Yamaha YZF-R1P manual

[...]

[...]

YZF-R1P YZF-R1PC SERVICE MANUAL LIT-11616-15-47 5PW-28197-10[...]

[...]

EAS00000 YZF-R1P/YZF-R1PC SERVICE MANUAL ©2001 by Yamaha Motor Corporation, U.S.A. First edition, December 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-15-47[...]

EAS00003 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily fo r use by Yamaha deal- ers and their qualified mechanics. It is not possib le to include all the knowledge of a mechanic in one manual. Therefore, anyone who u ses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding o[...]

EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read refer ence book for the mechanic. Comprehensive explanations of all installation , removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbrevia tion and symbol[...]

EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 General info rmation 2 Specifications 3 Periodic checks and ad justments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system 8 Electrical system 9 Troubleshooting Symbols 0 to G indicate the following. 0 Serviceab[...]

[...]

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 – +[...]

CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ................................................ .................1-1 VEHICLE IDENTIFICATION NUMBER ............................................. ....... 1-1 MODEL LABEL ......................................................................................... 1-1 FEATURES .....................[...]

TIGHTENING TORQUES ........................................ .....................................2-17 GENERAL TIGHTENING TORQUE SPECIFICATIONS ........................ 2-17 ENGINE TIGHTENING TORQUES ........................................................2-18 CHASSIS TIGHTENING TORQUES ......................................................2-21 LUBR[...]

ENGINE ............................................................................... ............................3-9 ADJUSTING THE VALVE CLEARANCE ................................. .................3-9 SYNCHRONIZING THE THROTTLE BODIES .......................................3-14 ADJUSTING THE ENGINE IDLING SPEED ..................................[...]

CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS .................... .......................................4-1 FRONT WHEEL ....................................... .................................................4-2 REMOVING THE FRONT WHEEL ...........................................................4-3 CHECKING THE FRONT WHEEL ......................[...]

HANDLEBARS ........................................................ .....................................4-56 REMOVING THE HANDLEBARS ............................................ ...............4-58 CHECKING THE HANDLEBARS ........................................................... 4-58 INSTALLING THE HANDLEBARS ....................................[...]

CYLINDER HEAD .............................. ........................................... ............... 5-19 REMOVING THE CYLINDER HEAD ......................................................5-20 CHECKING THE CYLINDER HEAD ....................................... ...............5-20 INSTALLING THE CYLINDER HEAD .......................... ...........[...]

OIL PAN AND OIL PUMP .................................................. ..........................5-51 OIL PUMP ................................................................................ ............... 5-53 REMOVING THE OIL PAN ................................................................ ..... 5-54 CHECKING THE OIL PUMP .................[...]

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

AIR INDUCTION SYSTEM ....... ..................................................... ...............7-37 AIR INDUCTION ..................................................................................... 7-37 AIR CUT-OFF VALVE .................. ..................................................... ..... 7-37 AIR INDUCTION SYSTEM DIAGRAMS ..........[...]

COOLING SYSTEM .................. ..................................................... ............... 8-41 CIRCUIT DIAGRAM ...............................................................................8-41 TROUBLESHOOTING .................................................. ..........................8-42 FUEL PUMP SYSTEM ..........................[...]

FAULTY FRONT FORK LEGS ........... ..................................................... ....... 9-5 LEAKING OIL ...........................................................................................9-5 MALFUNCTION ....................................... .......................................... ....... 9-5 UNSTABLE HANDLIN G ................[...]

1 - 1 GEN INFO 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 LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts. MOTORCYCLE IDENTIFICATION 1[...]

1 - 2 GEN INFO FEATURES FEATURES OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fue l to the combustion chamber at the opti- mum air-fuel ratio in accordance with the en gine operating conditions and the atmospheric tempera- ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied[...]

1 - 3 GEN INFO FEATURES FI SYSTEM The fuel pump delivers fuel to the inje ctor via the fuel filter. The pressure regulator mainta ins the fuel pressure that is applied to the injector at only 284 kPa (2.84 kg/cm 2 , 40.4 psi) higher than the intake manifold pressure. Accordingly, when the energizing signal from the ECU energizes the injector, the f[...]

1 - 4 GEN INFO FEATURES Fuel control block The fuel control block consists of the fo llowing main components: An engine trouble 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 In[...]

1 - 5 GEN INFO FEATURES COMPONENTS ECU (Electronic Control Unit) The ECU is mounted underneath the seat. The main fun ctions of the ECU are ignitio n control, fuel control, self-diagnosis, and lo ad control. • ECU ’ s internal construction an d functions The main components an d functions of the ECU can be broa dly divided into the following fo[...]

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

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 fu el system downstream of the pump. The pump consists of a pump unit, electric motor, f ilter, and [...]

1 - 8 GEN INFO FEATURES Pressure regulator It regulates the fuel pressure that is applied to the in jectors that are provided in th e cylinders in order to maintain a constant pressure d ifference with the pressure in the intake manifold. The fuel that is delivered by the fuel pump fills the fuel chamber 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 t he force of the spring, as illustrated. The plunger tha t is integrated with the bottom of the core keeps the fuel pa ssage closed. When the current flows to the coil in accordan[...]

1 - 10 GEN INFO FEATURES Crankshaft position sensor The crankshaft position sensor uses the signals of the pickup co il that is mounted on the right side of the crankshaft. When the rotatio n of the pickup rotor that is attached to th e crankshaft causes the projections on the rotor to pass by the pickup coil, an electromotive force is gene rated i[...]

1 - 11 GEN INFO FEATURES Cylinder identification sensor The cylinder identification sensor is mounted on the middle of exhaust side head cover. When the exhaust camshaft rotates, the sensor generates a signal and sends it to the ECU. Based on this sig- nal and the signal from the crankshaft positio n sensor, the ECU then actuates the injector o f t[...]

1 - 12 GEN INFO FEATURES Throttle position sensor The throttle position sensor measures the intake air volume by detectin g the position of the throt tle valve. It detects th e mechanical angle of the throttle valve through the posit ional relationship between the moving contact that moves in unison with the throttle shaft and the resistor boa rd. [...]

1 - 13 GEN INFO FEATURES Intake air pressure sensor and atmos pheric pressure sensor • Intake air pressure se nsor The intake air pressure sensor is used for measuring the intake air volume. The intake air volume of every intake stroke is proportionate to th e intake air pressure. Therefore, the intake air volume can be measured by measuring the [...]

1 - 14 GEN INFO FEATURES Coolant temperature sensor The signals from the coolant tempe rature sensor are used primarily for making fuel volume compen- sations during starting and warm-up. The coolan t temperature sensor converts the temperature of the coolant into electrical signals and sends them to the ECU. This sensor uses a semi-conductor therm[...]

1 - 15 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 motorcycle 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 proporti[...]

1 - 16 GEN INFO FEATURES FUEL INJECTION SYSTEM Operation and control The fuel injection timing, injection duration, ignitio n timing, and the coil energizing duration are con- trolled by the ECU. To determine the basic inje ction timing, the ECU calculates the intake air volume through the signals from the intake air pressu re sensor, throttle posi[...]

1 - 17 GEN INFO FEATURES Determining the final injection duration The intake air volume determines the basic injection duration. Ho wever, at a given intake air vol- ume, the volume of fuel that is required varies by th e engine operating conditions such a s accelera- tion or deceleration, or by weather conditions. This system use s various sensors[...]

1 - 18 GEN INFO FEATURES Reactive injection duration: A lag is created between the time the ECU outputs a fuel injection signal to the injector and the time the injector actually opens. Therefore, the ECU ca lculates this lag in advance before se nding the actuation signal to the injector. The battery voltage determines the re active injection dura[...]

1 - 19 GEN INFO FEATURES THREE-WAY CATALYTIC CONVERTER SYSTEM System outline This is a highly efficient exhaust gas cleaning system that effects air-fuel cont rol through a joint effort by the FI system and the three-way cata lytic converter system. By effecting comprehensive control of the air-fuel ratio in this ma nner, this system reduces the CO[...]

1 - 20 GEN INFO FEATURES INSTRUMENT FUNCTION Multi-function display The multi-function display is equipped with the following: • a speedometer (which shows the riding speed) • an odometer (which shows the total dis- tance traveled) • two tripmeters (which show the distance traveled since they were last set to zero) • a fuel reserve tripmete[...]

1 - 21 GEN INFO FEATURES Display brightness and engine speed indi- cator light control mode This mode cycles through five control func- tions, allowing you to make the following set- tings in the order listed below. 1. Displa y brightness: This function allo ws you to adjust the brightness of the multi-function displa y to suit the outside lighting[...]

1 - 22 GEN INFO FEATURES T o set the engine speed indicator light activ ation fun ction NOTE: _ The indicator light activation function can be set between 7,000 and 12 ,000 r/min in increments of 500 r/min. 1. Push the “ RESET ” button to sele ct the desired engine speed f or activating the indicator ligh t. 2. Push the “ SELECT ” button to[...]

1 - 23 GEN INFO IMPORTANT INFORMATION EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Bef ore remo v al and disassemb ly , remov e all dir t, mud, dust and f oreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “ SPECIAL TOOLS ” . 3. When disassemb ling, alw a ys k eep mated par ts togethe[...]

1 - 24 GEN INFO IMPORTANT INFORMATION 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 lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer [...]

1 - 25 GEN INFO CHECKING THE CONNECTIONS EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Chec k: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect se v- eral times. 3. Chec k:[...]

1 - 26 GEN INFO SPECIAL TOOLS EAS00027 SPECIAL TOOLS The following special tools are necessary for complete an d accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damag e caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the [...]

1 - 27 GEN INFO SPECIAL TOOLS YU-38411 Oil filter wrench This tool is needed t o loosen or tighten the oil filter cart ridge. YM-01434 Rod holder This tool is used to support the damper adjusting rod. Rod puller YM-01437 Rod puller These tools are used to pull up the front fork dampe r rod. YM-01441 Fork spring compre ssor This tool is used to dis [...]

1 - 28 GEN INFO SPECIAL TOOLS Middle driven shaft bearing driver YM-4058-1 Mechanical se al installer YM-33221 Middle driven shaf t bearing driver Mechanical seal installer These tools are used t o install the water pump seal . YM-91042 Universal clutch holder This tool is used to ho ld the clutch boss when removing or inst alling the clutch boss n[...]

1 - 29 GEN INFO SPECIAL TOOLS YM-03112 Pocket tester This instrument is needed f or checking the engine oil temperatur e. YB-35956 Mity vac This tool used to measure th e vacuum pressure. YM-8037 Piston ring compressor This tool is used to compress t he piston rings when installing the piston into the cylinder. YM-03176 Fuel pressure adapter This t[...]

2 - 1 SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5PW4 USA 5PW5 California 5PW6 Canada ---- ---- ---- Dimensions Overall length 2,040 mm (80.3 in) ---- Overall width 705 mm (27.8 in) ---- Overall height 1,105 mm (43.5 in) ---- Seat height 820 mm (32.3 in) ---- Wheelbase 1,395 mm (54.9 in) ---- Minimum ground clearance [...]

2 - 2 SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC ---- Displacement 998 cm 3 (60.9 cu.in) ---- Cylinder arrangement Forward-inclined parallel 4-cylinder ---- Bore × stroke 74 × 58 mm (2.91 × 2.28 in) ---- Compression ratio 11.8 : 1 ---- Engine idling speed 1,000 ~ 1,100 r/[...]

2 - 3 SPEC ENGINE SPECIFICATIONS Oil filter Oil filter type Cartridge (paper) ---- Bypass valve opening pressure 80 ~ 120 kPa (0.8 ~ 1.2 kg/cm 2 , 11.6 ~ 17.4 psi) ---- Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clearance 0.01 ~ 0.10 mm (0.0004 ~ 0.0039 in) 0.18 mm (0.0071 in) Outer-rotor-to-oil-pump-housing clearance 0.09 [...]

2 - 4 SPEC ENGINE SPECIFICATIONS Camshafts Drive system Chain drive (right) ---- Camshaft cap inside diameter 24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in) ---- Camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) ---- Camshaft-journal-to-ca mshaft- cap clearance 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) ---- Intake camshaft lobe dimensions Meas[...]

2 - 5 SPEC ENGINE SPECIFICATIONS Timing chain Model/number of links RH2015/130 ---- Tensioning system Automatic ---- Valves, valve seats, valve guides Valve clearance (cold) Intake 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) ---- Exhaust 0.21 ~ 0.27 mm (0.0083 ~ 0.0106 in) ---- Valve dimensions Valve head diameter A Intake 22.9 ~ 23.1 mm (0.9016 ~ 0.9094 i[...]

2 - 6 SPEC ENGINE SPECIFICATIONS Valve stem runout ---- 0.01 mm (0.0004 in) Valve seat width Intake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) ---- Exhaust 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) ---- Valve springs Free length Intake 38.9 mm (1.53 in) 37.0 mm (1.46 in) Exhaust 40.67 mm (1.60 in) 38.6 mm (1.52 in) Installed length (valve closed) Intake 34.5 mm (1.[...]

2 - 7 SPEC ENGINE SPECIFICATIONS Cylinders Cylinder arrangement Forward-inclined, parallel 4-cylinder ---- Bore × stroke 74 × 58 mm (2.91 × 2.28 in) ---- Compression ratio 11.8 : 1 ---- Bore 74.00 ~ 74.01 mm (2.9134 ~ 2.9138 in) ---- Max. taper ---- 0.05 mm (0.0020 in) Max. out-of-round ---- 0.05 mm (0.0020 in) Piston Piston-to-cylinder clearanc[...]

2 - 8 SPEC ENGINE SPECIFICATIONS 2nd ring Ring type Taper ---- Dimensions (B × T) 0.8 × 2.8 mm (0.03 × 0.11 in) ---- End gap (installed) 0.43 ~ 0.58 mm (0.017 ~ 0.023 in) 0.93 mm (0.037 in) Ring side clearance 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) 0. 115 mm (0.0045 in) Oil ring Dimensions (B × T) 1.5 × 2.6 mm (0.06 × 0.10 in) ---- End gap (in[...]

2 - 9 SPEC ENGINE SPECIFICATIONS Clutch Clutch type Wet, multiple disc ---- Clutch release method Outer pull, rack and pinion pull ---- Clutch release method operation Cable operation ---- Operation Left-hand operation ---- Clutch cable free play (at the end of the clutch lever) 10 ~ 15 mm (0.4 ~ 0.6 in) ---- Friction plates Thickness 2.9 ~ 3.1 mm [...]

2 - 10 SPEC ENGINE SPECIFICATIONS Air filter type Wet element ---- Fuel pump Pump type Electrical ---- Model (manufacturer) 5PW (DENSO) ---- Output pressure 94 kPa (2.94 kg/cm 2 , 42.6 psi) ---- Throttle position sensor Resistance 4.85 ~ 5.15 k Ω at 20 ° C (68 ° F) ---- Output voltage (at idle) Adjusted by tachometer ---- Throttle bodies Model [...]

2 - 11 SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond ---- Caster angle 24 ° ---- Trail 103 mm (4.06 in) ---- Front wheel Wheel type Cast wheel ---- Rim Size 17 M/C × MT3.50 ---- Material Aluminum ---- Wheel travel 120 mm (4.72 in) ---- Wheel runout Max. radial wheel runout ---- 1 mm (0.04 in) Max.[...]

