIAGRAM

9-1

9

STARTING FAILURESTRBLSHTG

NOTE:

FUEL SYSTEMFuel tankEmpty fuel tankClogged fuel filterClogged fuel tank drain hoseClogged rollover valveClogged rollover valve 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 sensorFaulty cylinder identification sensor

EAS00844

TROUBLESHOOTING

The following guide for troubleshooting does not cover all the possible causes of trouble. It should behelpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual forchecks, adjustments, and replacement of parts.

STARTING FAILURESENGINECylinder(s) and cylinder head(s)Loose spark plugLoose cylinder head or cylinderDamaged cylinder head gasketWorn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timingFaulty valve springSeized valve

Piston(s) and piston ring(s) Improperly installed piston ringDamaged, worn or fatigued piston ringSeized piston ringSeized or damaged piston

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

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 sensorFaulty cylinder identification sensor

Switches and wiringFaulty main switchFaulty engine stop switchBroken or shorted wiringFaulty neutral switchFaulty start switchFaulty sidestand switchFaulty clutch switch Improperly grounded circuitLoose connections

EAS00846

INCORRECT ENGINE IDLING SPEEDENGINECylinder(s) and cylinder head(s) Incorrect valve clearanceDamaged valve train components

Air filterClogged air filter element

FUEL SYSTEMThrottle body (-ies)Damaged or loose throttle body joint Improperly synchronized throttle bodies Improperly adjusted engine idling speed(throttle stop screw)

Improper throttle cable free playFlooded throttle bodyFaulty air induction system

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 push 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 ignitor unit

Cooling systemFaulty radiator fan motor relayFaulty coolant temperature sensorFaulty ECU

Loose union boltDamaged brake hoseOil or grease on the brake discOil or grease on the brake pad Incorrect brake fluid level

EAS00855

OVERHEATINGENGINECylinder 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 lower bracket(improperly tightened ring nut)

Bent steering stemDamaged ball bearing or bearing race

Front fork leg(s)Uneven oil levels (both front fork legs)Unevenly tensioned fork spring (both frontfork legs)

Broken fork springBent or damaged inner tubeBent or damaged outer tube

SwingarmWorn bearing or bushingBent or damaged swingarm

9-6

FAULTY LIGHTING OR SIGNALING SYSTEMTRBLSHTG

TURN SIGNAL DOES NOT COME ONFaulty turn signal switchFaulty turn signal relayBurnt-out turn signal bulb Incorrect connectionDamaged or faulty wire harness Improperly grounded circuitFaulty batteryBlown, damaged or incorrect fuse

TURN SIGNAL BLINKS SLOWLYFaulty turn signal relayFaulty main switchFaulty turn signal switch Incorrect turn signal bulb

TURN SIGNAL REMAINS LITFaulty turn signal relayBurnt-out turn signal bulb

TURN SIGNAL BLINKS QUICKLY Incorrect turn signal bulbFaulty turn signal relayBurnt-out turn signal bulb

HORN DOES NOT SOUND Improperly adjusted hornDamaged or faulty hornFaulty main switchFaulty horn switchFaulty batteryBlown, damaged or incorrect fuseFaulty wire harness

EAS00866

FAULTY LIGHTING OR SIGNALING SYSTEMHEADLIGHT DOES NOT COME ONWrong headlight bulbToo many electrical accessoriesHard charging Incorrect connection Improperly grounded circuitPoor contacts (main switch)Burnt-out headlight bulbFaulty headlight relay (on/off)

HEADLIGHT BULB BURNT OUTWrong headlight bulbFaulty batteryFaulty rectifier/regulator Improperly grounded circuitFaulty main 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

Rear turn signal light (right)Rear turn signal light (left)Front turn signal /position light (right)Front turn signal /position light (left)HeadlightLicense lightTail /brake light

COLOR CODEB 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/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. . . Br/Y Brown/Yellow. . . . G/B Green/Black. . . . G/W Green/White. . . . G/Y Green/Yellow. . . . 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/Y White/Yellow. . . . Y/B Yellow/Black. . . . Y/G Yellow/Green. . . . Y/L Yellow/Blue. . . . . Y/W Yellow/White. . . .

61626364656667

YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC WIRING DIAGRAMMain switchA.C. magnetoRectifier / regulatorFuse (backup)BatteryFuse (main)Starter relayStarter motorFuse (fuel injection)Fuse (ignition)Starting circuit cut-off relaySidestand switchFuel pumpECUIgnition coilSpark plugFuel injectorAir induction system solenoidNeutral switchCrankshaft position sensorIntake air temperature sensorCoolant temperature sensorThrottle position sensorIntake air pressure sensorAtmospheric pressure sensorCylinder identification sensorSpeed sensorLean angle cut-off switchMeter assemblyFuel level warning lightOil level warning lightNeutral indicator lightTachometerShift timing indicator lightMulti-function meterEngine trouble warning lightCoolant temperature indicator lightHigh beam indicator lightTurn signal indicator lightMeter lightOil level switchRight handlebar switchFront brake light switchEngine stop switchStart switchFuse (signal)Fuse (headlight)Fuse (radiator fan motor)Radiator fan motor relayRadiator fan motorHeadlight relay (on/off)Headlight relay (dimmer)Rear brake light switchLeft handlebar switchClutch switchDimmer switchHorn switchTurn signal switchHornTurn signal relay

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Rear turn signal light (right)Rear turn signal light (left)Front turn signal /position light (right)Front turn signal /position light (left)HeadlightLicense lightTail /brake light

61626364656667

YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC WIRING DIAGRAMMain switchA.C. magnetoRectifier / regulatorFuse (backup)BatteryFuse (main)Starter relayStarter motorFuse (fuel injection)Fuse (ignition)Starting circuit cut-off relaySidestand switchFuel pumpECUIgnition coilSpark plugFuel injectorAir induction system solenoidNeutral switchCrankshaft position sensorIntake air temperature sensorCoolant temperature sensorThrottle position sensorIntake air pressure sensorAtmospheric pressure sensorCylinder identification sensorSpeed sensorLean angle cut-off switchMeter assemblyFuel level warning lightOil level warning lightNeutral indicator lightTachometerShift timing indicator lightMulti-function meterEngine trouble warning lightCoolant temperature indicator lightHigh beam indicator lightTurn signal indicator lightMeter lightOil level switchRight handlebar switchFront brake light switchEngine stop switchStart switchFuse (signal)Fuse (headlight)Fuse (radiator fan motor)Radiator fan motor relayRadiator fan motorHeadlight relay (on/off)Headlight relay (dimmer)Rear brake light switchLeft handlebar switchClutch switchDimmer switchHorn switchTurn signal switchHornTurn signal relay

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PRINTED IN U.S.A.

YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC WIRING DIAGRAM

yamaha r6 2003 workshop manual

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