Yamaha FJR1300(N) manual

FJR1300 ( N ) 5JW1-AE1 SERVICE MANUAL 2001[...]

FJR1300R 5JW9-AE1 SERVICE MANUAL 5JW–28197–20[...]

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EAS00002 NOTICE This manual wa s produced by the Yamaha Motor Company, Ltd . primarily for use by Yamaha deal- ers and their qualified mechanics. It is not po ssible to include all the knowledge of a mechanic in one manual. Therefore, anyone wh o uses this book to perform mainte nance and repairs on Yamaha vehicles should have a basic understa ndin[...]

EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read re ference book for t he mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, rep air and check procedures are laid out with the individual steps in sequen tial order. 1 The manual is divided into chap ters. An abbreviation and symb[...]

EAS00008 SYMBOLS The following symbols ar e not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adju stments 4 Chassis 5 Engine 6 Cooling syst em 7 Fuel injection system 8 Electrical s ystem 9 Troubleshootin g Symbols 0 to G indicate the following. 0 Servic[...]

EAS00012 TABLE OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 FUEL INJECTION SYSTEM FI 7 ELECTRICAL SYSTEM ELEC 8 TROUBLESHOOTING TRBL SHTG 9 –+ Notice: This enhanced version has been prepared for persons who already own a copy of  the[...]

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GEN INFO 1[...]

GEN INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ......... ..................................................... .... 1-1 VEHICLE IDENTIFICATION NUMBER ................................................. .... 1-1 MODEL CODE ...................................................... .................................... 1-1 FEATURES .......[...]

GEN INFO[...]

1 - 1 GEN INFO MOTORCYCLE IDENTIFICATION EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL CODE The model code label 1 is aff ixed to the frame. This information will be needed to order spare parts[...]

1 - 2 GEN INFO FEATURES FEATURES OUTLINE The main function of a fuel supply system is to provide fuel to the combu stion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the com- b[...]

1 - 3 GEN INFO FEATURES FI SYSTEM The fuel pump delivers fuel to the in jector via the fuel filter. The pressure regu lator maintains the fuel pressure that is applied to the injector at only 2.55 kg /cm 2 higher than the intake manifold pres- sure. Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens,[...]

1 - 4 GEN INFO FEATURES Fuel control block The fuel control block consists of the following main components: An FI warning light is provided on meter p anel. Component Function Control block ECU Total FI system control Throttle body Air volume control Pressure regulator Fuel pressure detection Sensor block Intake air pressure sensor Intake air pres[...]

1 - 5 GEN INFO FEATURES COMPONENTS ECU (Electronic Control Unit) The ECU is mounted underneath the se at, b elow t he toolbox. The main fun ctio ns of th e ECU are ignition control, fuel control, self-diagnosis, an d load control. • ECU’s internal construction and functions The main components and functions of th e ECU can be broadly divided in[...]

1 - 6 GEN INFO FEATURES • Ignition control The ignition control function of the ECU controls the ignitio n timing and the duration of ignition energizing. The ignition timing control uses the signals from the throttle position sensor (t o detect the angle of the throttle), and the crankshaft position se nsor and speed sensor (to detect the speed [...]

1 - 7 GEN INFO FEATURES Fuel pump The fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps it to the injector. A filter that is provided in the fuel pump prevents any debris in the fuel tank from entering the fuel system downstream of the pump. The pump consists of a pump unit, electric motor, filter, and va[...]

1 - 8 GEN INFO FEATURES Pressure regulator It regulates the fuel pressure that is applied to the injectors th at are provided in the cylinders in order to maintain a constant pressure difference with th e pressure in the intake manifold. The fuel that is delivered by the fuel pump fills the fuel chamb er through the fuel inlet of the regulator and [...]

1 - 9 GEN INFO FEATURES Fuel injector Upon receiving injection signals from the ECU, the fuel injector injects fuel. In the normal state, the core is pressed downward by the f orce of the spring, as illustrated. The needle that is integrated with the bottom of the core keep s the fuel passage closed. When the current flows to the coil in accordance[...]

1 - 10 GEN INFO FEATURES Crankshaft position sensor The crankshaft position sensor use s the signals of the pickup coil that is mounted on the right side of the crankshaft. When the rotation of the pickup rotor that is at tached to the crankshaf t causes the projections on the rotor to pass by the pickup coil, an electromotive force is generated in[...]

1 - 11 GEN INFO FEATURES Cylinder identification sensor The cylinder identification sensor is mounted on the exhaust head cover of the #4 cylinder. When the exhaust cam of the #4 cylinder ro tates and the lift of the cam passes by the sensor, th e sensor generates a signal and send s it to the ECU. Based on this signal and the signal from the crank[...]

1 - 12 GEN INFO FEATURES Throttle position sensor The throttle position sensor measures the intake air volume by detecting the position of the throttle valve. It detects the mechanical angle of the throttle valve through the positional relationship between the moving contact that moves in unison with th e throttle shaft and the resistor board. In a[...]

1 - 13 GEN INFO FEATURES Intake air pressure sensor and atm ospheric pressure sensor • Intake air pressure sensor The intake air pressure sensor is used for measuring the intake air volume. The intake air volume of every intake stroke is proportionate to the intake air pressure. Therefore, the intake air volume can be measured by measuring the in[...]

1 - 14 GEN INFO FEATURES Coolant temper ature sens or The signals from the coolant temperature sensor are used primarily for making fuel volume compen- sations during starting and warm-up. The coolant temperature sen sor converts the temperature of the coolant into electrical signa ls and sends them to the ECU. 1 Connector 2 Terminal 3 Tube 4 Therm[...]

1 - 15 GEN INFO FEATURES O 2 sensor The O 2 sensor has been adopted to enable the catalyst to fun ction at a high degree of efficiency by maintaining the air-fuel mixture near the stoichiometric ratio (14.7:1). This sensor, which is a zirco- nia type, utilizes the oxygen ion conductivity of the solid electrolyte for detecting the oxygen concen- tra[...]

1 - 16 GEN INFO FEATURES Lean angle cut-off switch The lean angle cut-off switch stops the supply of fuel to the engine in case the moto rcycle overturns. When the motorcycle is in the normal state, the cut-off switch outputs a constant voltage of approxi- mately 1.0 V (low level). When the motorcycle tilts, the float in the switch tilts in proport[...]

1 - 17 GEN INFO FEATURES FUEL INJECTION SYSTEM Operation and control The fuel injection timing, injection duration, ignition timing, and the coil energizing duration are con- trolled by the ECU. To dete rmine the basic injection timing, the ECU calculates the intake air volume through the signals from the inta ke air pressure sensor, throttle posit[...]

1 - 18 GEN INFO FEATURES Determining the final injection dura tion The intake air volume d etermines the basic injection duration. However, at a given intake air vol- ume, the volume of fuel that is required varie s by the engine operating conditions such as accelera- tion or deceleration, or by weather conditions. This system uses various sensors [...]

1 - 19 GEN INFO FEATURES Composition of final injection duration 1 Injection at start *1 2 After-start enrichment *2 3 Warm-up enrichme nt *3 4 Acceleration compen- sation *5 5 Oxygen feed back *6 6 Fuel cut-off Deceleration compen- sation *5 7 Basic injection dura- tion 8 Voltage compensation duration È RPM É Injection duration Ê Cranking Ë Wa[...]

1 - 20 GEN INFO FEATURES Fuel control during normal driv ing In synchronous injection during normal driving, fuel is in jected on a cylinder-by-cylinder basis when all of the conditions below are met: 1 Other than the stop m ode 2 Cylinder identificati on completed 3 Other than overrun To determine the injection timin g, the ECU calculates the inje[...]

1 - 21 GEN INFO FEATURES Fuel injection compensation control • Starting injection control The coolant temperature is used for determining the injection duration in order to ensure proper start ability. To suit the engine’s op erating conditions, the starting injection duration is determined by applying a starting compensation coefficient t o th[...]

1 - 22 GEN INFO FEATURES • Starting cylinder control 1 Injectors #1,4 2 Injectors #2,3 3 Starting async hr o- nous injection 4 Group injection È Cylinder identification sensor É Crankshaft position sensor Ê Injection Ë Stop Ì Synchronous injection • After-start enrichment After-start enrichment provides enrichment compensation during a pre[...]

1 - 23 GEN INFO FEATURES • Warm-up enrichment When the coolant temperature is low, a warm-up coefficient is applied in accordance with the sig- nals from the coolant temperature sensor in order to effect fuel enrichment. Because the co olant temperature determines the coe fficient, the coefficient chan ges with the fluctuations in the coolant tem[...]

1 - 24 GEN INFO FEATURES • Acceleration enrichment Acceleration enrichment is provided in accordan ce with the signals fro m the throttle position sensor. As the rider operates the accelerator to accelerate th e motorcycle from a constant speed, the throt- tle position sensor actu ates in unison with the accelera tor. T he ECU interpret s t hat a[...]

1 - 25 GEN INFO FEATURES • Deceleration control Deceleration control is effe cted in accordance with the signals from the throttle position sensor. As the rider operates the accelera tor to decelerate the motorcycle that is in motion, the th rottle position sensor acutates in unison with the accelera tor. When the engine speed is greater t han a [...]

1 - 26 GEN INFO FEATURES THREE-WAY CATALYTIC CONVERTER SYSTEM System outline This is a highly efficient exhaust gas cleaning system that effects air-fuel control throu gh a joint effort by the FI system, O 2 sensor, and the three-way catalytic conver ter system. By effecting com- prehensive control of the air-fuel ratio in this manner, this system [...]

1 - 27 GEN INFO FEATURES Functions of components Catalyst Because the conditions in which NOx is generated are directly opposed to those of CO and HC, there is a limit to the extent to which the concentration levels of these harmful elements can be reduced in the combustion stage. Hence, the fun ction of the catalyst is to clean the exhaust gas at [...]

1 - 28 GEN INFO FEATURES Large amounts of b oth CO and HC are generated when t he mixture is rich (as indicated by insuffi- cient O 2 region A ). Conversely, large amounts of NOx are generated when the mixture is lean (as indicated by excessive O 2 region B ). Under these conflictin g characteristics, the system maintains the mixture within an extr[...]

1 - 29 GEN INFO FEATURES Air-fuel ratio compensation equipment An O 2 sensor is provided in the exhaust pipe upstream of the catalyst, to enable the catalyst to operate at a high degree of efficiency. The O 2 sensor detects th e level of concentration of the oxy- gen remaining in the exhaust gases. A high level of oxygen concentration signifies a l[...]

1 - 30 GEN INFO FEATURES AIR INDUCTION SYSTEM The air induction system (AI system) introduces fresh air into the exhaust port in order to b urn the unburned gas (wh ich is present in the exhaust g as) in the exhaust pipe. The burning of the unburned gases in this manner enhances the efficiency of the catalyst and results in cleaner exhaust gases. T[...]

1 - 31 GEN INFO FEATURES COMPONENTS 1.Air cut-off valve The air cut-off valve consists of a plunger that is mo unted inside the core of a solenoid coil, and a valve at the end of the plunger for o pening and clo sing the a ir passage. Due to the force o f a spring, the valve is in constant contact with valve block A, a nd thus keeps the air passage[...]

1 - 32 GEN INFO FEATURES Instrument panel Function indication The indications of the self-d iagn osis f unction can be checked and insp ection o perations ca n be per- formed through the use of the multi-function meter on the instrument panel. Based on the signals received from the sensors, the ECU inputs the signals into the multi-function meter. [...]

1 - 33 GEN INFO FEATURES 2. DIA G and CO mode in spection and adjustment (m ulti-function meter) Mode Selection (Mak e sure to disconnect the coupler from the fuel p ump .) CO/DIAG mode Normal mode 1. While keep ing both the SELECT and RESET b uttons pressed, tur n “ON” the main s witch. K eep the buttons pressed f or 8 seconds or more . * All [...]

1 - 34 GEN INFO FEATURES 1 Clock 2 TRIP meter 3 RESET button 4 SELECT button 5 Engine trouble warning light 220 240 260 280 200 180 Km/h F L H E SELECT RESET TRIP TRIP km mile km mile ODO[...]

1 - 35 GEN INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Bef ore remo v al a nd disassemb ly , remov e all dir t, mud, dust and f oreign mater ial. 2. Use only the proper tools and clea ning equipment. Ref er to the “SPECIAL T OOLS”. 3. When disassemb ling, alwa ys keep mated par ts together . This includes gear[...]

1 - 36 GEN INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lo ck tabs along a flat of the bolt o r nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers[...]

1 - 37 GEN INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connect ors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Chec k: • lead • coupler • connector Moisture → Dry with an air b lower. Rust/stains → Conn ect and d isconne ct sev- eral times. 3. Chec k: • all connections [...]

1 - 38 GEN INFO EAS00027 SPECIAL TOOLS The following special too ls are necessary for complete and accurate tune-up a nd assembly. Use only the appropriate special to ols as this will help preven t damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. Whe[...]

1 - 39 GEN INFO 90890-01403 Steering nut wrench This tool is needed to loosen and tighten th e steering ste m ring nut. 90890-01426 Oil filter wrench This tool is needed to re move and install the oil filter. 90890-01442 Fork seal driver This tool is needed when installing the slide metal, oil seal and dust seal int o the fork. 90890-01467 Gear las[...]

1 - 40 GEN INFO 90890-03094 Vacuum gauge This gauge is needed for thro ttle bodies synchroniza tion. 90890-03097 Dial gauge This tool is used to m easure th e middle gear backlash. 90890-03112 Pocket tester This instrument is needed for checking the electrical system. 90890-03132 Pocket tester This instrument is needed for checking the engine oil t[...]

1 - 41 GEN INFO 90890-04050 Bearing retainer wr ench This tool is needed when removing or installing the final drive housing bearing retainer. 90890-04057 Bearing retainer wr ench This tool is needed when removing or installing the middle drive shaft bearing retainer. Driver 90890-04058 Installer 90890-04078 Middle driven shaft bearin g driver Mech[...]

1 - 42 GEN INFO 90890-04101 Valve lapper This tool is needed to re move and install the valve lifter. 90890-05158 Piston ring c ompressor This tool is us ed to compress the piston rings when installing the piston into the cylinder. 90890-06754 Ignition checke r This tool is used to check the ignition system components. 90890-06756 Vacuum/pres sure [...]

SPEC 2[...]

SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ......................... .............................................. 2-1 ENGINE SPECIFICATIONS ....... ..................................................... .............. 2-2 CHASSIS SPECIFICATIONS ..................................................................... .. 2-11 ELECTRICAL SPECI[...]

SPEC[...]

2 - 1 SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5JW1 (for Europe) 5JW2 (for F) 5JW3 (for Oceania) ---- ---- ---- Dimensions Overall length 2,195 mm ---- Overall width 760 mm ---- Overall height 1,420 mm ---- Seat height 805 mm ---- Wheelbase 1,515 mm ---- Minimum ground clearance 135 mm ---- Minimum turning radius 3,[...]

2 - 2 SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC ---- Displacement 1,298 cm 3 ---- Cylinder arrangement Forward-inclined parallel 4-cylinder ---- Bore × stroke 79.0 × 66.2 mm ---- Compression ratio 10.8 : 1 ---- Engine idling speed 1,000 ~ 1,100 r/min ---- Vacuum pressure [...]

2 - 3 SPEC ENGINE SPECIFICATIONS Oil filter Oil filter type Formed type ---- Bypass valve opening pressure 78.4 ~ 117.6 kPa (0.78 ~ 1.18 kg/cm 2 , 0.78 ~ 1.18 bar) ---- Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clearance 0.0 9 ~ 0 .1 5 mm 0.2 3 m m Outer-rotor-to-oil-pump-housing clearance 0.03 ~ 0.08 mm 0.15 mm Cooling sy[...]

2 - 4 SPEC ENGINE SPECIFICATIONS Camshafts Drive system Chain drive (right) ---- Camshaft cap inside diameter 24.500 ~ 24.521 mm ---- Camshaft journal diameter 24.472 ~ 24.459 mm ---- Camshaft-journal-to-ca mshaft-cap clearance 0.028 ~ 0.062 mm ---- Intake camshaft lobe dimensions Measurement A 33.05 ~ 33.15 mm 32.05 mm Measurement B 24.997 ~ 25.09[...]

2 - 5 SPEC ENGINE SPECIFICATIONS Timing chain Model/number of links RH2015/136 ---- Tensioning system Automatic ---- Valves, valve seats, valve guid es Valve clearance (cold) Intake 0.15 ~ 0.22 mm ---- Exhaust 0.18 ~ 0.25 mm ---- Valve dimensions Valve head diameter A Intake 29.9 ~ 30.1 mm ---- Exhaust 25.9 ~ 26.1 mm ---- Valve face width B Intake [...]

2 - 6 SPEC ENGINE SPECIFICATIONS Valve springs Free length Intake 39.7 mm 37.7 mm Exhaust 39.7 mm 37.7 mm Installed length (valve closed) Intake 33 mm ---- Exhaust 33 mm ---- Compressed spring force (installed) Intake 136 ~ 158 N (13.9 ~ 16.1 kgf) ---- Exhaust 136 ~ 158 N (13.9 ~ 16.1 kgf) ---- Spring tilt Intake ---- 2 . 5 ° / 1 . 7 mm Exhaust --[...]

2 - 7 SPEC ENGINE SPECIFICATIONS Cylinders Cylinder arrangement Forward inclined parallel 4-cylinder ---- Bore × stroke 79.0 × 66.2 mm ---- Compression ratio 10.8 : 1 ---- Bore 79.00 ~ 79.01 mm ---- Max. taper ---- 0.05 mm Max. out-of-round ---- 0.05 mm Pistons Piston-to-cylinder clearance 0.020 ~ 0.045 mm 0.012 mm Diameter D 78.965 ~ 78.980 mm -[...]

2 - 8 SPEC ENGINE SPECIFICATIONS Oil ring Dimensions (B × T) 2.0 × 2.5 mm ---- End gap (installed) 0.2 ~ 0.6 mm ---- Ring side clearance 0.06 ~ 0.15 mm ---- Connecting rods Crankshaft-pin-to-big-end-bearing clearance 0.031 ~ 0.048 mm ---- Bearing color code 1 = Blue 2 = Black 3 = Brown 4 = Green 5 = Yellow 6 = Pink ---- Small end inside diameter [...]

2 - 9 SPEC ENGINE SPECIFICATIONS Clutch plates Thickness 1.9 ~ 2.1 mm ---- Plate quantity 8 ---- Max. warpage ---- 0.1 mm Clutch spring Free length 6.78 mm ---- Spring quantity 1 ---- Min. length ---- 6.44 mm Push rod bending limit ---- 0.2 mm Transmission Transmission type Constant mesh, 5-speed ---- Primary reduction system Helical gear ---- Prim[...]

2 - 10 SPEC ENGINE SPECIFICATIONS Throttle bodies Model (manufacturer) × quantity 42EHS (MIKUNI) × 4 ---- Intake vacuum pressure 33.3 kPa (250 mmHg) ---- Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm ---- ID mark 5JW1 ---- Shaft drive Final gear backlash 0.1 ~ 0.2 mm ---- Item Standard Limit[...]

2 - 11 SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond ---- Caster angle 26° ---- Trail 109 mm ---- Front wheel Wheel type Cast wheel ---- Rim Size 17 × MT3.50 ---- Material Aluminum ---- Wheel travel 135 mm ---- Wheel runout Max. radial wheel runout ---- 1 mm Max. lateral wheel runout ---- 0.5 mm R[...]

2 - 12 SPEC CHASSIS SPECIFICATIONS Rear tire Tire type Tubeless ---- Size 180/55ZR 17 (73W) ---- Model (manufacturer) M E Z 4 J ( M ET Z E L E R) / BT020R N (BRIDGESTONE) ---- Tire pressure (cold) 0 ~ 90 kg 250 kPa (2.5 kgf/cm 2 , 2.5 bar) ---- 90 ~ 208 kg 290 kPa (2.9 kgf/cm 2 , 2. 9 bar) ---- High-speed riding 290 kPa (2.9 kgf/cm 2 , 2. 9 bar) --[...]

2 - 13 SPEC CHASSIS SPECIFICATIONS Front suspension Suspension type Telescopic fork ---- Front fork type Coil spring/oil damper ---- Front fork travel 135 mm ---- Spring Free length 270 mm 264.6 mm Spacer length 143.5 mm ---- Installed length 258 mm ---- Spring rate (K1) 7.35 N/mm (0.735 kgf/mm) ---- Spring stroke (K1) 0 ~ 135 mm (0 ~ 13.5 kgf/mm) [...]

2 - 14 SPEC CHASSIS SPECIFICATIONS Rear suspension Suspension type Swingarm (link suspension) ---- Rear shock absorber assembly type Coil spring/gas-oil damper ---- Rear shock absorber assembly travel 60 mm ---- Upper spring Free length 159 mm 155.82 mm Installed length 138.1 mm ---- Lower spring Free length 74 mm 72.52 mm Installed length 65.4 mm [...]

2 - 15 SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 5° BTDC at 1,050 r/min ---- Advancer type Electric ---- Pickup coil resistance/color 420.8 ~ 569.3 Ω /Gy–B ---- Transistorized coil ignitio[...]

2 - 16 SPEC ELECTRICAL SPECIFICATIONS Bulbs (voltage/wattage × quantity) Headlight 12 V 60 W/55 W × 2 ---- Auxiliary light 12 V 5 W × 2 ---- Tail/brake light 12 V 5 W/21 W × 2 ---- Turn signal light 12 V 21 W × 4 ---- Meter light 14 V 1.12 W × 1 ---- Electric starting system System type Constant mesh ---- Starter motor Model (manufacturer) 5J[...]

2 - 17 SPEC ELECTRICAL SPECIFICATIONS Fuel pump maximum ampe rage 5.5 A ---- Fuel injection system relay model (manufacturer) ACM33211 M05 ---- Radiator fan Model 5JW ---- Running rpm 3,300 r/min ---- Fan motor relay Model ACM33211 M05 ---- Atmospheric pressure sensor Thermostat type (manufacturer) 4FM (NIPPON THERMOSTAT) ---- Valve opening tempera[...]

2 - 18 SPEC CONVERSION TABLE/ GENERAL TIGHTENING TORQUE SPECIFICATIONS EB201000 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. CONVERSION TABLE EAS00030 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for sta[...]

2 - 19 SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Part to be tightened Part name Thread size Q’ty Tightening torque Remarks Nm m·kgf Spark plug — M10 4 13 1.3 Camshaft sensor Bolt M6 1 10 1.0 LT Cylinder head cover Bolt M6 8 10 1.0 Camshaft cap Bolt M 6 20 10 1.0 E Camshaft sprocket Bolt M7 4 24 2.4 Timing chain tensi[...]

2 - 20 SPEC TIGHTENING TORQUES Oil pipe Bolt M6 2 10 1.0 LT Oil strainer Bolt M6 2 10 1.0 LT Oil pump assembly Bolt M6 3 12 1.2 LT Oil pump housing cover Bolt M6 3 12 1.2 Left middle gear cover Bolt M6 9 12 1.2 Right middle gear cover Bolt M6 3 12 1.2 Middle driven shaft assembly Bolt M8 3 25 2.5 LT Middle driven pinion gear Nut M28 1 110 11.0 Stak[...]

2 - 21 SPEC TIGHTENING TORQUES NOTE: *1: Tighten the cylinder head bolts to 25 Nm (2.5 m • kg) in the proper tightening sequence , loosen and retighten the cylinder head bolts to 25 Nm (2.5 m • kg) in the proper tighte ning sequence, and then tighten the cylinder head bolts fur ther to reach the specified angle 180° in the proper tightening se[...]

2 - 22 SPEC TIGHTENING TORQUES Cylinder head tightening se quence: Crankcase tightening sequence:[...]

2 - 23 SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Part to be tightened Thread size Tightening torque Remarks Nm m·kgf Engine mounting: Rear lower mounting bolt M10 45 4.5 Spacer bolt M16 18 1.8 Rear upper mounting bolt and nut M10 45 4.5 Front mounting bolt M12 55 5.5 Pinch bolt M8 24 2.4 Bolt (engine bracket 1 and frame) M10 32 3.2 Bolt ([...]

