Yamaha YZFR6X(C) 2008 Service Manual
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Yamaha YZFR6X(C) 2008 Service Manual

Yamaha motorcycle
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2008
SERVICE MANUAL
YZFR6X(C)
LIT-11616-21-61
13S-28197-10

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Summary of Contents for Yamaha YZFR6X(C) 2008

  • Page 1 2008 SERVICE MANUAL YZFR6X(C) LIT-11616-21-61 13S-28197-10...
  • Page 2 EAS20050 YZFR6X(C) SERVICE MANUAL ©2007 by Yamaha Motor Corporation, U.S.A. First edition, October 2007 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-11616-21-61...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 4: How To Use This Manual

    EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference 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. •...
  • Page 5 EAS20100 15.Molybdenum-disulfide grease SYMBOLS 16.Silicone grease The following symbols are used in this manual 17.Apply locking agent (LOCTITE®) for easier understanding. 18.Replace the part NOTE: The following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2. Filling fluid 3.

  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    MODEL LABEL..................1-1 FEATURES ....................1-2 OUTLINE OF THE FI SYSTEM ..............1-2 FI SYSTEM .....................1-3 YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake) ..........1-4 INSTRUMENT FUNCTIONS ..............1-8 IMPORTANT INFORMATION ..............1-12 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-12 REPLACEMENT PARTS...............1-12 GASKETS, OIL SEALS AND O-RINGS..........1-12 LOCK WASHERS/PLATES AND COTTER PINS .........1-12...

  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped on the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame under the passenger seat. This information will be needed to order spare parts.

  • Page 11: Features

    FEATURES EAS20170 FEATURES ET2C01025 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 12: Fi System

    FEATURES ET2C01019 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm², 46.1 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus- ing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 13: Ycc-T (Yamaha Chip Controlled Throttle) Ycc-I (Yamaha Chip Controlled Intake)

    YCC-I (Yamaha Chip Controlled Intake) Mechanism characteristics Yamaha developed the YCC-T and YCC-I system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a faster, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
  • Page 14 FEATURES Aims and advantages of using YCC-I system • Improvement of the engine power characteristics The high power design in all ranges is now provided by having both two features of the short intake function to ensure the power at the high speed revolution of engine, and the long intake function to ensure the power in the practical use range.
  • Page 15 FEATURES YCC-T/YCC-I system outline 20.Intake funnel servo motor 1. Throttle position sensor (for throttle cable pulley) 2. Throttle servo motor 3. Throttle position sensor (for throttle valves) 4. ECU (engine control unit) 5. ETV main CPU (32 bit) 6. ETV sub CPU (16 bit) 7.
  • Page 16 FEATURES YCC-T/YCC-I control outline 15.Throttle servo motor 1. Throttle position sensor (for throttle cable pulley) 16.ECU (engine control unit) 2. Throttle position sensor (for throttle valves) 17.Base map 3. Crankshaft position sensor 18.Idle speed control 4. Speed sensor 19.Calculated throttle valve opening angle 5.

  • Page 17: Instrument Functions

    FEATURES ET2C01020 • To switch the speedometer and odometer/ INSTRUMENT FUNCTIONS tripmeter displays between kilometers and miles, press the “SELECT” button for at least Multi-function meter unit one second. Tachometer 1. Clock 2. Speedometer 1. Tachometer 3. “SELECT” button 2. Tachometer red zone 4.
  • Page 18 FEATURES 5. Push the “RESET” button to set the min- 2. Push the “SELECT” button to stop the stop- utes. watch. 6. Push the “SELECT” button and then 3. Push the “SELECT” button again to reset release it to start the clock. the stopwatch.
  • Page 19 In this mode, the right display shows the cur- If the right display indicates any error codes, rent setting for each function (except the shift note the code number, and then have a timing indicator light activity function). Yamaha dealer check the vehicle. 1-10...
  • Page 20 FEATURES To adjust the brightness of the multifunction To set the shift timing indicator light deactiva- meter displays and tachometer tion function 1. Turn the key to “OFF”. NOTE: 2. Push and hold the “SELECT” button. • The shift timing indicator light deactivation 3.

  • Page 21: Important Information

    5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 22: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

  • Page 23: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead NOTE: • Coupler • If there is no continuity, clean the terminals. •...