2 - 12 SPEC CHASSIS SPECIFICATIONS Front brakes Brake type Dual disc brake ---- Operation Right hand operation ---- Recommended fluid DOT 4 ---- Brake lever free play 2.3 ~ 11.5 mm (0.09 ~ 0.45 in) ---- Brake discs Diameter × thickness 298 × 5 mm (11.73 × 0.20 in) ---- Min. thickness ---- 4.5 mm (0.18 in) Max. deflection ---- 0.1 mm (0.004 in) B[...]

2 - 13 SPEC CHASSIS SPECIFICATIONS Front suspension Suspension type Telescopic fork ---- Front fork type Coil spring/oil damper ---- Front fork travel 120 mm (4.72 in) ---- Spring Free length 251 mm (9.88 in) 246 mm (9.69 in) Spacer length 74 mm (2.91 in) ---- Installed length 244 mm (9.61 in) ---- Spring rate (K1) 8.34 N/mm (0.83 kg/mm, 47.62 lb/i[...]

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 65 mm (2.56 in) ---- Spring Free length 176.5 mm (6.95 in) ---- Installed length 162.5 mm (6.4 in) ---- Spring rate (K1) 88.3 N/mm (8.83 kg/mm, 504 l[...]

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 ---- Crankshaft position sensor resistance/color 248 ~ 372 Ω at 20 ° C (68 ° F)/Gy-B ---- Transis torized coil ig n[...]

2 - 16 SPEC ELECTRICAL SPECIFICATIONS Electric starting system System type Constant mesh ---- Starter motor Model (manufacturer) 5JJ (YAMAHA) ---- Power output 0.9 kW ---- Brushes Overall length 10.8 mm (0.43 in) 3.65 mm (0.14 in) Spring force 5.28 ~ 7.92 N (528 ~ 792 g, 19.01 ~ 28.51 oz) ---- Armature coil resistance 0.009 ~ 0.011 Ω at 20 ° C ([...]

2 - 17 SPEC CONVERSION TABLE/TIGHTENING TORQUES EAS00028 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 TIGHTENING TORQUES EAS00029 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- d[...]

2 - 18 SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Item Fastener Thread size Q ’ ty Tightening torque Remarks Nm m · kg ft · lb Spark plugs — M10 4 13 1.3 9.4 Cylinder head Nut M10 2 20 + 12 1 ° (50) 2.0 + 121 ° (5.0) 14 + 121 ° (36) E Cylinder head Nut M10 6 20 + 10 5 ° (50) 2.0 + 105 ° (5.0) 14 + 105 ° (36) Cylinder head Cap nut[...]

2 - 19 SPEC TIGHTENING TORQUES Exhaust pipe and exhaust valve Bolt M6 4 10 1.0 7.2 Exhaust valve and housing Bolt M6 3 10 1.0 7.2 EXUP pulley and arm shaft Bolt M5 2 5 0.5 3.6 Exhaust joint Bolt M4 4 3 0.3 2.2 Exhaust valve pipe Bolt M8 1 20 2.0 14 Air induction system pipe Clamp — 4 3.5 0.35 2.5 Crankcase (cylinder head) Stud bolt M10 10 10 1.0 [...]

2 - 20 SPEC TIGHTENING TORQUES NOTE: 1. First, tighten the bolt to appro ximately 20 Nm (2.0 m • kg, 14 ft • lb) with a torque wrench. 2. Retighten the bolt to 20 Nm (2.0 m • kg, 14 ft • lb), and tighten ano ther 41 ~ 46 ° with a angle gauge or 32 Nm (3.2 m • kg, 23 ft • lb) with a torq ue wrench. EXUP servo motor cover Screw M5 2 2 0.[...]

2 - 21 SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Item Thread size Tightening Remarks Nm m · kg ft · lb Upper bracket and front fork M8 26 2.6 19 Steering stem nut M28 115 11.5 83 Handlebar and front fork M6 13 1.3 9.4 Handlebar and upper bracket M6 13 1.3 9.4 Lower ring nut M30 9 0.9 6.5 See NOTE Lower bracket pinch bolt M8 23 2.3 17 Mai[...]

2 - 22 SPEC TIGHTENING TORQUES NOTE: 1.First, tighten the ring nut to appro ximately 50 Nm (5.0 m • kg, 36 ft • lb) with a torque wrench, t hen loosen the ring nut completely . 2.Retighten the low er ring nut to specification. Coolant reservoir and radiato r M6 5 0.5 3.6 Tail cowling and frame M5 4 0.4 2.9 Battery box and frame M6 7 0.7 5.1 Tai[...]

2 - 23 SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE 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 Valve stems (intake and exhaust) M V[...]

2 - 24 SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lo wer) 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 surfa ce LS Rear brake pedal shaft LS Sidestand pivoting point and meta[...]

2 - 25 SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Radiator fa n 2 Radiator 3 Water pump[...]

2 - 26 SPEC COOLING SYSTEM DIAGRAMS 1 Thermostat 2 Radiator ca p 3 Coolant reserv oir 4 Radiator 5 Oil cooler 6 Water jacket joint[...]

2 - 27 SPEC COOLING SYSTEM DIAGRAMS 1 Water pump 2 Radiator ca p 3 Thermostat 4 Thermostat hou sing[...]

2 - 28 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator[...]

2 - 29 SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART Exhaust camshaft Intake ca mshaft Piston cooler Main gallery Oil filter Oil cooler Relief valve Oil pump Strainer Main axle Mission cooler Drive axle[...]

2 - 30 SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Intake camsha ft 2 Exhaust camshaft 3 Oil filter cartridge 4 Oil level switch[...]

2 - 31 SPEC LUBRICATION DIAGRAMS 1 Intake camsha ft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Oil pipe 6 Oil strainer 7 Oil pump[...]

2 - 32 SPEC LUBRICATION DIAGRAMS 1 Oil cooler 2 Oil filter cartridge 3 Oil level switch 4 Oil strainer 5 Oil pump 6 Oil pipe[...]

2 - 33 SPEC LUBRICATION DIAGRAMS 1 Main axle 2 Oil delivery pipe 3 Drive axle[...]

2 - 34 SPEC LUBRICATION DIAGRAMS 1 Cylinder head 2 Crankshaft[...]

2 - 35 SPEC CABLE ROUTING EAS00035 CABLE ROUTING 1 Headlight drain pl ug È Make sure to securely insert the coupler and boot . É The headlight lead can be routed by either of the head- light or the boss. Do not catch the headlight lead when assembling the front cowling. Ê Do not make the lead stretch too much. Ë Secure the ju nction of the cor [...]

2 - 36 SPEC CABLE ROUTING 1 Handlebar switch (left) 2 Main switch 3 Throttle position sensor lead 4 Guide-air 5 Handlebar switch (right) 6 Wiring section ! 7 AC magneto lead 8 Speed sensor lead 9 ( – ) lead 0 Rear brake switch lead A EXUP servo motor lead B AC magneto lead C AI system lead D Oil level switch lead E Sidestand switch lead F Wire ha[...]

2 - 37 SPEC CABLE ROUTING È Route the horn lead under the rib of bracke t horn positionin g the stepped part of prot ector outside the ri b. É Make the horn lead face the outside. Ê Route the handlebar switch le ad along the groove of the guide-air. Ë Handlebar switch (right) lead coupler. Ì Fasten the wire har ness and coolant temper ature se[...]

2 - 38 SPEC CABLE ROUTING Ú Route under t he wire harness to the asse mbling point ! . Û Insert the holding clamp of the wire harness to th e frame. Ü Fasten the wire harn ess with the clamp inserted to t he frame. Ý Route the radiat or fan motor lead above the wire harness. Þ Assembling point # Beneath the und er bracket ß Route the handle b[...]

2 - 39 SPEC CABLE ROUTING Pass the filter of thrott le body through th e hole of rub ber baffle and releas e it under the ignition coil plate. Route the sub lead coupler behind the ignitio n coil. Pass the camshaft p osition sensor lead through the hole of COVER 1 and connect it. After branch ing the harness , clamp each lead of the (+) lead juncti[...]

2 - 40 SPEC CABLE ROUTING 1 Turn signal light lead 2 Radiator hose 3 Reservoir tank brea ther hose (L = 440) 4 Clutch cable 5 Crankshaft p osition sens or lead 6 Rear brake switch lead 7 Wiring section # 8 Coolant brea ther hose 9 Clutch cable 0 Handlebar switch lead A Main switch lead B Assembling point # C Cover steering D Assembling point $ E Wi[...]

2 - 41 SPEC CABLE ROUTING Ô To turn signal light Õ In this area, pass the han dlebar switch (ri ght) lead behind of th e throttle cable. Ö Route the coola nt temperature senso r lead between the engine and the radiator hose. × Route the clut ch cable through the inside of radiator hose and fa sten it with the clamp to th e radiator. Ø Fasten t[...]

2 - 42 SPEC CABLE ROUTING 1 Ignition coil plate 2 Rubber baffle 3 Assembling point ± 4 Assembling point ! 5 To wiring section ± 6 To wiring sections ± , # 7 Oil level switch lead 8 Sidestand switch lead 9 Clamp 0 EXUP servo motor lead A Air cleaner drain hose B AI system lead C Fuel tank breath er hose D Fuel tank drain hose ( No spe- cial order[...]

2 - 43 SPEC CABLE ROUTING Ê Clamp the air cleaner drain hose, fuel tan k breather hose, drain hose, AI system hose, AI system lead a nd AC magneto. Route the air cleaner drain hose, fuel tan k breather ho se and drain hose outsid e the AI system hose, AI system lead and AC magneto lea d. Route the fuel tank res erve hose and fuel tank drain hose u[...]

2 - 44 SPEC CABLE ROUTING Õ Point the tip of th e band to the inner side. Ö Routing position of each hose except the AI system hose is not regulated in th e clamp. × Pass all the hoses un der the injector sub lead and wire har- ness. Ø Neutral switch lead: Fasten the EXUP servo motor lead and rear brake switch lead with the clamp inserted to th[...]

2 - 45 SPEC for California 1 Canister 2 Roll over valve assembly 3 Hose (fuel tank breather – canister) 4 Hose (canister – roll over valve) 5 Hose (roll over valve – throttle body ) È To throttle bo dy É To atom osphere CABLE ROUTING[...]

3 - 1 CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information ne cessary to perform recommended checks and ad justments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information ap[...]

3 - 2 CHK ADJ * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the mainte nance intervals starting from 4,000 mi (7,000 km) or 6 months. NOTE: ● Air filter • This model ’ s air filter is equipped with a disposable oil-coated pa[...]

3 - 3 CHK ADJ SEATS EAS00039 SEATS T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the seats Remove the parts in th e order listed. 1 Passenger seat 1 2 Rider seat 1 For installation, reverse the removal procedure.[...]

3 - 4 CHK ADJ FUEL TANK EAS00040 FUEL TANK T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the fuel tank Remove the parts in the order listed. Rider seat Refer to “ SEATS ” . 1B o l t 1 2B o l t 1 3 Fuel sender coupler 1 Di[...]

3 - 5 CHK ADJ FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank throug h the fuel tank cap with a pump . 2. Remo v 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 fuel remain- ing in it. NOTE: Before removing the hose[...]

3 - 6 CHK ADJ FUEL TANK INSTALLING THE FUEL PUMP 1. Install: • fuel pump NOTE: • Do not damage the installation surfaces of the fuel tank when in stalling the fuel pump. • Always use a new fuel pump gasket. • Install the fuel pump as shown in the illustra- tion. • Tighten the fuel pump bolts in stages in a crisscross pattern and to the sp[...]

3 - 7 CHK ADJ COWLINGS EAS00042 COWLINGS Order Job/Part Q ’ ty Remarks Removing the cowlings Remove the parts in the order listed. Rider and passenger seats Refer to “ SEATS ” . 1 Tail cowling 1 2 Bottom cowling 1 3 Front cowling inner panel (left) 1 4 Front cowling inner panel (right) 1 5 Left side cowling 1 6 Right side cowling 1 7 Windshie[...]

3 - 8 CHK ADJ AIR FILTER CASE EAS00043 AIR FILTER CASE T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) 3 Nm (0.3 m • kg, 2.2 ft • Ib) T R . . Order Job/Part Q ’ ty Remarks Removing the air filter case Remove the parts in the order listed. Rider seat and fuel tank Refer to “ SEATS ” an d “ FUEL TANK ” . 1 Crankcase breather hose 1 2 Air fi[...]

3 - 9 CHK ADJ ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALV E CLEARANCE The following procedure applies to all of the valves. NOTE: _ • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the c[...]

3 - 10 CHK ADJ ADJUSTING THE VALVE CLEARANCE 4. Measure: • valve clearance Out of specification → Adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T urn the crankshaft cloc kwise. b . When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the pic[...]

3 - 11 CHK ADJ ADJUSTING THE VALVE CLEARANCE 5. Remo v e: • camshaft NOTE: _ • Refer to “ DISASSEMBLING THE ENGINE — CAMSHAFT AND CYLINDER HEAD ” in chapter 5. • When removing the timing chain and cam- shafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase. 6. Adjust: • valve clearance ▼▼▼ ▼ [...]

3 - 12 CHK ADJ ADJUSTING THE VALVE CLEARANCE c. Round off the original valv e pad number according to the f ollo wing tab le . Last digit Rounded value 0 or 2 0 55 81 0 EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm) Rounded value = 150 d. Locate the rounded n umber of the o riginal v alv e pad and the measured v alv e clear- ance in [...]

3 - 13 CHK ADJ ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLE INTAKE EXHAUST Measured clearance INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 17 0 175 180 185 190 195 200 205 210 215 220 225 230 235 240 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 ~ 0.07 120 125 130[...]

3 - 14 CHK ADJ ADJUSTING THE VALVE CLEARANC E/ SYNCHRONIZING THE THROTTLE BODIES NOTE: @ • Refer to “ ASSEMBLING AND ADJUSTING THE ENGINE — CYLINDER HEAD AND CAMSHAFT ” in chapter 5. • Lubricate the camshaft bea rings, camshaft lobes and camshaft journals. • First, install the exhaust camshaft. • Align the camshaft marks with the cams[...]

3 - 15 CHK ADJ SYNCHRONIZING THE THROTTLE BODIES 4. Install: • carburetor syncronizer 1 (onto the synchronizing hose) • digital tachometer (near the spark plug) 5. Install: • fuel tank Refer to “ FUEL TANK ” . 6. Star t the engine and let it war m up f or se v- eral min utes. 7. Measure: • engine idling speed Out of specification → Ad[...]

3 - 16 CHK ADJ SYNCHRONIZING THE THROTTLE BODIES/ ADJUSTING THE ENGINE IDLING SPEED NOTE: @ The difference in vacuum pressure between two throttle bodies should not exce ed 1.33 kPa (10 mmHg, 0.39 inHg). ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 9. Measure: • engine idling s[...]

3 - 17 CHK ADJ ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 2. Install: • digital tachometer (onto the spark plug lead of cylind er #1) 3. Chec k: • engine idling speed Out of specification → Adjust. 4. Adjust: • engine idling speed ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼?[...]

3 - 18 CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY 2. Remo v e: • rider seat Refer to “ SEATS ” . • fuel tank Refer to “ FUEL TANK ” . • air filter case Refer to “ AIR FILTER CASE ” . 3. Adjust: • throttle cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ [...]

3 - 19 CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS d. Tighten the loc kn ut. W ARNING _ After adjusting the throttle cable free p lay, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change. ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲[...]