2 - 24 SPEC TIGHTENING TORQUES NOTE: 1.First, tighten the lo wer ring nut appro ximately 52 Nm (5.2 m • kg) b y usin g the torque wrench, then loosen the ring nut completely . 2.Retighten the lo wer r ing nut to specification. Connecting arm and swingarm M10 48 4.8 Connecting arm and relay arm M10 48 4.8 Rear shock assembly and relay arm M10 40 4[...]

2 - 25 SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Oil seal lips LS O-rings LS Bearings E Crankshaft pins E Piston surfaces E Piston pins E Connecting rod bolts and nuts M Crankshaft journals E Camshaft lobes M Camshaft journals M Balanc[...]

2 - 26 SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Cylinder head cover mating surface Sealant Cylinder head cover Sealant Crankcase mating su rface Sealant Clutch cover (crankcase mating surface) Sealant Generator cover (crankcase mating surface) Sealant Pickup coil rotor co ver (crankcase mating surface) Sealant Left mi[...]

2 - 27 SPEC LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Steering bearings and bea ring races (upper and lower) LS Front wheel oil seal (right and left) LS Rear wheel oil seal LS Rear wheel drive hub oil seal LS Rear wheel drive hub mating surface LS Rear brake pedal pivot LS Foot[...]

2 - 28 SPEC OIL FLOW DIAGRAMS 1 Cranksh aft 2 Oil pump 3 Oil pipe 4 Relief valve 5 Oil filter cartridge 6 Main axle OIL FLOW DIAGRAMS[...]

2 - 29 SPEC 1 Cranksh aft 2 Main axle 3 Drive axle OIL FLOW DIAGRAMS[...]

2 - 30 SPEC 1 Oil nozzle 2 Main gallery bolt 3 Cranksh aft OIL FLOW DIAGRAMS[...]

2 - 31 SPEC 1 Main axle 2 Drive axle 3 Oil delivery pipe OIL FLOW DIAGRAMS[...]

2 - 32 SPEC 1 Exhaust camshaft 2 Oil check bolt 3 Intake ca ms haft OIL FLOW DIAGRAMS[...]

2 - 33 SPEC 1 Oil check bolt 2 Cranksh aft 3 Oil cooler 4 Oil pump 5 Oil strainer 6 Oil pipe OIL FLOW DIAGRAMS[...]

2 - 34 SPEC 1 Crank pi n 2 Cranksh aft OIL FLOW DIAGRAMS[...]

2 - 35 SPEC 1 Rear balancer 2 Oil delivery pipe 3 Cranksh aft 4 Front ba lancer 5 Crank pi n OIL FLOW DIAGRAMS[...]

2 - 36 SPEC 1 Oil strainer 2 Oil delivery pipe 3 Oil cooler 4 Engine oil drain bolt 5 Oil level switch 6 Oil filter cartridge 7 Oil pan 8 Oil pipe 9 Oil pump OIL FLOW DIAGRAMS[...]

2 - 37 SPEC 1 Main axle 2 Drive axle 3 Middle drive shaf t OIL FLOW DIAGRAMS[...]

2 - 38 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator COOLING SYSTEM DIAGRAMS[...]

2 - 39 SPEC 1 Water jacket joint 2 Oil cooler COOLING SYSTEM DIAGRAMS[...]

2 - 40 SPEC 1 Thermostat assembly 2 Coolant re se rvo ir 3 Radiator 4 Oil cooler COOLING SYSTEM DIAGRAMS[...]

2 - 41 SPEC 1 Coolant re se rvo ir 2 Radiator 3 Water pump COOLING SYSTEM DIAGRAMS[...]

2 - 42 SPEC CABLE ROUTING CABLE ROUTING 1 Throttle ca ble 2 Brake cable 3 Clutch cable 4 Main switch lead 5 Headlight lead 6 Fuse box 7 Thermostat assembly br eather hose 8 Coolant re se rvo ir ho se 9 Hazard switch 0 Rectifier/regulator A Plate B Plunger control unit ho se 2 C Radiator D Radiator fan coup ler[...]

2 - 43 SPEC CABLE ROUTING È Pass the r ight handleba r switch lead u nder the handlebar. É Pass the left handle bar switch lead under the handlebar. Ê Pass the wire harness, stat or coil lead, coo lant reservoir hose , and thermo stat assembly breather hose th rough the left slit of the pla te. Ë To the thermosta t housing Ì After pas sing the[...]

2 - 44 SPEC CABLE ROUTING 1 Brake cable 2 Right handlebar swit ch lead 3 Throttle ca ble 4 Starter relay 5 Battery 6 Positive battery lead 7 Main fuse 8 Front turn signal lead 9 Spark plug lead #4 0 Spark plug lead #1 A Ignition coil lead (#1, #4) B Ignition coil (#1, #4) C Coolant reser voir D Coolant reser voir breath er hose E Coolant reservoir [...]

2 - 45 SPEC CABLE ROUTING È Fasten the positive battery lead with a plastic locking tie to the batter y stay. É Fasten the positive batt ery lead and main fuse lead with a plastic locking tie to the bat tery stay. Ê Insert the front t urn signal leads into the inn er panel. Ë Install the conn ector so that the ig nition co il lead can be turned[...]

2 - 46 SPEC CABLE ROUTING Ñ Support the coolan t reservoir hose an d coolant reservoir breat her hose with the h ose holder located under the coolant reservoir. Ò Pass the coolant rese rvoir ho se thro ugh t he hole of the coolant reser voir hose holder. Ó Fasten spark plug lead #1 and #4 at the number tag. Ô Pass the wire harness, spar k plug [...]

2 - 47 SPEC CABLE ROUTING 1 Tail/brake light le ad[...]

2 - 48 SPEC CABLE ROUTING 1 Main switch lead 2 Left handlebar switch lead 3 Hazard switch 4 Rectifier/regulator 5 Clutch cable 6 Fuel tank overflow hos e 7 Fuel tank breather ho se 8 Stator coil lead 9 Sidestand switch 0 Sidestand switch lead A Oil level switch lead B Brake cable C Coolant reservoir ho se D Thermostat assemb ly br eather hose E Hea[...]

2 - 49 SPEC CABLE ROUTING È To the radiator f an É Pass the wire harness, stat or coil lead, coo lant reservoir hose , and thermo stat assembly breather hose th rough the left slit of the pla te. Ê To the right side of th e frame Ë Clamp the wire har ness with the plastic band attached to the fram e. Ì To the fuel ta nk Í Pass the stat or coi[...]

2 - 50 SPEC CABLE ROUTING 1 ECU 2 Tail/brake light le ad 3 Seat lock cable 4 Fuel tank breather ho se 5 Fuel tank overflow hos e 6 Air filter case breather ho se È To the intake ai r temperature se nsor É Fasten the wire har ness with a plastic band to the frame. Ê To the inside of the U- lock stor age box Ë Fasten the ta il/brake light lead wi[...]

2 - 51 SPEC 1 Air cut-off valv e 2 Clutch cable 3 Left handlebar switch lead 4 Headlight lead 5 Main switch lead 6 Throttle ca ble 7 Right handlebar swit ch lead 8 T-bar 9 Spark plug lead #3 0 Spark plug lead #2 A Spark plug lea d #1 B Spark plug lea d #4 C Throttle position sensor D Sidestand switch lead E Spark plug lea d #1 F Spark plug lea d #4[...]

2 - 52 SPEC È Connect the wir e harness and right handleb ar switch lead. É Pass the left handlebar switch lead, main switc h lead, headlight lead, an d clutch cable through the hole on the left side of the fram e. Ê Pass the right handle bar and thrott le cables through the hole on the right side of th e frame. Ë To the lower left slit of the [...]

2 - 53 SPEC Ò Support the t hrottl e cables with the T-ba r located behind the cable guide. Ó Pass the thr ottle cables un der spark p lug leads #1, #2, #3, an d #4, and the wir e harness, head- light lead, main switch lead, right handlebar switch lead, and left handlebar switch lead. Install the ther mostat, heat protector, thro ttle cables, spa[...]

2 - 54 SPEC 1 Engine stop switch 2 Starting circ uit cut-off relay 3 Atmospheric pressu re sensor 4 CYCLELOCK coupler 5 Seat lock cable CABLE ROUTING[...]

2 - 55 SPEC È To the rear brake light switch É Pass the en gine stop s witch through the lead guide attache d to the frame. Ê Pass the secu rity lead co upler thro ugh the inside of the storag e bo x of the U-lock. Ë Pass the security le ad coupler th rough the lead guide. Ì Pass the pressur e sensor lead and e ngine stop switch lead through t[...]

[...]

CHK ADJ 3[...]

CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION .......................................................... .................................... 3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .................... 3-1 SEATS AND FUEL TANK ................................................................. .............. 3-3 SEATS ....[...]

CHK ADJ CHASSIS ................................................ ..................................................... .. 3-55 ADJUSTING THE FRONT BRAKE ....................................................... .. 3-55 ADJUSTING THE REAR BRAKE ............................................................ 3-56 CHECKING THE BRAKE FLUID LEVEL............[...]

3 - 1 CHK ADJ INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION INTERVALS EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all informa tion necessary to perfo rm recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable veh icle operation, a longer service life and [...]

3 - 2 CHK ADJ PERIODIC MAINTENANCE AND LUBRICATION INTERVALS NOTE: • The air filter needs more frequent service if you are riding in unusually wet or dusty areas. • Hydraulic brake and clutch systems • After disassemblin g the brake o r clutch master cylin ders, ca liper cylinders or clutch release cylin- der, always change the fluid. Regular[...]

3 - 3 CHK ADJ SEATS AND FUEL TANK EAS00039 SEATS AND FUEL TANK SEATS Order Job/Part Q’ty Remarks Removing the seats Remove the parts in the order listed. 1 Rider seat 1 2 Passenger seat 1 For installation, reverse th e removal procedure.[...]

3 - 4 CHK ADJ SEATS AND FUEL TANK EAS00040 FUEL TANK Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the ord er listed. Rider seat Fuel Drain. 1 Fuel tank side panel (left and right) 1/1 2B o l t 2 3N u t 1 4 Fuel sender coupler 1 5 Fuel pump coupler 1 6 Fuel tank overflow hose 1 7 Fuel tank breather hose 1 8 Fuel hose hold[...]

3 - 5 CHK ADJ T-BAR Order Job/Part Q’ty Remarks Removing the T-bar Remove the parts in the ord er listed. Rider seat/fuel tank Refer to “SEATS AND FUEL TANK”. 1 Left rubber cover 1 2 Right rubber cover 1 3 T-bar 1 4 Rubber sheet 1 For installation, rever se the removal procedure. SEATS AND FUEL TANK[...]

3 - 6 CHK ADJ REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tan k through the fuel tank cap with a pump . 2. Remov e: • fuel return hose • fuel hose CAUTION: Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fue l remain- ing in it. NOTE: Before removing the hoses, place a[...]

3 - 7 CHK ADJ INSTALLING THE FUEL PUMP 1. Install: • fuel pump NOTE: • Do not damage the installation surfaces of the fuel tank when installing the fuel pump. • Always use a new fuel pump gaske t. • Install the fuel pump as shown in the illustra- tion. • Tighten the fuel pump bolts in sta ges in a crisscross pattern and to the specified t[...]

3 - 8 CHK ADJ EAS00043 AIR FILTER CASE Order Job/Part Q’ty Remarks Removing the air filter case Remove t he parts in the order listed. Seats/fuel tank Refer to “SEATS AND FUEL TANK”. Side covers (left and right) Refer to “COWLINGS AND COVERS”. 1 Air shroud 1 2 Air filter case cover 1 3 Air filter element 1 4 Lean angle cut-off switch 1 5T[...]

3 - 9 CHK ADJ Order Job/Part Q’ty Remarks 10 Air induction system hose 5 1 Disconnect. 11 Clamp screw 4 Loosen. 12 Air filter case 1 13 Air filter case breather hose 1 For installation, reverse the remo val procedure. AIR FILTER CASE[...]

3 - 10 CHK ADJ COWLINGS AND COVERS EAS00041 COWLINGS AND COVERS COWLINGS 1 2 3 4 5 6 7 8 9 10 11 12 13 T R . . 10 Nm (1.0 m • kg) Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed . Rider seat/fuel tank Refer to “SEATS AND FUEL TANK”. 1 Left side co wling 1 2 Right sid e cowling 1 3 Front bottom cowling [...]

3 - 11 CHK ADJ COWLINGS AND COVERS ( 7 ) Order Job/Part Q’ty Remarks Disassembling the front cowling assembly Remove the parts in the ord er listed. 1 Windshield outer bracket 1 2 Windshield 1 3 Grommet 7 4 Windshield inner bracket 1 5 Rear view mirror (left and right) 2 6 Panel 1 7 Front cowling 1 8 Auxiliary light coupler 2 9 Headlight coupler [...]

3 - 12 CHK ADJ 1 Order Job/Part Q’ty Remarks Removing the headlight assembly Remove t he parts in the order listed. 1 Headlight assembly 1 For installation, reverse the remo val procedure. COWLINGS AND COVERS[...]

3 - 13 CHK ADJ (4) (4) 9 8 7 4 6 5 3 2 1 Order Job/Part Q’ty Remarks Removing the windshield drive unit, meter assembly and rela ys Remove the parts in the order listed . 1 Windshield drive unit 1 2 Windshield drive unit coupler 2 3 Meter assembly 1 4 Meter assembly coupler 1 5 Headlight relay 1 1 6 Headlight relay 2 1 7 Fuel injection system rel[...]

3 - 14 CHK ADJ COWLINGS AND COVERS COVERS Order Job/Part Q’ty Remarks Removing the covers Remove the parts in the order listed . Seats Refer to “SEATS AND FUEL TANK”. 1 Left side co ver 1 2 Right side co ver 1 3 Rear carrier 1 4 Rear cover 1 For installation, reverse th e removal procedure.[...]

3 - 15 CHK ADJ ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: @ • Valve clearance adjustment should be made on a cold engine, at room te mperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the [...]

3 - 16 CHK ADJ ADJUSTING THE VALVE CLEARANCE 3. Remov e: • hose holder 1 • lead holder 2 • pickup coil rot or cover 3 4. Measure: • valve clearance Out of specification → Adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T ur n the crankshaft cloc kwise. b . When p[...]

3 - 17 CHK ADJ ADJUSTING THE VALVE CLEARANCE É Degrees that t he crankshaft is turned counter - clockwise Ê Cylinder Ë Combustion cycle ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Remov e: • rubber plug 1 • timing chain tensio ner cap bolt 2 • gasket Cylinder #2 180°[...]

3 - 18 CHK ADJ ADJUSTING THE VALVE CLEARANCE NOTE: @ • Cover the timing chain opening with a rag to prevent the valve pad from fallin g into the crankcase. • Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place. b . Select the proper v alv e pad from the f ollo w- ing tab le. NOTE[...]

3 - 19 CHK ADJ ADJUSTING THE VALVE CLEARANCE e. Install the ne w v alv e pad 1 and t he v alv e lifter 2 . NOTE: @ • Lubricate the valve pad with molybde num disulfide grease. • Lubricate the valve lifter with molybde num disulfide oil. • The valve lifter must turn smoothly when rotated by hand. • Install the valve lifter and the valve pad [...]

3 - 20 CHK ADJ INTAKE EXHAUST MEASURED CLEARANCE ORIGINAL VALVE PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 ~ 0.08 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195[...]

3 - 21 CHK ADJ ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE THROTTLE BODIES 9. Install: • all removed parts NOTE: @ For installation, reverse the removal p roce- dure. EAS00050 SYNCHRONIZING THE THROTTLE BODIES NOTE: @ Prior to synchronizing the throttle b odies, the valve clearance and the engine idling speed should be properly adjusted and [...]

3 - 22 CHK ADJ SYNCHRONIZING THE THROTTLE BODIES 7. Measure: • engine idling speed Out of specification → Adjust. Refer to “ADJUSTING THE ENGINE IDLING SPEED”. Engine idling speed 1,000 ~ 1,100 r/min 8. Adjust: • throttle body synchronization ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼?[...]

3 - 23 CHK ADJ SYNCHRONIZING THE THROTTLE BODIES/CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE 11.Adjust: • throttle cable free p lay Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm 12.Remo v e: • engine tachometer • vacuum gauge 13.Remo v e: • fuel tank 14.Insta[...]

3 - 24 CHK ADJ CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE 3. Install: • pocket tester 1 (onto the engine oil drain bolt ) • engine tachometer (onto the spark plug lead of cylinder #1) • exhaust attachment 2 (onto the exhaust pipe) 4. Install: • fuel tank Refer to “SEATS AND FUEL TANK”. 5. Star t the engine and warm it up until the s[...]

3 - 25 CHK ADJ CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE/ADJUSTING THE EXHAUST GAS VOLUME 8. Measure: • carbon monoxide density Out of specification → Adjust. Within specification → Measure the exh aust gas when induction system is operating. Carbon monoxide density (when air induction system is not oper- ating) 3.0 ~ 4.0% Hydrocarbon de[...]

3 - 26 CHK ADJ b . T o s witch to the “CO” adjusting mode 1) Push the “SELECT” button to switch the display between the “CO” adjusting mode and the “DIAG” mode. 2) Push the “SELECT” button and “RESET” button together for more than two sec- onds to set the desired mode. c. T o select the cylinder to be ad justed • Push the [...]

3 - 27 CHK ADJ CHECKING THE EXHAUST GAS AT IDLE CHECKING THE EXHAUST GAS AT IDLE (Measuring the exhaust gas at idle [when air induction system is operating]) 1. Stand the motorcycle on a le vel surf ace . NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Remov e: •r i d e r s e a t • fuel tank • T[...]

3 - 28 CHK ADJ CHECKING THE EXHAUST GAS AT IDLE/ ADJUSTING THE ENGINE IDLING SPEED 7. Install: • carbon monoxide and hydrocarbon tester 1 • sampling probe 2 NOTE: • Since it is necessary to insert the sampling probe 600 mm into the exhaust pipe, be sure to use a heat-resistant rubber tube as shown in the illustration. • Be sure to set the h[...]

3 - 29 CHK ADJ ADJUSTING THE ENGINE IDLING SPEED 1. Star t th e engine and let it w arm up f or se v- eral minutes . 2. Remov e: • fuel tank side panels (left and right) • fuel tank front mounting bolts 3. Lift up the front of the f uel tank. 4. Attach: • engine tachometer (onto the spark plug lead of cylinder #1) 5. Measure: • engine idlin[...]

3 - 30 CHK ADJ ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 7. Adjust: • throttle cable free p lay Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm 8. Install: • fuel tank front mounting bolts • fuel tank side panels (left and right) Refe[...]

3 - 31 CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY 3. Adjust: • throttle cable free p lay NOTE: @ When the throttle is opened, the accelerator cable 1 is pulled. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ Throttle body side a. Loosen the loc knut 2 on the deceler ator c abl[...]

3 - 32 CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS W ARNING @ After adjusting the throttle ca ble free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ?[...]

3 - 33 CHK ADJ CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING 5. Chec k: • electrodes 1 Damage/wear → Replace the spark plug. • insulator 2 Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • spark plug (with a spark plug cleaner or wire brush ) 7. Measure: • spark plug gap a (with a wire ga[...]

3 - 34 CHK ADJ CHECKING THE IGNITION TIMING 1. Remov e: •r i d e r s e a t • fuel tank • T-bar Refer to “SEATS AND FUEL TANK”. • right side cowling Refer to “COWLINGS AND COVERS”. • timing mark accessing screw 1 2. Attach: • timing light 1 • engine tachometer (onto the spark plug lead of cylinder #1) 3. Install: • fuel tank [...]

3 - 35 CHK ADJ CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 5. Remov e: • fuel tank • engine tachometer • timing light 6. Install: • timing mark accessing screw • right side cowling Refer to “COWLINGS AND COVERS”. • T-bar • fuel tank •r i d e r s e a t Refer to “SEATS AND FUEL TANK”. EAS00065 MEASURING TH[...]

3 - 36 CHK ADJ MEASURING THE COMPRESSION PRESSURE 6. Install: • compression gauge adapter 1 • compression gauge 2 7. Install: • fuel tank 8. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.[...]

3 - 37 CHK ADJ MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL Refer to the following table. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 9. Remov e: • fuel tank Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than with- out o[...]

3 - 38 CHK ADJ CHECKING THE ENGINE OIL LEVEL 3. Chec k: • engine oil leve l The engine oil level should be between the minimum level mark a and maximum le vel mark b . Below the minimum level mark → Add the recommended engine oil to the proper level. CAUTION: @ • Engine oil also lubricates the clutch and the wrong oil types or add itives coul[...]

3 - 39 CHK ADJ CHANGING THE ENGINE OIL EAS00073 CHANGING THE ENGINE OIL 1. Star t the engine, warm it up f or se v era l min- utes, an d then tur n it off. 2. Place a container under the engine o il drain bolt. 3. Remov e: • engine oil fille r cap 1 • engine oil d rain bolt 2 (along with the gasket) 4. Drain: • engine oil (completely from the[...]

3 - 40 CHK ADJ CHANGING THE ENGINE OIL 6. Chec k: • engine oil dr ain bolt gasket Damage → Replace. 7. Install: • engine oil drain bolt T R . . 43 Nm (4.3 m · kg) 8. Fill: •c r a n k c a s e (with the specified amount of the recom- mended engine oil) 9. Install: • engine oil fille r cap 10.Star t the engine, warm it up f or se ver al min[...]

3 - 41 CHK ADJ CHANGING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE 13.Chec k: • engine oil pr essure ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Slightly loosen the oil galler y bolt 1 . b . Star t the engine and k eep it idling until engine oil star ts to seep from t[...]

3 - 42 CHK ADJ MEASURING THE ENGINE OIL PRESSURE 4. Remov e: • main gallery bolt W ARNING @ The engine, muffler and engine oil are extremely hot. 5. Install: • pressure gauge 1 • oil pressure adapter B 2 6. Measure: • engine oil pr essure (at the following conditions) Out of specification → Adjust. 7. Install: • main gallery bolt Pressu[...]

3 - 43 CHK ADJ ADJUSTING THE CLUTCH LEVER/ CHECKING THE CLUTCH FLUID LEVEL EAS00082 ADJUSTING THE CLUTCH LEVER 1. Adjust: • clutch lever position (distance a from the handlebar grip to the clutch lever) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While pushing the clutch le [...]

3 - 44 CHK ADJ CHECKING THE CLUTCH FLUID LEVEL/ BLEEDING THE HYDRAULIC CLUTCH SYS TEM W ARNING @ • Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • Refill with the same type of clutch fluid that is already in the sy stem. Mixing clutch fluids may [...]

3 - 45 CHK ADJ BLEEDING THE HYDRAULIC CLUTCH SYS TEM NOTE: @ • Be careful not to spill any clutch fluid or allow the clutch master cylinder reservoir to over- flow. • When bleeding the hydraulic clutch system, make sure there is always enough clutch fluid before applying t he clutch lever. Ignor- ing this precaution could allow air to enter the[...]

3 - 46 CHK ADJ BLEEDING THE HYDRAULIC CLUTCH SYSTEM/ CLEANING THE AIR FILTER ELEMENT k. Add the recommended clutch fluid to the proper le v el. Refer to “CHECKING THE C LUTCH FLUID LEVEL”. W ARNING @ After bleeding the hydraulic clutch system, check the clutch operation. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ?[...]

3 - 47 CHK ADJ CLEANING THE AIR FILTER ELEMENT/ CHECKING THE THROTTLE BODY JOINTS 6. Install: • air filter ele ment • air filter case cover CAUTION: @ Never operate the eng ine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter e[...]

3 - 48 CHK ADJ EAS00096 CHECKING THE FUEL AND VACUUM HOSES The following procedure applies to all of the fuel and vacuum hoses. 1. Remov e: •r i d e r s e a t • fuel tank Refer to “SEATS AND FUEL TANK”. 2. Chec k: • vacuum hose • fuel hose Cracks/damage → Replace. Loose connection → Connect properly. 3. Install: • fuel tank •r i[...]

3 - 49 CHK ADJ CHECKING THE EXHAUST SYSTEM EAS00099 CHECKING THE EXHAUST SYSTE M The following procedure applies to all of the exhaust pipes and gaskets. 1. Remov e: • side cowlings Refer to “COWLINGS AND COVERS”. 2. Chec k: • exhaust pipe 1 • muffler 2 Cracks/damage → Replace. • gasket 3 Exhaust gas leaks → Replace. 3. Chec k: • [...]