  • Page 24: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Extension 3-10 90890-04136 Oil filter wrench 3-12 90890-01426 YU-38411 Oil pressure gauge set 3-13 90890-03120 Oil pressure adapter H 3-13 90890-03139 Steering nut wrench 3-28, 4-57 90890-01403 Spanner wrench YU-33975 Fork spring compressor 4-47, 4-52 90890-01441 YM-01441...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fork seal driver 4-50 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Rod puller 4-51, 4-52 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10) 4-51, 4-52 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703...
  • Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder (24 mm) 4-65, 4-66 90890-01328 YM-01328 Valve spring compressor 5-19, 5-24 90890-04019 YM-04019 Valve spring compressor attachment 5-19, 5-24 90890-04108 Valve spring compressor adapter 22 mm YM-04108 Valve guide remover (ø4.5) 5-21 90890-04116 Valve guide remover (4.5 mm)
  • Page 28 Sheave holder 5-27, 5-28, 5-30 90890-01701 Primary clutch holder YS-01880-A Flywheel puller 5-27 90890-01404 Flywheel puller YM-01404 Yamaha bond No. 1215 5-28, 5-30, 5- 90890-85505 55, 6-11 (Three Bond No.1215®) Universal clutch holder 5-40, 5-44 90890-04086 YM-91042 Thickness gauge 5-41 90890-03180 0.15 0.10 0.05...
  • Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston pin puller set 5-58 90890-01304 Piston pin puller YU-01304 YU-01304 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 YU-33984 Pressure gauge 7-12 90890-03153 Pressure gauge...
  • Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fuel pressure adapter 7-12 90890-03176 YM-03176 Digital circuit tester 7-13, 7-14 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Ignition checker 8-92 90890-06754 Opama pet-4000 spark checker YM-34487 1-21...

  • Page 31: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-9 ELECTRICAL SPECIFICATIONS...............2-12 TIGHTENING TORQUES................2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-15 ENGINE TIGHTENING TORQUES ............2-16 CHASSIS TIGHTENING TORQUES ............2-20 LUBRICATION POINTS AND LUBRICANT TYPES ........2-24 ENGINE ....................2-24 CHASSIS ....................2-25 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-27 ENGINE OIL LUBRICATION CHART ...........2-27 LUBRICATION DIAGRAMS ..............2-29 COOLING SYSTEM DIAGRAMS ...............2-41...

  • Page 32: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 13S4/13S7 (USA) 13S5/13S8 (California) Dimensions Overall length 2040 mm (80.3 in) Overall width 705 mm (27.8 in) Overall height 1100 mm (43.3 in) Seat height 850 mm (33.5 in) Wheelbase 1380 mm (54.3 in) Ground clearance 130 mm (5.12 in) Minimum turning radius...

  • Page 33: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid-cooled 4-stroke, DOHC Displacement 599 cm³ (36.55 cu.in) Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 67.0 × 42.5 mm (2.64 × 1.67 in) Compression ratio 13.1:1 Standard compression pressure (at sea level) 1600 kPa/400 r/min (227.6 psi/400 r/min) (16.0 kgf/cm²/400 r/min) Minimum–maximum...
  • Page 34 ENGINE SPECIFICATIONS Thermostat 71 °C (159.8 °F) Valve opening temperature 85 °C (185 °F) Valve full open temperature Valve lift (full open) More than 8 mm (0.31 in) Radiator core Width 374.0 mm (14.72 in) Height 257.8 mm (10.15 in) Depth 24.0 mm (0.94 in) Water pump...
  • Page 35 ENGINE SPECIFICATIONS Timing chain Model/number of links 98XRH2015/118 Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.12–0.19 mm (0.0047–0.0075 in) Exhaust 0.16–0.23 mm (0.0063–0.0091 in) Valve dimensions Valve head diameter A (intake) 26.90–27.10 mm (1.0591–1.0669 in) Valve head diameter A (exhaust) 22.90–23.10 mm (0.9016–0.9094 in) Valve face width B (intake)
  • Page 36 ENGINE SPECIFICATIONS Valve stem runout 0.040 mm (0.0016 in) Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.06 in) Cylinder head valve seat width (exhaust) 1.10–1.30 mm (0.0433–0.0512 in) Limit 1.8 mm (0.07 in) Valve spring Free length (intake) 37.47 mm (1.48 in) Limit...
  • Page 37 ENGINE SPECIFICATIONS Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 15.002–15.013 mm (0.5906–0.5911 in) Limit 15.043 mm (0.5922 in) Piston pin outside diameter 14.991–15.000 mm (0.5902–0.5906 in) Limit 14.971 mm (0.5894 in) Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.00007–0.00068 in) Piston ring Top ring...
  • Page 38 ENGINE SPECIFICATIONS Small end free play F 0.32–0.50 mm (0.01–0.02 in) ® Journal oil clearance (using plastigauge 0.020–0.044 mm (0.0008–0.0017 in) Bearing color code 0.White 1.Blue 2.Black 3.Brown 4.Green Clutch Clutch type Wet, multiple-disc Clutch release method Outer pull, rack and pinion pull Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Friction plate thickness...
  • Page 39 ENGINE SPECIFICATIONS Output pressure 319.0–329.0 kPa (46.3–47.7 psi) (3.19–3.29 kgf/cm²) Fuel injector Model/quantity 297500–0640/4, 297500–1250/4 Manufacturer DENSO Throttle body Type/quantity 41EIDW/1 Manufacturer MIKUNI ID mark 13S1 00 (USA) 13S5 10 (California) Throttle valve size Throttle position sensor Resistance 2.0–3.0 kΩ Output voltage (at idle) 0.68 V Fuel injection sensor...