3 - 20 CHK ADJ CHECKING THE SPARK PLUGS/ MEASURING THE COMPRESSION PRESSURE 4. Chec k: • electrode 1 Damage/wear → Rep lace the spark plug. • insulator 2 Abnormal color → Replace the spa rk plug. Normal color is medium-to-light tan. 5. Clean: • spark plug (with a spark plug cleaner or wire brush) 6. Measure: • spark plug gap a (with a w[...]

3 - 21 CHK ADJ MEASURING THE COMPRESSION PRESSURE 1. Measure: • valve clearance Out of specification → Adjust. Refer to “ ADJUSTING THE VALVE CLEAR- ANCE ” . 2. Star t the engine, w ar m it up f or se v er al min- utes, and t hen tur n it off . 3. Remo v e: • rider seat Refer to “ SEATS ” . • fuel tank Refer to “ FUEL TANK ” . ?[...]

3 - 22 CHK ADJ MEASURING THE COMPRESSION PRESSURE ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main s w itch to “ ON ” . b . With the throttle wide open, crank the engine until the reading on the compression gauge stabiliz es. W ARNING _ To prevent sparking, ground[...]

3 - 23 CHK ADJ MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL 7. Install: • spark plug • ignition coil 8. Install: • rubber baffle • ignition coil plates • air filter case Refer to “ AIR FILTER CASE ” . • fuel tank Refer to “ FUEL TANK ” . • rider seat Refer to “ SEATS ” . T R . . 13 Nm (1.3 m · kg, 9.4[...]

3 - 24 CHK ADJ CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 4. Star t the engine, w ar m it up f or se v er al min- utes, and t hen tur n it off . 5. Chec k the engine oil le vel again. NOTE: _ Before checking the engine oil level, wait a few minutes until the oil has settled. EAS00073 CHANGING THE ENGINE OIL 1. Star t the engine, w ar m [...]

3 - 25 CHK ADJ CHANGING THE ENGINE OIL c. Tighten th e ne w oil filter car tr idge to specifi- cation with an oil filter wrench. ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ T R . . Oil filter cartridge 17 Nm (1.7 m · kg, 12 ft · lb) 6. Chec k: • engine oil drain bolt gasket [...]

3 - 26 CHK ADJ CHANGING THE ENGINE OIL/ ADJUSTING THE CLUTCH CABLE FREE PLAY 13.Chec k: • engine oil pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Slightly loosen the oil gallery bolt 1 . b . Star t the engine and keep it idling until engine oil star ts to seep from [...]

3 - 27 CHK ADJ ADJUSTING THE CLUTCH CABLE FREE PLAY 2. Adjust: • clutch cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ Handlebar side a. T ur n the adjusting dial 1 in direction a or b until the specified clutch cab le free pla y is obtained. NOTE: _ If the specif[...]

3 - 28 CHK ADJ REPLACING THE AIR FILTER ELEMEN T EAS00086 REPLACING THE AIR FILTER ELEMENT 1. Remo v e: • rider seat Refer to “ SEATS ” . • fuel tank Refer to “ FUEL TANK ” . 2. Remo v e: • air filter case cover 1 3. Chec k: • air filter element 1 Damage → Replace. NOTE: Replace the air filter element at periodic inter- vals of 40[...]

3 - 29 CHK ADJ CHECKING THE FUEL AND B REATHER HOSES/ CHECKING THE CRANKCASE BREATHER HOSE EAS00096 CHECKING THE FUEL AND BREATHER HOSES The following procedure applies to all of the fuel and breather hoses. 1. Remo v e: • rider seat Refer to “ SEATS ” . • fuel tank Refer to “ FUEL TANK ” . 2. Chec k: • breather hose 1 • fuel hose 2[...]

3 - 30 CHK ADJ CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM 3. Install: • fuel tank Refer to “ FUEL TANK ” . • rider seat Refer to “ SEATS ” . EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Remo v e: • radiator Refer to “ RADIATOR ” in chapter 6[...]

3 - 31 CHK ADJ ADJUSTING THE EXUP CABLES EAS00101 ADJUSTING THE EXUP CABLES 1. Remo v e: • bottom cowling Refer to “ COWLINGS ” . 2. Remo v e: • EXUP valve pulley cov er 1 3. Chec k: • EXUP system operation ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T ur n the main[...]

3 - 32 CHK ADJ ADJUSTING THE EXUP CABLES/ CHECKING THE COOLANT LEVEL 7. Install: • bottom cowling Refer to “ COWLINGS ” . EAS00102 CHECKING THE COOLANT 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. Chec k: • coolant level The coolant leve[...]

3 - 33 CHK ADJ CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Remo v e: • bottom cowling • side cowlings Refer to “ COWLINGS ” . 2. Chec k: • radiator 1 • radiator inlet hose 2 • radiator outlet hose 3 • oil cooler 4 • oil cooler inlet hose 5 • oil cooler outlet hose 6 • water jacket join t inlet hose 7 ?[...]

3 - 34 CHK ADJ CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remo v e: • side cowling • bottom cowling Refer to “ COWLINGS ” . 2. Disconnect: • coolant reservoir hose 1 3. Drain: • coolant (from the coolant reservoir) 4. Remo v e: • radiator cap 1 W ARNING _ A hot radiator is under pressure. Therefore, do not remove the radiat[...]

3 - 35 CHK ADJ CHANGING THE COOLANT 10.Fill: • cooling system (with the specified amount of the recom- mended coolant) Handling notes for coolant Coolant is potentially harmful and should be handled with special care. W ARNING _ • If coolant splashes in your eyes, thor- oughly wash them with water a nd consult a doctor. • If coolant splashes [...]

3 - 36 CHK ADJ CHANGING THE COOLANT 11.Install: • radiator cap 12.Fill: • coolant reservoir (with the recommended coolant to the maxi- mum level mark a ) 13.Install: • coolant reservoir cap 14.Star t the engine, wa r m it up f or se veral min- utes, and t hen stop it. 15.Chec k: • coolant level Refer to “ CHECKING THE COOLANT LEVEL ” . [...]

3 - 37 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 brake lever is in the desired position. • Be sure to align the setting on the adjustin[...]

3 - 38 CHK ADJ ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Chec k: • brake pedal position (distance a from the top of the brake pedal to the bottom of the rider footrest bracket) Out of specification → Adjust. 2. Adjust: • brake pedal position ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼[...]

3 - 39 CHK ADJ ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL 3. Adjust: • rear brake light 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 - 40 CHK ADJ CHECKING THE FRONT AND REAR BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00122 CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate th e brak e . 2. Chec k: • front brake pad • rear brake pad Wear indicator groove 1 almost disap- peared → Replace the brake pads as a[...]

3 - 41 CHK ADJ CHECKING THE FRONT AND REAR BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00131 CHECKING THE FRONT AND REAR BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Chec k: • brake hose Cracks/damage/wear → Replace . 2. Chec k: • brake hose clamp Loose → Tighten the clamp bolt. 3. [...]

3 - 42 CHK ADJ BLEEDING THE HYDRAULIC BRAKE SYSTEM 1. Bleed: • hydraulic brake system ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fill the brak e fluid reservoir to the proper le v el with the recommended br ak e fluid. b . Install the bra ke f luid reser v oir diaphragm. c[...]

3 - 43 CHK ADJ ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK EAS00136 ADJUSTING THE SHIFT PEDAL 1. Chec k: • shift pedal position (distance a from the bottom of the rider footrest bracket to the top of the shift pedal) Out of specification → Adjust. 2. Adjust: • shift pedal position ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ [...]

3 - 44 CHK ADJ ADJUSTING THE DRIVE CHAIN SLACK 3. Chec k: • drive chain slack a Out of specification → Adjust. T R . . Drive chain slack 40 ~ 50 mm (1.57 ~ 1.97 in) 4. Adjust: • drive chain slack ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the wheel axle n ut 1 .[...]

3 - 45 CHK ADJ LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Th erefore, the drive chain should be serviced, especially when the motorcycle is used in d usty area[...]

3 - 46 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD 3. Remo v e: • upper bracket Refer to “ HANDLEBARS ” and “ STTERLING HEAD ” in chapter 4. 4. Adjust: • steering head ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remo v e the loc k wash er 1 , the upper ring n[...]

3 - 47 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD e. Install the rubber w asher 3 . f . Install th e upper ring nut 2 . g. Finger tigh ten the upper ring nut 2 , then align the slots of both ring nuts. If nece s- sar y , hold the lo wer ring nut and tighten the upper ring nut until their slots are aligned. h. Install the loc k w asher 1 . NOT[...]

3 - 48 CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK g. Reinstall the upper brack et and measure the steering head tension again as descr ibed abov e . h. Repeat the abo v e procedure until the steer- ing head tension is within specification. i. Grasp the bottom of the fro nt f ork legs and gently roc k the front f ork. [...]

3 - 49 CHK ADJ ADJUSTING THE FRONT FORK LEGS EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies 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 motorc ycle so that there is no danger of it falli[...]

3 - 50 CHK ADJ ADJUSTING THE FRONT FORK LEGS Rebound damping CAUTION: _ Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • rebound damping ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T urn the adjusting scre w 1 in direction a or b . ▲▲▲ ▲ ?[...]

3 - 51 CHK ADJ ADJUSTING THE FRONT FORK LEGS/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Direction a Compression damping is increased (suspen- sion is harder). Direction b Compression damping is decreased (suspen- sion is softer). Adjus[...]

3 - 52 CHK ADJ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Rebound damping CAUTION: _ Never go beyond the maximum or mini- mum adjustment positions. Direction a Spring preload is increased (suspension is harder) . Direction b Spring pre[...]

3 - 53 CHK ADJ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRES 1. Adjust: • compression damping ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T urn the adjusting scre w 1 in direction a or b . ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ▲▲▲ ▲ [...]

3 - 54 CHK ADJ CHECKING THE TIRES * Total weight of ride r, passenger, cargo and acces- sories W ARNING _ It is dangerous to ride with a worn-out tire. When the tire tread reaches the we ar limit, replace the tire immediately. Basic weight (with oil and a full fuel tank) For USA, Canada 193 kg (426 lb) For California 194 kg (428 lb) Maximum load* F[...]

3 - 55 CHK ADJ CHECKING THE TIRES W ARNING _ • Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. • When using a tube tire, be sure to install the correct tube. • Always replace a new tube tire and a new tube as a set. • To avoid pinching the tube, make sure th[...]

3 - 56 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 have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. NOTE: _ For tires with a direction of rotation mark 1 : • Insta[...]

3 - 57 CHK ADJ CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND PEDALS/LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. W ARNING _ Damaged outer cable may cause the c able to corrode and interfere with its movem[...]

3 - 58 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 - 59 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. Remo v e: • rider seat Refer to ?[...]

3 - 60 CHK ADJ CHECKING AND CHARGING THE BATTERY 5. Charge: • battery (refer to the appropriate chargin g 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-amperage current into the battery quickly and can cause [...]

3 - 61 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) c harger Measure the open- circuit voltage prior to charging. Connect a charge r and AMP meter to th e battery and start char ging. Make sure that th e current is higher than th e standard charging current writt en on the battery. NO YES Charger AMP [...]

3 - 62 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 AMP meter to the ba ttery and start charging. NO YES Make sure that the current is higher than the standard charging current wr itten on the battery. Charge the battery un til [...]

3 - 63 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 b rush. Loose connection → Connect properly[...]

3 - 64 CHK ADJ CHECKING THE FUSES 3. Replace: • blown fuse ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main s w itch to “ OFF ” . b . Install a ne w fuse of the correct a mperage rating. c. Set on th e s witches to v erify if the electrical circuit is operationa[...]

3 - 65 CHK ADJ REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: • headlight coupler 1 2. Remo v e: • headlight bulb cover 2 3. Remo v e: • headlight bulb holder 1 4. Remo v e: • headlight bulb 2 W ARNING _ Since the headlight bulb gets extreme[...]

3 - 66 CHK ADJ ADJUSTING THE HEADLIGHT BEAM EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • headlight beam (vertically) ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T urn the adjusting scre w 1 in direction a or b . ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ?[...]

4 - 1 CHAS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q ’ ty Remarks Removing the front wheel an d brake discs Remove the parts in the order listed. NOTE: _ Place the motorcycle on a suitable stand so that the front wheel is elevated. 1 Brake hose holder (left and right) 2 2 Brake caliper (left and right) 2 3 Wheel axle pinch bol[...]

4 - 2 CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 FRONT WHEEL Order Job/Part Q ’ ty Remarks Disassembling the fron t wheel Remove the parts in the order listed. 1 Oil seal (left and right) 2 2 Wheel bearing (left and right) 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 motorcycle 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. Remo v e: • left brake caliper • right brake cal[...]

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 (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) 4. Chec k: • wheel bearings Front wheel turns roughly or is loose → Replace the wheel b earings. • oil seals Damag[...]

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: • brake disc Damage/galling → Repla ce. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc. ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ [...]

4 - 6 CHAS FRONT WHEEL AND BRAKE DISCS d. Measure the brak e disc deflect ion. e. If out of specification, repeat the adjustment steps until the br ak e disc deflection is with in specification. f . If the br ak e disc deflection ca nnot be brought within specification, re place the brak e disc. ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ?[...]

4 - 7 CHAS FRONT WHEEL AND BRAKE DISCS 8. Tighten wheel axle pinch bolt 1 , and then pinch bolt 2 to the specified t orque. 9. T ap the outer side of the right f ork leg with a rubber mallet to align it with the end of the wheel axle . 10.Tighten wheel axle pinch bo lt 3 , and then pinch bolt 4 to the specified t orque. 11.While applying the front [...]

4 - 8 CHAS FRONT WHEEL AND BRAKE DISCS ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Spin the front wh eel. b . When the front wheel stops , put an “ X 1 ” mark at the bottom of the wheel. c. T urn the front wheel 90 ° so that the “ X 1 ” mark is positioned as shown. d[...]

4 - 9 CHAS REAR WHEEL AND BRAKE DISC EAS00551 REAR WHEEL AND BRAKE DISC T R . . 27 Nm (2.7 m • kg, 20 ft • Ib) T R . . 150 Nm (15.0 m • kg, 108 ft • lb) Order Job/Part Q ’ ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: @ Place the motorcycle on a suitable stand so that the rear wheel is elevated . 1 Brake c[...]

4 - 10 CHAS REAR WHEEL AND BRAKE DISC EAS00560 REAR WHEEL Order Job/Part Q ’ ty Remarks Disassembling the rear whe el Remove the parts in the order listed. 1 Spacer 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For installation, reverse the disassembly procedure.[...]

4 - 11 CHAS REAR WHEEL AND BRAKE DISC T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) T R . . 100 Nm (10 m • kg, 72 ft • lb) Order Job/Part Q ’ ty Remarks Remove the brake disc and rear wheel sprocket Remove the parts in the order listed. 1 Brake disc 1 2 Rear wheel sprocket 1 3 Collar (left and right) 2 4O i l s e a l 1 5B e a r i n g 1 6 Rear wh[...]

4 - 12 CHAS REAR WHEEL AND BRAKE DISC EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Securely support the motorcycle 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. Remo v e: • brake caliper 1 NOTE: _ Do not depress th[...]

4 - 13 CHAS REAR WHEEL AND BRAKE DISC 5. Remo v e: • left collar 1 • rear wheel drive hub 2 • rear wheel drive hub damper • right collar EAS00565 CHECKING THE REAR WHEEL 1. Chec k: • wheel axle • rear wheel • wheel bearings • oil seals Refer to “ CHECKING THE FRONT WHEEL ” . 2. Chec k: • tire • rear wheel Damage/wear → Rep[...]