3 - 50 CHK ADJ CHECKING THE COOLANT LEVEL EAS00102 CHECKING TH E COOLANT L EVEL 1. Stand the motorcycle on a le vel surf ace . NOTE: @ • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Remov e: • right side cowling Refer to “COWLINGS AND COVERS”. 3. Chec k: • coolant level The coolant level should be [...]

3 - 51 CHK ADJ CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Remov e: •r i d e r s e a t • fuel tank Refer to “SEATS AND FUEL TANK”. • side cowlings • front cowling assembly Refer to “COWLINGS AND COVERS”. 2. Chec k: • radiator 1 • radiator inlet hose 2 • radiator outlet hose 3 • oil cooler inlet hose 4[...]

3 - 52 CHK ADJ CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Stand the motorcycle on a le vel surf ace . NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Remov e: • side cowlings • front cowling assembly Refer to “COWLINGS AND COVERS”. 3. Disconnect: • coolant reservoir hose 1 4. Drai[...]

3 - 53 CHK ADJ CHANGING THE COOLANT 8. Chec k: • copper washer 1 (coolant drain bolt 2 ) Damage → Replace. 9. Install: • coolant drain bolt 10.Connect: • coolant reservoir hose T R . . 10 Nm (1.0 m · kg) 11.Fill: • cooling sy stem (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol[...]

3 - 54 CHK ADJ CHANGING THE COOLANT CAUTION: @ • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the an tifreeze concentration of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft wa ter may be used. •[...]

3 - 55 CHK ADJ ADJUSTING THE FRONT BRAKE EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: • brake lever position (distance a from the throttle grip to the brake lever) NOTE: @ • While pushing the brake lever forward, turn the adjusting dial 1 until the br ak e lever is i n the desired position. • Be sure to alig n the setting on the a dj[...]

3 - 56 CHK ADJ EAS00110 ADJUSTING THE REAR BRAKE 1. Chec k: • brake pedal position (distance a from the top of the rider foot- rest to the top of the brake pedal) Out of specification → Adjust. 2. Adjust: • brake pedal position ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.[...]

3 - 57 CHK ADJ ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL 3. Adjust: • rear brake lig ht switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a le vel surf ace . NOTE: @ • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2.[...]

3 - 58 CHK ADJ CHECKING THE BRAKE FLU ID LEVEL/ CHECKING THE BRAKE PAD S / ADJUSTING THE REAR BRAKE LIGHT SWITCH CAUTION: @ Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. NOTE: @ In order to ensure a correct re ading of the brake fluid level, make sure the top of the brake fl[...]

3 - 59 CHK ADJ ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE BRAKE HOSES 1. Chec k: • rear brake ligh t operation timing Incorrect → Adjust. 2. Adjust: • rear brake ligh t operation timing ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the right footrest bra ck[...]

3 - 60 CHK ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00134 BLEEDING THE HYDRAULIC BRAKE SYSTEM W ARNING @ Bleed the hydraulic brake sy stem when- ever: the system is disassembled , a brake hose is loosened, di sconnected or replaced, the brake fluid level is very low, brake operation is faulty. NOTE: @ • Be careful not to spill any brake fluid o[...]

3 - 61 CHK ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL g. Loosen the b leed scre w . NOTE: @ Loosening the blee d screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. h. Tighten the b leed scre w and then release the brak e le ver or br ak e pedal. i. Repea[...]

3 - 62 CHK ADJ ADJUSTING THE SHIFT PEDAL/CHECKING THE FINAL DRIVE OIL LEVEL/CHANGING THE FINAL DRIVE OIL NOTE: Make sure that the mark on the shift pedal is between the marks on the fr ame. c. Tighten both lockn uts. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS00144 CHECKING T[...]

3 - 63 CHK ADJ CHANGING THE FINAL DRIVE OIL/ CHECKING AND ADJUSTING THE STEERING HEAD 3. Chec k: • final drive housing oil d rain bolt gasket Damage → Replace. 4. Install: • final drive housing o il drain bolt T R . . 23 Nm (2.3 m · kg) 5. Fill: • final drive housing (with the specified amount of the recom- mended final drive oil) Refer to[...]

3 - 64 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD 4. Remov e: • steering stem nut 1 •w a s h e r • upper bracket 2 (with the handlebars) 5. Adjust: • steering head ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remov e the lock w asher 1 , the upper ring nut 2 , and[...]

3 - 65 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK g. Finger tighten the upper ring nut, th en align the slots of both ring nuts. If necessary , hold the low er ring nut and tighten the upper ring nut until their slots are aligned . h. Install the loc k washer . NOTE: @ Make sure the lock washer tabs a sit correctly in[...]

3 - 66 CHK ADJ ADJUSTING THE FRONT FORK LEGS EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure ap plies to both of the front fork legs. W ARNING @ • Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. • Securely support the motorcycle so that there is no danger of it falli[...]

3 - 67 CHK ADJ ADJUSTING THE FRONT FORK LEGS ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T ur n the adjusting knob 1 in direction a or b . *: from the fully turned-in position ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ?[...]

3 - 68 CHK ADJ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EAS00157 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY W ARNING @ Securely support the mo torcycle so that there is no danger of it falling over. Spring preload 1. Adjust: • spring preloa d ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼[...]

3 - 69 CHK ADJ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/C HECKING THE TIRES * from the fully turned-in position a ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Adjusting positions Minimum: 20 clicks out* Standard: 10 clicks out* Maximum: 3 clicks out* EAS00162 CHECKING THE TIRES [...]

3 - 70 CHK ADJ CHECKING THE TIRES W ARNING @ It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Chec k: • tire surfac e s Damage/wear → Replace the tire. 1 Tire trea d de pt h 2 Sidewall 3 Wear indicator W ARNING @ • Do not use a tubeless tire on a wheel designed only for[...]

3 - 71 CHK ADJ CHECKING THE TIRES/ CHECKING THE WHEELS Front tire Rear tire W ARNING @ New tires have a relatively low grip on the road surface until they ha ve been slightly worn. Therefore, approximately 100 km should be traveled at normal sp eed before any high-speed riding is done. NOTE: @ For tires with a direction of rotation mark 4 : • Ins[...]

3 - 72 CHK ADJ CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE SIDESTAND EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables. W ARNING @ Damaged cable sheaths may cause the cable to corrode and interfere with its movement. Replace damaged cable s[...]

3 - 73 CHK ADJ LUBRICATING THE CENTERSTAND/ LUBRICATING THE REAR SUSPENSION EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. Recommended lubricant Lithium soap base grease EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the [...]

3 - 74 CHK ADJ CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY W ARNING @ Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or work[...]

3 - 75 CHK ADJ CHECKING AND CHARGING THE BATTERY NOTE: @ Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remov e: • right inner panel (fro[...]

3 - 76 CHK ADJ CHECKING AND CHARGING THE BATTERY 5. Charge: • battery (refer to the appropriate charging method illustration) W ARNING @ Do not quick charge a battery. CAUTION: @ • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amp erage current into the battery quickly and can cause [...]

3 - 77 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable voltage charger Measure the open- circuit voltage prior to charging. Connect a char ger and ammeter to the batt ery and start charging. Is the ampera ge higher than the standar d charging amperage writ ten on the battery? NO YES Charger Ammeter Adjust the voltage to o[...]

3 - 78 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open- circuit voltage prior to charging. Connect a char ger and ammeter to the batter y and start charging. NO YES Is the amp erage higher than the st andard charging amperage writ ten on the battery? Charge the battery until th e charging [...]

3 - 79 CHK ADJ CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: @ First, connect the positive battery lead 1 , and then the negative battery lead 2 . 8. Chec k: • battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly.[...]

3 - 80 CHK ADJ CHECKING THE FUSES NOTE: @ Set the pocket tester selector to “ Ω × 1”. b . If the pock et tester indicates “ ∞ ”, replace the fuse. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Pocket tester 90890-03112 3. Replace: • blown fuse ▼▼▼ ▼ ▼ ▼?[...]

3 - 81 CHK ADJ CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULBS W ARNING @ Never use a fuse with an amp erage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive dama ge to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. 4.[...]

3 - 82 CHK ADJ REPLACING THE HEADLIGHT BULBS/ ADJUSTING THE HEADLIGHT BE AMS 5. Install: • headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: @ Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will[...]

3 - 83 CHK ADJ ADJUSTING THE HEADLIGHT BE AMS 2. Adjust: • headlight bea m (horizontally) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T ur n the adjusting scre w 1 in direction a or b . Left headlight Right headlight ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲?[...]

[...]

CHAS 4[...]

CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS .............................................. .............. 4-1 REMOVING THE FRONT WHEEL .............................................. .............. 4-3 CHECKING THE FRONT WHEEL ............................................................ 4-3 CHECKING THE BRAKE DISCS ...........................[...]

CHAS FRONT FORK ......................................... ..................................................... .. 4-60 REMOVING THE FRONT FORK LEGS .................................................. 4-63 DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-63 CHECKING THE FRONT FORK LEGS ....................................[...]

4 - 1 CHAS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Removing the front wheel and brake discs Remove the parts in the ord er listed. NOTE: @ Place the motorcycle on a suitable stand so that the front wheel is e levated. 1 Brake caliper (left a nd right) 2 Refer to “REMOVING/ INSTALLING THE FRONT WHEEL”. 2 Wheel [...]

4 - 2 CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the ord er listed. 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly, reverse the disassembly procedure.[...]

4 - 3 CHAS FRONT WHEEL AND BRAKE DISCS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a le vel surf ace . W ARNING @ Securely support the mo torcycle so that there is no danger of it falling over. NOTE: @ Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remov e: • left brake caliper • right brake ca[...]

4 - 4 CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: • radial wheel runout 1 • lateral wheel runout 2 Over the specified limits → Replace. Radial wheel runout limit 1.0 mm Lateral wheel runout limit 0.5 mm 4. Chec k: • wheel bearings Front wheel turns roug hly or is loose → Replace the wheel bearings. •o i l s e a l s Damage/wear → Repl[...]

4 - 5 CHAS FRONT WHEEL AND BRAKE DISCS EAS00533 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Chec k: •b r a k e d i s c Damage/galling → Re place. 2. Measure: • brake disc deflection Out of specifica tion → Correct the brake disc deflection or replace the brake disc. ▼▼▼ ▼ ▼ ▼▼▼ ▼ [...]

4 - 6 CHAS FRONT WHEEL AND BRAKE DISCS 4. Adjust: • brake disc deflection ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remov e the brak e disc. b . Rotate the brak e disc b y one bolt hole . c. Install the brak e disc. NOTE: @ Tighten the brake disc bolts in stages and in a c[...]

4 - 7 CHAS FRONT WHEEL AND BRAKE DISCS 3. Install: • brake caliper W ARNING @ Make sure the brake hose is routed prop- erly. T R . . 40 Nm (4.0 m · kg) EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: @ • After replacing the tire, wheel or both, the front wheel static balance should be adjusted. • Adjust the front wheel static balance[...]

4 - 8 CHAS FRONT WHEEL AND BRAKE DISCS 3. Adjust: • front wheel static ba lance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install a balancing weight 1 onto the rim e xactly opposite the hea vy spot “X”. NOTE: @ Start with the lightest we ight. b . T ur n the front whee[...]

4 - 9 CHAS REAR WHEEL AND BRAKE DISC EAS00551 REAR WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Removing the rear wheel and brake disc Remove the parts in the order listed . NOTE: @ Place the motorcycle on a suitable stand so that the rear wheel is eleva ted. 1 Brake torque rod nu t/bolt 1/1 Refer to “INSTALLING THE REAR WHEEL”. 2 Wheel a[...]

4 - 10 CHAS REAR WHEEL AND BRAKE DISC AS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. 1 Dust cover 1 2 Rear wheel drive hub 1 3 Dust seal 1 4 Wheel bearing 2 5 Rear wheel drive hub damper 6 6 Oil seal 1 7 Circlip 1 8 Wheel bearing 1 9 Spacer 1 0 Collar 1 A Oil seal 1 B Bearing 1 For assembly,[...]

4 - 11 CHAS REAR WHEEL AND BRAKE DISC EEAS00562 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a le vel surf ace . W ARNING @ Securely support the mo torcycle so that there is no danger of it falling over. NOTE: @ Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remov e: • brake caliper bracket NOTE: @ Do not de[...]

4 - 12 CHAS REAR WHEEL AND BRAKE DISC 3. Measure: • radial wheel runout • lateral wheel runout Refer to “FRONT WHEEL AND BRAKE DISCS”. EEAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: • wheel axle • wheel bearings • oil seal lips Recommended lubricant Lithium soap base grease 2. Tighten: • brake torque rod nut • wheel axle nut ?[...]

4 - 13 CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. 1 Brake hose holder bolt 1 2 Brake caliper bolt 2 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad sp[...]

4 - 14 CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the ord er listed. 1 Retaining bolt 2 2 Brake pad 2 3 Brake pad shim 2 4B l e e d s c r e w 1 For installation, rever se the removal procedure.[...]

4 - 15 CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: @ Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble bra ke components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be dis assembled, drained[...]

4 - 16 CHAS FRONT AND REAR BRAKES 2. Remov e: • brake pad clips 1 • brake pad pins 2 • brake pad spring 3 • brake pads (along with the brake pad shims) 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.5 mm 4. Install: • brake pad shims (onto the brake pads) • brake p[...]

4 - 17 CHAS FRONT AND REAR BRAKES 5. Install: • brake pad pins • brake pad clips • brake caliper • brake hose holder T R . . 40 Nm (4.0 m · kg) T R . . 7 Nm (0.7 m · kg) 6. Chec k: • brake fluid level Below the minimu m level mark a → Add the recommended brake flu id to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” i[...]

4 - 18 CHAS FRONT AND REAR BRAKES 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.8 mm 4. Install: • brake pad springs • brake pad shims (onto the brake pads) • brake pads NOTE: @ Always install new brake pads, brake pad shims, and a brake pad spring a s a set. ▼▼▼ [...]

4 - 19 CHAS FRONT AND REAR BRAKES 6. Chec k: • brake fluid level Below the minimu m level mark a → Add the recommended brake flu id to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Chec k: • brake pedal operation Soft or spongy feeling → Ble ed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYS[...]

4 - 20 CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the front brake master cylinder Remove t he parts in the order listed. Brake fluid Drain . 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir dia- phragm holder 1 3 Brake master cylinder reservoir dia- phragm 1 4B r a[...]

4 - 21 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks 6 Union bolt 1 Refer to “DISASSEMBLING/ ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER”. 7 Copper washer 2 8 Brake hose 1 Disconnect. 9 Brake master cylinder holde r 1 10 Brake master cylinder 1 11 Front brake light switch 1 For installation, reverse the removal procedur[...]

4 - 22 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake mas- ter cylinder Remove the parts in the order listed . 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder 1 For assembly, reverse the disassembly procedure.[...]

4 - 23 CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the rear brake master cyl- inder Remove the parts in the order listed. Side cover (right) Refer to “COWLINGS AND COVERS” in chapter 3. Brake fluid Drain . 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake f[...]

4 - 24 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks 9 Union bolt 1 Refer to “DISASSEMBLING/ ASSEMBLING THE REAR BRAKE MASTER CYLINDER”. 10 Copper washer 2 11 Brake hose 1 Disconnect. 12 Cotter pin 1 13 Pin 1 14 Brake master cylinder 1 For installation, reverse the remo val procedure.[...]

4 - 25 CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake mas- ter cylinder Remove the parts in the order listed . 1 Dust boot 1 2 Circlip 1 3 Push rod 1 4 Brake master cylinder kit 1 5 Brake master cylinder 1 For assembly, reverse the disassembly procedure.[...]

4 - 26 CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: @ Before disassembling the front brake master cylinder, drain the brake fluid fro m the entire brake system. 1. Remov e: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: @ To collect any remaining brake fluid, place a container under the maste[...]

4 - 27 CHAS FRONT AND REAR BRAKES EAS00592 CHECKING THE FRONT AN D REAR BRAKE MASTER CYLINDERS The following procedure ap plies to the both of the brake master cylinders. 1. Chec k: • brake master cyl inder 1 Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed [...]

4 - 28 CHAS FRONT AND REAR BRAKES 5. Chec k: • brake hoses Cracks/damage/wear → Replace. EAS00606 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER W ARNING @ • Before installation, all internal b rake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components. 1. I[...]

4 - 29 CHAS FRONT AND REAR BRAKES CAUTION: @ When installing the bra ke hose onto the brake master cylinder, make sure the brake pipe touches the projection a as shown. NOTE: Turn the handlebars to the left and to the right to make sure the brake hose does not touch other parts (e.g., wire harne ss, cables, leads). Correct if necessary. 3. Fill: ?[...]

4 - 30 CHAS FRONT AND REAR BRAKES 5. Chec k: • brake fluid level Below the minimu m level mark a → Add the recommended brake flu id to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 6. Chec k: • brake lever operation Soft or spongy feeling → Ble ed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYS[...]

4 - 31 CHAS FRONT AND REAR BRAKES W ARNING • Use only the designa ted brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same ty pe of brake fluid that is already in the sy stem. Mixing brake fluids may result in a harmful chemical reaction, leadi ng to poor b[...]

4 - 32 CHAS FRONT AND REAR BRAKES 6. Adjust: • rear brake ligh t operation timing Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH” in chapter 3.[...]

4 - 33 CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake fluid Drain . 1 Brake hose holder bolt 1 Refer to “DISASSEMBLING/ ASSEMBLING AND INSTALLING THE FRONT BRAKE[...]

4 - 34 CHAS FRONT AND REAR BRAKES EAS00615 Order Job/Part Q’ty Remarks Disassembling the front brake cali- pers Remove t he parts in the order listed. The following procedure applies to both of the front brake calipers. 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad/brake pad shim 2/2 5 Brake caliper piston 4 Refer to “DI[...]

4 - 35 CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain . 1 Union bolt 1 Refer to “DISASSEMBLING/ ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER”. 2 Copper washer 2 3 Brake hose 1 Disconnect. 4 Retaining bolt 2 Loosen. 5[...]

4 - 36 CHAS FRONT AND REAR BRAKES EAS00617 Order Job/Part Q’ty Remarks Disassembling the rear brake cali- per Remove the parts in the order listed . 1 Retaining bolt 2 2 Brake pad/brake pad shim 2/2 3 Brake pad spring 2 4 Rear brake caliper bracket 1 5 Brake caliper piston 1 Refer to “ DISASSEMBLING THE REAR BRAKE CALIPER”. 6 Brake caliper pi[...]

4 - 37 CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure ap plies to both of the brake calipers. NOTE: @ Before disassembling either brake caliper, drain the brake fluid from the entire brake sys- tem. 1. Remov e: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: @ Put the end of the brake[...]

4 - 38 CHAS FRONT AND REAR BRAKES EAS00626 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: @ Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remov e: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: @ Put the end of the brake hose into a cont ainer and pump out the brake fluid carefu lly. 2. Rem[...]

4 - 39 CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AN D REAR BRAKE CALIPERS 1. Chec k: • brake caliper pistons 1 Rust/scratches/wear → Replace the brake caliper. • brake caliper cylinders 2 Scratches/wear → Replace the brake cali- per. • brake calipers Cracks/damage → Replace. • brake fluid delivery passages (brake caliper [...]

4 - 40 CHAS FRONT AND REAR BRAKES EAS00638 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIP ERS The following procedure ap plies to both of the brake calipers. W ARNING @ • Before installation, all internal b rake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as the[...]

4 - 41 CHAS FRONT AND REAR BRAKES 3. Install: • brake pads • brake pad spring • brake caliper • brake hose holder Refer to “REPLACING THE FRONT BRAKE PADS”. T R . . 40 Nm (4.0 m · kg) T R . . 7 Nm (0.7 m · kg) 4. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) W ARNING @ • Use o[...]

4 - 42 CHAS FRONT AND REAR BRAKES 6. Chec k: • brake fluid level Below the minimu m level mark a → Add the recommended brake flu id to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Chec k: • brake lever operation Soft or spongy feeling → Ble ed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYS[...]

4 - 43 CHAS FRONT AND REAR BRAKES 2. Tighten: • brake torque rod • wheel axle nut • wheel axle pinch bolt T R . . 30 Nm (3.0 m · kg) T R . . 125 Nm (12.5 m · kg) T R . . 16 Nm (1.6 m · kg) 3. Install: • brake caliper (temporarily) • copper washers 1 • brake hose 2 • union bolt 3 W ARNING @ Proper brake hose routing is essential to [...]

4 - 44 CHAS FRONT AND REAR BRAKES 6. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) W ARNING @ • Use only the designa ted brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same ty pe of brake fluid that is already[...]

4 - 45 CHAS FRONT AND REAR BRAKES 9. Chec k: • brake pedal operation Soft or spongy feeling → Ble ed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.[...]

4 - 46 CHAS EAS00305 HYDRAULIC CLUTCH CLUTCH MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the clutch master cylin- der Remove the parts in the order listed . Clutch fluid Drain. 1 Clutch master reservoir cap 1 2 Clutch master reservoir diaphram holder 1 3 Clutch master reservoir diap hram 1 4 Clutch lever 1 5 Bushing 1 6 Clutch switch cou[...]

4 - 47 CHAS Order Job/Part Q’ty Remarks 7 Union bolt 1 Refer to “DISASSEMBLING/ ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER”. 8 Copper washer 2 9 Clutch hose 1 Disconnect. 10 Clutch master cylinder holder 1 11 Clutch master cylinder 1 Refer to “ ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER”. 12 Clutch switch 1 For install[...]

4 - 48 CHAS EAS00306 Order Job/Part Q’ty Remarks Disassembling the clutch master cylinder Remove the parts in the order listed. 1 Clutch master cylinder push rod 1 2 Dust seal 1 3 Circlip 1 4 Washer 1 5 Clutch master cylind er kit 1 6 Clutch master cylind er 1 For assembly, reverse the disassembly procedure. HYDRAULIC CLUTCH[...]

4 - 49 CHAS EAS00307 CAUTION: @ Clutch components rare ly require disas- sembly. Therefore, always follow these preventive measures: • Never disassemble clutch components unless absolutely necessary. • If any connection on the hydraulic clutch system is disconnected, the entire clutch system must be dis assembled, drained, cleaned, properly fil[...]

4 - 50 CHAS EAS00308 CHECKING TH E CLUTCH MAST ER CYLINDER Recommended clutch comp onent replacement schedule Piston seals Every two years Clutch hose Every two years Clutch fluid Every two ye ars and whenever the clutch is disassem- bled 1. Chec k: • clutch master cylinder body 1 Cracks/damage → Replace the clutch mas- ter cylinder. • clutch[...]

4 - 51 CHAS EAS00309 EAS00310 ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER W ARNING @ • Before installation, all intern al clutch components must be clea ned and lubri- cated with clean or new clutch fluid. • Never use solvents on internal clutch components as they will cause the piston seals to swell and distort. Recommended clutch flu[...]

4 - 52 CHAS CAUTION: @ When installing the clutch hose onto the clutch master cylinde r, make sure the clutch pipe touches the projection a as shown. NOTE: Turn the handlebars to the left and to the right to make sure the clutch hose does not touch other parts (e.g., wire harne ss, cables, leads). Correct if necessary. 3. Fill: • clutch master cy[...]

4 - 53 CHAS 4. Bleed: • clutch system Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in chapter 3. 5. Chec k: • clutch fluid level Below the minimu m level mark a → Add the recommended clutch fluid to the proper level. Refer to “CHECKING THE C LUTCH FLUID LEVEL” in chapter 3. 6. Chec k: • clutch lever operation Soft or spongy feeli[...]

4 - 54 CHAS EAS00311 CLUTCH RELEASE CYLINDER Order Job/Part Q’ty Remarks Removing the clutch releas e cylin- der Remove the parts in the order listed . Clutch fluid Drain. 1 Union bolt 1 Refer to “DISASSEMBLING/ ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER”. 2 Copper washer 2 3 Clutch hose 1 Disconnect. 4 Clutch release cylinder 1 5 D[...]

4 - 55 CHAS Order Job/Part Q’ty Remarks Disassembling the clutch rele ase cylinder Remove the parts in the ord er listed. 1 Clutch release cylinder piston 1 Refer to “ DISASSEMBLING THE CLUTCH RELEASE CYLINDER”. 2 Clutch release cylinder spring 1 3 Clutch release cylinder piston seal 1 4 Bleed screw 1 For assembly, reverse the disassembly pro[...]