  • Page 40: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 24.00° Trail 97.0 mm (3.82 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 115.0 mm (4.53 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 41 CHASSIS SPECIFICATIONS Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter 16.00 mm (0.63 in) 30.20 mm × 1 (1.19 in × 1) Caliper cylinder inside diameter 27.00 mm ×...
  • Page 42 CHASSIS SPECIFICATIONS Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 60.0 mm (2.36 in) Spring free length 161.5 mm (6.36 in) Installed length 152.5 mm (6.00 in) Spring rate K1 103.00 N/mm (588.13 lb/in) (10.50 kgf/mm) Spring stroke K1 0.0–60.0 mm (0.00–2.36 in) Optional spring available Enclosed gas/air pressure (STD)

  • Page 43: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Throttle position sensor and electrical Ignition timing (B.T.D.C.) 10.0°/1300 r/min Engine control unit Model/manufacturer TBDF61/DENSO Ignition coil Model/manufacturer F6T568/MITSUBISHI Minimum ignition spark gap 6.0 mm (0.24 in) 0.85–1.15 Ω...
  • Page 44 ELECTRICAL SPECIFICATIONS Electric starting system System type Constant mesh Starter motor Model/manufacturer SM14/MITSUBA Power output 0.60 kW 0.0012–0.0022 Ω at 20 °C (68 °F) Armature coil resistance Brush overall length 10.0 mm (0.39 in) Limit 3.50 mm (0.14 in) Brush spring force 7.16–9.52 N (25.77–34.27 oz) (730–971 gf) Commutator diameter 28.0 mm (1.10 in)
  • Page 45 ELECTRICAL SPECIFICATIONS Fan motor relay Model/manufacturer ACM33211M05/MATSUSHITA Fuses Main fuse 50.0 A Headlight fuse 15.0 A Signaling system fuse 10.0 A Ignition fuse 15.0 A 15.0 A × 2 Radiator fan fuse Fuel injection system fuse 15.0 A Backup fuse 7.5 A Electric throttle valve fuse 7.5 A...

  • Page 46: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.

  • Page 47: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Camshaft cap bolt (intake and 10 Nm (1.0 m·kg, 7.4 ft·lb) exhaust) Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kg, 11 ft·lb) pipe assembly) Cylinder head nut (1st) 25 Nm (2.5 m·kg, 18 ft·lb) Cylinder head nut (final) 42 Nm (4.2 m·kg, 31 ft·lb)
  • Page 48 TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Intake funnel to throttle body 4 Nm (0.4 m·kg, 3.0 ft·lb) Intake funnel bolt 3 Nm (0.3 m·kg, 2.2 ft·lb) Locknut (throttle cable) 5 Nm (0.5 m·kg, 3.7 ft·lb) Exhaust pipe assembly nut 20 Nm (2.0 m·kg, 15 ft·lb) Exhaust pipe assembly bolt 20 Nm (2.0 m·kg, 15 ft·lb)
  • Page 49 TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Crankcase stud bolt See NOTE Pressure plate bolt 8 Nm (0.8 m·kg, 5.9 ft·lb) Stake Clutch boss nut 115 Nm (11.5 m·kg, 85 ft·lb) Clutch boss plate stud bolt 25 Nm (2.5 m·kg, 18 ft·lb) Stake Drive sprocket nut 85 Nm (8.5 m·kg, 63 ft·lb)
  • Page 50 TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence: 2-19...