4 - 14 CHAS REAR WHEEL AND BRAKE DISC EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Chec k: • rear wheel sprocket More than 1/4 tooth a wear → Replace the rear wheel sprocket. Bent teeth → Replace the rear wheel sprocket. b Correct 1 Drive chain roller 2 Rear wheel sprocket 2. Replace: • rear wheel sprocket ▼▼▼ ▼ ▼ ?[...]

4 - 15 CHAS REAR WHEEL AND BRAKE DISC 2. Adjust: • drive chain slack Refer to “ ADJUSTING THE DRIVE CHAIN SLACK ” in ch apter 3. 3. Tighten: • wheel axle nut • brake caliper bolts W ARNING _ Make sure the brake hose is routed prop- erly. CAUTION: _ Do not loosen the wheel axle nut after tight- ening it to the specified torque. If the groo[...]

4 - 16 CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the front brake pads Remove the parts in the order listed. The following procedure applies to both[...]

4 - 17 CHAS FRONT AND REAR BRAKES REAR BRAKE PADS T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) T R . . 27 Nm (2.7 m • kg, 20 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the rear brake pads Remove the parts in th e order listed. 1 Brake caliper 1 2B r a k e p a d 2 3 Brake pad shim 2/2 4 Brake pad spring 2 5 Bleed screw 1 For installation, r[...]

4 - 18 CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: _ Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: W ARNING • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, [...]

4 - 19 CHAS FRONT AND REAR BRAKES 2. Remo v e: • brake pad clips 1 • brake pad pins 2 • brake pad spring 3 3. Remo v e: • brake pads 1 (along with the brake pad shims) 4. Measure: • brake pad wear limit Out of specification → Replace the brake pads as a set. 5. Install: • brake pad shims (onto the brake pads) • brake pads • brake [...]

4 - 20 CHAS FRONT AND REAR BRAKES ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose 1 tightly to the ble ed scre w 2 . Put the other end of the hose into an open contain er . b . Loosen the b leed scre w and push the brak e caliper pistons into the br a[...]

4 - 21 CHAS FRONT AND REAR BRAKES EAS00583 REPLACING THE REAR BRAKE PADS NOTE: _ When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disa s- semble the brake caliper. 1. Remo v e: • brake caliper 1 2. Remo v e: • brake pads 1 (along with the brake pad shims) 3. Measure: • brake pad wear limit Out of specificat[...]

4 - 22 CHAS FRONT AND REAR BRAKES ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose 1 tightly to the ble ed scre w 2 . Put the other end of the hose into an open contain er . b . Loosen the b leed scre w and push the brak e caliper pistons into the br a[...]

4 - 23 CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 9 Nm (0.9 m • kg, 6.5 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the front brake master cylinder Remove the parts in the order listed. Brake fluid Drain. 1 Brake fluid reservoir cap stopper 1 2 Brake fluid reservoir c[...]

4 - 24 CHAS FRONT AND REAR BRAKES T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 9 Nm (0.9 m • kg, 6.5 ft • Ib) Order Job/Part Q ’ ty Remarks 13 Br ake hos e 1 14 Brake master cylinder bracke t 1 15 Brake master cylinder 1 16 Front brake switch 1 For installation, reverse the removal procedure.[...]

4 - 25 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q ’ ty Remarks Disassembling the front brake master 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 - 26 CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 3 Nm (0.3 m • kg, 2.2 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the rear brake master cylinder Remove the parts in the order listed. Brake fluid Drain. 1 Brake fluid reservoi[...]

4 - 27 CHAS FRONT AND REAR BRAKES EAS00587 T R . . 16 Nm (1.6 m • kg, 12 ft • Ib) Order Job/Part Q ’ ty Remarks Disassembling the rear brake master cylinder Remove the parts in the order listed. 1 Brake master cylinder kit 1 2 Brake master cylinder 1 For assembly, reverse the disassembly procedure.[...]

4 - 28 CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: _ Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: • brake switch coupler 1 (from the brake switch) 2. Remo v e: • union bolt 2 • copper washers 3 • brake hoses 4 NOTE: _ To c[...]

4 - 29 CHAS FRONT AND REAR BRAKES EAS00593 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders. 1. Chec k: • brake master cylinder Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. È F[...]

4 - 30 CHAS FRONT AND REAR BRAKES EAS00607 ASSEMBLING AND INSTALLIN G THE FRONT BRAKE MASTER CYLINDER W ARNING _ • Before installation, all internal brake com- ponents should be cleaned and lub ricated with clean or new brake fluid. • Never use solvents on internal brake components. Recommended brake fluid DOT 4 1. Install: • brake master cyl[...]

4 - 31 CHAS FRONT AND REAR BRAKES 3. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) W ARNING _ • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already i[...]

4 - 32 CHAS FRONT AND REAR BRAKES EAS00610 ASSEMBLING THE REAR BRAK E MASTER CYLINDER 1. Install: • copper washers • brake hose • union bolt CAUTION: _ When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection a on the brake master cylinder. W ARNING _ Proper brake hose routing is esse[...]

4 - 33 CHAS FRONT AND REAR BRAKES 3. Bleed: • brake system Refer to “ BLEEDING THE HYDRAULIC BRAKE SYSTEM ” in chapter 3. 4. Chec k: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “ CHECKING THE BRAKE FLUID LEVEL ” in chapter 3. 5. Adjust: • brake pedal position a R[...]

4 - 34 CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the front brake calipers Re move the parts in the order listed. The following procedure applies to both of the front[...]

4 - 35 CHAS FRONT AND REAR BRAKES EAS00615 T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) Order Job/Part Q ’ ty Remarks Disassembling the front brake calipers Remove the 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 2 5 Brake calipe[...]

4 - 36 CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER T R . . 30 Nm (3.0 m • kg, 22 ft • Ib) T R . . 27 Nm (2.7 m • kg, 20 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. 1 Uni on bol t 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installat[...]

4 - 37 CHAS FRONT AND REAR BRAKES EAS00617 T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) Order Job/Part Q ’ ty Remarks Disassembling the rear brake caliper Remove the parts in the order listed. 1 Brake caliper piston 2 2 Brake caliper piston seal 4 3 Bleed screw 1 For assembly, reverse the disassembly procedure.[...]

4 - 38 CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: _ Before disassembling the brake caliper, drain the brake fluid from the entire b rake system. 1. Remo v e: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: _ Put the end of the brake hos[...]

4 - 39 CHAS FRONT AND REAR BRAKES EAS00627 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: _ Before disassembling the brake caliper, drain the brake fluid from the entire b rake system. 1. Remo v e: • union bolt 1 • copper washers 2 • brake hose NOTE: _ Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remo [...]

4 - 40 CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is disassem- bled 1. Chec k: • brake caliper pistons 1 Rust/scratches/wear → R[...]

4 - 41 CHAS FRONT AND REAR BRAKES EAS00640 ASSEMBLING AND INSTALLIN G THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. W ARNING _ • Before installation, all internal brake com- ponents should be cleaned and lub ricated with clean or new brake fluid. • Never use solvents on internal brake components as they[...]

4 - 42 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) W ARNING _ • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already i[...]

4 - 43 CHAS FRONT AND REAR BRAKES ASSEMBLING AND INSTALLIN G THE REAR BRAKE CALIPER W ARNING @ • Before installation, all internal brake com- ponents should be cleaned and lub ricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort. • Whenever a brake ca[...]

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

4 - 45 CHAS FRONT FORK EAS00647 FRONT FORK T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 6 Nm (0.6 m • kg, 4.3 ft • Ib) T R . . 23 Nm (2.3 m • kg, 17 ft • Ib) T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) T R . . 26 Nm (2.6 m • kg, 19 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the front fork legs Re move the parts in the order[...]

4 - 46 CHAS FRONT FORK EAS00648 T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) Order Job/Part Q ’ ty Remarks Disassembling the front fork legs Remove the parts in the order listed. 1 Cap bolt 1 2 O-ring 1 3 Spacer 1 4 Nut 1 5 Spring seat 1 6 Fork spring 1 7 Damper adjusting rod 1 8 Outer tube 1 9 Dust seal 1 0 Oil seal clip 1 A Oil seal 1 B Washer 1[...]

4 - 47 CHAS FRONT FORK T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) Order Job/Part Q ’ ty Remarks C Damper rod assembly bolt 1 D Copper washer 1 E Damper rod assembly 1 F Inner tube 1 For assembly, reverse the disassembly procedure.[...]

4 - 48 CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Securely support the motorcycle 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. [...]

4 - 49 CHAS FRONT FORK NOTE: @ Use the side of the rod holder that is marked “ B ” . c. Loosen the nut. d. Remov e the cap bolt. e. Remov e the rod holder and f ork spr ing com- pressor . W ARNING _ The fork spring is compressed. f . Remo v e the spacer and nut. ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ [...]

4 - 50 CHAS FRONT FORK EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Chec k: • inner tube 1 • outer tube 2 Bends/damage/scratches → Repla ce. W ARNING @ Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: • spring free length a Out of specif[...]

4 - 51 CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. W ARNING _ • Make sure the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor han- dling and a loss of stability. NOTE: _ • When assembling the front fork leg, be sure to replace the [...]

4 - 52 CHAS FRONT FORK 4. Install: • dust seal 1 • oil seal clip 2 • oil seal 3 • washer 4 CAUTION: @ Make sure the numbered side o f the oil seal faces out side. NOTE: _ • Before installing the oil seal, lubricate its lips with lithium-soap-based grea se. • Lubricate the outer surface of th e inner tube with fork oil. • Before instal[...]

4 - 53 CHAS FRONT FORK 8. Install: • rod puller 1 (onto the damper rod 2 ) Rod puller YM-01437 9. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) NOTE: _ • While filling the front fork leg, keep it upright. • After filling, slowly pump the front f ork leg up and down to distribute the fork oil. 10.Install: ?[...]

4 - 54 CHAS FRONT FORK d. Press down on the spacer with the f or k spring compressor 1 . e. Pull up the rod puller and in stall the rod holder 2 between the n ut 3 and the spacer 4 . NOTE: _ Use the side of the rod holder that is marked “ B ” . f . Remo v e the rod p uller and adapter . g. Install the nut 1 and position it as spe cified b . h. [...]

4 - 55 CHAS FRONT FORK EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: _ Make sure the inner fork tube is flush with the top of the handlebar holder. 2. Tighten: • lower bracket pinch bolt • c[...]

4 - 56 CHAS HANDLEBARS EAS00665 HANDLEBARS T R . . 9 Nm (0.9 m • kg, 6.5 ft • Ib) T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) T R . . 26 Nm (2.6 m • kg, 19 ft • Ib) T R . . 115 Nm (11.5 m • kg, 83 ft • lb) T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the [...]

4 - 57 CHAS HANDLEBARS T R . . 9 Nm (0.9 m • kg, 6.5 ft • Ib) T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) T R . . 26 Nm (2.6 m • kg, 19 ft • Ib) T R . . 115 Nm (11.5 m • kg, 83 ft • lb) T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) Order Job/Part Q ’ ty Remarks 11 Front brake switch connector 2[...]

4 - 58 CHAS HANDLEBARS EAS00667 REMOVING THE HANDLEBARS 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Securely support the motorcycle so that there is no danger of it falling over. 2. Remo v e: • handlebar grip NOTE: _ Blow compressed air between the left handle- bar and the handlebar grip, and gradually push the grip off the handle ba[...]

4 - 59 CHAS HANDLEBARS 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: • brake master cylinder holder 1 CAUTION: _ • Install the brake master cylinder holder with the “ UP ” mark facing up. • First, tighten the upper bolt, then the lo[...]

4 - 60 CHAS HANDLEBARS 6. Install: • left handlebar switch 1 NOTE: _ Align the projection a on the left handlebar switch with the hole b in the left handlebar. 7. Install: • handlebar grip ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a thin coat of rubber adhesiv e o[...]

4 - 61 CHAS STEERING HEAD EAS00676 STEERING HEAD T R . . 1st 50 Nm (5.0 m • kg, 36 ft • lb) 2nd 9 Nm (0.9 m • kg, 6.5 ft • lb) T R . . 115 Nm (11.5 m • kg, 83 ft • lb) T R . . 26 Nm (2.6 m • kg, 19 ft • Ib) T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the lower bracket Remove the parts in the [...]

4 - 62 CHAS STEERING HEAD T R . . 1st 50 Nm (5.0 m • kg, 36 ft • lb) 2nd 9 Nm (0.9 m • kg, 6.5 ft • lb) T R . . 115 Nm (11.5 m • kg, 83 ft • lb) T R . . 26 Nm (2.6 m • kg, 19 ft • Ib) T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) Order Job/Part Q ’ ty Remarks 12 Lower ring nut 1 13 Lower bracket 1 14 Bea ring co ver 1 15 Bearing inn[...]

4 - 63 CHAS STEERING HEAD EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Securely support the motorcycle so that there is no danger of it falling over. 2. Remo v e: • ring nut 1 (with the steering nut wrench 2 ) W ARNING _ Securely support the lower bracket so that there is no danger of it falling. EA[...]

4 - 64 CHAS STEERING HEAD b . Remo v e the bearing r ace 3 from the lo wer brac k et with a floor chisel 4 and h ammer . c. Install a ne w rubber seal and ne w bearing rac es. CAUTION: _ If the bearing race is not installed properly, the steering head pipe could be damaged . NOTE: _ • Always replace the bearings and bearing races as a set. • Wh[...]

4 - 65 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY T R . . 45 Nm (4.5 m • kg, 33 ft • Ib) T R . . 45 Nm (4.5 m • kg, 33 ft • Ib) T R . . 45 Nm (4.5 m • kg, 33 ft • Ib) 1 Order Job/Part Q ’ ty Remarks Removing the rear shock absorber assembly Remove the parts in the order listed. 1 Self-locking nut/bolt 1/1 [...]

4 - 66 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER W ARNING _ This rear shock absorber and gas c ylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and m ake sure you understand the following information. The manufacturer cannot be held respo[...]

4 - 67 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Becurely support the motorcycle 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. Remo v e: • rear shock absorber [...]

4 - 68 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00695 CHECKING THE REAR SHOCK ABSORB ER ASSEMBLY 1. Chec k: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. • spring Damage/wear → Replace the rear shock absorber assembly. [...]

4 - 69 CHAS SWINGARM AND DRIVE CHAIN EAS00700 SWINGARM AND DRIVE CHAIN T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 5 Nm (0.5 m • kg, 3.6 ft • Ib) T R . . 1 05 Nm (1 0.5 m • kg, 76 ft • lb) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the swingarm and dr[...]

4 - 70 CHAS SWINGARM AND DRIVE CHAIN T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 5 Nm (0.5 m • kg, 3.6 ft • Ib) T R . . 1 05 Nm (1 0.5 m • kg, 76 ft • lb) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) Order Job/Part Q ’ ty Remarks 8 Drive chain 1 9D u s t c o v e r 2 10 Drive chain guide 1 11[...]

4 - 71 CHAS SWINGARM AND DRIVE CHAIN EAS00703 REMOVING THE SWINGARM 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Securely support the motorcycle 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. Remo v e: • relay arm-to-swingarm bolt 1 • connecting [...]

4 - 72 CHAS SWINGARM AND DRIVE CHAIN EAS00704 REMOVING THE DRIVE CHAIN 1. Stand the motorcycle on a le vel surf ace. W ARNING _ Securely support the motorcycle 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. Remo v e: • drive chain (with the drive chain cutter)[...]