4 - 56 CHAS EAS00313 DISASSEMBLING THE CLUTCH RELEASE CYLINDER NOTE: Before disassembling the clutch release cylin- der, drain the clutch fluid from the entire clutch system. 1. Remov e: • union bolt 1 • copper washers 2 • clutch hose 3 NOTE: Put the end of the clut ch hose into a container and pump out the clutch fluid carefully. 2. Remov e:[...]

4 - 57 CHAS EAS00314 CHECKING THE CLUTCH RELEASE CYLINDER 1. Chec k: • clutch release cylinder body 1 Cracks/damage → Replace the clutch release cyl inder. Recommended clutch comp onent replacement schedule Piston seal Every two years Clutch hose Every two years Clutch fluid Every two ye ars and whenever the clutch is disassem- bled 2. Chec k: [...]

4 - 58 CHAS 2. Fill: • clutch master cylinder reservoir (with the specified amount of the recom- mended clutch fluid) W ARNING @ • Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • Refill with the same type of clutch fluid that is already in the [...]

4 - 59 CHAS 5. Chec k: • clutch lever operation Soft or spongy feeling → Bleed the clutch system. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in chapter 3. HYDRAULIC CLUTCH[...]

4 - 60 CHAS FRONT FORK EAS00647 FRONT FORK Order Job/Part Q’ty Remarks Removing the front fork legs Remove t he parts in the order listed. The following procedure applies to both of the front fork legs. Front cowling assembly Refer to “COWLI NGS” AND “COVERS” in chapter 3. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”. 1 Front fe[...]

4 - 61 CHAS FRONT FORK EAS00648 Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. 1 Cap bolt/O-ring 1/1 Refer to “DISASSEMBLING/ ASSEMBLING THE FRONT FORK LEGS”. 2 Damper adjusting rod 1 3 Nut 1 4 Spacer 1 5 Washer 1 6 Fork spring[...]

4 - 62 CHAS Order Job/Part Q’ty Remarks B Damper rod assembly 1 Refer to “DISASSEMBLING/ ASSEMBLING THE FRONT FORK LEGS”. C Inner tube 1 D Oil seal 1 Refer to “ASSEMBLING THE FRONT FORK LEGS”. E Seal spacer 1 F Outer tube bushing 1 G Inner tube bushing 1 H Oil flow stopper 1 I Outer tube 1 For assembly, reverse the disassembly procedure. [...]

4 - 63 CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure ap plies to both of the front fork legs. 1. Stand the motorcycle on a le vel surf ace . W ARNING @ Securely support the mo torcycle so that there is no danger of it falling over. NOTE: @ Place the motorcycle on a suitable stand so that the front wheel is elevated. [...]

4 - 64 CHAS FRONT FORK 4. Remov e: • dust seal 1 • oil seal clip 2 (with a flat-head screwdriver) CAUTION: @ Do not scratch the inner tube. NOTE: @ • Do not remove the fork leg protector from the outer tube. • If the front fork leg protector must be removed, always install a new one. 5. Remov e: •w a s h e r • damper rod assembly bolt 1[...]

4 - 65 CHAS FRONT FORK EAS00657 CHECKING THE FRONT FORK LEGS The following procedure ap plies to both of the front fork legs. 1. Chec k: • inner tube 1 • outer tube 2 Bends/damage/scratches → Replace. W ARNING @ Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: • spring free le ngth a Out of speci[...]

4 - 66 CHAS FRONT FORK 4. Chec k: • cap bolt O-ring Damage/wear → Replace. EAS00661 ASSEMBLING THE FRONT FORK LEGS The following procedure ap plies to both of the front fork legs. W ARNING @ • Make sure th e oil levels in both front fork legs are equal. • Uneven oil levels can res ult in poor han- dling and a loss of stability. NOTE: @ • [...]

4 - 67 CHAS FRONT FORK 3. Tighten: • damper rod assembly bolt 1 NOTE: @ • If the washer has not been removed during disassembly, strike the washer lightly, and then remove it. • While holding th e damper rod assembly with the damper rod holder 2 , tighten the damper rod assembly bolt. Damper rod holder 90890-01447 T R . . 35 Nm (3.5 m · kg) [...]

4 - 68 CHAS FRONT FORK 6. Install: • oil seal clip 1 NOTE: @ Adjust the oil seal clip so that it fits into the groove of the outer tube. 7. Install: • dust seal 1 (with the fork seal driver) New 8. Fully compress the front f or k leg. 9. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) CAUTION: @ • Be sure to[...]

4 - 69 CHAS FRONT FORK 11.Slowly strok e th e inner tube 1 up and down. 12.Bef ore measuring the f ork oil le v el, w ait ten minutes until the oil has settled and the air bu bb les ha v e dispersed. NOTE: @ Be sure to bleed the front fork leg of any resid- ual air. 13.Measure: • front fork leg oil level a Out of specification → Correct. Front [...]

4 - 70 CHAS FRONT FORK EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure ap plies to both of the front fork legs. 1. Install: • front fork leg NOTE: • Make sure that the inner tube e nd is flush with the top of the upper bracket. • Tempo rarily tighten the upper and lower bracket pinch bolts. W ARNING @ Make sure the brake hoses[...]

4 - 71 CHAS HANDLEBARS EAS00665 HANDLEBARS LEFT HANDLEBAR Order Job/Part Q’ty Remarks Removing the left handlebar Remove the parts in the order listed . 1 Clutch switch coupler 1 Disconnect. 2 Clutch master cylinder holder 1 Refer to “REMOVING/INSTALLING THE HANDLEBARS”. 3 Clutch master cylinder 1 4 Left handlebar switch 1 5 Grip end 1 6 Hand[...]

4 - 72 CHAS HANDLEBARS RIGHT HANDLEBAR Order Job/Part Q’ty Remarks Removing the right handlebar Remove t he parts in the order listed. 1 Front brake light switch connector 2 Disconnect. 2 Brake master cylinder holde r 1 Refer to “REMOVING/ INSTALLING THE HANDLEBARS”. 3 Brake master cylinder 1 4 Grip end 1 5 Throttle cable housing 1 6 Throttle[...]

4 - 73 CHAS HANDLEBARS EAS00667 REMOVING THE HANDLEBARS 1. Stand the motorcycle on a le vel surf ace . W ARNING @ Securely support the mo torcycle so that there is no danger of it falling over. 2. Remov e: • handlebar grip NOTE: @ Blow compressed air between the left handle- bar and the handleb ar grip, and gradually push the grip off the handleb[...]

4 - 74 CHAS HANDLEBARS EAS00674 INSTALLING THE HANDLEBARS 1. Stand the motorcycle on a le vel surf ace . W ARNING @ Securely support the mo torcycle so that there is no danger of it falling over. 2. Install: • right handlebar switch 1 NOTE: @ Align the projection a on the right handlebar switch with the hole b in the right handlebar. 3. Install: [...]

4 - 75 CHAS HANDLEBARS 4. Install: • brake master cyl inder • brake master cylinder holder 1 NOTE: @ • Install the brake master cylinder holder with the “UP” mark facing up. • First, tighten the upper bolt, and then the lower bolt. • Align the mating surfaces of the brake mas- ter cylinder holder with the punch mark a in the right han[...]

4 - 76 CHAS HANDLEBARS 7. Install: • clutch master cylinder • clutch master cylinder holder 1 NOTE: @ Align the slit in the clutch master cylinder holder with the punch mark a in the left han- dlebar. T R . . 10 Nm (1.0 m · kg) 8. Adjust: • throttle cable free p lay Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. Throttle[...]

4 - 77 CHAS STEERING HEAD EAS00676 STEERING HEAD Order Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”. Front fork legs Refer to “FRONT FORK”. Handlebars Refer to “HANDLEBARS”. 1 Lead guide 2 2 Main switch coupler 2 Disconnect. Refer to “INSTAL[...]

4 - 78 CHAS STEERING HEAD Order Job/Part Q’ty Remarks 7 Lock washer 1 Refer to “ REMOVING THE LOWER BRACKET” and “INSTALLING THE STEERING HEAD”. 8 Upper ring nut 1 9 Rubber washer 1 10 Lower ring nut 1 11 Lower bracket 1 12 Bearing cover 1 13 Bearing inner race 2 14 Upper bearing 1 15 Lower bearing 1 16 Bearing outer race 2 17 Dust seal 1[...]

4 - 79 CHAS STEERING HEAD EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a le vel surf ace . W ARNING @ Securely support the mo torcycle so that there is no danger of it falling over. 2. Remov e: • lower ring nut 1 (with the special tool 2 ) W ARNING @ Securely support the lower brack et so that there is no danger of it falling. S[...]

4 - 80 CHAS STEERING HEAD b . Remov e the bearing race from the lo wer brac k et with a floor chisel 2 and hammer . c. Install a ne w rubber seal and ne w bearing race s. CAUTION: @ If the bearing race is not instal led properly, the steering head pipe could be dama ged. NOTE: @ • Always replace the bearings and bearing races as a set. • Whenev[...]

4 - 81 CHAS STEERING HEAD 3. Install: • upper bracket • steering stem nut NOTE: @ Temporarily tighten the steering stem nut. 4. Install: • front fork legs Refer to “FRONT FORK”. NOTE: @ Temporarily tighten the lower and upper bracket pinch bolts. 5. Tighten: • steering stem nut T R . . 115 Nm (11.5 m · kg)[...]

4 - 82 CHAS REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM EAS00685 REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM T R . . 64 Nm (6.4 m • kg) 5 5 8 2 2 T R . . 40 Nm (4.0 m • kg) T R . . 55 Nm (5.5 m • kg) 3 3 4 13 11 13 10 14 13 13 13 3 3 4 15 15 13 12 14 1 (3) T R . . 48 Nm (4.8 m • kg) 7 8 T R . . 40 Nm (4.0 m • kg) LS 9 6 LS Order Job/Part Q?[...]

4 - 83 CHAS REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM T R . . 64 Nm (6.4 m • kg) 5 5 8 2 2 T R . . 40 Nm (4.0 m • kg) T R . . 55 Nm (5.5 m • kg) 3 3 4 13 11 13 10 14 13 13 13 3 3 4 15 15 13 12 14 1 (3) T R . . 48 Nm (4.8 m • kg) 7 8 T R . . 40 Nm (4.0 m • kg) LS 9 6 LS Order Job/Part Q’ty Remarks 11 Collar 1 12 Collar 1 13 Oil seal 6 1[...]

4 - 84 CHAS REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM EAS00686 HANDLING THE REAR SHOCK ABSORBER W ARNING @ This rear shock absorber con tains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held responsible for property damage or per-[...]

4 - 85 CHAS REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM 2. Remov e: • rear shock absorber assembly lower bolt 1 • connecting arms NOTE: @ While removing the connecting arm bolt, hold the swingarm so that it does not drop down. 3. Remov e: • rear shock absorbe r assembly upper bolt 1 • rear shock absorber assembly NOTE: @ Raise the swingarm a[...]

4 - 86 CHAS REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM 2. Chec k: • bearings •o i l s e a l s Damage/pitting → Replace. 3. Chec k: •s p a c e r s Damage/scratches → Replace. INSTALLING THE RELAY ARM 1. Lubricate: •s p a c e r s • bearings 2. Install: • bearing 1 , 2 (to the relay arm) Recommended lubricant Lithium soap base grease I[...]

4 - 87 CHAS SWINGARM EAS00701 SWINGARM Order Job/Part Q’ty Remarks Removing the swingarm Remove the parts in the order listed . Mufflers Refer to “ENGINE” in chapter 5. Rear wheel Refer to “REAR WHEEL AND BRAKE DISC”. Final drive assembly/universal joint Refer to “SHAFT DRIVE”. Rear shock absorber assembly Refer to “REAR SHOCK ABSOR[...]

4 - 88 CHAS SWINGARM Order Job/Part Q’ty Remarks 9 Oil seal 2 10 Bearing 2 Refer to “INSTALLING THE SWINGARM”. 11 Spacer 1 12 Oil seal 1 13 Bushing 1 14 Oil seal 1 15 Circlip 1 16 Bearing 1 17 Spacer 1 18 Bearing 1 Refer to “INSTALLING THE SWINGARM”. For installation, rever se the removal procedure.[...]

4 - 89 CHAS SWINGARM EAS00702 REMOVING THE SWINGARM 1. Stand the motorcycle on a le vel surf ace . W ARNING @ Securely support the mo torcycle so that there is no danger of it falling over. NOTE: @ Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side play • swingarm vertical movement ▼▼▼[...]

4 - 90 CHAS SWINGARM 2. Chec k: • pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. W ARNING @ Do not attempt to straighten a bent pivot shaft. 3. W ash: • pivot shaft •s p a c e r s • bushing • bearings Recommended cleaning solvent Kerosene 4. Chec k: •s p a c e r s • bushing •o i l s e a l s Damage/wear → Re[...]

4 - 91 CHAS 3. Install: • bearing 1 (to the swingarm) Installed depth a 4.0 mm SWINGARM[...]

4 - 92 CHAS SHAFT DRIVE EAS00715 SHAFT DRIVE TROUBLESHOOTING NOTE: @ Causes A, B, and C may be extremely difficult to diagnose. The symptoms are quite subtle and dif- ficult to distinguish from normal operating noises. If there is reason to believe that these compo- nents are damaged, remove t hem and check them individual. @ A Symptom B Possible c[...]

4 - 93 CHAS SHAFT DRIVE Inspection notes 1. Inv estigate any un usual noises . ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ The following noises may indicate a mechanical defect: a. A rolling “rumble” during coasting, accelera- tion or deceleration (increases with the rear whe[...]

4 - 94 CHAS SHAFT DRIVE EAS00716 Troubleshooting chart When causes (A) or (B) shown in the table at the beginning of the “TROUBLESHOOTING” section exist, check the following po ints. Place the motorcycle on a suitable stan d so that the front wheel is elevated and then spin the front wheel. Is the wheel bearing damage d? YES Replace the wheel b[...]

4 - 95 CHAS SHAFT DRIVE EAS00717 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKIN G THE SHAFT DRIVE FOR LEAKS 1. Drain: • final drive oil (from the final drive housing) Refer to “CHANGING THE FINAL DRIVE OIL” in chapter 3. 2. Chec k: • final drive oil Large amount of metal particles → Check for bearing seizure. NOTE: @ A small a[...]

4 - 96 CHAS SHAFT DRIVE EAS00719 MEASURING THE RING GEAR BACKLASH 1. Secure the final driv e assemb ly in a vise. 2. Remov e: • final drive oil d rain bolt 3. Drain: • final drive oil (from the final drive assembly) 4. Measure: • ring gear backlash Out of specification → Adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼?[...]

4 - 97 CHAS SHAFT DRIVE EAS00720 ADJUSTING THE RING GEAR BACKLASH 1. Remov e: • ring gear bearing housing nuts • ring gear bearin g housing bolts NOTE: @ Working in a crisscross pa ttern, loosen each nut 1/4 of a turn. After all of the nuts are fully loosened, remove them and the bolts. @ 2. Remov e: • ring gear bearin g housing 1 • dust co[...]

4 - 98 CHAS SHAFT DRIVE EAS00721 MEASURING THE RING-GEAR-TO- STOPPER-BOLT CLEARANCE 1. Remov e: • ring gear bearin g housing (along with the ring gear) Refer to “ADJUSTING THE RING GEAR BACKLASH”. 2. Measure: • ring-gear-to-stopper-bolt clearance a Out of specification → Adjust. 1 Stopper bolt 2 Ring gear 3. Install: • ring gear bearin [...]

4 - 99 CHAS SHAFT DRIVE 3. Install: • stopper bolt shim(s) 1 • stopper bolt 2 • ring gear 3 • ring gear bearin g housing CAUTION: @ • The stopper bolt has left-hand threa ds. To tighten the stopper bolt, turn it counter- clockwise. • Apply LOCTITE ® onto the sto pper bolt. @ 4. Measure: • ring-gear-to-stopper-bolt clearance NOTE: @ I[...]

4 - 100 CHAS SHAFT DRIVE EAS00718 Order Job/Part Q’ty Remarks Removing the final drive assembly Remove the parts in the order listed. Final gear oil Drain. Rear wheel Refer to “REAR WHEEL AND BRAKE DISC”. 1 Final drive assembly 1 Refer to “INSTALLING THE UNIVERSAL JOINT AND FINAL DRIVE ASSEMBLY”. For installation, rever se the removal pro[...]

4 - 101 CHAS Order Job/Part Q’ty Remarks Removing the universal joint Remove the parts in the ord er listed. Final drive assembly 1 Shift arm 1 Refer to “INSTALLING THE UNIVERSAL JOINT AND FINAL DRIVE ASSEMBLY”. 2 Left footrest bracket 1 Refer to “REMOVING THE LEFT FOOTREST BRACKET”. 3D u s t c o v e r 1 4 Dust seal 1 5 Universal joint 1 [...]

4 - 102 CHAS SHAFT DRIVE EAS00723 Order Job/Part Q’ty Remarks Disassembling the final drive assembly Remove the parts in the ord er listed. 1 Circlip 2 2 Oil seal 1 3 Drive shaft 1 4 Spring 1 5 Ring gear bearing housing/oil seal 1/1 Refer to “ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR”. 6 Dust cover 1 7 Ring gear/bearing 1/1 8 Ring ge[...]

4 - 103 CHAS SHAFT DRIVE Order Job/Part Q’ty Remarks B Nut 1 Left-hand threads. Refer to “DISASSEMBLING THE FINAL DRIVE ASSEMBLY” and “ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR”. C Gear coupling 1 D Bearing retainer/oil seal 1/1 Left-hand threads. E Final drive pinion gear/bearing 1/1 F Final drive pinion gear shim(s) G Bearing 1[...]

4 - 104 CHAS SHAFT DRIVE REMOVING THE LEFT FOOTREST BRACKET 1. Remov e: • left footrest bracke t bolt 1 (with the T50 torx wrench) EAS00724 DISASSEMBLING THE FINAL DRIVE ASSEMBLY 1. Remov e: • ring gear bearing housing nuts • ring gear bearin g housing bolts NOTE: @ Working in a crisscross pa ttern, loosen each nut 1/4 of a turn. After all of[...]

4 - 105 CHAS SHAFT DRIVE 4. Remov e: • bearing retainer (with the bearing retainer wrench 1 ) CAUTION: @ The bearing retainer has left-hand threads. To loosen the bearing retainer, turn it clockwise. @ 5. Remov e: • final drive pinion gear W ARNING @ Always use new bearings. @ CAUTION: @ The final drive pinion gear should only be removed if rin[...]

4 - 106 CHAS SHAFT DRIVE 3. Remov e: • bearing 1 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Heat the final drive housing to appro xi- mately 150 °C . b . Remov e the bearing outer r aces with an appropriately shaped punch 2 . c. Remov e the inner race from th e final drive[...]

4 - 107 CHAS SHAFT DRIVE EAS00726 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR NOTE: @ Aligning the final drive pinion gear and ring gear is necessary when any of the following parts are replaced: • Final drive housing • Ring gear bearing housing • Any bearing @ 1. Select: • final drive pinion gear shim(s) 1 • ring gear shim(s) 2 ?[...]

4 - 108 CHAS SHAFT DRIVE Therefore, the calculated final drive pinion gear shim thickness is 0.51 mm. Shim sizes are supplied in the followin g thicknesses. Since the final drive pinion gear shims are only available in 0.10 mm increments, round off to the hundredths digit. In the example above, the calculated final drive pinion gear shim thickness [...]

4 - 109 CHAS SHAFT DRIVE Example: If the final drive housing is marked “51”, the ring gear bearing housing is marked “3 5”, the ring gear is marked “– 05”, and “ f ” is 13.00: B = (45 + 51/100) + (3 + 35/100) – [(35.40 – 5/100) + 13] = (45 + 0.51) + (3 + 0.35) – [(35.40 – 0.05) + 13] = 45.51 + 3.35 – [(35.40 – 0.05) + [...]

4 - 110 CHAS SHAFT DRIVE 2. Install: • shims (as calculated) • final drive pinion gear • bearing retainer (with the bearing retainer wrench 1 ) CAUTION: @ The bearing retainer has left-hand threads. To tighten the bearing retainer, turn it counterclockwise. @ Bearing retainer wrench 90890-04050 T R . . 110 Nm (11.0 m · kg) 3. Install: • ge[...]

4 - 111 CHAS SHAFT DRIVE 7. Measure: • ring-gear-to-thrust-washer cle arance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remo v e the ring gear bearing housing (along with the ring gear). b . Place f our pieces of Plastigauge ® between the original thr ust washer and the ri[...]

4 - 112 CHAS SHAFT DRIVE EAS00727 CHECKING THE DRIVE SHAFT 1. Chec k: • drive shaft splines Damage/wear → Replace the drive shaft. EAS00728 INSTALLING THE UNIVERSAL JOINT AND FINAL DRIVE ASSEMBLY 1. Lubricate: • universal joint splines • drive shaft splines 2. Install: • universal joint • final drive assembly NOTE: Align the drive shaft[...]

ENG 5[...]

ENG CHAPTER 5 ENGINE ENGINE ............................................................. .............................................. 5-1 MUFFLERS AND EXHAUST PIPE ASSEMBLY ....................................... 5-1 LEADS AND HOSES ............................................. .................................... 5-2 ENGINE ....................[...]

ENG CLUTCH ................................................. ..................................................... .. 5-45 CLUTCH COVER .................................................................................. .. 5-45 CLUTCH ...................................................... ............................................ 5-46 REMOVING TH[...]

ENG CONNECTING RODS AND PISTONS .......................................................... 5-92 REMOVING THE CONNECTING RODS AND PISTONS ....................... 5-93 CHECKING THE CYLINDERS AND PISTONS ...................................... 5-94 CHECKING THE PISTON RINGS ............................................... ............ 5-95 CHECKING THE [...]

ENG[...]

5 - 1 ENG ENGINE EAS00188 ENGINE ENGINE MUFFLERS AND EXHAUST PIPE ASSEMBLY Order Job/Part Q’ty Remarks Removing the mufflers and exh aust pipe assembly Remove the parts in the order listed . Seats/fuel tank/T-bar/rubber seat Refer to “SEATS AND FUEL TANK” in chapter 3. Side cowlings/front cowling assembly Refer to “COWLINGS” in chapter 3.[...]

5 - 2 ENG ENGINE LEADS AND HOSES Order Job/Part Q’ty Remarks Removing the leads and hoses Remo ve the parts in the order listed. Air filter case Refer to “AIR FILTER CASE” in chapter 3. Throttle bodies Refer to “FUEL INJECTION SYSTEM” in chapter 7. Air cut-off valve assembly/hoses/reed valves Refer to “AIR INDUCTION SYSTEM” in chapter[...]

5 - 3 ENG ENGINE Order Job/Part Q’ty Remarks Left footrest bracket/dust cover Refer to “SHAFT DRIVE” in cha pter 4. 1 Clutch release cylinder 1 2 Dowel pin 2 3 Sidestand switch coupler 1 Disconnect. 4 Crankcase breather hose 1 5 Starter motor lead 1 Disconnect. 6 Stator assembly coupler 1 Disconnect. 7 Oil level sensor connector 1 Disconnect.[...]

5 - 4 ENG ENGINE EAS00191 ENGINE 7 7 11 9 14 9 5 6 12 4 4 15 1 2 3 6 5 8 10 13 10 T R . . 45 Nm (4.5 m • kg) T R . . 55 Nm (5.5 m • kg) T R . . 45 Nm (4.5 m • kg) T R . . 55 Nm (5.5 m • kg) T R . . 24 Nm (2.4 m • kg) T R . . 24 Nm (2.4 m • kg) T R . . 55 Nm (5.5 m • kg) T R . . 18 Nm (1.8 m • kg) T R . . 16 Nm (1.6 m • kg) T R . .[...]

5 - 5 ENG 7 7 11 9 14 9 5 6 12 4 4 15 1 2 3 6 5 8 10 13 10 T R . . 45 Nm (4.5 m • kg) T R . . 55 Nm (5.5 m • kg) T R . . 45 Nm (4.5 m • kg) T R . . 55 Nm (5.5 m • kg) T R . . 24 Nm (2.4 m • kg) T R . . 24 Nm (2.4 m • kg) T R . . 55 Nm (5.5 m • kg) T R . . 18 Nm (1.8 m • kg) T R . . 16 Nm (1.6 m • kg) T R . . 32 Nm (3.2 m • kg) T[...]