  • Page 51: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Engine mounting bolt (front right 45 Nm (4.5 m·kg, 33 ft·lb) side) Engine mounting bolt (front left 45 Nm (4.5 m·kg, 33 ft·lb) side) Engine mounting nut (rear upper 64 Nm (6.4 m·kg, 47 ft·lb) side) Engine mounting nut (rear lower...
  • Page 52 TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Lower bracket and front brake 10 Nm (1.0 m·kg, 7.4 ft·lb) hose joint bracket bolt Front brake hose joint and front 10 Nm (1.0 m·kg, 7.4 ft·lb) brake hose joint bracket bolt Cap bolt 20 Nm (2.0 m·kg, 15 ft·lb) Cap bolt (damper rod assembly...
  • Page 53 TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size Front cowling assembly bolt 13 Nm (1.3 m·kg, 9.6 ft·lb) Seat lock assembly bolt 7 Nm (0.7 m·kg, 5.2 ft·lb) Rider seat and frame 7 Nm (0.7 m·kg, 5.2 ft·lb) Battery box and frame 4 Nm (0.4 m·kg, 3.0 ft·lb) Rear upper cowling damper plate...
  • Page 54 TIGHTENING TORQUES NOTE: Lower ring nut 1. First, tighten the lower ring nut to approximately 52 Nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 14 Nm (1.4 m·kg, 10 ft·lb) with a torque wrench. NOTE: Lower bracket pinch bolt Tighten each bolt to 23 Nm (2.3 m·kg, 17 ft·lb) in the order pinch bolt “1”...

  • Page 55: Lubrication Points And Lubricant Types

    Clutch boss nut Clutch pull rod Transmission gears (wheel and pinion) and collars Main axle and drive axle Shift forks and shift fork guide bars Shift shaft Yamaha bond No.1215 Cylinder head cover mating surface (Three Bond ® No.1215 Cylinder head cover gasket...

  • Page 56: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond No.1215 Crankshaft position sensor lead grommet (Three Bond ® No.1215 Yamaha bond No.1215 Stator coil lead grommet (Three Bond ® No.1215 EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing cover lip...
  • Page 57 LUBRICATION POINTS AND LUBRICANT TYPES 2-26...

  • Page 58: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-27...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil filter 5. Oil cooler 6. Main gallery 7. Oil nozzle 8. Timing chain tensioner 9. Intake camshaft 10.Exhaust camshaft 11.Oil pipe 12.Main axle 13.Shift fork 14.Drive axle 2-28...

  • Page 60: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-29...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Ventilation chamber cover 2. Relief valve 3. Ventilation chamber oil drain pipe 4. Oil cooler 2-30...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Oil check bolt 5. Oil strainer 6. Ventilation chamber oil drain pipe 7. Oil pipe 8. Oil pump 2-32...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil filter 3. Oil pipe 4. Oil pump 5. Oil strainer 2-34...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil pump 3. Oil pipe 4. Ventilation chamber oil drain pipe 5. Relief valve 2-36...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Oil nozzle 2-38...
  • Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
  • Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pipe 2. Main axle 3. Drive axle 2-40...

  • Page 72: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-41...
  • Page 73 COOLING SYSTEM DIAGRAMS 1. Radiator inlet hose 2. Radiator inlet pipe 3. Thermostat outlet hose 4. Radiator 2-42...
  • Page 74 COOLING SYSTEM DIAGRAMS 2-43...
  • Page 75 COOLING SYSTEM DIAGRAMS 1. Water pump breather hose 2. Coolant reservoir hose 3. Coolant reservoir 4. Radiator 5. Radiator outlet hose 6. Oil cooler outlet hose 7. Radiator outlet pipe 8. Water jacket joint inlet hose 9. Water pump outlet pipe 10.Water pump inlet hose 11.Water pump outlet hose 12.Water pump...