4 - 73 CHAS SWINGARM AND DRIVE CHAIN 3. W ash: • pivot shaft • dust covers • spacer • washers • bearings Recommended cleaning solvent Kerosene 4. Chec k: • dust covers 1 • spacer 2 Damage/wear → Replace. • bearings 3 Damage/pitting → Replace. 5. Chec k: • connecting arms 1 • relay arm 2 Damage/wear → Replace. 6. Chec k: ?[...]

4 - 74 CHAS SWINGARM AND DRIVE CHAIN 2. Chec k: • drive chain Stiffness → Clean and lubricate o r replace. 3. Clean: • drive chain ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Wipe the drive chain with a clean cloth. b . Put the driv e chain in k erosene and remo v e any[...]

4 - 75 CHAS SWINGARM AND DRIVE CHAIN 6. Chec k: • drive sprocket • rear wheel sprocket More than 1/4 tooth a wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. b Correct 1 Drive chain roller 2 Drive chain sprocket EAS00711 INSTALLING THE SWINGARM 1. Lubricate: • bearings • spacers[...]

5 - 1 ENG EAS00188 OVERHAULING THE ENGINE ENGINE DRIVE SPROCKET T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 85 Nm (8.5 m • kg, 61 ft • Ib) Order Job/Part Q’ty Remarks Removing the drive spro cket Remove the parts in the order listed. 1 Locknut 2 2 Shift rod 1 3 Drive sprocket c over 1 4 Lock washer 1 5 Drive sprocket 1 6 Shift arm 1 F[...]

5 - 2 ENG ENGINE EAS00189 EXHAUST PIPE T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 38 Nm (3.8 m • kg, 27 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the exhaust pipe Remove the parts in the order listed.[...]

5 - 3 ENG ENGINE T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 38 Nm (3.8 m • kg, 27 ft • Ib) T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) Order Job/Part Q ’ ty Remarks 7 Exhaust valve pipe 1 8 Muffler 1 For installation, reverse the removal procedure.[...]

5 - 4 ENG ENGINE LEADS AND HOSES T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks Disconnecting the leads and hoses Disconnect the parts in th e order listed. Air filter case Refer to “ AIR FILTER CASE ” in chapter 3. Throttle body assembly Refer to “ THROTTLE BODIES ” in[...]

5 - 5 ENG ENGINE T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks 3 Clutc h cable 1 4 Crankcase breather hose 1 5 Starter motor lead 1 Disconnect. 6 Ground lead 1 Disconnect. 7 Starter motor 1 8 Stator coil assembly coupler 1 Disconnect. 9 Pickup coil coupler 1 Disconnect. 10 Oil[...]

5 - 6 ENG ENGINE EAS00191 ENGINE T R . . 50 Nm (5.0 m • kg, 36 ft • Ib) 45 Nm (4.5 m • kg, 33 ft • Ib) T R . . T R . . 45 Nm (4.5 m • kg, 33 ft • Ib) T R . . 50 Nm (5.0 m • kg, 36 ft • Ib) T R . . 24 Nm (2.4 m • kg, 17 ft • Ib) 6 T R . . 45 Nm (4.5 m • kg, 33 ft • Ib) 8 T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Pa[...]

5 - 7 ENG ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: • engine mounting adjust bolts 1 • rear mounting bolts 2 • self-locking nuts 3 • left front mounting bolt 4 • right front mounting bolt 5 • pinch bolt 6 NOTE: _ • Lubricate the rear mounting bolt thread s with lithium soap base grease. • Do not fully tighten the bolts. NOTE[...]

5 - 8 ENG CAMSHAFT EAS00194 CAMSHAFT CYLINDER HEAD COVERS T R . . 13 Nm (1.3 m • kg, 9.4 ft • Ib) T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q’ty Remarks Removing the cylinder head covers Remove the parts in the order listed. Throttle body assembly Refer to “THROTTLE BODIES” in c[...]

5 - 9 ENG CAMSHAFT EAS00196 CAMSHAFTS T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 24 Nm (2.4 m • kg, 17 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the camshafts Remove the parts in the order listed. P[...]

5 - 10 ENG CAMSHAFT T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 24 Nm (2.4 m • kg, 17 ft • Ib) Order Job/Part Q ’ ty Remarks 13 Pin 1 14 Timing chain guide (intake side) 1 For installation, reverse the rem[...]

5 - 11 ENG CAMSHAFT EAS00198 REMOVING THE CAMSHAFTS 1. Align: • TDC mark on the pickup coil rotor (with the crankcase mating surf ace) ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T urn the crankshaft cloc kwise. b . When piston #1 is at TDC on the compres- sion stroke, alig[...]

5 - 12 ENG CAMSHAFT 6. Remo v e: • timing chain guide (exhaust side) 1 • camshaft caps • dowel pins CAUTION: _ To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 7. Remo v e: • intake camshaft 1 • exhaust camshaft 2 EAS0020[...]

5 - 13 ENG CAMSHAFT 3. Measure: • camshaft runout Out of specification → Replace. 4. Measure: • camshaft-journal-to-camshaft-cap clear- ance Out of speci fication → Measure the cam- shaft journal diameter. Camshaft runout limit 0.03 mm (0.0012 in) Camshaft-journal-to-camshaft- cap clearance 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) ▼▼▼ ?[...]

5 - 14 ENG CAMSHAFT 5. Measure: • camshaft journal diameter a Out of specification → Replace the cam- shaft. Within specification → Repla ce the cylinder head and the camshaft caps as a set. Camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMIN G CHAIN GUIDES The fo[...]

5 - 15 ENG CAMSHAFT EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Chec k: • timing chain tensioner Cracks/damage → Replace. 2. Chec k: • one-way cam operation Rough movement → Replace the timing chain tensioner housing. 3. Chec k: • cap bolt • copper washer • spring • one-way cam • gasket • timing chain tensioner rod Damage/we[...]

5 - 16 ENG CAMSHAFT CAUTION: _ The camshaft cap bolts must be tightened evenly or damage to the cylinder h ead, camshaft caps, and camshafts wil l result. 4. Install: • intake camshaft sprocket • exhaust camshaft sprocket ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. T urn [...]

5 - 17 ENG CAMSHAFT 6. Install: • timing chain tensioner ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. While lightly pressing the timing chain ten- sioner rod b y hand, turn the tensioner rod fully cloc kwise with a thin scre wdriver 1 . b . With the timing chain tensioner ro[...]

5 - 18 ENG CAMSHAFT 9. Tighten: • camshaft sprocket bolts CAUTION: _ Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine. 10.Install: • timing chain guide (top side) 11.Measure: • valve clearance Out of specification → Adjust. Refer to “ ADJUSTIN[...]

5 - 19 ENG CYLINDER HEAD EAS00221 CYLINDER HEAD 2nd 140˚ or 65 Nm (6.5 m • kg, 47 ft • lb) T R . . 1st 20 Nm (2.0 m • kg, 14 ft • lb) 2nd 105˚ or 50 Nm (5.0 m • kg, 36 ft • lb) T R . . 1st 20 Nm (2.0 m • kg, 14 ft • lb) 2nd 121˚ or 50 Nm (5.0 m • kg, 36 ft • lb) T R . . 1st 20 Nm (2.0 m • kg, 14 ft • lb) T R . . 12 Nm (1.[...]

5 - 20 ENG CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remo v e: • cylinder head nuts • cylinder head bolts NOTE: _ • Loosen the nuts in t he proper sequence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. EAS00227 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion ch[...]

5 - 21 ENG CYLINDER HEAD EAS00233 INSTALLING THE CYLINDER HEAD 1. Install: • gasket 1 • dowel pins 2 2. Install: • cylinder head NOTE: _ Pass the timing chain through the timing cha in cavity. 3. Tighten: • cylinder head nuts 1 ~ 6 1st 2nd • cylinder head nuts 7 , 0 1st 2nd • cylinder head nuts 8 , 9 1st 2nd • cylinder head bolt A , B[...]

5 - 22 ENG VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS 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 Intake valve lifter 12 2 Intake valve pad 12 3 Intake valve cotter 24 4 Intake valve upper spring seat 12 5 Intake valve sp[...]

5 - 23 ENG VALVES AND VALVE SPRINGS Order Job/Part Q ’ ty Remarks 10 Exhaust valve lifter 8 11 Exhaust valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve upper spring seat 8 14 Exhaust valve spring 8 15 Exhaust valve oil seal 8 16 Exhaust valve lower spring seat 8 17 Exhaust valve 8 18 Exhaust valve guide 8 For installation, reverse the remo[...]

5 - 24 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. Remo v e: • valve lifter 1 • valve pad 2 NOTE: _ Make a[...]

5 - 25 ENG VALVES AND VALVE SPRINGS 4. Remo v e: • upper spring seat 1 • valve spring 2 • valve stem seal 3 • lower spring seat 4 • valve 5 NOTE: _ Identify the position of e ach part very carefully so that it can be reinstalled in its origin al place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of[...]

5 - 26 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 larger than the b[...]

5 - 27 ENG VALVES AND VALVE SPRINGS EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: • carbon deposits (from the valve face and valve seat) 2. Chec k: • valve seat Pitting/wear → Replace the cylinder head. 3. Measure: • valve seat width a Out of specification → Replace t[...]

5 - 28 ENG VALVES AND VALVE SPRINGS ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a coarse lapping compound a to the val ve fa c e. CAUTION: _ Do not let the lapping compound en ter the gap between the valve stem an d the valve guide. b . Apply molybdenum disulfide oil on[...]

5 - 29 ENG VALVES AND VALVE SPRINGS 2. Measure: • compressed valve spring force a Out of specification → Replace the valve spring. b Installed length Compressed valve spring forc e (installed) Intake valve spring 82 ~ 96 N (8.2 ~ 9.6 kg, 18.43 ~ 21.58 lb) at 34.5 mm (1.36 in) Exhaust valve spring 110 ~ 126 N (11.0 ~ 12.6 kg, 24.73 ~ 28.32 lb) a[...]

5 - 30 ENG VALVES AND VALVE SPRINGS 2. Lubricate: • valve stem 1 • valve stem seal 2 (with the recommended lubricant ) Recommended lubricant Molybdenum disulfide oil 3. Install: • valve 1 • lower spring seat 2 • valve stem seal 3 • valve spring 4 • upper spring seat 5 (into the cylinder head) NOTE: _ Install the valve spring with the [...]

5 - 31 ENG VALVES AND VALVE SPRINGS 5. T o secure the v alv e cotters onto the v alv e stem, lightly tap the v alv e tip with a soft-f ace hammer . CAUTION: _ Hitting the valve tip with excessive force could damage the valve. 6. Install: • valve pad 1 • valve lifter 2 NOTE: _ • Lubricate the valve lifter and valve pad with molybdenum disulfid[...]

5 - 32 ENG GENERATOR T R . . 14 Nm (1.4 m • kg, 10 ft • Ib) T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 65 Nm (6.5 m • kg, 47 ft • Ib) + 60 ˚ Order Job/Part Q ’ ty Remarks Removing the stator coil assembly Remove the parts in the order listed. Rider seat and fuel tank Refer to “ SEATS ” an d “ FUEL TANK ” in chapter 3. Bo[...]

5 - 33 ENG GENERATOR REMOVING THE GENERATOR 1. Remo v e: • generator rotor cover 1 NOTE: @ Loosen each bolt 1/4 of a turn a t a time, in stages and in a crisscross p attern. After all of the bolts are f ully loosened, remove them. 2. Remo v e: • generator rotor bolt 1 • washer NOTE: @ While holding the generator rotor 2 with the rotor holding[...]

5 - 34 ENG GENERATOR CAUTION: • Clean the tapered portion of the crank- shaft and the generator rotor hub with lacquer thinner. • Lubricate the generator roto r bolt threads with engine oil. 3. Tighten: • generator rotor bolt 1 NOTE: @ While holding the generator rotor 2 with the rotor holding tool 3 , tighten the generator rotor bolt. W ARNI[...]

5 - 35 ENG GENERATOR W ARNING When the bolt are tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one a nd per- form the procedure again. CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle. • Tighten the bolt until it is at the specified angle. NOTE: [...]

5 - 36 ENG PICKUP COIL PICKUP COIL T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 15 Nm (1.5 m • kg, 11 ft • Ib) T R . . 60 Nm (6.0 m • kg, 43 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the pickup coil and pickup coil rotor Remove the parts in the order listed. Rider seat and fuel tank[...]

5 - 37 ENG PICKUP COIL T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 15 Nm (1.5 m • kg, 11 ft • Ib) T R . . 60 Nm (6.0 m • kg, 43 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks 7 Crankshaft position sensor coupler 1 Disconnect. 8 Crankshaft position sensor 1 9 Pickup coil rotor 1 For installation,[...]

5 - 38 ENG PICKUP COIL REMOVING THE PICKUP COIL ROTOR 1. Remo v e: • clutch cable holder 1 • pickup coil lead holder 2 • pickup coil rotor cover 3 NOTE: @ Loosen each bolt 1/4 of a turn a t a time, in stages and in a crisscross p attern. After all of the bolts are f ully loosened, remove them. 2. Remo v e: • pickup coil rotor bolt 1 • was[...]

5 - 39 ENG PICKUP COIL 2. Tighten: • pickup coil rotor bolt 1 NOTE: @ While holding the generator rotor 2 with the rotor holding tool 3 , tighten the pickup coil rotor bolt. Rotor holding tool YU-01235 T R . . 60 Nm (6.0 m · kg, 43 ft · lb) 3. Apply: • sealant (onto the crankshaft position sensor lead grommet) Quick Gasket ® ACC-11001-05-01 [...]

5 - 40 ENG CLUTCH CLUTCH CLUTCH COVER T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the clutch cover Remove the parts in the order listed. Bottom cowling and right side co wling Refer to “ COWLINGS ” in chapter 3. Engine oil Drain. Refer to “ CHANGING THE ENGIN[...]

5 - 41 ENG CLUTCH PULL LEVER SHAFT Order Job/Part Q ’ ty Remarks Removing the pull lever shaf t Remove the parts in the order listed. 1C i r c l i p 2 2 Pull lever 1 3 Pull lever spring 1 4 Pull lever shaft 1 5O i l s e a l 1 6B e a r i n g 2 For installation, reverse the removal procedure.[...]

5 - 42 ENG CLUTCH EAS00274 CLUTCH T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 105 Nm (10.5 m • kg, 76 ft • lb) T R . . 8 Nm (0.8 m • kg, 5.8 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the clutch Remove the parts in the order listed. 1 Clutch spring plate retainer 1 2 Clutch spring plate 1 3 Clutch spring plate seat 1 4 Pressu[...]

5 - 43 ENG CLUTCH T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 105 Nm (10.5 m • kg, 76 ft • lb) T R . . 8 Nm (0.8 m • kg, 5.8 ft • Ib) Order Job/Part Q ’ ty Remarks 15 Thrust was her 1 16 Clutch housing 1 17 Beari ng 1 18 Starter clutch gear 1 19 Beari ng 1 20 Starter clutch assembly 1 21 Circlip 1 22 Starter clutch idle gear 1 For[...]

5 - 44 ENG CLUTCH EAS00277 REMOVING THE CLUTCH 1. Straigh ten the loc k w asher tab . 2. Loosen: • clutch boss nut 1 NOTE: _ While holding the clutch boss 2 with the uni- versal clutch holder 3 , loosen the clutch boss nut. 3. Remo v e: • clutch boss nut 1 • lock washer 2 • clutch boss ass embly 3 • thrust washer NOTE: _ There is a built-[...]