5 - 6 ENG ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: •s p a c e r 1 • spacer bolt 2 • rear lower mounting bolt 3 • rear upper mounting bolt 4 • front mounting bolts 5 , 6 • engine bracket 2 7 • engine bracket 1 8 NOTE: @ Do not fully tighten the bolts. 2. Tighten the bolts in the f ollowing order . • front mounting bolts (le [...]

5 - 7 ENG 4. Tighten the bolts in the f ollowing order . • bolts (engine bracket 2 and e ngine) 1 • bolts (engine bracket 2 and fra me) 2 T R . . 36 Nm (3.6 m · kg) T R . . 16 Nm (1.6 m · kg) 5. T emporarily tighten the bolt (engine brac ket 1 and frame) 1 and b olts (engine brac k et 1 and engine) 2 . NOTE: When temporarily tightened, the bo[...]

5 - 8 ENG CAMSHAFTS EAS00194 CAMSHAFTS CYLINDER HEAD COVER 1 LT LS New 4 5 6 2 3 T R . . 13 Nm (1.3 m • kg) T R . . 10 Nm (1.0 m • kg) T R . . 10 Nm (1.0 m • kg) (8) Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Reed valves Refer to “AIR INDUCTION SYSTEM” in chapter 7. Engine oil Drai[...]

5 - 9 ENG CAMSHAFTS EAS00196 CAMSHAFTS Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed . Throttle bodies Refer to “FUEL INJECTION SYSTEM” in chapter 7. Pickup coil rotor cover Refer to “PICKUP COIL ROTOR”. 1 Timing ch ain tensi oner 1 Refer to “REMOVING/INSTALLING THE CAMSHAFTS”. 2 Timing chain [...]

5 - 10 ENG Order Job/Part Q’ty Remarks 10 Timing chain guide (exhaust side) 1 11 Pin 1 12 Timing chain guide (intake side) 1 For installation, reverse the removal procedure. CAMSHAFTS[...]

5 - 11 ENG CAMSHAFTS EAS00198 REMOVING THE CAMSHAFTS 1. Align: • “T” mark on the pickup coil rotor (with the crankcase mating surface) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T ur n the crankshaft cloc kwise. b . When pist on #1 is at TDC on the comp res- sion strok [...]

5 - 12 ENG CAMSHAFTS 5. Remov e: • intake camshaft 1 • exhaust camshaft 2 NOTE: @ To prevent the timing chain from falling into the crankcase, fasten it with a wire 3 . EAS00204 CHECKING TH E CAMSHAFTS 1. Chec k: • camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • camshaft lobe dimensions a and b Ou[...]

5 - 13 ENG CAMSHAFTS ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the camshaft into the cylinder head (without the do wel pins and camshaft caps). b . P o sition a strip of Plastigauge ® 1 onto the camshaft journal as shown. c. Install the dow el pins and camshaft caps[...]

5 - 14 ENG CAMSHAFTS EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Chec k: • timing ch ain tensi oner Cracks/damage/rough movement → Replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While lightly pressing the timing chain ten- sioner rod b y hand, tur n the tensioner[...]

5 - 15 ENG CAMSHAFTS 2. Install: • exhaust camshaft 1 • intake camshaft 2 (with the camshaft sprockets) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T ur n the crankshaft cloc kwise. b . When pist on #1 is at TDC on the comp res- sion strok e, align the “T” mark a on th[...]

5 - 16 ENG CAMSHAFTS 4. Install: • camshaft cap bolts NOTE: @ Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. CAUTION: @ • Lubricate the camshaft cap bolts with the engine oil. • The camshaft cap bolts mus t be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts [...]

5 - 17 ENG CAMSHAFTS d. Remov e the screwdriv er , make sure the tim- ing chain tensioner rod re leases, and then tighten the cap bolt to the spe cified torque. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ T R . . Cap bolt 10 Nm (1.0 m · kg) 6. T ur n: • crankshaft (several tur[...]

5 - 18 ENG CAMSHAFTS 9. Install: • cylinder head cover gasket • cylinder head cover NOTE: Out of spe cificatio n → Adjust. • Apply bond T1541 1 onto the mating sur- faces of the cylinder head cover and cylinder head cover gasket. • Apply bond YGK8624-C1 2 onto the mating surfaces of the cylinder head cover gasket and cylinder head. • Ti[...]

5 - 19 ENG CYLINDER HEAD EAS00221 CYLINDER HEAD T R . . 12 Nm (1.2 m • kg) T R . . 20 Nm (2.0 m • kg) New New E 3 3 2 New 1 (10) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Radiator Refer to “RADIATOR” in chapter 6. Exhaust pipe assembly Refer to “ENGINE”. Camshafts Refer to “CAMSHAFT[...]

5 - 20 ENG CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remov e: • cylinder head bolts NOTE: @ Loosen each bolt 1/2 of a turn at a time. After all of the bolt are fully loosened, remove them. EAS00229 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: @ Do not use a sharp instrum[...]

5 - 21 ENG CYLINDER HEAD d. Place a 400 ~ 600 grit wet sandpaper on the surf ace plate and resurf ace the cylinder head using a figure-eight san ding pattern. NOTE: @ To ensure an even surface, rotate the cylinder head several times. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EA[...]

5 - 22 ENG CYLINDER HEAD d. Loosen and retighten the cylinder head bolts in the proper tightening seq uence as sho wn. T R . . Cylinder head bolt (M10) 2nd 25 Nm (2.5 m · kg) e. Tighten the cylinder head bolts fur ther to reach the specified angle 180° in the proper tightening sequence as sho wn. W ARNING When the bolts are tightened more than th[...]

5 - 23 ENG CYLINDER HEAD 4. Tighten: • cylinder head bolts (M6) 1 T R . . 12 Nm (1.2 m · kg)[...]

5 - 24 ENG VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS 1 2 3 4 5 6 7 3 1 2 3 4 5 6 7 3 M M M M 10 9 10 8 M New New Order Job/Part Q’ty Remarks Removing the valves and valve springs Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”. 1 Valve lifter 16 Refer to “REMOVING/INSTALLING THE VALVES”. 2 Val[...]

5 - 25 ENG VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: @ Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remov e: • valve lifter 1 • valve pad 2 NOTE: @ Make a [...]

5 - 26 ENG VALVES AND VALVE SPRINGS 3. Remov e: • valve cotters 1 NOTE: @ Remove the valve cotters by comp ressing the valve spring with the valve spring compressor 2 and attachment 3 . Valve spring compressor 90890-04019 Attachment 90890-04108 4. Remov e: • upper spring seat 1 • valve spring 2 •o i l s e a l 3 • lower spring seat 4 •v [...]

5 - 27 ENG VALVES AND VALVE SPRINGS 1. Measure: • valve-stem-to-valve-guide clearance Out of specification → Re place the valve guide. Valve-stem-to-valve-guide clearance = Valve guide inside diameter a – Valve stem diameter b Valve-stem-to-valve-guide clear- ance Intake 0.010 ~ 0.037 mm <Limit>: 0.08 mm Exhaust 0.025 ~ 0.052 mm <Lim[...]

5 - 28 ENG VALVES AND VALVE SPRINGS 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Chec k: • valve face Pitting/wear → Grind the valve face. • valve stem end Mushroom shape or diameter lar ger than the body of the valve stem → Replace the valve. 5. Measure: • valve margin thickness a Out of specification → Rep[...]

5 - 29 ENG VALVES AND VALVE SPRINGS 3. Measure: • valve seat width a Out of specification → Replace the cylinder head. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply Mechanic’ s blueing dye (Dyke m) b onto the v alv e f ace . b . Install the valv e into the cylinder h[...]

5 - 30 ENG VALVES AND VALVE SPRINGS c. Install the v alv e into the cylinder head. d. T ur n the v alv e until the v alv e face and v alv e seat are e venly polished, th en clean off all of the lapping compound. NOTE: @ For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. e. Apply a fi[...]

5 - 31 ENG VALVES AND VALVE SPRINGS 2. Measure: • compressed valve spring force a Out of specification → Re place the valve spring. b Installed length Compressed valve sp ring force (installed) 13.9 ~ 16.1 kg at 33 mm 3. Measure: • valve spring ti lt a Out of specification → Re place the valve spring. Maximum valve spring tilt 1.7 mm EAS002[...]

5 - 32 ENG VALVES AND VALVE SPRINGS EAS00249 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Debu rr : • valve stem end (with an oil stone) 2. Lubricate: • valve stem 1 •o i l s e a l 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: •v a l v e[...]

5 - 33 ENG VALVES AND VALVE SPRINGS 4. Install: • valve cotters 1 NOTE: @ Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 . Valve spring compressor 90890-04019 Attachment 90890-04108 5. T o secure the v alve cotters onto t he v alv e stem, lightly tap the v alv e tip with a soft-f ace [...]

5 - 34 ENG EAS00343 GENERATOR AND STARTER CLUTCH GENERATOR ROTOR AND STARTE R CLUTCH Order Job/Part Q’ty Remarks Removing the generator rotor and starter clutch Remove the parts in the order listed. Fuel tank/seats/T-bar/rubber seat Refer to “SEATS AND FUEL TANK” in chapter 3. Side covers/front cowling assembly Refer to “COWLINGS AND COVERS[...]

5 - 35 ENG Order Job/Part Q’ty Remarks 5 Starter clutch idle gear shaft 1 6 starter clutch idle gear 1 7 Generator rotor 1 Refer to “REMOVING/INSTALLING THE GENERATOR”. 8 Woodruff key 1 9 Starter clutch g ear 1 Refer to “REMOVING/INSTALLING THE STARTER CLUTCH”. 10 Starter clutch 1 For installation, rever se the removal procedure. GENERATO[...]

5 - 36 ENG STATOR ASSEMBLY Order Job/Part Q’ty Remarks Removing the stator assembly Remove the parts in the order listed. 1 Lead holder 1 Refer to “INSTALLING THE GENERA- TOR”. 2 Stator assembly 1 For installation, reverse the removal procedure. GENERATOR AND STARTER CLUTCH[...]

5 - 37 ENG EAS00346 REMOVING THE GENERATOR 1. Remov e: • generator cover 1 NOTE: @ Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosen ed, remove them. 2. Remov e: • generator rotor bolt 1 •w a s h e r NOTE: @ While holding the generator rotor 2 with the sheave holder 3 , lo[...]

5 - 38 ENG REMOVING THE STARTER CLUTCH 1. Remov e: • starter clutch bolts 1 • starter clutch NOTE: @ While holding the ge nerator rotor with the sheave holder, remove the starter clutch bo lts. Sheave holder 90890-01701 EAS00351 CHECKING THE STARTER CLUTCH 1. Chec k: • starter clutch rollers 1 Damage/wear → Replace. 2. Chec k: • starter c[...]

5 - 39 ENG b . When tur ning the star ter clutch drive gear cloc kwise È , the star ter clutch and the star ter clutch drive gear should engage , otherwise the star ter clutch is f aulty and must be replaced . c. When turn ing the star ter clutch drive gear countercloc kwise É , it should tur n freely , otherwise the star ter clutch is f aulty an[...]

5 - 40 ENG 2. Install: • stator assembly 1 • lead holder 2 T R . . 10 Nm (1.0 m · kg ) LT T R . . 6 Nm (0.6 m · kg) 3. Install: • woodruff key • generator rotor •w a s h e r • generator rotor bolt NOTE: @ • Clean the tapered portion of t he crankshaft and the generator rotor hub. • When installing the generator ro tor, make sure t[...]

5 - 41 ENG PICKUP COIL ROTOR Order Job/Part Q’ty Remarks Removing the pickup coil rotor Remove the parts in the order listed. Fuel tank/seats/T-bar/rubber seat Refer to “SEATS AND FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE” in chapter 3. Side covers/front cowling assembly Refer to “COWLINGS AND COVERS” in chapt[...]

5 - 42 ENG Order Job/Part Q’ty Remarks 3 Dowel pin 2 4 Crankshaft position sen sor coupler 1 Disconnect. 5 Crankshaft position sen sor 1 Refer to “INSTALLING THE PICKUP COIL ROTOR”. 6 Pickup coil rotor 1 Refer to “REMOVING/INSTALLING THE PICKUP COIL ROTOR”. For installation, rever se the removal procedure. PICKUP COIL ROTOR[...]

5 - 43 ENG REMOVING THE PICKUP COIL ROTOR 1. Remov e: • pickup coil rot or cover 1 NOTE: @ Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosen ed, remove them. 2. Remov e: • pickup coil rotor bolt 1 •w a s h e r • pickup coil rot or 2 NOTE: @ While holding the generator ro[...]

5 - 44 ENG 2. Tighten: • pickup coil rotor bolt 1 NOTE: @ While holding the generator rotor 2 with the sheave holder 3 , tighten the pickup coil rotor bolt. Sheave holder 90890-01701 T R . . 45 Nm (4.5 m · kg) 3. Apply: • seala nt • (onto the crankshaft po sition sensor lead grommet) Yamaha bond No. 1215 90890-85505 4. Install: • pickup co[...]

5 - 45 ENG EAS00273 CLUTCH CLUTCH COVER T R . . 12 Nm (1.2 m • kg) T R . . 12 Nm (1.2 m • kg) 1 2 5 4 3 3 (10) (5) LT New Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed . Right side cowling Refer to “COWLINGS AND COVERS” in chapter 3. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in c[...]

5 - 46 ENG EAS00274 CLUTCH Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the ord er listed. Clutch release cylinder Refer to “HYDRAULIC CLUTCH” in chap- ter 4. Rear balancer Refer to “BALANCERS”. 1 Oil guide plate 1 Refer to “REMOVING/INSTALLING THE CLUTCH”. 2 Clutch spring plate retainer 1 3 Clutch spring plate [...]

5 - 47 ENG Order Job/Part Q’ty Remarks 12 Lock washer 1 Refer to “REMOVING/INSTALLING THE CLUTCH”. 13 Clutch boss 1 14 Wire circlip 1 15 Clutch plate 2 1 16 Friction plate 3 1 17 Clutch damper spring 1 18 Clutch damper spring seat 1 19 Thrust washer 1 20 Spacer 1 21 Clutch housing 1 For installation, reverse the remo val procedure. CLUTCH[...]

5 - 48 ENG EAS00275 EAS00277 REMOVING THE CLUTCH 1. Remov e: • rear balancer weight Refer to “BALANCERS”. 2. Remov e: •c l u t c h c o v e r 1 NOTE: @ Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosen ed, remove them. 3. Straighten the loc k w asher tab . 4. Loosen: • [...]

5 - 49 ENG CLUTCH 6. Remov e: •s p a c e r 1 NOTE: @ • Insert a cross-headed screwdriver into on e of the holes of the clutch housing an d primary driven gear, and then rotate the in ner pri- mary driven gear until both primary driver gears are aligned. T he teeth of both primary driven gears must be aligned for installation. • Insert two 5-m[...]

5 - 50 ENG EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Chec k: • clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge 1 ) Out of specification → Replace the clutch plates as a set. Maximum Maximum clutch [...]

5 - 51 ENG EAS00285 CHECKING THE CLUTCH BOSS 1. Chec k: • clutch boss splines Damage/pitting/wear → Replace the clutch boss. NOTE: @ Pitting on the clutch boss splines will cause erratic clutch operation. EAS00286 CHECKING THE PRESSURE PLATE 1. Chec k: • pressure plate 1 Cracks/damage → Replace. • bearing 2 Damage/wear → Replace. EAS002[...]

5 - 52 ENG EAS00294 INSTALLING THE CLUTCH 1. Install: • clutch housing 1 NOTE: @ • Make sure that the slots a into the clutch housing align with the tabs b onto the oil pump drive sprocket. • Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly. • Insert a cross-headed screwdriver into on e of the holes o[...]

5 - 53 ENG 4. Install: • thrust washer • clutch boss 1 • lock washer • clutch bos s nut 2 NOTE: @ While holding the clutch b oss with the univer- sal clutch holder 3 , tighten th e clutch boss nut. 5. Bend the loc k washer tab alo ng a flat side of the nut. Universal clutch holder 90890-04086 New T R . . 90 Nm (9.0 m · kg) 6. Lubricate: ?[...]

5 - 54 ENG 9. Install: • friction plates • clutch plates NOTE: @ First, install a friction plate and then alternate between a clutch plate and a friction plate. 10.Install: • pressure plate 1 • clutch spring plate seat 2 • clutch spring plate 3 • clutch spring plate retainer 4 NOTE: @ Tighten the clutch spring bolts in stages and in a c[...]

5 - 55 ENG EAS00326 SHIFT SHAFT Order Job/Part Q’ty Remarks Removing the shift shaft Remove the parts in the order listed. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Clutch housing Refer to “CLUTCH”. 1 Oil baffle plate 1 2 Shift arm 1 3 Circlip 1 4 Shift shaft 1 Refer to “INSTALLING THE SHIFT SHAFT”. 5 Shift sh[...]

5 - 56 ENG Order Job/Part Q’ty Remarks 6 Stopper lever spring 1 Refer to “INSTALLING THE SHIFT SHAFT”. 7 Stopper lever 1 8 Circlip 1 9C o l l a r 1 10 Shift shaft spring stopper 1 For installation, reverse the removal procedure. SHIFT SHAFT[...]

5 - 57 ENG EAS00329 CHECKING THE SHIFT SHAFT 1. Chec k: • shift shaft 1 • shift shaft pawl 2 Bends/damage/wear → Replace. • shift shaft spring 3 Damage/wear → Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Chec k: • stopper lever 1 Bends/damage → Replace. • Roller turns roughly → Repla ce the stopper lever. • stopper lever spri[...]

5 - 58 ENG 3. Install: • shift arm 1 NOTE: @ Align the punch mark a in the shift shaft with the slot in the shift arm. T R . . 10 Nm (1.0 m · kg) SHIFT SHAFT[...]

5 - 59 ENG EAS00356 OIL PAN AND OIL PUMP Order Job/Part Q’ty Remarks Removing the oil pan and oil pump Remove the parts in the order listed. Exhaust pipe assembly Refer to “ENGINE”. Air filter case Refer to “AIR FILTER CASE” in chapter 3. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. 1 Sidestand 1 2 Oil level swit[...]

5 - 60 ENG Order Job/Part Q’ty Remarks 9 Oil strainer 1 Refer to “INSTALLING THE OIL STRAINER”. 10 Dowel pin 2 11 Oil pump 1 Refer to “INSTALLING THE OIL PUMP”. 12 Relief valve assembly 1 For installation, reverse the removal procedure. OIL PAN AND OIL PUMP[...]

5 - 61 ENG EAS00360 OIL PUMP Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. 1 Oil pump housing cover 1 2 Pin 2 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Washer 1 7 Oil pump shaft 1 8 Oil pump housing 1 For assembly, reverse the disassembly procedure. OIL PAN AND OIL PUMP[...]

5 - 62 ENG EAS00362 REMOVING THE OIL PAN 1. Remov e: • oil level switch 1 • oil pan 2 • gasket • dowel pins NOTE: @ Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosen ed, remove them. EAS00363 CHECKING THE OIL PUMP 1. Chec k: • oil pump shaft 1 • oil pump housing 2 ?[...]

5 - 63 ENG 3. Chec k: • oil pump operation Rough movement → Repeat steps (1) and (2) or replace the defective part(s). EAS00365 CHECKING THE RELIEF VALVE 1. Chec k: • relief valve body 1 • relief valve 2 • spring 3 • O-ring 4 Damage/wear → Replace the defect ive part(s). EAS00367 CHECKING THE OIL DELIVERY PIPES The following procedure[...]

5 - 64 ENG 2. Chec k: • oil pump operation Refer to “CHECKING THE OIL PUMP”. EAS00376 INSTALLING THE OIL PUMP 1. Install: • oil pump 1 W ARNING Align the projection a on the oil pump with the slit b on the impeller shaft. CAUTION: @ After tightening the bolts, make sure the oil pump turns smoothly. T R . . 12 Nm (1.2 m · kg) LT EAS00378 IN[...]

5 - 65 ENG W ARNING @ Always use new copper washers. NOTE: @ • Tighten the oil pan bolts in stag es and in a crisscross pattern. • Lubricate the oil level switch O-ring with engine oil. OIL PAN AND OIL PUMP[...]

5 - 66 ENG EAS00431 MIDDLE GEAR Order Job/Part Q’ty Remarks Removing the middle gear Remove the parts in the order listed. Engine Refer to “ENGINE”. Oil pan/oil pump Refer to “OIL PAN AND OIL PUMP”. 1 Left middle g ear cover 1 2 Left middle gear cover gasket 1 3 Dowel pin 2 4 Right middle gear cover 1 5 Bearing 1 6 Middle driven shaft end[...]

5 - 67 ENG Order Job/Part Q’ty Remarks 11 Middle drive pinion gear nut 1 Refer to “REMOVING THE MIDDLE GEAR” and “INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY”. 12 Lock washer 1 13 Middle drive pinion gear 1 14 Middle drive shaft assembly 1 15 Spacer 1 16 Middle driven gear 1 17 Bearing retainer 1 Refer to “REMOVING THE MIDDLE GEAR” and[...]

5 - 68 ENG Order Job/Part Q’ty Remarks Disassembling the middle drive shaft assembly Remove the parts in the ord er listed. 1 Spring retainer 2 Refer to “DISASSEMBLING/ASSEM- BLING THE MIDDLE DRIVE SHAFT ASSEMBLY”. 2 Spring seat 1 3 Damper spring 1 4 Damper driven cam 1 5 Damper drive cam 1 6 Middle drive shaft 1 For assembly, reverse the dis[...]

5 - 69 ENG Order Job/Part Q’ty Remarks Disassembling the middle driven shaft assembly Remove the parts in the ord er listed. 1 Middle driven pinion gear nut 1 2 Middle driven shaft 1 3 Middle driven pinion gear 1 4 Bearing retainer 1 Refer to “DISASSEMBLING/ASSEM- BLING THE MIDDLE DRIVEN SHAFT ASSEMBLY”. 5 Bearing 1 6 Middle driven shaft bear[...]

5 - 70 ENG EAS00432 REMOVING THE MIDDLE GEAR 1. Straighten the punched point of the middle driven shaf t nut. 2. Loosen: • middle driven shaft nut 1 NOTE: While holding the middle drive sh aft 2 . 3. Straighten the loc k w asher tab . 4. Loosen: • middle drive shaft nut 1 NOTE: While holding the middle drive sh aft 2 . 5. Straighten the punched[...]

5 - 71 ENG EAS00433 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Remov e: • spring retainers 1 NOTE: @ While compressing the spring with the damper spring compressor 2 , remove the spring retainers. Damper spring compressor 90890-04090 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. Straighten the punched point of the bearing retainer . 2. [...]

5 - 72 ENG EAS00439 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. Chec k: • middle driven gear Galling/pitting/wear → Replace the middle driven shaft assembly. 2. Chec k: • bearings Damage/pitting → Replace the middle drive shaft bearing housing asse mbly. 3. Chec k: • O-ring •o i l s e a l Damage → Replace the defective part(s). EAS00[...]

5 - 73 ENG NOTE: @ Lock the threads on the bearin g retainer by staking them with a center punch. 2. Install: • middle driven shaft nut 1 NOTE: @ Temporarily tighten the middle driven shaft nut. INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Install: • middle drive shaft shim • bearing • bearing retainer 1 (with the bearing retainer wrench 2[...]

5 - 74 ENG NOTE: While holding the middle drive sh aft 2 . 3. Bend the loc k washer tab alo ng a flat side of the nut. INSTALLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. Install: • middle driven shaft assembly 1 • middle driven shaft shims 2 • middle driven shaft bearing housing bolts NOTE: @ Finger tighten the middle driven shaft housing bolts. [...]

5 - 75 ENG 3. Tighten: • middle driven shaft bearing housing bolts NOTE: @ Before tightening the bolts: 1. Adjust the middle gear bac klash. Refer to “ADJUSTING THE MIDDLE GEAR BACKLASH”. 2. Chec k that the middle driven g ear tur ns smoothly . T R . . 25 Nm (2.5 m · kg) EAS00449 MEASURING THE MIDDLE GEAR BACKLASH 1. Measure: • middle gear[...]

5 - 76 ENG d. While gently turning the middle dr iv en shaft bac k and f or th, measure the middle gear bac klash. NOTE: @ Measure the middle gear backlash at four positions. Rotate the middle driven shaft 90° each time and observe the reading on the dial gauge. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ [...]