  • Page 76: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-45...
  • Page 77 CABLE ROUTING 1. Clutch cable 2. Main switch lead 3. Left handlebar switch lead 4. Horn lead 5. Horn 6. Front brake hose 7. Throttle cable (return side) 8. Throttle cable (pull side) 9. Right handlebar switch lead 10.Steering cover 11.Front fork A.
  • Page 78 CABLE ROUTING 2-47...
  • Page 79 CABLE ROUTING L. Bend the lead on the side of the fan motor 1. Coolant reservoir breather hose main harness toward the back of the vehi- 2. Clutch cable cle as shown in the illustration and insert it 3. Hose clamp into the right coupler holder.
  • Page 80 CABLE ROUTING 2-49...
  • Page 81 CABLE ROUTING O. Route the AC magneto lead under the left 1. Main switch lead radiator fan motor lead. 2. Left handlebar switch lead P. Fasten the left handle bar switch lead with 3. Left radiator fan motor lead a plastic locking tie, making sure the left 4.
  • Page 82 CABLE ROUTING 2-51...
  • Page 83 CABLE ROUTING H. Fasten the main harness, right radiator fan 1. Clutch cable motor lead, throttle position sensor lead, 2. Throttle cable (return side) throttle servo motor lead and accelerator 3. Throttle cable (pull side) position sensor lead with a plastic locking 4.
  • Page 84 CABLE ROUTING 2-53...
  • Page 85 CABLE ROUTING AA.Route each lead under the frame plate. There is no order for placing each lead. Insert the plastic locking tie from upper part of the frame and direct the remaining part of the tip toward inner side of the vehicle. AB.Route the sub-wire harness (secondary injector) through the area shown in the illustration.
  • Page 86 CABLE ROUTING 2-55...
  • Page 87 CABLE ROUTING 1. Headlight sub-wire harness 2. Headlight lead (low beam) 3. Headlight relay lead (on/off) 4. Headlight relay lead (dimmer) 5. Headlight lead (high beam) 6. Air temperature sensor lead 7. Atmospheric pressure sensor lead A. Secure the headlight sub-wire harness with the air duct hook.
  • Page 88 CABLE ROUTING 2-57...
  • Page 89 CABLE ROUTING 1. Battery 2. Battery negative lead 3. Main fuse lead 4. Starting circuit cut-off relay lead 5. Fuse box lead 6. ECU (engine control unit) 7. Turn signal relay lead 8. Rear left turn signal light lead 9. Rear right turn signal light lead 10.License plate light lead 11.Tail/brake light lead 12.Seat lock cable...
  • Page 90 CABLE ROUTING 2-59...
  • Page 91 CABLE ROUTING 1. Fuel tank breather hose (Except for Califor- nia) 2. Fuel tank drain hose 3. Main harness 4. Fuel hoses 5. Fuel tank breather hose (Except for Califor- nia) 6. Fuel tank drain hose 7. Clamp 2-60...
  • Page 92 CABLE ROUTING 2-61...

  • Page 93: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM............3-1 GENERAL MAINTENANCE AND LUBRICATION CHART.....3-1 ENGINE......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODIES ........3-7 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-8 CHECKING THE SPARK PLUGS............3-9 MEASURING THE COMPRESSION PRESSURE .........3-9 CHECKING THE ENGINE OIL LEVEL ..........3-11...
  • Page 94 LUBRICATING THE REAR SUSPENSION ..........3-35 ELECTRICAL SYSTEM................3-36 CHECKING AND CHARGING THE BATTERY........3-36 CHECKING THE FUSES..............3-36 REPLACING THE HEADLIGHT BULBS..........3-36 ADJUSTING THE HEADLIGHT BEAMS ..........3-36...

  • Page 96: Periodic Maintenance

    PERIODIC MAINTENANCE EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. 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 applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 97 PERIODIC MAINTENANCE INITIAL ODOMETER READING 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) 1 month 6 months 12 months 18 months 24 months 30 months √...
  • Page 98 28 * and switches • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.

  • Page 99: Engine

    ENGINE EAS20470 ENGINE Valve clearance (cold) Intake 0.12–0.19 mm (0.0047–0.0075 EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the Exhaust valves. 0.16–0.23 mm (0.0063–0.0091 NOTE: • Valve clearance adjustment should be made ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ on a cold engine, at room temperature. a.
  • Page 100 ENGINE 5. Remove: NOTE: • Camshafts • If the valve clearance is incorrect, note the measured reading. NOTE: • Measure the valve clearance in the following • Refer to “CAMSHAFTS” on page 5-7. sequence. • When removing the timing chain and cam- shafts, fasten the timing chain with a wire to Valve clearance measuring sequence retrieve it if it falls into the crankcase.
  • Page 101 ENGINE Measured valve clearance = 0.23 mm Example: (0.009 in) Valve pad number = 158 0.23 mm (0.009 in) – 0.20 mm (0.008 in) = Rounded value = 160 0.03 mm (0.001 in) New valve pad number = 160 c. Check the thickness of the current valve f.