5 - 45 ENG CLUTCH 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. Clutch plate war[...]

5 - 46 ENG CLUTCH EAS00286 CHECKING THE PRESSURE PLATE 1. Chec k: • pressure plate 1 Cracks/damage → Replace. • bearing 2 Damage/wear → Replace. EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Chec k: • pull lever shaft pinion gear teeth 1 • pull rod teeth 2 Damage/wear → Replace the pull rod and pull lever shaft pinion gear as[...]

5 - 47 ENG CLUTCH 2. Chec k: • starter clutch operation ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the star ter clutch drive ge ar onto the star ter clutch and hold the star ter clutch. b . When tur ning the star ter clutch dr iv e gear cloc kwise È , the star ter[...]

5 - 48 ENG CLUTCH 5. Install: • friction plates • clutch plates NOTE: _ First, install a friction plate and then alternate between a clutch plate and a friction plat e. 6. Install: • pressure plate 1 • clutch spring plate seat 2 • clutch spring plate 3 • clutch spring plate retainer 4 NOTE: Tighten the clutch spring plate retainer bolts[...]

5 - 49 ENG SHIFT SHAFT EAS00327 SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 22 Nm (2.2 m • kg, 16 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the shift shaft and stop- per lever Remove the parts in the order listed. Drive sprocket cover Refer to “ ENGINE ” . 1 Throttle stop screw holde[...]

5 - 50 ENG SHIFT SHAFT CHECKING THE SHIFT SHAFT 1. Chec k: • shift shaft 1 Bends/damage/wear → Replace. • shift shaft spring 2 Damage/wear → Replace. CHECKING THE STOPPER LEVER 1. Chec k: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever. INSTALLING THE SHIFT SHAFT 1. Install: • shift shaft s[...]

5 - 51 ENG OIL PAN AND OIL PUMP EAS00356 OIL PAN AND OIL PUMP T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 43 Nm (4.3 m • kg, 31 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • [...]

5 - 52 ENG OIL PAN AND OIL PUMP T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 43 Nm (4.3 m • kg, 31 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/P[...]

5 - 53 ENG OIL PAN AND OIL PUMP EAS00360 OIL PUMP T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 15 Nm (1.5 m • kg, 11 ft • Ib) Order Job/Part Q ’ ty Remarks Disassembling the oil pump Remove the parts in the order listed. 1 Oil/water pump assemb ly driven sprocket 1 2 Washer 1 3 Oil pump housing 1 4 Bearing 1 5 Pin 2 6 Oil pump outer ro[...]

5 - 54 ENG OIL PAN AND OIL PUMP EAS00362 REMOVING THE OIL PAN 1. Remo v e: • oil level switch 1 • oil pan 2 • gasket • dowel pins NOTE: _ Loosen each bolt 1/4 of a turn a t a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EAS00364 CHECKING THE OIL PUMP 1. Chec k: • oil pump driven gear[...]

5 - 55 ENG OIL PAN AND OIL PUMP 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 defective part(s). EAS00367 CHECKING THE OIL DELIVERY PIPES The[...]

5 - 56 ENG OIL PAN AND OIL PUMP EAS00374 ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant ) 2. Install: • pin 1 • inner rotor 2 • outer rotor 3 • oil pump housing 4 • oil pump housing screw NOTE: _ When installing the inner rotor, alig n the pin 1 in the oil pump sh a[...]

5 - 57 ENG OIL PAN AND OIL PUMP EAS00378 INSTALLING THE OIL STRAINER 1. Install: • oil strainer housing 1 NOTE: _ The arrow mark a on the oil strainer housing must point towards the front of the engin e. T R . . 10 Nm (1.0 m · kg, 7.2 ft · lb) EAS00380 INSTALLING THE OIL PAN 1. Install: • dowel pins • gasket • oil pan 1 • oil level swit[...]

5 - 58 ENG CRANKCASE EAS00381 CRANKCASE T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the crankcase Remove the parts in the order listed. Engine Refer to “ ENGINE ” . Cylinder head Refer to “ CYLINDER HEAD ” . Pickup coil and pickup coil rotor Refer to “ PI[...]

5 - 59 ENG CRANKCASE T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks 6W a s h e r 1 7 Oil/water pump assembly drive sprocket 1 8W a s h e r 1 9P l a t e 1 10 Lower crankcase 1 11 Dowel pin 3 For installation, reverse the removal procedure.[...]

5 - 60 ENG CRANKCASE EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside do wn. 2. Remo v e: • crankcase bolts 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 loosened, remove them. • Loosen the bolts in de creasing numerical order (refer to the numbers in[...]

5 - 61 ENG CRANKCASE EAS00399 CHECKING THE CRANKCASE 1. Thoroughly w ash the crankcase halv es in a mild solv ent. 2. Thoroughly clean all the gask et surf aces and crankcase mating surf aces. 3. Chec k: • crankcase Cracks/damage → Replace. • oil delivery passages Obstruction → Blow out with compressed air. EAS00401 CHECKING THE BEARINGS AN[...]

5 - 62 ENG CRANKCASE EAS00414 ASSEMBLING THE CRANKCAS E 1. Lubricate: • crankshaft journal bearings (with the recommended lubricant ) Recommended lubricant Engine oil 2. Apply: • sealant (onto the crankcase mating surfaces) NOTE: _ Do not allow any sealant to come into conta ct with the oil gallery or crankshaft journal bear- ings. Do not apply[...]

5 - 63 ENG CRANKCASE 6. Install: • lower crankcase 1 (onto the upper crankcase 2 ) CAUTION: _ Before tightening the crankcase bolts, make sure the transmission gears shift cor- rectly when the shift drum assembly is turned by hand. 7. Install: • crankcase bolts NOTE: _ • Lubricate the bolt threads with e ngine oil. • Tighten the bolts in in[...]

5 - 64 ENG CONNECTING RODS AND PISTONS EAS00382 CONNECTING RODS AND PISTONS T R . . 20 Nm (2.0 m • kg, 14 ft • Ib) + 120 ˚ 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 2 Big end lower bearing 4 3 Piston pin [...]

5 - 65 ENG CONNECTING RODS AND PISTONS EAS00393 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remo v e: • connecting rod 1 • big end bearings NOTE: _ Identify the position of each big end bearing so that it can be reinstalled in its original place. 2. Remo v e: • piston [...]

5 - 66 ENG CONNECTING RODS AND PISTONS 3. Remo v e: • top ring • 2nd ring • oil ring NOTE: _ When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remo v e: • crankshaft assembly 1 • crankshaft journal upper bearin gs (from th[...]

5 - 67 ENG CONNECTING RODS AND PISTONS b . If out of specification, replace the cylinder , and the pistons and piston rings as a set. Cylinder bore “ C ” 74.00 ~ 74.01 mm (2.9134 ~ 2.9138 in) Wear limit 74.06 mm (2.9157 in) Taper limit “ T ” 0.05 mm (0.002 in) Out of round “ R ” 0.05 mm (0.002 in) “ C ” = maximum of D 1 ~ D 6 “ T [...]

5 - 68 ENG CONNECTING RODS AND PISTONS EAS00263 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: _ Before measuring the piston ring side clear- ance, eliminate any carbon deposits f rom the piston ring grooves and piston rings. 2. Install: • piston ri[...]

5 - 69 ENG CONNECTING RODS AND PISTONS CHECKING THE PISTON PINS The following procedure applies to all of the piston pins. 1. Chec k: • piston pin Blue discoloration/grooves → Replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter a Out of specification → Replace the piston pin. Piston pin ou[...]

5 - 70 ENG CONNECTING RODS AND PISTONS ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ The following procedure applies to all of the connecting rods. CAUTION: @ Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clear[...]

5 - 71 ENG CONNECTING RODS AND PISTONS e. Tighten the connecting rod n uts . f . Replace the connecting rod bolts and n uts with ne w ones . CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts. g. Clean the connecting rod bolts and n uts . h. Tighten the connecting rod n uts [...]

5 - 72 ENG CONNECTING RODS AND PISTONS 2. Select: • big end bearings (P1 ~ P4) NOTE: @ • The numbe rs È stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. •“ P1 ” ~ “ P4 ” refer to the bearings shown in the crankshaft illustration. For example, if the [...]

5 - 73 ENG CONNECTING RODS AND PISTONS 2. Install: • piston 1 (onto the respective connecting rod 2 ) • piston pin 3 • piston pin clip 4 NOTE: @ • Apply engine oil onto the piston p in. • Make sure that the “ Y ” mark a on the con- necting rod faces left when the arrow mark b on the piston is pointing up. Refer to the illustration. ?[...]

5 - 74 ENG CONNECTING RODS AND PISTONS 6. Install: • big end bearings • connecting rod assembly (into the cylinder and onto the crankshaft pin). • connecting rod cap (onto the connecting rod) NOTE: @ • Align the projections on the big end bearings with the notches in the connecting rod s and connecting rod caps. • Be sure to reinstall eac[...]

5 - 75 ENG CONNECTING RODS AND PISTONS e. Tighten the nut fur ther to reach the speci- fied angle (120 ° ). W ARNING When the nut is tightened more than the specified angle, do not loos en the nut and then retighten it. Replace the bolt with a new one a nd per- form the procedure again. CAUTION: • Do not use a torque wrench to tighten the nut to[...]

5 - 76 ENG CRANKSHAFT CRANKSHAFT Order Job/Part Q ’ ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Crankcase Separate. Refer to “ CRANKCASE ” . Connecting rod caps Refer to “ CONNECTING RODS AND PISTONS ” . 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 For insta[...]

5 - 77 ENG CRANKSHAFT EAS00395 CHECKING THE CRANKSHAFT 1. Measure: • crankshaft runout Out of specification → Replace the crank- shaft. 2. Chec k: • crankshaft journal surfaces • crankshaft pin surfaces • bearing surfaces Scratches/wear → Replace the crankshaft. Crankshaft runout Less than 0.03 mm (0.0012 in) CHECKING THE CRANKSHAFT JOU[...]

5 - 78 ENG CRANKSHAFT c. Install th e crankshaft journal upper bearings 1 and the cra nkshaft into the upper cr ank- case. NOTE: _ Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the upper crankcase. d. Put a piece of Plastigauge ® 2 on each crankshaft journal. NOTE: _ Do not put the Plastig auge ® over th[...]

5 - 79 ENG CRANKSHAFT g. Remov e the lower cr ankcase and the crank- shaft journal lower bearings . h. Measure the compressed Plastigauge ® width c on each cr ankshaft jour nal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. ▲▲▲ ▲ ▲ ▲▲▲ [...]

5 - 80 ENG CRANKSHAFT EAS00407 INSTALLING THE CRANKSHAFT 1. Install: • crankshaft journal upper bearin gs 1 (into the upper 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 cra nkshaft journal upper bearing in its original place. 2. Insta[...]

5 - 81 ENG TRANSMISSION EAS00419 TRANSMISSION T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the transmission, shift drum assembly, and shift fork s Remove the parts in the order listed. Crankcase Separate. Refer to “ CRANKCASE ” . Stopper lever Refer to “ SHIFT[...]

5 - 82 ENG TRANSMISSION T R . . 12 Nm (1.2 m • kg, 8.7 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks 10 Shift dr um assembly 1 11 Shift fork “ C ” 1 12 Main axle assembly 1 For installation, reverse the removal procedure.[...]

5 - 83 ENG TRANSMISSION Order Job/Part Q ’ ty Remarks Disassembling the main axle assembly Disassembly the parts in the order listed. 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Toothed spacer 1 6 Toothed washer 2 7 Circlip 2 8 3rd/4th pinion gears 1 9 5th pinion gear 1 0 Collar 1[...]

5 - 84 ENG TRANSMISSION 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.[...]

5 - 85 ENG TRANSMISSION Order Job/Part Q ’ ty Remarks Disassembling the drive axle assembly Disassembly the parts in the order listed. 1 Washer 1 2 1st wheel gear 1 3 Spacer 1 4 5th wheel gear 1 5 Circlip 3 6 Washer 3 7 3rd wheel gear 1 8 Toothed spacer 2 9 Toothed lock washer 1 0 Toothed lock washer retainer 1[...]

5 - 86 ENG TRANSMISSION Order Job/Part Q ’ ty Remarks A 4th wheel gear 1 B 6th wheel gear 1 C 2nd wheel gear 1 D Spacer 1 E Drive axle 1 F Bearing 1 G Spacer 1 For assembly, reverse the disassembly procedure.[...]

5 - 87 ENG TRANSMISSION EAS00420 REMOVING THE TRANSMISSION 1. Remo v e: • main axle assembly 1 (with the Torx ® wrench T30) ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Inser t two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing[...]

5 - 88 ENG TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Chec k: • shift drum grooves Damage/scratches/wear → Replace the shift drum assembly. • shift drum segment 1 Damage/wear → Replace the shift drum assembly. • shift drum bearing 2 Damage/pitting → Replace the shift drum assembly. EAS00425 CHECKING THE TRANSMISSION 1. Me[...]

5 - 89 ENG TRANSMISSION 4. Chec k: • transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 5. Chec k: • transmission gear movement Rough movement → Repla ce the defective part(s). 6. Chec k: • circlips Bends/damage/lo oseness → Replace. EAS00428 INSTALLING T[...]

6 - 1 COOL EAS00454 COOLING SYSTEM RADIATOR Order Job/Part Q ’ ty Remarks Removing the radiator Remove the parts in the order listed. Rider seat and fuel tank Refer to “ SEATS ” and “ FUEL TANK ” in chapter 3. Air filter case and rubber cover Refer to “ AIR FILTER CASE ” in chapter 3. Bottom cowling and side cowlings Refer to “ COWL[...]

6 - 2 COOL RADIATOR Order Job/Part Q ’ ty Remarks 3 Radiator inlet hose 1 4 Radiator outlet hose 1 5 Water pump breather hose 1 6R a d i a t o r 1 7 Radiator fan 1 8 Water pump inlet pipe 1 For installation, reverse the removal procedure.[...]

6 - 3 COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Chec k: • radiator fins Obstruction → Clean. 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 • radiator pipes Cracks/damage → Replace. 3. Measure: ?[...]

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

6 - 5 COOL OIL COOLER EAS00457 OIL COOLER T R . . 35 Nm (3.5 m • kg, 25 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the oil cooler Remove the parts in th e order listed. Radiator assembly Refer to “ RADIATOR[...]

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 th in- n[...]

6 - 7 COOL THERMOSTAT EAS00460 THERMOSTAT T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the thermostat assembly Remove the parts in the order listed. Rider seat and fuel tank Refer to “ SEATS ” an d “ FUEL TANK ” in chapter 3. Air filter case and rubber cover[...]

6 - 8 COOL THERMOSTAT T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks 5 Thermostat assembly 1 6 Thermostat assembly inlet pipe (left) 1 For installation, reverse the removal procedure.[...]

6 - 9 COOL THERMOSTAT EAS00461 ‘ T R . . 18 Nm (1.8 m • kg, 13 ft • Ib) T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks Disassembling the thermostat housing Remove the parts in the order listed. 1 Thermostat housing cover 1 2 Thermostat 1 3 Thermostat housing 1 For assembly, reverse the disassembly procedure.[...]

6 - 10 COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Chec k: • thermostat Does not open at 71 ~ 85 ° C (160 ~ 185 ° F) → Replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat in a container filled with water . b . Slowly heat the w ater . c. [...]