5 - 77 ENG NOTE: @ • Tighten the middle driven shaft bearing housing bolts carefully, one thread turn at a time only. Push in the middle driven shaft bearing housing and then tighten the bolts to specification. • Clearance between the crankcase and the middle driven shaft bearing housing should be approximately 2 mm, when measured with a thickn[...]

5 - 78 ENG 7. Select: •s h i m ( s ) 1 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Shims can only be selected in 0.05 mm increments, theref ore round off to the hun- dredth’ s digit of the calculated thickne ss and select the appropriate shim with the f ol- lowing chart. b[...]

5 - 79 ENG EAS00452 ALIGNING THE MIDDLE GEAR NOTE: @ Aligning the middle gear is necessa ry when any of the following parts are replaced: •C r a n k c a s e • Middle drive shaft • Middle driven shaft bearing housing 1. Select: • middle drive shaft shim(s) 1 • middle driven shaft shim(s) 2 NOTE: @ Select the middle driven shaft shim(s) 2 b[...]

5 - 80 ENG NOTE: @ In the above example, the calcula ted number is 0.51. The chart instructs you to round off the 1 to 0. Thus, the shim t hickness is 0.50 mm. Shims are supplied in the following thick- nesses. Hundredth Rounded value 0, 1, 2 0 3, 4, 5, 6, 7 5 8, 9 10 Middle drive shaft shim Thickness (mm) 0.10 0.15 0.30 0.40 0.50 0.60 c. T o find [...]

5 - 81 ENG Shims are supplied in the following thick- nesses. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Hundredth Rounded value 0, 1, 2 0 3, 4, 5, 6, 7 5 8, 9 10 Middle drive shaft shim Thickness (mm) 0.10 0.15 0.30 0.40 0.50 0.60 MIDDLE GEAR[...]

5 - 82 ENG CRANKCASE U P 9 3 2 T R . . 10 Nm (1.0 m • kg) 1 4 5 6 10 7 8 T R . . 10 Nm (1.0 m • kg) 10 10 LT Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed . Engine Refer to “ENGINE”. Cylinder head Refer to “CYLINDER HEAD”. Generator rotor Refer to “GENERATOR AND STARTER CLUTCH”. Pickup c[...]

5 - 83 ENG U P 9 3 2 T R . . 10 Nm (1.0 m • kg) 1 4 5 6 10 7 8 T R . . 10 Nm (1.0 m • kg) 10 10 LT Order Job/Part Q’ty Remarks 5C o l l a r 1 6 Spacer 1 7 Neutral switch 1 8 Speed sensor 1 9 Lower crankcase 1 Refer to “DISASSEMBLING/ASSEM- BLING THE CRANKCASE”. 10 Dowel pin 3 For installation, reverse the removal procedure. CRANKCASE[...]

5 - 84 ENG T R . . 10 Nm (1.0 m • kg) T R . . 70 Nm (7.0 m • kg) T R . . 12 Nm (1.2 m • kg) 10 LS 2 LT LT LT 4 8 3 LT 5 7 6 1 9 11 Order Job/Part Q’ty Remarks Removing the oil baffle plates and bearings Remove the parts in the ord er listed. Connecting rod assemblies Refer to “CONNECTING RODS AND PISTONS”. Crankshaft/crankshaft journal [...]

5 - 85 ENG T R . . 10 Nm (1.0 m • kg) T R . . 70 Nm (7.0 m • kg) T R . . 12 Nm (1.2 m • kg) 10 LS 2 LT LT LT 4 8 3 LT 5 7 6 1 9 11 Order Job/Part Q’ty Remarks 6 Oil seal 1 7 Bearing 1 8 Upper crankcase 1 9 Bearing 1 10 Oil filter bolt 1 11 Lower crankcase 1 For installation, reverse the removal procedure. CRANKCASE[...]

5 - 86 ENG EAS00384 DISASSEMBLING THE CRANKCASE 1. Remov e: • crankcase bolts NOTE: @ • Loosen each b olt 1/4 of a turn at a t ime, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • Loosen the bolts in decre asing numerical order (refer to the numbers in the illustra- tion). • The numbers embos[...]

5 - 87 ENG EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the cr ankcase halv es in a mild solv ent. 2. Thoroughly clean all the gask et surf aces and crankcase mating su rf aces . 3. Chec k: •c r a n k c a s e Cracks/damage → Replace. • oil delivery passa ges Obstruction → Blow out with compressed air. EAS00401 CHECKING THE BEARINGS AN[...]

5 - 88 ENG EAS00208 CHECKING THE TIMING CHAIN AND OIL PUMP DRIVE CHAIN The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Chec k: • timing chain 1 Damage/stiffness → Replace the timing chain and camshaft sprockets as a set. • oil pump drive chain 2 Damage/stiffness → Replace the oil pump drive chain[...]

5 - 89 ENG 2. Apply: • sealant (onto the crankcase mating surfaces) NOTE: @ Do not allow any sealant to come into co ntact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2 ~ 3 mm of the crankshaft journal bearings. 3. Install: • dowel pins Yamaha bond No. 1215 90890-85505 4. Set the shift drum assembly and[...]

5 - 90 ENG 6. Install: • crankcase bolts NOTE: @ • Lubricate the bolt threads and washers with engine oil. • Finger tighten the crankcase bolts. M9 × 115 mm bolts: 1 ~ 0 M8 × 65 mm bolts: A M8 × 50 mm bolts: B M6 × 80 mm bolts: M , O M6 × 65 mm bolts: C , D M6 × 65 mm bolts: I , L , N , P M6 × 55 mm bolts: E ~ H , J , K , Q ~ T M6 × 4[...]

5 - 91 ENG c. Tighten the crankcase bolts f ur ther to reach the specified angle 120° in the proper tight- ening sequence as sho wn. W ARNING When the bolts are tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and p er- form the procedure again. CAUTION: • Do not use a torque [...]

5 - 92 ENG EAS00252 CONNECTING RODS AND PISTONS 1 2 7 6 5 4 3 8 9 10 3 E E E E New New M M M New New New Order Job/Part Q’ty Remarks Removing the connecting rods and pistons Remove the parts in the order listed . Crankcase Separate. Refer to “CRANKCASE”. 1 Connecting rod cap 4 Refer to “REMOVING THE CONNECT- ING RODS AND PISTONS” and “I[...]

5 - 93 ENG EAS00393 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remov e: • connecting rod cap 1 • big end bearin gs NOTE: @ Identify the position of each big end bearing so that it can be reinstalled in its origina l place. 2. Remov e: • piston pin clips 1 • piston p[...]

5 - 94 ENG 3. Remov e: • top ring • 2nd ring •o i l r i n g NOTE: @ When removing a piston ring, ope n the end gap with your fingers and lift the other side of the ring over the piston crown. EAS00258 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Chec k: • piston wall • cylinder[...]

5 - 95 ENG c. Measure piston skir t diameter “P” with the micrometer . a 5 mm from the bottom ed ge of the piston d. If out of specification, replace the piston and piston rings as a set. e. Calculate the piston-to-cylinder cleara nce with the f ollo wing f or mula. f . If out of specification, replace the cylind er , and the piston and piston [...]

5 - 96 ENG 2. Install: • piston ring (into the cylinder) NOTE: @ Level the piston ring in the cylinder wit h the piston crown. a 5 mm 3. Measure: • piston ring end gap Out of specifica tion → Replace the piston ring. NOTE: @ The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all t[...]

5 - 97 ENG 2. Measure: • piston pin outside diameter a Out of specifica tion → Replace the piston pin. Piston pin outside diameter 11.9 ~ 12.1 mm <Limit>: 11.88 mm 3. Measure: • piston pin bore diameter (in t he piston) b Out of specification → Replace the piston. Piston pin bore diameter (in the piston) 19.004 ~ 19.015 mm <Limit&g[...]

5 - 98 ENG EAS00396 CHECKING THE CONNECTING RODS 1. Measure: • crankshaft-pin-to-big-end-bearing clear- ance Out of specification → Replace the big end bearings. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ The following procedure applies to all of the connecting rods. CAUTION[...]

5 - 99 ENG e. Tighten the connecting rod n uts . Refer to “INSTALLING THE CONNECTING RODS AND PISTONS”. f . Remov e the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS AND PISTONS”. g. Measure the compressed Plastigaug e ® width e on the crankshaft pin. If the crankshaft-pin-to-big-end-bearing clearance is out o[...]

5 - 100 ENG EAS00271 EAS00404 INSTALLING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the pistons and connecting ro ds. 1. Install: • top ring • 2nd ring •o i l r i n g NOTE: @ Be sure to install the piston rings so that the manufacturer’s marks or numbers face up. 2. Install: • piston 1 • connecting rod 2 ?[...]

5 - 101 ENG 4. Lubricate: • piston • piston rings • cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Lubricate: • bolt threads • nut seats (with the recommended lubricant) Recommended lubricant Molybdenum disulfide grease 6. Lubricate: • crankshaft pins • big end bearin gs • connecting rod inner su rface[...]

5 - 102 ENG • Make sure the “Y” marks a on the connect- ing rods face towards the left side of the crankshaft. • Make sure the characters b on both the con- necting rod and connecting rod cap are aligned. 8. Align: • bolt heads (with the connecting rod) Piston ring compressor 90890-05158 6D 9. Tighten: • connecting rod nuts W ARNING @ ?[...]

5 - 103 ENG W ARNING When the nuts are tightened more than the specified angle, do not lo osen the nut and then retighten it. Replace the nut with a new one and per- form the procedure again. CAUTION: • Do not use a torque wrench to tighten the nut to the specified angle. • Tighten the nut until it is at the sp ecified angle. NOTE: When using a[...]

5 - 104 ENG EAS00381 CRANKSHAFT 2 1 3 3 E E Order Job/Part Q’ty Remarks Removing the crankshaft Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Connecting rod caps Refer to “CONNECTING RODS AND PISTONS”. 1 Crankshaft 1 Refer to “REMOVING/INSTALLING THE CRANKSHAFT”. 2 Crankshaft journal lower bear ing 5 [...]

5 - 105 ENG EAS00387 REMOVING THE CRANKSHAFT 1. Remov e: • crankshaft 1 • crankshaft journal lower bearings (from the lower crankcase) • crankshaft journal upper bearings (from the upper crankcase) NOTE: @ Identify the position of each cran kshaft journal bearing so that it can be reinstalled in its o rigi- nal place. EAS00396 CHECKING THE CR[...]

5 - 106 ENG CAUTION: @ Do not interchange the crankshaft journal bearings. To obtain the correct crankshaft- journal-to-crankshaft-journal-bearing clear- ance and prevent engine damage, the crankshaft journal bearings must be installed in their original positions. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼[...]

5 - 107 ENG h. Measure the co mpressed Plastigauge® width c on each crankshaft jou r nal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 22[...]

5 - 108 ENG EAS00407 INSTALLING THE CRANKSHAFT 1. Install: • crankshaft journal upper bearings (into the upper crankcase) • crankshaft journal lower bearings (into the lower crankcase) NOTE: @ • Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase. • Be sure to install each crankshaft jo[...]

5 - 109 ENG EAS00419 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission, shift drum assembly, and shift forks Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. 1 Drive axle assembly 1 Refer to “INSTALLING THE TRANSMIS- SION”. 2 Bearing 1 3 Washer 1 4 Shift drum retainer 1 5 Long shift fork gui[...]

5 - 110 ENG Order Job/Part Q’ty Remarks 10 Shift drum assembly 1 Refer to “INSTALLING THE TRANSMIS- SION”. 11 Shift fork “C” 1 12 Main axle assembly 1 Refer to “REMOVING/INSTALLING THE TRANSMISSION”. For installation, rever se the removal procedure. TRANSMISSION[...]

5 - 111 ENG New M M M M New Order Job/Part Q’ty Remarks Disassembling the main axle assem- bly Remove the parts in the order listed . 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 5th pinion gear 1 5 Toothed spacer 1 6 Toothed washer 2 7 Circlip 2 8 3rd pinion gear 1 9 4th pinion gear 1 0 Collar 1 TRANSMISSION[...]

5 - 112 ENG New M M M M New Order Job/Part Q’ty Remarks A Main axle/1st pinion gear 1 B Bearing 1 C Main axle bearing housing 1 For assembly, reverse the disassembly procedure. TRANSMISSION[...]

5 - 113 ENG M M M M M M Order Job/Part Q’ty Remarks Disassembling the drive axle assembly Remove the parts in the ord er listed. 1 Middle drive gear 1 2 Bearing 1 3 Washer 1 4 2nd wheel gear 1 5 Collar 1 6 washer 1 7 5th wheel gear 1 8 Circlip 2 9 Toothed washer 2 0 3rd wheel gear 1 TRANSMISSION[...]

5 - 114 ENG M M M M M M Order Job/Part Q’ty Remarks A Toothed spacer 1 B Toothed lock washer 1 C Toothed lock washer retainer 1 D 4th wheel gear 1 E Washer 1 F 1st wheel gear 1 G Bearing 1 H Washer 1 I Drive axle 1 For assembly, reverse the disassembly procedure. TRANSMISSION[...]

5 - 115 ENG EAS00420 REMOVING THE TRANSMISSION 1. Remov e: • bearing housing bolts 1 (with the Torx wrench T30) 2. Remov e: • main axle assembly (from the clutch side) NOTE: @ Remove the main axle assembly with the slide hammer bolt 1 and weight. Slide hammer bolt 90890-01083 Weight 90890-01084 EAS00421 CHECKING THE SHIFT FORKS The following pr[...]

5 - 116 ENG 2. Chec k: • shift fork guide bar Roll the shift fork guide bar on a fla t surface. Bends → Replace . W ARNING @ Do not attempt to straighten a bent shift fork guide bar. 3. Chec k: • shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift forks and shift fork guide bar as a set. EAS00422 CHECKING[...]

5 - 117 ENG 2. Measure: • drive axle runout (with a centering device and dial g auge 1 ) Out of specification → Replace the drive axle. Drive axle runout limit 0.08 mm 3. Chec k: • transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). • transmission gear dogs Cracks/damage/rounded edges → Replace the defect[...]

5 - 118 ENG INSTALLING THE TRANSMISSION 1. Install: • main axle assembly • shift fork “C” • shift drum asse mbly • shift fork “R” • shift fork “L” • shift fork guide bars • shift drum retainer • drive axle assembly NOTE: @ • When installing the main a xle assembly, use a pin to align the bearin g housing bolt hole with[...]

5 - 119 ENG BALANCERS FRONT BALANCER Order Job/Part Q’ty Remarks Removing the front balancer Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. 1 Balancer lever 1 Refer to “INSTALLING THE FRONT BALANCER”. 2 Balancer shaft 1 3 Washer 2 4 Bearing 2 5 Balancer gear 1 6 Absorber 4 7 Balancer weight 1 For installat[...]

5 - 120 ENG REAR BALANCER Order Job/Part Q’ty Remarks Removing the rear balancer Remove the parts in the order listed. Throttle bodies Refer to “FUEL INJECTION SYSTEM” in chapter 7. Clutch cover Refer to “CLUTCH”. 1 Balancer cover 1 2 Balancer cover gasket 1 3 Balancer lever 1 Refer to “INSTALLING THE REAR BAL- ANCER”. 4 Balancer shaf[...]

5 - 121 ENG CHECKING THE BALANCER 1. Chec k: • front balancer gear Damage/wear → Replace the front bal- ancer gear and crankshaft. • rear balancer gear Damage/wear → Replace the rear balancer gear and primary driven gear. 2. Chec k: • balancer shaft 1 Cracks/damage/wear → Replace the bal- ancer shaft and bearings. Dirt → Clean. • be[...]

5 - 122 ENG 3. Install: • balancer shaft 1 NOTE: @ • Align the punch mark a in the balancer weight with the oil hole b in the upper crank- case. • Make sure that the front balancer gear teeth and the primary drive gear teeth mesh cor- rectly. • Make sure that the slot c is facing in the direction indicated in the illustration when installin[...]

5 - 123 ENG 7. Star t the engine and check that there is no abnor mal noise coming from the balancer gear . If noise is abnormal, adjust the gear lash b y tur ning the balancer shaft. NOTE: With each adjustment, turn the balancer shaft one scale. Clockwise Decrease gear lash Counterclockwise Increase gear lash INSTALLING THE REAR BALANCER 1. Instal[...]

5 - 124 ENG 3. Install: • balancer shaft 1 NOTE: @ • Align the punch marks a in the balancer weight with the oil hole b in the upper crank- case. • Make sure that the rear balancer gear teeth and the primary driven gear teeth mesh cor- rectly. • Make sure that the balan cer gear punch mark c is aligned wit h the primary driven gear point d [...]

5 - 125 ENG 5. Tighten: • balancer shaft 1 NOTE: Tighten the balancer shaft to the specified torque by turning it counterclockwise, and then turn it two scales back on the balancer lever scale. T R . . 0.4 Nm (0.04 m · kg) 6. Tighten: • balancer lever bolt 1 • balancer shaft pinch bolt 2 NOTE: Make sure that the balancer shaft does not rotat[...]

[...]

COOL 6[...]

COOL CHAPTER 6 COOLING SYSTEM RADIATOR ............................................................................. ......................... 6-1 CHECKING THE RADIATOR ................................................................ .... 6-3 INSTALLING THE RADIATOR .............................................................. .... 6-4 OIL COOLER [...]

COOL[...]

6 - 1 COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed . Rider seat/fuel tank Refer to “SEATS AND FUEL TANK” in chapter 3. Side cowlings/front cowling assembly Refer to “COWLINGS AND COVERS” in chapter 3. Coolant Drain. Refer to “CHANGING THE COOLANT”[...]

6 - 2 COOL RADIATOR Order Job/Part Q’ty Remarks 8 Radiator outlet ho se 1 9 Thermostat assembly breather hose 1 Disconnect. 10 Conduit 1 11 Conduit hose 1 12 Radiator inlet hose 1 Disconnect. 13 Plunger control unit hose 2 1 Disconnect. 14 Oil cooler outlet hose 1 Disconnect. 15 Horn connector 4 Disconnect. 16 Radiator fan motor coupler 1 Disconn[...]

6 - 3 COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Chec k: • radiator fins Obstruction → Clea n. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: @ Straighten any flattened fins with a thin, flat- head screwdriver. 2. Chec k: • radiator hoses Cracks/damage → Replace. 3. Measure: • radiator cap ope[...]

6 - 4 COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: • cooling sy stem (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Chec k: • cooling sy stem Leaks → Repair or replace any faulty part . 3. Measure: • radiator cap opening pressure Below the specified pressure → Repla[...]

6 - 5 COOL OIL COOLER EAS00457 OIL COOLER Order Job/Part Q’ty Remarks Removing the oil cooler Remove the parts in the order listed . Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Radiator assembly Refer to “RADIATOR”. 1 Water pump outlet hose 1 2 Water pump outlet pipe 1 3 Water jacket joint inl et hose 1 4 Water jack[...]

6 - 6 COOL OIL COOLER EAS00458 CHECKING THE OIL COOLER 1. Chec k: • oil cooler Cracks/damage → Replace. 2. Chec k: • oil cooler inlet hose • oil cooler outlet hose Cracks/damage/wear → Replace. EAS00459 INSTALLING THE OIL COOLER 1. Clean: • mating surfaces of the oil cooler and the crankcase (with a cloth dampened with lacquer thin- ner[...]

6 - 7 COOL OIL COOLER 4. Chec k: • cooling sy stem Leaks → Repair or replace any faulty part . 5. Measure: • radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR”.[...]

6 - 8 COOL THERMOSTAT EAS00460 THERMOSTAT Order Job/Part Q’ty Remarks Removing the thermostat assembly Remove the parts in the order listed. Side cowlings/front cowling assembly Refer to “COWLINGS AND COVERS” in chapter 3. Coolant Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Air cut-off valve assembly/hoses Refer to “AIR IND UCT[...]

6 - 9 COOL THERMOSTAT EAS00461 Order Job/Part Q’ty Remarks Disassembling the thermostat assembly Remove the parts in the order listed . 1 Thermostat housing cover 1 Refer to “ASSEMBLING THE THERMO- STAT ASSEMBLY”. 2 Thermostat 1 3 Thermostat housing 1 For assembly, reverse the disassembly procedure.[...]

6 - 10 COOL THERMOSTAT EAS00463 CHECKING THE THERMOSTAT 1. Chec k: • thermostat 1 Does not open at 71 ~ 85 °C → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat in a container filled with wa ter . b . Slowly heat the w ater . c. Place a ther mometer in the w[...]

6 - 11 COOL THERMOSTAT EAS00464 ASSEMBLING THE THERMOSTAT ASSEMBLY 1. Install: • thermostat housing 1 • thermostat 2 • thermostat housing cover NOTE: @ Install the thermostat with its breather hole a a facing up. EAS00466 INSTALLING THE THERMOSTAT ASSEMBLY 1. Lubricate: • O-ring (thermostat assemb ly and thermo- stat assembly inl et pipe) 2[...]

6 - 12 COOL WATER PUMP EAS00468 WATER PUMP Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the ord er listed. NOTE: It is not necessary to remove the water pump unless the coolan t level is extremely low or the coolant contains engine oil. Right side cowling Refer to “COWLINGS AND COVERS” in chapter 3. Engine oil Drain[...]

6 - 13 COOL WATER PUMP Order Job/Part Q’ty Remarks 1 Water pump breather hose 1 Disconnect. 2 Radiator outlet ho se 1 Disconnect. 3 Water pump outlet hose 1 Disconnect. 4 Water pump 1 Refer to “INSTALLING THE WATER PUMP”. For installation, rever se the removal procedure.[...]

6 - 14 COOL WATER PUMP EAS00469 Order Job/Part Q’ty Remarks Disassembling the water pump Remove the parts in the order listed. 1 Water pump housing cover 1 Refer to “ASSEMBLING THE WATER PUMP”. 2 O-ring 1 3 Circlip 1 4 Impeller shaft 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 2 0 Water pump housing[...]

6 - 15 COOL WATER PUMP EAS00470 DISASSEMBLING THE WATER PUMP 1. Remov e: • rubber damper holder 1 • rubber damper 2 (from the impeller, with a thin, flat-head screwdriver) NOTE: @ Do not scratch the impeller shaft . 2. Remov e: • water pump seal 1 NOTE: @ Tap out the water pump seal from the inside of the water pump housing 2 . 3. Remov e: ?[...]

6 - 16 COOL WATER PUMP EAS00475 ASSEMBLING THE WATER PUMP 1. Install: •o i l s e a l 1 (into the water pump housing 2 ) NOTE: @ • Before installing the oil seal, app ly tap water or coolant onto its out surf ace. • Install the oil seal with a socket that matches its outside diameter. 2. Install: • water pump seal 1 CAUTION: @ Never lubricat[...]

6 - 17 COOL WATER PUMP 4. Measure: • impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: @ Make sure the rubber damper and rubber damper holder are flush with the impeller. 1 Straightedg e 2 Impeller Max. impeller shaft tilt 0.15 mm 5. Install: • impeller 1 •c i r c l i p NOTE: @ After installation, check that the [...]

6 - 18 COOL WATER PUMP EAS00478 INSTALLING THE WATER PUMP 1. Install: •O - r i n g • water pump assembly 1 W ARNING @ • Align the slit a on the impeller shaft with the projection b on the oil pump shaft. • Lubricate the O-ring with a thin coat of lithium soap base grease. New T R . . 12 Nm (1.2 m · kg ) 2. Fill: • cooling sy stem (with t[...]

FI 7[...]

FI CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM .............................................................. .............. 7-1 WIRING DIAGRAM .......................................................... ......................... 7-2 ECU’S SELF-DIAGNOSTIC FUNCTION ................................................... 7-3 SUBSTITUTE CHARACT[...]

FI[...]

7 - 1 FI FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Ignition coil 2 Air filter case 3 Intake tem perature sensor 4 Fuel delivery hose 5 Fuel tank 6 Fuel pump 7 Fuel retu rn hose 8 Intake air pressure sensor 9 Throttle position sensor 0 Fuel injector A O 2 sensor B Catalytic converter C Crankshaft position sensor D Coolant t[...]