  • Page 102: Synchronizing The Throttle Bodies

    ENGINE EAS20570 • Throttle body synchronization SYNCHRONIZING THE THROTTLE BODIES ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: Basic procedure Prior to synchronizing the throttle bodies, the a. Start the engine, warm it up for several valve clearance and the engine idling speed minutes, and then let it run at the specified should be properly adjusted.

  • Page 103: Adjusting The Throttle Cable Free Play

    ENGINE • If you are unable to adjust the throttle body Refer to “ADJUSTING THE THROTTLE synchronization using this procedure, use CABLE FREE PLAY” on page 3-8. the following procedure instead. Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 104: Checking The Spark Plugs

    ENGINE Damage/wear → Replace the spark plug. • Insulator “2” Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • Spark plug (with a spark plug cleaner or wire brush) 6. Measure: • Spark plug gap “a” EWA12910 (with a wire thickness gauge) Out of specification →...
  • Page 105 ENGINE NOTE: Standard compression pres- Insufficient compression pressure will result in sure (at sea level) a loss of performance. 1600 kPa/400 r/min (227.6 psi/ 400 r/min) (16.0 kgf/cm²/400 r/ 1. Measure: min) • Valve clearance Minimum–maximum Out of specification → Adjust. 1350–1650 kPa (195.8–239.3 Refer to “ADJUSTING THE VALVE psi) (13.5–16.5 kgf/cm²)

  • Page 106: Checking The Engine Oil Level

    ENGINE 8. Install: EC2C01005 CAUTION: • Radiator Refer to “RADIATOR” on page 6-1. • Since engine oil also lubricates the • Side cowling assembly clutch, the wrong oil types or additives Refer to “GENERAL CHASSIS” on page could cause clutch slippage. Therefore, 4-1.
  • Page 107 ENGINE • Engine oil filler cap “1” d. Lubricate the O-ring “1” of the new oil filter cartridge with a thin coat of engine oil. EC2C01006 5. Remove: CAUTION: • Engine oil drain bolt “1” Make sure the O-ring “1” is positioned cor- (along with the gasket) rectly in the groove of the oil filter car- tridge.

  • Page 108: Measuring The Engine Oil Pressure

    ENGINE 8. Check: to measure the engine oil pressure after • Engine oil drain bolt gasket warming up the engine. Damage → Replace. 3. Remove: 9. Install: • Side cowling assembly • Engine oil drain bolt Refer to “GENERAL CHASSIS” on page (along with the gasket) 4-1.

  • Page 109: Adjusting The Clutch Lever Free Play

    ENGINE Engine oil pressure Possible causes • Faulty oil pump • Clogged oil filter Below specification • Leaking oil passage • Broken or damaged oil seal • Leaking oil passage • Faulty oil filter Above specification • Oil viscosity too high NOTE: If the specified clutch lever free play cannot be...

  • Page 110: Checking The Throttle Body Joints

    ENGINE EC2C01007 CAUTION: Never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect the throttle body synchronization, leading to poor engine performance and possible overheating.

  • Page 111: Checking The Fuel Line

    ENGINE 3. Install: EAS21070 CHECKING THE CRANKCASE BREATHER • Throttle body HOSE Refer to “THROTTLE BODIES” on page 1. Remove: 7-9. • Rider seat • Air filter case Refer to “GENERAL CHASSIS” on page Refer to “AIR FILTER CASE” on page 7- 4-1.

  • Page 112: Adjusting The Exup Cables

    ENGINE • Exhaust pipe assembly bracket (left upper side and right side) and frame bolts “5” • Exhaust pipe assembly bracket (left upper side) and exhaust pipe assembly bracket (left lower side) bolt “6” • Exhaust pipe assembly and exhaust pipe assembly bracket (left and right) bolts “7”...