6 - 11 COOL THERMOSTAT EAS00464 ASSEMBLING THE THERMOSTAT ASSEMBLY 1. Install: • thermostat housing 1 • thermostat 2 • O-ring 3 • thermostat housing cover 4 NOTE: _ Install the thermostat with its breather hole a facing up. New 2. Install: • coolant temperature sensor 1 CAUTION: _ Use extreme care when handlin g the thermo switch and temp[...]

6 - 12 COOL WATER PUMP EAS00468 WATER PUMP T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the impeller shaft Re move the parts in the order listed. NOTE: • The water pump and oil pump are com- bined into one unit (oil/water pump assembly). • It is not necessary to remove the impel- ler shaft unless the cool[...]

6 - 13 COOL WATER PUMP T R . . 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order Job/Part Q ’ ty Remarks 5 Water pump seal 1 6O i l s e a l 1 7B e a r i n g 1 For installation, reverse the removal procedure.[...]

6 - 14 COOL WATER PUMP EAS00471 DISASSEMBLING THE WATER PUMP 1. Remo v e: • water pump seal 1 NOTE: _ Tap out the water pump seal from the inside of the water pump housing. 2 Water pump housing 2. Remo v e: • oil seal 1 • bearing 2 NOTE: _ Tap out the bearing and oil seal from the out- side of the water pump housing. 3 Water pump housing 3. R[...]

6 - 15 COOL WATER PUMP EAS00475 ASSEMBLING THE WATER PUMP 1. Install: • oil seal 1 (into the water pump housing 2 ) NOTE: _ • Before installing the oil seal, apply tap water or coolant onto its out surface. • Install the oil seal with a socket that matches its outside dia meter. 2. Install: • water pump seal 1 CAUTION: _ Never lubricate the[...]

6 - 16 COOL WATER PUMP 4. Measure: • impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: _ Make sure the ru bber damper and rubber damper holder are flush with the imp eller. 1 Straightedge 2 Impeller Impeller shaft tilt limit 0.15 mm (0.0059 in)[...]

7 - 1 FI FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Ignition coil 2 Air filter case 3 Intake temper ature sensor 4 Fuel delivery hose 5 Fuel tank 6 Fuel pump 7 Fuel return hose 8 Intake air pressure sensor 9 Throttle posit ion sensor 0 Fuel injector A Catalytic conver ter B Crankshaft po sition sensor C Coolant tem perature sensor D Spark pl ug [...]

7 - 2 FI FUEL INJECTION SYSTEM WIRING DIAGRAM OFF RUN L / R R / Y Br / W P / W Y B / L (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G R / L L / B R / B O / B G / B L (BLACK) G / B L R / B O / B R / L L / B R / B O / G O Gy / G Gy / R L Gy / R L O Gy / G R / B O / G Y / L Y [...]

7 - 3 FI FUEL INJECTION SYSTEM ECU ’ S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the eng ine control sys- tem is operating normally. If this function d etects a malfunction in the system, it immediately oper- ates the engine under substitute characteristics and illuminate s the engine tro[...]

7 - 4 FI FUEL INJECTION SYSTEM SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the motorcycle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with substitute characteristic operation instructions that are appropriat e for the type[...]

7 - 5 FI FUEL INJECTION SYSTEM TROUBLESHOORING CHART “ Engine runs irregularly. ” or “ Engine trouble warning light is illuminated. ” * Engine trouble warning light may not be illuminated even if the engine runs irregularly. When the engine trouble warning light is illumi- nated Checking the self-diagnostic fault code number: Check the self[...]

7 - 6 FI FUEL INJECTION SYSTEM DIAGNOSTIC MODE • In this mode, diagnostic codes are input into the ECU in accordance with the number of times the start switch has been operated. • In accordance with the diagnostic codes, the ECU displays the values received from the sensors and actuates the actuators. • Whether or not the system is op erating[...]

7 - 7 FI FUEL INJECTION SYSTEM Diagnostic fault code table Fault Code No. Symptom Probable cause of malfunction Code of diagnostic mode 11 No nor mal signals are received from the cylinder identification sensor . NOTE: This code number appears if the con- dition continued f or 10 seconds in which the star ter motor does not run ev en if the star te[...]

7 - 8 FI FUEL INJECTION SYSTEM 33 Open circuit is detected in the primar y lead of the ignition coil (#1). • Open or short circuit in wiring harness. • Malfunction in ignition coil. • Malfunction in ECU. • Malfunction in a component of ignition cut-off circuit system. 30 34 Open circuit is detected in the primar y lead of the ignition coil [...]

7 - 9 FI FUEL INJECTION SYSTEM Diagnostic mode table Set the meter display from the regular mode to t he diagnosis mode. For the setting method, refer to “ DIAGNOSTIC MODE ” . NOTE: • Check the intake temperature and coolant temperature as close as possible to the area in which the respective sensor is mounted. • If it is not possible to ch[...]

7 - 10 FI FUEL INJECTION SYSTEM 32 Ignition coil #3 After 1 second has elapsed from the time the engine stop s witch has been tur ned from OFF to ON, it actuates ignition coil #3 for fiv e times e v ery second and illuminates the en gine trouble w arning light . * Connect an ig nition check er . * If the engine stop switch is ON, tur n it OFF once,[...]

7 - 11 FI FUEL INJECTION SYSTEM 52 Headlight relay 1 After 1 second has elapsed f rom the time the engine stop s witch has been turn ed from OFF to ON, it actuates the head- light rela y five times e v ery 5 seconds and illuminates the engine trouble warning light. (ON 2 seconds, OFF 3 seconds) * If the engine stop switch is ON, tur n it OFF once, [...]

7 - 12 FI FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter.Carry out check and maintenance on items or componen ts that could be a cause of malfunction in accordance with the order. When the check and maintenance o f malfunctioned part is completed, restore the meter disp[...]

7 - 13 FI FUEL INJECTION SYSTEM Fault code No. 12 Symptom No normal signals are received from the crankshaft position sensor. Used diagnostic code No.-- Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Installed condition of sensor Check the installed area for looseness or pinching. Reinstated by c[...]

7 - 14 FI FUEL INJECTION SYSTEM Fault 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. 1. Connect the [...]

7 - 15 FI FUEL INJECTION SYSTEM Fault code No. 14 Symptom Intake air pressure sensor - hose system malfunction (clogged or detached hose). Used diagnostic code No. 03 (intake air pressure sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Intake air pressure sensor hose detached, clogged, kin[...]

7 - 16 FI FUEL INJECTION SYSTEM Fault code No. 17 Symptom EXUP servo motor potention circuit - open or short circuit detected. Used diagnostic code 53 Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective EXUP servo motor potention circuit. Replace if defective. 1. Disconnect the EXUP servomot[...]

7 - 17 FI FUEL INJECTION SYSTEM Fault code No. 18 Symptom EXUP servo motor is stuck. Used diagnostic code 53 Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective EXUP servo motor. Replace if defective. 1. Disconnect the EXUP cables from the EXUP servomotor pulley. 2. Disconnect the EXUP servo[...]

7 - 18 FI FUEL INJECTION SYSTEM Fault code No. 19 Symptom Open circuit is detected in the input line from the sidestand switch to the ECU. Used diagnostic code No. 20 (sidestand switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective sidestand switch Replace if defective. Refer to “ CH[...]

7 - 19 FI FUEL INJECTION SYSTEM Fault code No. 22 Symptom Open or short circuit detected from the intake temperature sensor. Used diagnostic code No. 05 (intake temperature sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Installed condition of sensor Check the installed area for looseness [...]

7 - 20 FI FUEL INJECTION SYSTEM Fault 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. Replace if defective. 1. C[...]

7 - 21 FI FUEL INJECTION SYSTEM Fault 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 Replace if defective. 1. Remove the emergency stop switch from the mo[...]

7 - 22 FI FUEL INJECTION SYSTEM Fault code No. 33 Symptom Malfunction detected in the primary lead of the ignition coil (#1). Used diagnostic code No. 30 (ignition coil #1) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective ignition coil (test the primary and secondary coils for continuity)[...]

7 - 23 FI FUEL INJECTION SYSTEM Fault code No. 36 Symptom Malfunction detected in the primary lead of the ignition coil (#4). Used diagnostic code No. 33 (ignition coil #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 - 24 FI FUEL INJECTION SYSTEM Fault code No. 42 Symptom 1 No normal signals are received from the speed sensor. 2 Open or short circuit is detected in the neutral switch. Used diagnostic code No. 07 (speed sensor) No. 21 (neutral switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective [...]

7 - 25 FI FUEL INJECTION SYSTEM Fault code No. 43 Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09 (fuel system voltage) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Malfunction in ECU Fuel injection system relay is on. Reinstated by starting the engine and [...]

7 - 26 FI FUEL INJECTION SYSTEM Fault code No. 44 Symptom Error is detected while reading or writing on EEP-ROM. Used diagnostic No. 60 (EEP-ROM improper cylinder indication) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Malfunction in ECU Execute diagnostic code 60 * Check the faulty cylinder. [...]

7 - 27 FI FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signal are received from the ECU. Used diagnostic code No. -- Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Open or short circuit in wiring harness and/or sub lead. Repair or replace if there is an open or short circuit. Between sens[...]

7 - 28 FI FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Used diagnostic code No. -- Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Open or short circuit in wiring harness and/or sub lead. Repair or replace if there is an open or short circ[...]

7 - 29 FI THROTTLE BODIES THROTTLE BODIES Order Job/Part Q ’ ty Remarks Removing the throttle bodies Remove the parts in the order listed. Seats/fuel tank/ru bber sheet Refer to “ SEATS ” and “ FUEL TANK ” in chapter 3. Air filter case Refer to “ AIR FILTER CASE ” in chapter 3. Coolant Drain. Refer to “ CHANGING THE COOLANT ” in c[...]

7 - 30 FI THROTTLE BODIES Order Job/Part Q ’ ty Remarks 5 Throttle cable 2 Disconnect. 6 Plunger control unit hose 2 Disconnect. 7 Throttle body joint 4 For installation, reverse the removal procedure.[...]

7 - 31 FI THROTTLE BODIES Order Job/Part Q ’ ty Remarks Removing the injector Remove the parts in the order listed. 1 Throttle position 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 #3-injector coupler 1 Disconnect. 6 Cyl[...]

7 - 32 FI THROTTLE BODIES 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 the removal procedure.[...]

7 - 33 FI THROTTLE BODIES 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 → Clean. ▼▼▼ ▼ ▼ ▼▼▼ ?[...]

7 - 34 FI THROTTLE BODIES CHECKING THE PRESSURE REGULATOR 1. Chec k: • pressure regulator Damage → Replace. CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Chec k: • pressure regulator operation ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remov e the fuel tan[...]

7 - 35 FI THROTTLE BODIES Faulty → Replace the pressure regulato r. ▲▲▲ ▲ ▲ ▲▲▲ ▲▲ ▲ ▲ ▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Increase the vacuum pressure → Fuel pressure is decreased Decrease the vacuum pressure → Fuel pressure is increased EAS00500 CHECKING AND ADJUSTING THE THROTTLE [...]

7 - 36 FI THROTTLE BODIES f . While slo wly opening the throttle , chec k that the throttle position sensor resistance is within the specified rang e. The resistance does not change or it changes abruptly → Replace the throt tle position sensor. The slot is worn or broken → Replace the throttle position sensor. NOTE: Check mainly that the resis[...]

7 - 37 FI AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INDUCTION The air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the re ed valve opens, allowing secondary air to flow into the e [...]

7 - 38 FI AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut-off valve 2 Reed valve 3 Air cleaner È To cylinder #1 É To cylinder #2 Ê To cylinder #3 Ë To cylinder #4[...]

7 - 39 FI AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Chec k: • hoses Loose connection → Connect properly. Cracks/damage → Replace. • pipes Cracks/damage → Replace. 2. Chec k: • reed valve 1 • reed valve stopper • reed valve seat Cracks/damage → Replace the reed valve. 3. Measure: • reed valve bending limi[...]

7 - 40 FI AIR INDUCTION SYSTEM 5. Chec k • Al system soleno id ▼▼▼ ▼ ▼ ▼▼▼ ▼▼ ▼ ▼ ▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remo v e the AI system solenoid coup ler from the wire harness. b . Connect the poc k et tester ( Ω × 1) to the AI system solenoid ter minal as shown. c. Measure th[...]

8 - 1 – + ELEC EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 Fuse box 2 Front brake swit ch 3 Clutch switch 4 Battery 5 Starter relay 6 Fuel injection system fuse 7 Main fuse 8 Neutral switch 9 Rear brake switch 0 Sidestand switch A Oil level switch B Radiator fan motor C Horn D Ignition coil ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8[...]

8 - 2 – + ELEC ELECTRICAL COMPONENTS 1 Coolant temp erature sensor 2 Intake air temp erature sensor 3 Intake air pressure se nsor 4 Lean angle cut -off switch 5 Atmospheric pre ssure sensor 6 ECU 7 Starting circuit c ut-off relay 8 Turn signal relay 9 Speed sensor 0 Crankshaft positio n sensor A Cylinder identifica tion sensor B Radiator fan moto[...]

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 prob[...]

8 - 4 – + ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “ CHECKING SWITCH CONTINUITY ” . Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading → Replace the swit[...]

8 - 5 – + ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connectio ns, and also fo r con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly con nect. No continuity → Re[...]

8 - 6 – + ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remo v e: • bulb 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 firm[...]

8 - 7 – + 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 continu ity) (with the pocket tester) No continuity → Re place. NOTE: _ Check each bulb socke t for continuity in the same manner as described in the bulb secti[...]

8 - 8 – + ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM Y / B L / R B / R Ch Dg B / Y Y / L Sb / W L / R R / Y Br / W P / W Y B / L (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G R / L L / B R / B O / B G / B L (BLACK) G / B L R / B O / B R / L L / B R / B[...]

8 - 9 – + ELEC IGNITION SYSTEM EAS00737 TROUBLESHOOTING Check: 1. main and ignition fuses 2. batter y 3. spark plugs 4. ignition spark gap 5. ignition coil resistance 6. crankshaft posit ion sensor resistance 7. main s witch 8. engine stop s witch 9. neutral s witch 10.sidestand s witch 11.star ting circuit cut-off rela y 12.wiring connections (o[...]

8 - 10 – + ELEC IGNITION SYSTEM EAS00743 EAS00 747 4. Ignition spark gap The following procedure applies to all of the spark plugs. • Disconnect the spark plug cap from the spark plug. • Connect the ignition checker 1 as shown. 2 Ignition coil • Set the main switch to “ ON ” . • Measure the ignition spark gap a . • Crank the engine [...]

8 - 11 – + ELEC IGNITION SYSTEM EAS00748 EAS00749 EAS00750 EAS00751 EAS00752 6. Crankshaft position sensor resistance • Disconnect the crankshaft position sensor coupler from the wire harness. • Connect the pocket tester ( Ω × 100) to the crankshaft position sensor coupler as shown. Positive tester probe → gray 1 Negative tester probe ?[...]

8 - 12 – + ELEC IGNITION SYSTEM EAS00753 EAS00 754 11.Star ting circuit cut-off rela y • Disconnect the starting circuit cut-off relay coupler from the wire harness. • Connect the pocket tester ( Ω × 1) to the starting circuit cut-off relay coupler as shown. • Check the starting circuit cut-off relay for continuity. Positive tester probe[...]

8 - 13 – + ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G R / L L / B R / B O / B G / B L (BLACK) G / B L R / B O / B R / L L / B R / B O / G O Gy / G Gy / R L[...]