7 - 2 FI FUEL INJECTION SYSTEM WIRING DIAGRAM ON OFF P 1 5 R R R Br / L Br / R L L / R B B Y Br L L / Y L / B Br / W P Lg B R / Y P B G / B R / Y Br / W Lg YD g Ch L / YB / Y Sb Ch B / Y Y Sb Dg L / Y BL Y Ch Dg Y Dg B L / R Ch B B B B B B Dg Ch Br/W Br/W Ch Dg R / Y L / B L L L / B R / Y Br / W Br / G BB B B B B B B B B B Br B / R R / B B / R R / [...]

7 - 3 FI FUEL INJECTION SYSTEM ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagn ostic function in order to ensure that the e ngine control sys- tem is operating normally. If this function detects a malfunction in the system, it immediately oper- ates the engine under substitute characteristics and illumina tes the engine troub[...]

7 - 4 FI FUEL INJECTION SYSTEM Engine trouble warning light indication and FI sys tem operating conditions (normal mode) Warning light indication ECU’s operating condition FI operating con dition Starting and driving ON and OFF *1 Self-diagnostic func- tion in operation FI function in operation Able Blinking *2 Warning control when unable to star[...]

7 - 5 FI FUEL INJECTION SYSTEM *3 Function to check for blown warning light bulb The engine trouble warning light illuminates 1 for 1.4 seconds after the main switch has been turned “ON” and while the starter switch is being pressed. If the warning light does not illuminate under these conditions, a problem may have possibly occurred, such as a[...]

7 - 6 FI FUEL INJECTION SYSTEM * Table of self-diagnostic fault code numbers displayed on meter • How to erase the self-diagnostic fault code f rom memory: If the ECU detects a normal signal upon the completion of the repair of the malfunction, the self- diagnostic fault code disappears from the meter and is replaced by the normal clock display. [...]

7 - 7 FI FUEL INJECTION SYSTEM SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an ab normal signal from a se nsor while the motorcycle is being driven, the ECU illuminates the engin e trouble warning light an d provides the engine with substitute characteristic operation instructions that are ap propriate for the [...]

7 - 8 FI FUEL INJECTION SYSTEM TROUBLESHOOTING Diagnosis mode troubleshooting 1 (self-diagnostic malfunction detected) By entering a diagnostic code in the ECU through the use of th e “SELECT” and “RESET” buttons on the multi-function meter, the sensor output values can be displayed and the actuators can be oper- ated in accordance with the[...]

7 - 9 FI FUEL INJECTION SYSTEM Verifying the operation of various sensors and actuators 1. Disconnect the wiring harness coupler from the fuel pump. 2. Turn the engine stop switch “OFF”. · Turn the engine stop switch “ON” if diag- nostic code numbers 03 and 09 are shown. 3. Select the diagnostic code number that applies to the item that wa[...]

7 - 10 FI FUEL INJECTION SYSTEM Erase the codes appearing on the meter upon the completion of the operation (reinstat ing the ECU). * Verify the reinstatement procedures detailed in the troubleshooting details in order to carry out the reinstateme nt opera- tion that is applicable to the malfunctioning item. Refer to the troubleshooting details. Er[...]

7 - 11 FI FUEL INJECTION SYSTEM Self-diagnostic fault codes, symptoms , and probable causes Diagnostic code indication Code No. Symptom Probable cause of malfunction Diagnostic code 11 No nor mal signals are received from the cylinder identification sensor . • Open or short circuit in wiring sub lead. • Open or short circuit in w iring harness.[...]

7 - 12 FI FUEL INJECTION SYSTEM Code No. Symptom Probable cause of malfunction Diagnostic code 23 Atmospheric pressure sensor - open or shor t circuit detected. • Open or short circuit in w iring harness. • Defective atmospheric pressure sensor. • Improperly installed sensor. • Malfunction in ECU. 02 24 No nor mal signals are received from [...]

7 - 13 FI FUEL INJECTION SYSTEM Sensor operation data display verification table NOTE: • Check the intake temperature and coolan t temperature as close as possible to the area in which the respective sensor is mounted. • If it is not possible to check it with an atmospheric pressure gauge, judge it by using 760 mmHg as the standard. • If it i[...]

7 - 14 FI FUEL INJECTION SYSTEM Actuator operation verification table Diag code Item Description of action Data displayed on meter (reference value) 30 Ignition coil #1, 4 After 1 second has elapsed from the time the engine stop s witch has been turn ed from OFF to ON, it actuates ignition coils #1, and 4 f or fiv e times e v ery second and illumin[...]

7 - 15 FI FUEL INJECTION SYSTEM Troubleshooting Basic procedure 1 Inspect battery and fuse OK NG Replace fuse Recharge or replace battery Check engine trouble warning light After main switch is turned ON, light turns ON 1.4 seconds and t hen turns OFF. NG OK Light does not t urn OFF. Check the star ting disable warning function through the engine t[...]

7 - 16 FI FUEL INJECTION SYSTEM Troubleshooting details Troubleshooting the self-diagnostic fault code Code No. 11 Symptom No normal signals are received from the cylinder identification sensor. Used diagnostic code No. Inspection operation item Operation item and countermeasure Reinstatement method Installed state of sensor Check the installed are[...]

7 - 17 FI FUEL INJECTION SYSTEM Code No. 13 Symptom Intake air pressure sensor - open or short circuit detected. Used diagnostic code No. 03 (intake air pressure sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective intake air pressure sensor Replace if defective. Refer to “FUEL INJE[...]

7 - 18 FI FUEL INJECTION SYSTEM Code No. 14 Symptom 1 Intake air pressure sensor - pipe system malfunction (clogged or detached hose). 2 Intake air pressure sensor - open or short circuit detected. 3 Stuck throttle position sensor detected. Used diagnostic code No. 03 (intake air pressure sensor) No. 02 (atmospheric pressure sensor) No. 01 (throttl[...]

7 - 19 FI FUEL INJECTION SYSTEM Code No. 15 Symptom Throttle position sensor - open or short circuit detected. Used diagnostic code No. 01 (throttle position sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective throttle position sensor. Replace if defective. Refer to “FUEL INJECTION[...]

7 - 20 FI FUEL INJECTION SYSTEM Code No. 16 Symptom 1 Stuck throttle position sensor detected. 2 Intake air pressure sensor - pipe system malfunction (clogged or detached hose). Used diagnostic code No. 03 (intake air pressure sensor) No. 02 (atmospheric pressure sensor) No. 01 (throttle position sensor) Inspection operation item and probable cause[...]

7 - 21 FI FUEL INJECTION SYSTEM 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) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective sidestand switch Replace if defective. Refer to “CHECKING [...]

7 - 22 FI FUEL INJECTION SYSTEM Code No. 23 Symptom Open or short circuit detected from the atmospheric pressure sensor. Used diagnostic code No. 02 (atmospheric pressure sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective atmospheric pressure sensor. Replac e if defective. Refer to [...]

7 - 23 FI FUEL INJECTION SYSTEM Code No. 30 Symptom The motorcycle has overturned. Used diagnostic code No. 08 (lean angle cut-off switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective lean angle cut-off switch Replac e if defective. Reinstated by turn- ing the main switch ON (however,[...]

7 - 24 FI FUEL INJECTION SYSTEM Code No. 32 Symptom The amount of air-fuel ratio feedback compensation is maintained contin- uously in the vicinity of the lower limit (air-fuel ratio is rich). Used diagnostic code No. 01 (throttle position sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method De[...]

7 - 25 FI FUEL INJECTION SYSTEM Code No. 33 Symptom Malfunction detected in the primary wire of the ignition coil (#1, 4). Used diagnostic code No. 30 (ignition coil #1, 4) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective ignition coil (test the primary and secondary coils for continuity)[...]

7 - 26 FI FUEL INJECTION SYSTEM 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) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Defective spee[...]

7 - 27 FI FUEL INJECTION SYSTEM Code No. 44 Symptom Error is detected while reading or writing on EEPROM (CO adjustment value). Used diagnostic No. 60 (EEPROM improper cylinder indication) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Malfunction in ECU Execute diagnostic code 60 * Check the fau[...]

7 - 28 FI FUEL INJECTION SYSTEM Diagnosis mode troubleshooting 2 (self-diagnostic malfunction not detected) Even if the malfunctions of some of the sensors d o not appear on the meter because they are not detected by the self-diagnostic fun ction, they can be inspected in the diagnosis mode . Basic procedure Troubleshooting details Troubleshooting [...]

7 - 29 FI FUEL INJECTION SYSTEM Symptom The headlight does not turn ON or OFF. Probable mal- function area • Malfunction in the headlight relay 1 • Malfunction in the headlight • Open or short circuit in the headlight wiring harness • Malfunction in the handlebar switch • Open circuit in the headlight bulb Inspection method 1 Inspection b[...]

7 - 30 FI FUEL INJECTION SYSTEM Symptom Fan does not operate. Probable mal- function area • Malfunction in radiator fan motor relay • Malfunction in fan • Open or short circuit in fan wiring harness Inspection method 1 Inspection by diagnosis mode Inspection method 2 Inspection of a malfunction that cannot be identified in the diagnosis mode,[...]

7 - 31 FI FUEL INJECTION SYSTEM Symptom Clock LCD displays “Er-2”. (No signals are received from the ECU within the specified duration.) Probable mal- function area • Improper operation of communication line • Malfunction in meter • Malfunction in ECU Inspection method 1 Inspection by diagnosis mode Inspection method 2 Inspection of a mal[...]

7 - 32 FI FUEL INJECTION SYSTEM Symptom Sidestand switch does not function (the engine does not stop when the stand is extended). Probable mal- function area • Short circuit in the input line to ECU • Malfunction in the starter circuit cut-off relay Inspection method 1 Inspection by diagnosis mode Inspection method 2 Inspection of a malfunction[...]

7 - 33 FI FUEL INJECTION SYSTEM THROTTLE BODIES 8 9 2 4 1 5 5 5 5 10 10 3 7 7 6 10 10 Order Job/Part Q’ty Remarks Removing the throttle bodies Remove the parts in the order listed. Seats/fuel tank/T-bar/rubber sheet Refer to “SEATS AND FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE” in chapter 3. Coolant Drain. Refer t[...]

7 - 34 FI FUEL INJECTION SYSTEM 8 9 2 4 1 5 5 5 5 10 10 3 7 7 6 10 10 Order Job/Part Q’ty Remarks 7 Throttle cable 2 Disconnect. 8 Plunger control unit hose 1 1 Disconnect. 9 Plunger control unit hose 2 1 Disconnect. 10 Throttle body joint 4 For installation, reverse th e removal procedure.[...]

7 - 35 FI FUEL INJECTION SYSTEM 9 11 3 4 5 6 1 7 2 8 10 12 13 14 Order Job/Part Q’ty Remarks Removing the injector Remove t he parts in the order listed. 1 Throttle posit ion sensor coupler 1 Disconnect. 2 Intake air pressure sensor 1 Disconnect. 3 Cylinder #1-injector coupler 1 Disconnect. 4 Cylinder #2-injector coupler 1 Disconnect. 5 Cylinder [...]

7 - 36 FI FUEL INJECTION SYSTEM 9 11 3 4 5 6 1 7 2 8 10 12 13 14 Order Job/Part Q’ty Remarks 11 Intake air pressure sensor 1 12 Fuel distributor 1 13 Injector 4 14 Throttle position sensor 1 For installation, reverse th e removal procedure.[...]

7 - 37 FI CAUTION: The throttle bodies should not be disas- sembled unnecessarily. CHECKING THE INJECTOR 1. Chec k: • injector Damage → Replace. CHECKING THE THROTTLE BODY 1. Chec k: • throttle body Cracks/damage → Replace the throttle bodies. 2. Chec k: • fuel passages Obstruction → Clea n. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼[...]

7 - 38 FI CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Chec k: • pressure regulator operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remov e the fuel tank. Ref er to “SEA TS AND FUEL T ANK” in chap- ter 3. b . Disconnect the negativ e pressure hose 1 f[...]

7 - 39 FI h. Use the v acuum pressure pump gauge set to adjust the fuel pressure in relation to the v acuum pressure as described below . NOTE: The vacuum pressure should not exceed 100 kPa (1 mmHg). Faulty → Replace the pressure regulator. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲[...]

7 - 40 FI AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducin g the emission of hydrocarbons. When there is negative pressure a t the exhaust port, the reed valve opens, allowing secondary air to flow into the e[...]

7 - 41 FI AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut-off valv e 2 Reed valve 3 Air-filter case È To cylinder #4 É To cylinder #3 Ê To cylinder #2 Ë To cylinder #1 12 4 3[...]

7 - 42 FI AIR INDUCTION SYSTEM AIR CUT-OFF VALVE ASSEMBLY AND AIR INDUCTION SYSTEM HOSES 1 5 3 6 2 3 4 2 2 7 10 8 9 Order Job/Part Q’ty Remarks Removing the air cut-off valve assembly and hoses Remove the parts in the order listed. Rider seat/fuel tank/T-bar/rubber sheet Refer to “SEATS AND FUEL TANK” in chapter 3. 1 Air cut-off valve assembl[...]

7 - 43 FI AIR INDUCTION SYSTEM REED VALVES Order Job/Part Q’ty Remarks Removing the reed valves Remove the parts in the order listed. Air cut-off valve assembly/hoses Thermostat assembly Refer to “THERMOSTAT” in chapter 6. Spark plug caps 1 Reed valve cover (1) 1 2 Reed valve cover (2, 3) 1 3 Reed valve cover (4) 1 4 Reed valve assembly 4 5P [...]

7 - 44 FI AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Chec k: • hoses Loose connection → Connect properly. Cracks/damage → Replace. •p i p e s Cracks/damage → Replace. 2. Chec k: • fibre reed • fibre reed stop per • reed valve seat Cracks/damage → Replace the reed valve assembly. 3. Chec k: • air cut-off v[...]

ELEC 8 –+[...]

–+ ELEC CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS .................................... .................................... 8-1 CHECKING SWITCH CONTINUITY ................................................................ 8-3 CHECKING THE SWITCHES .......................................................................... 8-5 CHECKING THE BULB S AN[...]

–+ ELEC FUEL INJECTION SYSTEM .............................................................. ............ 8-52 CIRCUIT DIAGRAM .............................................................................. .. 8-52 TROUBLESHOOTING ..................................................... ....................... 8-53 CHECKING THE FUEL PUMP ............[...]

8 - 1 –+ ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COM PONENTS 1 Windshield drive unit 2 Battery 3 Starter relay 4 Fuel injection system fuse 5 Front brake switch 6 Clutch switch 7 Fuse box 8 Radiator fan mo tor 9 Wire harness 0 Neutral switch A Sidestand switch B Oil level switch C Rear brake switc h D Horn E Ignition coil F Main[...]

8 - 2 –+ ELEC ELECTRICAL COMPONENTS 1 Coolant temperat ure sensor 2 Intake air pres su re sensor 3 Intake air t emperature sensor 4 Atmospheric pressu re sensor 5 Lean angle cut-off swit ch 6 ECU 7 Starting circ uit cut-off relay 8 Speed sensor 9 Cylinder ident ifica tio n se ns or 0 O 2 sensor A Crankshaft po sition sensor B Headlight relay 1 C [...]

8 - 3 –+ ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. CAUTION: @ Never insert the tester probes into the cou- pler terminal slots 1 . Always insert the probe[...]

8 - 4 –+ ELEC CHECKING SWITCH CONTINUITY[...]

8 - 5 –+ ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for dama ge or wear, proper connections, and also for continuity between th e ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading → Replace the switch[...]

8 - 6 –+ ELEC 1 Main fuse 2 Main switch 3 Clutch switch 4 Pass switch 5 Dimmer switch 6 Horn switch 7 Windshield position switch 8 Turn signal switch 9 Front brake light switch 0 Light switch A Engine stop switch B Start switch C Rear brake lig h t switch D Neutral switch E Sidestand switch F Hazard switch G Fuse CHECKING THE SWITCHES[...]

8 - 7 –+ ELEC EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socke t for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly connect. No continuity → Repair or replace the bulb, bulb socket o[...]

8 - 8 –+ ELEC CHECKING THE BULBS AND BULB SOCKETS W ARNING @ Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: @ • Be sure to hold the socket firmly when removing the bulb. Never pull th e lead, otherwise it may be pulled out of the ter- minal in the coupler[...]

8 - 9 –+ ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Chec k: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. NOTE: @ Check each bulb socket for continuity in the same manner as described in the bulb section; [...]

8 - 10 –+ ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM ON OFF P 1 5 R R R Br / L Br / R L L / R B B Y Br L L / Y L / B Br / W P Lg B R / Y P B G / B R / Y Br / W Lg YD g Ch L / YB / Y Sb Ch B / Y Y Sb Dg L / Y BL Y Ch Dg Y Dg B L / R Ch B B B B B B Dg Ch Br/W Br/W Ch Dg R / Y L / B L L L / B R / Y Br / W Br / G BB B B B B B B B B[...]

8 - 11 –+ ELEC IGNITION SYSTEM EAS00737 TROUBLESHOOTING Procedure Check: 1. main and ignition fuses 2. batter y 3. spark plugs 4. ignition spark gap 5. spark plug cap resistance 6. ignition coil resistance 7. crankshaft position sen sor resistance 8. main s witch 9. engine stop s wit ch 10.neutr al s witch 11.sidestand s witch 12.star ting circui[...]

8 - 12 –+ ELEC IGNITION SYSTEM EAS00743 NO YES EAS00745 YES NO EAS00747 4. Ignition spar k gap The following procedure applies to all of the spark plugs. Disconnect the spark plug cap from the spark plu g. • Disconnect the spark plug cap from the spark plug. • Connect the ignition checker 1 as shown. 2 Spark plug cap • Set the main switch t[...]

8 - 13 –+ ELEC IGNITION SYSTEM YES NO EAS00748 YES NO EAS00749 YES NO EAS00750 YES NO EAS00751 YES NO Tester negative probe → spark plug lead 1 Tester positive probe → spark plug lead 2 • Measure the secondary coil resistance. Secondary coil resistance 12 ~ 18 k Ω at 20 °C • Is the ignition coil OK? Replace the ignition coil. 7. Cranks[...]

8 - 14 –+ ELEC IGNITION SYSTEM EAS00752 YES NO EAS00753 YES NO EAS00754 YES NO 11.Sidestand s witch • Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the sidestand switch OK? Replace the side- stand switch. 12.Star ting circuit cut-off rela y • Disconnect the starting circuit cut-off relay from the wire[...]

8 - 15 –+ ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ON OFF P 1 5 R R R Br / L Br / R L L / R B B Y Br L L / Y L / B Br / W P Lg B R / Y P B G / B R / Y Br / W Lg YD g Ch L / YB / Y Sb Ch B / Y Y Sb Dg L / Y BL Y Ch Dg Y Dg B L / R Ch B B B B B B Dg Ch Br/W Br/W Ch Dg R / Y L / B L L L / B R / Y Br / W Br / G [...]

8 - 16 –+ ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the ne utral switch is [...]

8 - 17 –+ ELEC ELECTRIC STARTING SYSTEM EAS00757 TROUBLESHOOTING Check: 1. main and ignition fuses 2. Batter y 3. star ter mo tor 4. star t ing circuit cut-off rela y 5. star ter circuit cut-off rela y (diode) 6. star ter rela y 7. main s witch 8. engine stop s wit ch 9. neutral s witch 10.sidestand s witch 11.clutc h s witch 12.star t s witch 13[...]

8 - 18 –+ ELEC ELECTRIC STARTING SYSTEM EAS00759 YES NO EAS00760 4. Star ting circuit cut-off rela y • Disconnect the starting circuit cut-off relay from the wire harness. • Connect the pocket tester ( Ω × 1) a nd bat- tery (12 V) to the starting circuit cut-off relay terminals as shown. Battery positive terminal → red/black 1 Battery ne[...]

8 - 19 –+ ELEC ELECTRIC STARTING SYSTEM YES NO EAS00761 YES NO EAS00749 YES NO EAS00750 YES NO EAS00751 YES NO EAS00752 YES NO NOTE: @ When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed. @ • Are the testing readings corr ect? Replace the starting circuit cut-off relay. 6. Star ter rela [...]

8 - 20 –+ ELEC ELECTRIC STARTING SYSTEM EAS00763 YES NO EAS00764 YES NO EAS00766 YES NO 11.Clutch s witch • Check the clutch switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the clutch switch OK? Replace the clutch switch. 12.Star t switch • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is[...]

8 - 21 –+ ELEC STARTER MOTOR EAS00767 STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed . Throttle bodies Refer to “FUEL INJECTION SYSTEM” in chapter 7. 1 Starter motor lead 1 Disconnect. 2 Starter motor 1 For installation, reverse the remo val procedure.[...]

8 - 22 –+ ELEC New New New T R . . 4 Nm (0.4 m • kg) Order Job/Part Q’ty Remarks Disassembly the starter motor Remove the parts in the order listed. 1 O-ring 1 2 Starter motor front cover 1 3 Brush 2 4 Brush seat 1 5 Washer 1 6 Lock washer 1 7 Oil seal 1 8 Bearing 1 9 Starter motor rear cover 1 0 Collar 1 STARTER MOTOR[...]

8 - 23 –+ ELEC New New New T R . . 4 Nm (0.4 m • kg) Order Job/Part Q’ty Remarks A O-ring 1 B Starter motor yoke 1 C Armature assembly 1 For assembly, reverse the disassembly procedure. STARTER MOTOR[...]

8 - 24 –+ ELEC STARTER MOTOR EAS00770 CHECKING THE STARTER MOTOR 1. Chec k: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 23.5 mm 3. Measure: • mica undercut a Out of specification → Scrape the mica to the proper measuremen[...]

8 - 25 –+ ELEC STARTER MOTOR 4. Measure: • armature assembly resistances (commuta- tor and insulation) Out of specification → Replace the starter motor. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure the armature assemb ly resis- tances with the poc ket test er . b [...]

8 - 26 –+ ELEC STARTER MOTOR EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: • brush seat 1 NOTE: @ Align the slot a on the brush seat with the tab b in the starter motor front cover. 2. Install: • starter motor yoke 1 • starter motor front cover 2 • starter motor rear cover 3 NOTE: @ Align the match marks a on the starter motor yoke wi[...]

8 - 27 –+ ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM ON OFF P 1 5 R R R Br / L Br / R L L / R B B Y Br L L / Y L / B Br / W P Lg B R / Y P B G / B R / Y Br / W Lg YD g Ch L / YB / Y Sb Ch B / Y Y Sb Dg L / Y B B B B B B Dg Ch Br/W Br/W Ch Dg R / Y L / B L L L / B R / Y Br / W Br / G BB B B B B B B B B B Br B / R R / B B / R R /[...]

8 - 28 –+ ELEC CHARGING SYSTEM EAS00774 TROUBLESHOOTING Check: 1. main fuse 2. batter y 3. charging v oltage 4. stator assembly resistance 5. wiring connections (of the entire charging system) NOTE: @ • Before troubleshooting, remove the following part(s): 1) front cowling assemb ly 2) fuel tank 3) air filter case • Troubleshoot with the foll[...]

8 - 29 –+ ELEC CHARGING SYSTEM NO YES EAS00776 YES NO EAS00779 YES NO NOTE: @ Make sure the battery is f ully charged. @ • Is the charging voltage within specification? The charging cir cuit is OK. 4. Stator assemb ly resistance • Remove the generator cover. • Connect the pocket tester ( Ω × 1) to the sta- tor assembly coupler as shown. [...]

8 - 30 –+ ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM ON OFF P 1 5 R R R Br / L Br / R L L / R B B Y Br L L / Y L / B Br / W P Lg B R / Y P B G / B R / Y Br / W Lg YD g Ch L / YB / Y Sb Ch B / Y Y Sb Dg L / Y BL Y Ch Dg Y Dg B L / R Ch B B B B B B Dg Ch Br/W Br/W Ch Dg R / Y L / B L L L / B R / Y Br / W Br / G BB B B B B B B B B[...]

8 - 31 –+ ELEC LIGHTING SYSTEM EAS00781 TROUBLESHOOTING Check: 1. main, parking lighting and headlight fuses 2. batter y 3. main s witch 4. light s witch 5. dimmer s witch 6. pass s wit ch 7. headlight rela y 1 8. headlight rela y 2 9. wiring connections (of the entire lighting system) NOTE: @ • Before troubleshooting, remove the following part[...]

8 - 32 –+ ELEC LIGHTING SYSTEM EAS00784 YES NO EAS00786 YES NO YES NO 5. Dimmer switch • Check the dimmer switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the dimmer switch OK? The dimmer switch is faulty. Replace the left handlebar switch. 6. P ass swi tch • Check the pass switch for continuity. Refer to “CHECKING THE SW[...]