  • Page 113: Checking The Coolant Level

    ENGINE position). If the projection does not contact the d. Turn the adjusting bolt “4” in direction “a” or stopper, adjust the EXUP cable free play. “b” until the specification. Direction “a” Free play is increased. Direction “b” Free play is decreased. EXUP cable free play (at the EXUP valve pulley) d: 1.5 mm (0.06 in) or less...

  • Page 114: Checking The Cooling System

    ENGINE the recommended coolant to the proper • Oil cooler outlet hose “8” level. • Oil cooler inlet hose “9” • Water pump outlet hose “10” NOTE: • Water pump inlet hose To access the coolant reservoir cap, remove • Water pump outlet pipe “11” the right side panel.
  • Page 115 ENGINE EWA13030 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause seri- ous injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radia- tor cap and slowly turn the radiator cap...
  • Page 116 ENGINE • If coolant splashes on your clothes, Refer to “GENERAL CHASSIS” on page quickly wash it away with water and then 4-1. with soap and water. • If coolant is swallowed, induce vomiting and get immediate medical attention. ECA13480 CAUTION: •...

  • Page 117: Chassis

    CHASSIS EAS21140 EAS21190 CHASSIS ADJUSTING THE REAR DISC BRAKE 1. Adjust: • Brake pedal position EAS21150 ADJUSTING THE FRONT DISC BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. Adjust: a. Loosen the locknut “1”. • Brake lever position b. Turn the adjusting bolt “2” in direction “a” or (distance “a”...

  • Page 118: Checking The Brake Fluid Level

    CHASSIS 2. Adjust: • Refill with the same type of brake fluid • Rear brake light switch that is already in the system. Mixing brake Refer to “ADJUSTING THE REAR fluids may result in a harmful chemical BRAKE LIGHT SWITCH” on page 3-24. reaction, leading to poor brake perfor- mance.

  • Page 119: Checking The Front Brake Hoses

    CHASSIS Limit 1.0 mm (0.04 in) 3. Hold the vehicle upright and apply the brake several times. 4. Check: • Brake hoses Brake fluid leakage → Replace the dam- EAS21280 CHECKING THE FRONT BRAKE HOSES aged hose. The following procedure applies to all of the Refer to “REAR BRAKE”...

  • Page 120: Bleeding The Hydraulic Brake System

    CHASSIS EAS21360 BLEEDING THE HYDRAULIC BRAKE SYS- EWA13100 WARNING Bleed the hydraulic brake system when- ever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. NOTE: •...

  • Page 121: Adjusting The Shift Pedal

    CHASSIS Bleed screw (front brake master Direction “a” Installed shift rod length increases. cylinder) Direction “b” 6 Nm (0.6 m·kg, 4.4 ft·lb) Installed shift rod length decreases. Bleed screw (front brake cali- per) 5 Nm (0.5 m·kg, 3.7 ft·lb) Bleed screw (rear brake caliper) 5 Nm (0.5 m·kg, 3.7 ft·lb) k.

  • Page 122: Lubricating The Drive Chain

    CHASSIS e. Tighten the drive chain adjusting bolts in Drive chain slack direction “a” to specification. 30.0–45.0 mm (1.18–1.77 in) Drive chain adjusting bolt 2 Nm (0.2 m·kg, 1.5 ft·lb) NOTE: Measure the drive chain slack halfway f. Tighten the locknuts to specification. between the drive axle and the rear wheel axle.
  • Page 123 CHASSIS 3. Remove: Lower ring nut (final tightening • Upper bracket torque) Refer to “STEERING HEAD” on page 4- 14 Nm (1.4 m·kg, 10 ft·lb) 4. Adjust: d. Check the steering head for looseness or • Steering head binding by turning the front fork all the way ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 124: Checking The Front Fork

    CHASSIS 2. Check: • Inner tube “1” Damage/scratches → Replace. • Oil seal “2” Oil leakage → Replace. d. Hold the spring gauge at a 90° angle from the handlebar, pull the spring gauge, and then record the measurement when the handlebar starts to run.
  • Page 125 CHASSIS Spring preload 2. Current setting ECA13570 3. Cap bolt collar CAUTION: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Grooves are provided to indicate the adjustment position. Rebound damping • Never go beyond the maximum or mini- ECA13590 mum adjustment positions. CAUTION: 1. Adjust: Never go beyond the maximum or minimum •...