8 - 14 – + 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 cond itions is met: • The transmission is in neutral (the neutral switch i[...]

8 - 15 – + ELEC ELECTRIC STARTING SYSTEM EAS00757 TROUBLESHOOTING Check: 1. main and ignition fuses 2. batter y 3. star ter motor 4. star ting circuit cut-off relay 5. star ter rela y 6. main s witch 7. engine stop s witch 8. neutral s witch 9. sidestand s witch 10.clutch s witch 11.star t switch 12.wiring connections (of the entire starting syst[...]

8 - 16 – + ELEC EAS00759 EAS00761 EAS00749 EAS00750 EAS00751 4. Star ting circuit cut-off rela y • Disconnect the starting circuit cut-off relay coupler from the wire harness. • Connect the pocket tester ( Ω × 1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown. Positive battery terminal → red/black 1 Negative [...]

8 - 17 – + ELEC ELECTRIC STARTING SYSTEM EAS00752 EAS00763 EAS00764 EAS00766 9. Sidestand s witch • Check the sidestand switch for continuity. Refer to “ CHECKING THE SWITCHES ” . • Is the sidestand switch OK? YES NO Replace the side- stand switch. 10.Clutch s witch • Check the clutch switch for continuity. Refer to “ CHECKING THE SWI[...]

8 - 18 – + ELEC ELECTRIC STARTING SYSTEM EAS00767 STARTER MOTOR T R . . 5 Nm (0.5 m • kg, 3.6 ft • Ib) T R . . 7 Nm (0.7 m • kg, 5.1 ft • Ib) Order Job/Part Q ’ ty Remarks Removing the starter motor Remove the parts in the order listed. Rider seat Refer to “ SEATS ” in chapter 3. Fuel tank Refer to “ FUEL TA NK ” in chapter 3. L[...]

8 - 19 – + ELEC ELECTRIC STARTING SYSTEM EAS00768 T R . . 5 Nm (0.5 m • kg, 3.6 ft • Ib) Order Job/Part Q ’ ty Remarks Disassembling the starter motor Disassembly the parts in th e order listed. 1 Starter motor rear cover 1 2 Bearing 1 3 Starter motor yoke 1 4 O-ring 2 5 Armature assembly 1 6 Brush 2 7 Brush holder 1 8 Starter motor front c[...]

8 - 20 – + ELEC ELECTRIC STARTING SYSTEM EAS00769 CHECKING THE STARTER MOTOR 1. Chec k: • commutator Dirt → Clean with 600-grit sa ndpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. 3. Measure: • mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw [...]

8 - 21 – + ELEC ELECTRIC STARTING SYSTEM 5. Measure: • brush length a Out of specification → Re place the brushes as a set. Brush length wear limit 3.65 mm (0.14 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set. 7. Chec k: • gear teeth Damage/wear → Rep lace the gear. EAS00772 ASSEMBLING T[...]

8 - 22 – + ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM (BLACK) R Br / L R Br / L L / YL / B L / BL / Y R B (GRA Y) W W W ON OFF RW R / WL / W R / W L / W R R R R B B B B B R W R B R B R W W W W W R W B R Br / L Br / L L / B R / W L / Y (RED) (RED) R R / G 1 23 4 5 8 6 7 9 w 2 AC magneto 3 Rectifier/regulator 5 Battery 6 Fuse (ma[...]

8 - 23 – + ELEC CHARGING SYSTEM EAS00774 TROUBLESHOOTING Check: 1. main fuse 2. batter y 3. charging v oltage 4. stator coil resistance 5. wiring connections (of the entire charging system) NOTE: _ • Before troubleshooting, remove the following part(s): 1. seat 2. fuel tank 3. bottom cowling • Troubleshoot with the following special tool(s). [...]

8 - 24 – + ELEC CHARGING SYSTEM EAS00776 EAS00779 4. Stator coil resistance • Remove the generator cover. • Connect the pocket tester ( Ω × 1) to the stator coils as shown. Positive tester probe → white 1 Negative tester probe → white 2 Positive tester probe → white 1 Negative tester probe → white 3 • Measure the stator coil resi[...]

8 - 25 – + ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G R / L L / B R / B O / B G / B L (BLACK) G / B L R / B O / B R / L L / B R / B O / G O Gy / G Gy / R L Gy / R L O Gy / G[...]

8 - 26 – + ELEC LIGHTING SYSTEM 1 Main switch 5 Battery 6 Fuse (main ) C ECU X Hi beam indicator light [ Meter light c Dimmer switch l Auxiliary light m Headlight n License light o Taillight u Headlight relay (on/off) v Headlight relay (dimmer) x Fuse (signal) y Fuse (headlight)[...]

8 - 27 – + ELEC LIGHTING SYSTEM EAS00781 TROUBLESHOOTING Check: 1. main, signal and headlight fuses 2. batter y 3. main s witch 4. dimmer s witch 5. headlight rela y (on/off) 6. headlight rela y (dimmer) 7. wiring connections (of the entire lighting system) NOTE: _ • Before troubleshooting, remove the following part(s): 1. seat 2. fuel tank 3. [...]

8 - 28 – + ELEC LIGHTING SYSTEM YES NO YES NO EAS00787 5. Headlight rela y (on/off) • Disconnect the headlight relay (o n/off) from the coupler. • Connect the pocket tester ( Ω × 1) and bat- tery (12 V) to the he adlight relay (on/off) coupler as shown. Positive battery lead → red/yellow 1 Negative battery l e a d → yellow/bla ck 2 Pos[...]

8 - 29 – + ELEC LIGHTING SYSTEM EAS00788 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light f ail t o come on. YES NO YES NO 1. Headlight b ulb and soc k et • Check the headlight bulb and so cket for continuity. Refer to “ CHECKING THE BULBS AN D BULB SOC KETS ” • Are the headlight bulb and socket OK? Replace [...]

8 - 30 – + ELEC LIGHTING SYSTEM EAS00789 2. The meter light f ails to come o n. EAS00790 3. The tail/brak e light f ails to come on. 1. Meter light b ulb and so ck et • Check the meter light bulb and socket for continuity. Refer to “ CHECKING THE BULBS AN D BULB SOC KETS ” • Are the meter light bulb and socket OK? YES NO Replace the meter[...]

8 - 31 – + ELEC LIGHTING SYSTEM EAS00791 4. The auxiliar y light f ails to come on. EAS00792 5. The license plate light f ails to come on. 1. A uxiliar y light bulb and sock et • Check the auxiliary light bulb and socket for continuity. Refer to “ CHECKING THE BULBS AN D SOCKETS ” • Are the auxiliary light bulb and socket OK? YES NO Repla[...]

8 - 32 – + ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G R / L L / B R / B O / B G / B L (BLACK) G / B L R / B O / B R / L L / B R / B O / G O Gy / G Gy / R L Gy / R L O Gy /[...]

8 - 33 – + ELEC SIGNALING SYSTEM 1 Main switch 4 Fuse (back up) 5 Battery 6 Fuse (main ) 0 Starting circuit c ut-off relay B Fuel pump C ECU I Speed sensor R Neutral switch S Fuel level warning light T Oil level warning light U Neutral indicator light W Coolant temper ature indicator light Y Turn signal indicator light (L) Z Turn signal indicator[...]

8 - 34 – + ELEC SIGNALING SYSTEM EAS00794 TROUBLESHOOTING Check: 1. main, ignition, signaling and bac k up fuses 2. batter y 3. main s witch 4. wiring connections (of the entire signaling system) NOTE: _ • Before troubleshooting, remove the following part(s): 1. seat 2. fuel tank 3. bottom cowling 4. side cowling s 5. tail co wling • Troubles[...]

8 - 35 – + ELEC SIGNALING SYSTEM EAS00797 2. The tail/brak e light f ails to come on. 2. V oltage • Connect the po cket tester (DC 20 V) to the horn connector at th e horn terminal as shown. Positive tester probe → pink 1 Negative tester probe → ground • Set the main switch to “ ON ” . • Push the horn switch. • Measure the voltage[...]

8 - 36 – + ELEC SIGNALING SYSTEM EAS00799 3. The tur n signal light, turn signal indicator light or both f ail to b link. YES NO This circuit is OK. The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired. 1. T ur n signal indicator light b ulb and soc k et • Check the turn signal light bulb and so[...]

8 - 37 – + ELEC SIGNALING SYSTEM EAS00801 4. The neutral indica tor light f ails to come on. Left turn signal light Positive tester probe → c hocolate 1 Negative tester pro be → ground Right turn signal light Positive tester probe → da rk green 2 Negative tester pro be → ground ÈÉ Ê • Set the main switch to “ ON ” . • Set the t[...]

8 - 38 – + ELEC SIGNALING SYSTEM EAS00802 5. The oil le v el w ar ning light f ails to come on. EAS00803 6. The fuel le vel indicator light f ails to come on. 1. Oil le v el w arning light bulb and soc k et • Check the oil level warning light bulb and socket for continuity. Refer to “ CHECKING THE BULBS AN D BULB SOC KETS ” • Are the oil [...]

8 - 39 – + ELEC SIGNALING SYSTEM EAS00806 7. The speedometer f ails to come on. 2. Fuel sender • Drain the fuel from the fuel tank and remove the fuel pump from the fuel tank. • Disconnect the fuel sender coupler from the wire harness. • Connect the pocket tester ( Ω × 1) to the fuel sender as shown. Positive tester probe → green/white[...]

8 - 40 – + ELEC SIGNALING SYSTEM 2. V oltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Positive tester probe → yellow/blue 1 Negative tester probe → black/white 2 • Set the main switch to “ ON ” . • Elevate the rear wheel and slowly rotate it. • Measure the voltage (DC 5 V) o[...]

8 - 41 – + ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G R / L L / B R / B O / B G / B L (BLACK) G / B L R / B O / B R / L L / B R / B O / G O Gy / G Gy / R L Gy / R L O Gy / G R[...]

8 - 42 – + ELEC COOLING SYSTEM EAS00808 TROUBLESHOOTING Check: 1. main, ignition and radiator f an motor fuses 2. batter y 3. main s witch 4. radiator f an motor 5. radiator f an motor relay 6. coolant temper ature sensor 7. wiring connections (the entire cooling system) NOTE: _ • Before troubleshooting, remove the following part(s): 1. seat 2.[...]

8 - 43 – + ELEC COOLING SYSTEM EAS00809 YES NO 4. Radiator f an mot or • Disconnect the radiator fan moto r coupler from the wire harness. • Connect the battery (DC 12 V) as shown. Positive battery lead → blue 1 Negative battery lead → black 2 • Does the radiator fan motor turn? YES NO The radiator fan motor is faulty and must be replac[...]

8 - 44 – + ELEC COOLING SYSTEM EAS00812 EAS00813 6. Coolant temperatur e sensor • Remove the coolant temperature sensor from the thermostat housing. • Connect the pocket tester ( Ω × 1k) to the coolant temperature sensor 1 as shown. • Immerse the coolant tempe rature sensor in a container filled with coo lant 2 . NOTE: _ Make sure the co[...]

8 - 45 – + ELEC FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM L / R R / Y Br / W P / W Y B / L (BLACK) (BLACK) Y B / L Br / W P / W (BLACK) G / W B R / L B CORD HEAD LIGHT MAIN HARNESS A WIRE SUB LEAD 4 MAIN HARNESS G R / L L / B R / B O / B G / B L (BLACK) G / B L R / B O / B R / L L / B R / B O / G O Gy / G Gy / R L Gy / R L O Gy / G R / B [...]

8 - 46 – + ELEC FUEL PUMP SYSTEM EAS00815 FUEL PUMP SYSTEM The ECU includes the co ntrol unit for the fuel pump. 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 ECU 7 Fuel injection system fuse 8 Fuel injection system relay 9 Fuel pump[...]

8 - 47 – + ELEC FUEL PUMP SYSTEM EAS00816 TROUBLESHOOTING Check: 1. Main and fuel injection system fuses 2. Batter y 3. Main s witch 4. Engine stop s witch 5. Star ting circuit cut-off rela y (the fuel injection system relay) 6. Fuel pump 7. Wiring connections (the entire fuel system) NOTE: _ • Before troubleshooting, remove the following part([...]

8 - 48 – + ELEC FUEL PUMP SYSTEM EAS00759 EAS00 817 EAS00818 5. Star ting circuit cut-off rela y • Disconnect the starting circuit cut-off relay coupler from the wire harness. • Connect the pocket tester ( Ω × 1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown. Positive battery lead → red/black 1 Negative batt[...]

8 - 49 – + ELEC FUEL PUMP SYSTEM EAS00819 CHECKING THE FUEL PUMP W ARNING _ Gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refueling. • Do not smoke, and keep away from open flames, sparks, or any othe[...]

9 - 1 TRBL SHTG EAS00844 TROUBLESHOOTING NOTE: _ The following guide for trouble shooting does not cover all the possible cause s of trouble. It should be helpful, however, as a guide to basic troubleshooting . Refer to the relative procedure in this man- ual for checks, adjustments, and replacemen t of parts. STARTING FAILURES ENGINE Cylinder(s) a[...]

9 - 2 TRBL SHTG STARTING FAILURES/ INCORRECT ENGINE IDLING SPEED ELECTRICAL SYSTEMS Battery • Discharged battery • Faulty battery Fuse(s) • Blown, damaged or 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 o[...]

9 - 3 TRBL SHTG POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ FAULTY GEAR SHIFTING/FAULTY CLUTCH EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “ STARTING FAILURES ” . 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 ” [...]

9 - 4 TRBL SHTG OVERHEATING/OVERCOOLING/ POOR BRAKING PERFORMANCE EAS00855 OVERHEATING ENGINE Clogged coolant passages • Cylinder head(s) and piston(s) • Heavy carbon buildup Engine oil • Incorrect oil level • Incorrect oil viscosity • Inferior oil quality COOLING SYSTEM Coolant • Low coolant level Radiator • Damaged or leaking radiat[...]

9 - 5 TRBL SHTG FAULTY FRONT FORK LEGS/ UNSTABLE HANDLING EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL • Bent, damaged or rusty inner tube • Cracked or damaged outer tube • Improperly installed oil seal • Damaged oil seal lip • Incorrect oil level (hi gh) • Loose damper rod assembly bolt • Damaged damper rod assembly bolt copper washer[...]

9 - 6 TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON • Wrong headlight bulb • Too many electrical accessories • Hard charging • Incorrect connection • Improperly grounded circuit • Poor contacts (main switch) • Burnt-out headlight bulb HEADLIGHT BULB BURNT OUT • [...]

YZF-R1P/YZF-R1PC WIRING DIAGRAM 1 Main switch 2 AC magneto 3 Rectifier/regulator 4 Fuse (back up) 5 Battery 6 Fuse (main) 7 Fuse (fuel injection system) 8 Starter relay 9 Starter motor 0 Starting circuit cut-off relay A Sidestand switch B Fuel pump C ECU D Ignition coil E Spark plug F Fuel injector G AI system solenoid H EXUP servo motor I Speed se[...]

YZF-R1P/YZF-R1PC WIRING DIAGRAM Dark green Green Gray Black Blue Brown Chocolate COLOR CODE Orange Pink Red Sky blue Black / White Black / Yellow Blue / Black Blue / Red Blue / White Blue / Yellow Brown / Blue Brown / Red Brown / White Green / Red Green / White Green / Yellow White Yellow Black / Green Black / Blue Black / Red Green / Black Gray / [...]

Y AMAHA MO T OR CO . , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN PRINTED IN U.S.A.[...]