8 - 33 –+ ELEC LIGHTING SYSTEM YES NO EAS00787 YES NO EAS00788 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light f ail to come on. YES NO Battery positive terminal → green/black 3 Battery negative terminal → black 4 Tester positive probe → green/blue 5 Tester negative probe → yellow 6 • Does the headlight r[...]

8 - 34 –+ ELEC LIGHTING SYSTEM YES NO EAS00789 2. The meter light f ails to come on. YES NO YES NO High beam indicator light Tester positive probe → yellow 4 Tester negative probe → black/white 5 Meter assembly coupler • Set the main switch to “ON”. • Set the light switch to “ ”. • Set the dimmer switch to “ ” or “ ”. ?[...]

8 - 35 –+ ELEC EAS00790 3. The tail/brak e light f ails to come on. YES NO YES NO EAS00791 4. The auxiliar y light f a ils to come on. YES NO YES NO 1. T ail/brak e light b ulb and soc k et • Check the tail/brake light bulb and socket for continuity. • Are the tail/brake light bulb and socket OK? Replace the tail/ brake light bulb, socket or [...]

8 - 36 –+ ELEC LIGHTING SYSTEM[...]

8 - 37 –+ ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM ON OFF P 1 5 R R R Br / L Br / R L L / R B B Y Br L L / Y L / B Br / W P Lg B R / Y P B G / B R / Y Br / W Lg YD g Ch L / YB / Y Sb Ch B / Y Y Sb Dg L / Y BL Y Ch Dg Y Dg B L / R Ch B B B B B B Dg Ch Br/W Br/W Ch Dg R / Y L / B L L L / B R / Y Br / W Br / G BB B B B B B B B[...]

8 - 38 –+ ELEC SIGNALING SYSTEM 1 Main switch 4 Backup fuse (odometer , clock and wind shield) 5 Main fuse 6 Battery A Starting circ uit cut-off relay B Neutral switch D Fuel pump Y Oil level warning light Z Neutral indicator light [ Multi-function me ter Engine trouble warning light _ Left turn signal ind i cator light a Right turn signal indi[...]

8 - 39 –+ ELEC SIGNALING SYSTEM EAS00794 TROUBLESHOOTING Check: 1. main, sign aling system, hazard lighting, windshield motor and bac kup fu ses 2. batter y 3. main s witch 4. wiring connections (of the entire signaling system) NOTE: @ • Before troubleshooting, remove the following part(s): 1) fuel tank 2) front cowling assemb ly 3) air filter [...]

8 - 40 –+ ELEC SIGNALING SYSTEM EAS00796 CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. YES NO YES NO NO YES 1. Hor n switch • Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the horn switch OK? Replace the left han- dlebar switch. 2. V o ltage • Connect the pocket tester (DC 20 V) to the horn con[...]

8 - 41 –+ ELEC SIGNALING SYSTEM EAS00797 2. The tail/brak e light f ails to come on. YES NO YES NO YES NO 1. T ail/brak e light b ulb and soc k et • Check the tail/brake light bulb and socket for continuity. • Are the tail/brake light bulb and socket OK? Replace the tail/ brake light bulb, socket or both. 2. Brak e light s witches • Check t[...]

8 - 42 –+ ELEC SIGNALING SYSTEM EAS00799 3. The tur n signal light, tur n signal indicator light or both f ail to b link. YES NO YES NO YES NO 1. T u r n signal indicator light bulb and so ck et • Check the turn signal light bulb and socket for continuity. • Are the turn signal light bulb and socket OK? Replace the turn sig- nal light bulb, s[...]

8 - 43 –+ ELEC SIGNALING SYSTEM YES NO YES NO EAS00800 4. The neutral in dicator light f ails to come on. YES NO YES NO • Set the main switch to “ON”. • Set the turn signal switch to “ ” or “ ”. • Measure the voltage (12 V) on brown/white 1 at the turn signal relay coupler. • Is the voltage within specification? The turn signa[...]

8 - 44 –+ ELEC SIGNALING SYSTEM EAS00753 YES NO YES NO 3. Star ting circuit cut-off rela y • Disconnect the starting circuit cut-off relay from the wire harness. • Connect the pocket te ster ( Ω × 1) to the starting circuit cut-off relay te rminals as shown. • Check the starting circuit cut-off relay for continuity. Tester positive probe[...]

8 - 45 –+ ELEC SIGNALING SYSTEM EAS00802 5. The oil le vel w ar ning light f ails to come on. YES NO YES NO YES NO 1. Oil le v el w arning light bulb and soc k et • Check the oil level warning light bulb and socket for continuity. • Are the oil level warning light bulb and socket OK? Replace the oil level warning light bulb, socket or both. 2[...]

8 - 46 –+ ELEC SIGNALING SYSTEM EAS00804 6. The fuel le v el gauge f ails to operate. YES NO YES NO 1. Fuel sender • Drain the fuel from the fuel tank and remove the fuel pump from the fuel tank. • Connect the pocket tester ( Ω × 10) to the fuel sender terminals as shown. Tester positive probe → green/white 1 Tester negative probe → bl[...]

8 - 47 –+ ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM ON OFF P 1 5 R R R Br / L Br / R L L / R B B Y Br L L / Y L / B Br / W P Lg B R / Y P B G / B R / Y Br / W Lg YD g Ch L / YB / Y Sb Ch B / Y Y Sb Dg L / Y BL Y Ch Dg Y Dg B L / R Ch B B B B B B Dg Ch Br/W Br/W Ch Dg R / Y L / B L L L / B R / Y Br / W Br / G BB B B B B B B B B B[...]

8 - 48 –+ ELEC COOLING SYSTEM EAS00808 TROUBLESHOOTING Check: 1. main, ignition, and radiato r f an motor fuses 2. batter y 3. main s witch 4. radiator fan motor 5. radiator fan motor rela y 6. coolant temperature se nsor 7. wiring connections (the entire cooling system) NOTE: @ • Before troubleshooting, remove the following part(s): 1) fuel ta[...]

8 - 49 –+ ELEC COOLING SYSTEM EAS00809 YES NO EAS00810 YES NO YES NO 4. Radiator f an motor (test 1) • Disconnect the radiator fan motor coupler from the wire harness. • Connect the battery (12 V) as shown. Battery positive lead → blue 1 Battery negative lead → black 2 • Does the radiator fan motor turn? The radiator fan motor is faulty[...]

8 - 50 –+ ELEC COOLING SYSTEM EAS00811 YES NO 7. Coolant temperature sensor • Remove the coolant temperature senso r from the thermostat assembly inlet pipe. • Connect the pocket te ster ( Ω × 1) to the coolant temperature sensor 1 as shown. • Immerse the coolant temperature sensor in a container filled with coolant 2 . NOTE: Make sure t[...]

8 - 51 –+ ELEC EAS00813 YES NO 8. Wir ing • Check the entire cooling system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the cooling system’s wiring prop erly con- nected and without defects? Replace the ECU. Properly connect or repair the cooling system’s wiring. COOLING SYSTEM[...]

8 - 52 –+ ELEC FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM CIRCUIT DIAGRAM ON OFF P 1 5 R R R Br / L Br / R L L / R B B Y Br L L / Y L / B Br / W P Lg B R / Y P B G / B R / Y Br / W Lg YD g Ch L / YB / Y Sb Ch B / Y Y Sb Dg L / Y BL Y Ch Dg Y Dg B L / R Ch B B B B B B Dg Ch Br/W Br/W Ch Dg R / Y L / B L L L / B R / Y Br / W Br / G BB B B B B B B [...]

8 - 53 –+ ELEC FUEL INJECTION SYSTEM EAS00816 TROUBLESHOOTING Check: 1. main, fuel injection system and ignition fuses 2. batter y 3. main s witch 4. engine stop s wit ch 5. fuel injection system rela y 6. fuel pump resistance 7. crankshaft position sen sor 8. cylinder indication sensor 9. speed sensor 10.coolant temper ature sensor 11.intak e ai[...]

8 - 54 –+ ELEC FUEL INJECTION SYSTEM EAS00759 YES NO EAS00817 YES NO EAS00748 5. Fuel injection system rela y • Disconnect the fuel injection system rela y from the wire harness. • Connect the pocket tester ( Ω × 1) a nd bat- tery (12 V) to the fuel injection system rela y terminals as shown. Battery positive terminal → red/black 1 Batte[...]

8 - 55 –+ ELEC FUEL INJECTION SYSTEM YES NO YES NO YES NO Crankshaft position sensor resis- tance 420 ~ 569 Ω at 20 °C (between gray and black) • Is the crankshaft position sensor OK? Replace the crank- shaft position sensor. 8. Cylinder identification sensor output v olt- age • Connect the pocket tester (DC 20 V) to the cylinder identific[...]

8 - 56 –+ ELEC FUEL INJECTION SYSTEM EAS00811 YES NO 10.Coolant temper ature sensor • Remove the coolant temperature senso r from the thermostat assembly inlet pipe. • Connect the pocket te ster ( Ω × 1) to the coolant temperature sensor 1 as shown. • Immerse the coolant temperature sensor in a container filled with coolant 2 . NOTE: Mak[...]

8 - 57 –+ ELEC FUEL INJECTION SYSTEM YES NO YES NO 11.Intak e air temperature senso r resistance • Remove the intake air temperature senso r from the air filter case. • Connect the pocket tester ( Ω × 100) to the intake air temperature sensor terminal as shown. Tester positive probe → brown/white 1 Tester negative probe → black/blue 2 [...]

8 - 58 –+ ELEC FUEL INJECTION SYSTEM YES NO YES NO EAS00818 YES NO 13.Atmospheric pressure sensor output volt- age • Connect the pocket tester (DC 20 V) to the atmospheric pressure sensor coupler termi- nal as shown. Tester positive probe → blue 1 Tester negative probe → black/blue 2 • Set the main switch to “ON”. • Measure the atmo[...]

8 - 59 –+ ELEC FUEL INJECTION SYSTEM EAS00819 CHECKING THE FUEL PUMP W ARNING @ Gasoline is extremely flammable and under certain circumstances there can b e a dan- ger of an explosion or fire. Be extremely careful and note the followin g points: • Stop the engine before refueling. • Do not smoke, and keep away from open flames, sparks, or an[...]

8 - 60 –+ ELEC FUEL INJECTION SYSTEM EAS00502 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the th rottle position se nsor, the engine idling speed should be properly adjusted. 1. Chec k: • throttle posit ion sensor (installed on the throttle body) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ [...]

8 - 61 –+ ELEC FUEL INJECTION SYSTEM ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Throttle position sens or resis- tance (520 ~ 900 Ω ) ~ (4.0 ~ 6.0 k Ω ) at 20 °C (yellow — black/blue) 2. Chec k: • throttle posit ion sensor (removed from the throttle body) ▼▼▼ ?[...]

8 - 62 –+ ELEC FUEL INJECTION SYSTEM e. Connect the poc k et tester ( Ω × 1k) to the throttle position sensor . f . While slowly open ing the throttle , chec k that the throttle position sensor resistance is within the specified range . The resistance does not change or it changes abruptly → Replace the throttle position sensor. The slot is [...]

8 - 63 –+ ELEC FUEL INJECTION SYSTEM Example: If the maximum resistance = 5 k Ω , then the throttle position sensor’s maximum resista nce when the throttle is fully closed should be: 5 k Ω × (0.13 ~ 0.15) = 650 ~ 750 Ω Lift the throttle body assembly slig htly out of the intake manifolds. Loosen the throttle posi- tion sensor screws 4 . [...]

8 - 64 –+ ELEC WINDSHIELD DRIVE SYSTEM WINDSHIELD DRIVE SYSTEM CIRCUIT DIAGRAM ON OFF P 1 5 R R R Br / L Br / R L L / R B B Y Br L L / Y L / B Br / W P Lg B R / Y P B G / B R / Y Br / W Lg YD g Ch L / YB / Y Sb Ch B / Y Y Sb Dg L / Y BL Y Ch Dg Y Dg B L / R Ch B B B B B B Dg Ch Br/W Br/W Ch Dg R / Y L / B L L L / B R / Y Br / W Br / G BB B B B B [...]

8 - 65 –+ ELEC WINDSHIELD DRIVE SYSTEM TROUBLESHOOTING Check: 1. main, windshield motor and bac k up fuses 2. batter y 3. main s witch 4. windshield position adjusting s witch 5. wiring connections (of the windshield drive system) NOTE: @ • Before troubleshooting, remove the following part(s): 1) fuel tank 2) front cowling assemb ly 3) air filt[...]

8 - 66 –+ ELEC WINDSHIELD DRIVE SYSTEM EAS00795 YES NO NOTE: • If the windshield is up, it will go down when the gear is in the neutral position and the main switch is set to “OFF”. • The neutral indicator light will blink u ntil the windshield has stopped and is all the way down. If the neutral indicator light does not turn off, replace [...]

TRBL SHTG 9[...]

TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING PROBLEMS ............................................................................. .... 9-1 ENGINE ....................................................... .............................................. 9-1 FUEL SYSTEM ................................. .................................................[...]

TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM .............................................. 9-6 HEADLIGHT DOES NOT LIGHT............................................................... 9-6 HEADLIGHT BULB BURNT OUT .............................................................. 9-6 TAIL/BRAKE LIGHT DOES NOT LIGHT .....................................[...]

9 - 1 TRBL SHTG STARTING PROBLEMS EAS00844 TROUBLESHOOTING NOTE: @ The following guide for troubleshootin g does not cover all the possible causes of trou ble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man- ual for checks, adjustments, and replacement of parts. STARTING PROBLEMS ENGI[...]

9 - 2 TRBL SHTG STARTING PROBLEMS/ INCORRECT ENGINE IDLING SPEED ELECTRICAL SYSTEMS Battery • Discharged battery • Faulty battery Fuse(s) • Blown, damaged o r incorrect fuse • Improperly installed fuse Spark plug(s) • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn [...]

9 - 3 TRBL SHTG POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY GEAR SHIFTING EAS00848 POOR MEDIUM-AND-HIGH-SP EED PERFORMANCE Refer to “STARTING PROBLEMS”. ENGINE Air filter • Clogged air filter element FUEL SYSTEM Fuel pump • Faulty fuel pump EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to “CLUTCH DRAGS”. SHIFT PEDAL DOES [...]

9 - 4 TRBL SHTG FAULTY CLUTCH/OVERHEATING EAS00852 FAULTY CLUTCH CLUTCH SLIPS Clutch • Improperly assembled clutch • Improperly assembled clutch master cylin- der • Improperly assembled clutch release cylin- der • Incorrect clutch fluid level • Damaged clutch hose • Loose or fatigued clutch spring • Loose union bolt • Worn friction [...]

9 - 5 TRBL SHTG POOR BRAKING PERFORMANCE/ FAULTY FRONT FORK LEGS EAS00857 POOR BRAKING PERFORMANCE • Worn brake pad • Worn brake disc • Air in hydraulic brake system • Leaking brake fluid • Faulty brake caliper seal • Loose union b olt • Damaged brake h ose • Oil or grease on the brake disc • Oil or grease on the brake pad • Inc[...]

9 - 6 TRBL SHTG UNSTABLE HANDLING/ FAULTY LIGHTING OR SIGNALING SYSTEM EAS00863 UNSTABLE HANDLING Handlebars • Bent or improperly installed righ t handlebar • Bent or improperly installed left handlebar Steering head components • Improperly installed upper bracket • Improperly installed lower bracket (improperly tightened ring nut) • Bent[...]

9 - 7 TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM TURN SIGNAL BLINKS QUICKLY • Incorrect turn signal bulb • Faulty turn signal relay • Burnt-out turn sig nal bulb HORN DOES NOT SOUND • Improperly adjusted horn • Damaged or faulty horn • Faulty mai n switch • Faulty horn switch • Faulty battery • Blown, damaged o r incorrect fuse[...]

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FJR1300 WIRING DIAGRAM (for Europe) 1 Main switch 2 Rectifier/regulator 3 Generator 4 Backup fuse (odometer, clock and windshield) 5 Main fuse 6 Battery 7 Fuel injection system fuse 8 Starter relay 9 Starter motor 0 Diode A Starting circuit cut-off relay B Neutral switch C Sidestand switch D Fuel pump E O 2 sensor F Cylinder identification sensor G[...]

FJR1300 WIRING DIAGRAM (for Oceania) 1 Main switch 2 Rectifier/regulator 3 Generator 4 Backup fuse (odometer, clock and windshield) 5 Main fuse 6 Battery 7 Fuel injection system fuse 8 Starter relay 9 Starter motor 0 Diode A Starting circuit cut-off relay B Neutral switch C Sidestand switch D Fuel pump E O 2 sensor F Cylinder identification sensor [...]

FJR1300 WIRNING DIAGRAM (for Europe) ON OFF P 1 5 R R R Br / L Br / R L L / R B B Y Br L L / Y L / B Br / W P Lg B R / Y P B G / B R / Y Br / W Lg YD g Ch L / YB / Y Sb Ch B / Y Y Sb Dg L / Y BL Y Ch Dg Y Dg B L / R Ch B B B B B B Dg Ch Br/W Br/W Ch Dg R / Y L / B L L L / B R / Y Br / W Br / G BB B B B B B B B B B Br B / R R / B B / R R / B R / B B[...]

FJR1300 WIRNING DIAGRAM (for Oceania) ON OFF 1 5 R R R Br / L W / L Y Br L / Y L / B Br / W P Lg B R / Y P B G / B R / Y Br / W Lg YD g Ch L / YB / Y Sb Ch B / Y Y Sb Dg L / Y BL Y Ch Dg Y Dg B L Ch Dg Ch Br/W Br/W Ch Dg Br / W Br / G B / R R / B B / R R / B R / B B / R Br Y B B B B (RED) (RED) Br R / W R / B L / W Y B R / W B / W B / R B R / W L /[...]

FJR1300R WIRING DIAGRAM ON OFF 1 5 R R R Br / L W / L L / Y Y Br BL Y Ch Dg Y Dg B L Ch Dg Ch Br/W Br/W Ch Dg Br / W Br / G B / R R / B B / R R / B R / B B / R Br Y B B B B (RED) (RED) Br R / W R / B L / W Y B R / W B / W B / R B R / W L / W (BLACK) (BLACK) L / Y B / Y B / Y L / Y (BLACK) (BLACK) R Br R R R Br / L (BLACK) (GRAY) W W W B G / W B R /[...]

The "Barbarian Jumper Mod" The "Barbarian Jumper Mod" Index Home Tom Barber (aka Barbarian ) and Dwayne Verhey (aka Torch ) from the FJROwners online forum figured out how to enable a North American spec'd FJR1300 to have it's EFI's CO setting adjusted, like the European and OZ/NZ models allow. On 03/05/03 Torch p[...]

The "Barbarian Jumper Mod" First, remove the seat and two left sidecovers. As with the dash panels, Yamaha used a variety of fasteners on this job, including Allen head fasteners, push-pin fasteners, and 1/4 turn Philips head fasteners. See your owner's manual for a more complete description of removing each. Don't forget the tw[...]

The "Barbarian Jumper Mod" Next, remove the airbox cover. At least all 4 of these are the same 1/4 turn fastener. Unfortunately, the one indicated by the screwdriver is recessed and a PITA. http://www.micapeak.com/bike/FJR1300/howto/jumper.html (3 of 9) [15/05/2003 5:41:02 PM][...]

The "Barbarian Jumper Mod" With the covers out of the way, the ECU is now accessible. Squeeze the black latch on the top of the connector as you pull it out of the ECU. On the underside of the connector are 3 white bars. Using a fingernail or http://www.micapeak.com/bike/FJR1300/howto/jumper.html (4 of 9) [15/05/2003 5:41:02 PM][...]

The "Barbarian Jumper Mod" small screwdriver, push the left one (as pictured) in about 1/32". This unlocks the wires in the connector. Pin #27 is the 5th from the left on the bottom row. It houses a yellow wire with a red stripe -- 1/2 of the Barbarian Jumper. Carefully remove this wire from the connector. Make sure you have the wire[...]

The "Barbarian Jumper Mod" Using a small piece of stiff wire (I used some .030 MIG wire, but a paperclip or safety pin would probably work) gently push up from the ECU side of the connector to lift the wire to pin 27 and the white plug in pin 25. Do not force anything! The metal terminal ends on the wires are fragile and easily damaged. L[...]

The "Barbarian Jumper Mod" The plug is small. Very small. And bouncy. It can travel a surprising distance when deflected off the airbox. If you drop it you are in for more fun than a snipe hunt. Do not ask me how I know this. Use tweezers. Put the plug in pin 27. Put the wire you removed in pin 25. Make sure they are fully seated and then[...]

The "Barbarian Jumper Mod" pictured) white bar on the top of the connector down until flush (about 1/32") It does not take a lot of force, so if it doesn't want to go you probably have a wire pulled slightly out. Make sure all the wires in the left 1/3 of the connector are fully seated and try again. When you are all done, inser[...]

The "Barbarian Jumper Mod" Nonetheless: all the standard disclaimers apply: Do this at your own risk. I am not responsible if you let the smoke out of your ECU. YMMV. Etc. -- Torch. Copyright © 2003, by H. Marc Lewis, Tom Barber, and Dwayne Verhey. All rights reserved. http://www.micapeak.com/bike/FJR1300/howto/jumper.html (9 of 9) [15/0[...]

Installing Riv-Nut ports in the FJR's Headers Installing Riv-Nut ports in the FJR's Headers Index Home On 03/05/03 Dwayne Verhey (aka Torch ) from the FJROwners online forum wrote this Web page describing how to install " Riv-nuts " into the FJR1300's header pipes. This is required to properly modify the EFI's CO setti[...]

Installing Riv-Nut ports in the FJR's Headers This is a riv-nut tool. Similar to a standard pop rivet gun, but with interchangeable adapters and anvils sized for the insert being installed. The appropriate adapter is screwed into the tool, followed by the corresponding anvil. In use the riv-nut is threaded onto the adapter, inserted into the h[...]

Installing Riv-Nut ports in the FJR's Headers First a hole is drilled into the pipe where the port is required. European and Oceanic models have ports installed from the factory. Migmagal reports they are located "About 5 inches after the cylinder exits on each tube" and Woody concurs saying they are "about 125mm from the top of[...]

Installing Riv-Nut ports in the FJR's Headers Here the riv-nut is assembled on the tool and inserted into the hole ready to go. One squeeze of the handle is sufficient. Attempting to compress the riv-nut further will only strip the threads. As described earlier, unscrew the tool from the insert using the removal knob. http://www.micapeak.com/b[...]

Installing Riv-Nut ports in the FJR's Headers The end result. The upper portion of the riv-nut has been mushroomed firmly against the wall of the pipe, following the curve, providing a threaded port. I chose 1/4"-20 NCT aluminium inserts for this example. Following this I inserted an oxy-acetelene torch into the other end and adjusted it [...]

Installing Riv-Nut ports in the FJR's Headers The hole is sealed with a bolt when not in use. As can be seen from this picture, the bolt may protrude into the pipe unless cut to length. Besides being a potential for further restriction, the exposed threads could become clogged with carbon deposits from the exhaust making future removal difficu[...]

Installing Riv-Nut ports in the FJR's Headers When cutting a thread, it's a good idea to temporarily install a nut first. Cut the thread off beyond the nut, then wind the thread past the end of the nut. If the thread binds while removing the nut, make sure the thread is not protruding past the nut and simply tap it against something solid[...]

Installing Riv-Nut ports in the FJR's Headers The trimmed bolt no longer protrudes into the pipe. http://www.micapeak.com/bike/FJR1300/howto/rivnut.html (8 of 10) [15/05/2003 5:56:43 PM][...]

Installing Riv-Nut ports in the FJR's Headers In an effort to reduce any possible restriction, I tried cutting 1/2 the threaded portion of a riv-nut off before installing it. The threads stripped out before it fully mushroomed, resulting in this failed installation on the right. The insert is loose, but cannot be removed and there are no threa[...]

Installing Riv-Nut ports in the FJR's Headers long night ;-) -- torch Copyright © 2003, by H. Marc Lewis and Dwayne Verhey. All rights reserved. http://www.micapeak.com/bike/FJR1300/howto/rivnut.html (10 of 10) [15/05/2003 5:56:43 PM][...]