  • Page 126: Adjusting The Rear Shock Absorber Assembly

    CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Compression damping adjusting a. Turn the adjusting bolt “1” in direction “a” or positions (slow compression “b”. damping) Direction “a” Minimum Compression damping increased 20 click(s) out* (suspension is harder). Standard Direction “b” 15 click(s) out* Compression damping decreased Maximum (suspension is softer).
  • Page 127 CHASSIS Spring preload adjusting posi- tions Minimum Standard Maximum ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping ECA13590 CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: • Compression damping (fast compression damping) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Rebound damping a. Turn the adjusting screw “1” in direction “a” ECA13590 or “b”.

  • Page 128: Checking The Tires

    CHASSIS 2. Adjust: • Compression damping (slow compres- sion damping) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. Direction “a” (turn in) Compression damping increased (suspension is harder). Direction “b” (turn out) EWA13180 Compression damping decreased WARNING (suspension is softer).
  • Page 129 No guarantee concerning handling characteristics can be 1. Tire tread depth given if a tire combination other than one 2. Side wall approved by Yamaha is used on this vehi- 3. Wear indicator cle. EWA14080 WARNING...

  • Page 130: Checking The Wheels

    CHASSIS NOTE: Recommended lubricant For tires with a direction of rotation mark “1”: Engine oil or a suitable cable • Install the tire with the mark pointing in the lubricant direction of wheel rotation. • Align the mark “2” with the valve installation NOTE: point.

  • Page 131: Electrical System

    ELECTRICAL SYSTEM EAS21750 EWA13320 ELECTRICAL SYSTEM WARNING Since the headlight bulb gets extremely EAS21760 hot, keep flammable products and your CHECKING AND CHARGING THE BATTERY hands away from the bulb until it has Refer to “ELECTRICAL COMPONENTS” on cooled down. page 8-77.
  • Page 132 ELECTRICAL SYSTEM A. Left headlight B. Right headlight ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: • Headlight beam (horizontally) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. Direction “a” Headlight beam moves to the left. Direction “b” Headlight beam moves to the right. A.
  • Page 133 CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEEL ....................4-6 REMOVING THE FRONT WHEEL ............4-8 DISASSEMBLING THE FRONT WHEEL ..........4-8 CHECKING THE FRONT WHEEL............4-8 ASSEMBLING THE FRONT WHEEL .............4-9 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-9 CHECKING THE FRONT BRAKE DISCS ..........4-10 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) .....4-10 REAR WHEEL ....................4-12 REMOVING THE REAR WHEEL ............4-15 DISASSEMBLING THE REAR WHEEL ..........4-15...
  • Page 134 ASSEMBLING THE REAR BRAKE MASTER CYLINDER ....4-39 INSTALLING THE REAR BRAKE MASTER CYLINDER......4-39 HANDLEBARS ...................4-41 REMOVING THE HANDLEBARS ............4-43 CHECKING THE HANDLEBARS ............4-43 INSTALLING THE HANDLEBARS............4-43 FRONT FORK.....................4-45 REMOVING THE FRONT FORK LEGS ..........4-47 DISASSEMBLING THE FRONT FORK LEGS ........4-47 CHECKING THE FRONT FORK LEGS..........4-48 ASSEMBLING THE FRONT FORK LEGS ...........4-49 INSTALLING THE FRONT FORK LEGS ..........4-53...
  • Page 136 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery Order Job/Parts to remove Q’ty Remarks Rider seat Passenger seat Fuel tank bracket Battery negative lead Disconnect. Battery positive lead Disconnect. Battery band Battery For installation, reverse the removal proce- dure.

  • Page 137: General Chassis

    GENERAL CHASSIS Removing the tail/brake light assembly Order Job/Parts to remove Q’ty Remarks Rider seat/Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. Battery Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Owner’s tool kit Rear upper cowling cover Rear upper cowling...
  • Page 138 GENERAL CHASSIS Removing the tail/brake light assembly Order Job/Parts to remove Q’ty Remarks EC2C01026 CAUTION: Passenger footrest Install the cowling hole cover if the vehi- cle is registered for only a solo rider. License plate light assembly Rear lower cowling assembly Tail/brake light assembly Rear lower cowling Tail/brake light cover...
  • Page 139 GENERAL CHASSIS Removing the side cowlings and front cowling assembly Order Job/Parts to remove Q’ty Remarks Side panel Side cowling assembly Front turn signal light coupler Disconnect. Middle side cowling Air intake duct Front turn signal light bracket Front turn signal light Bottom cowling Upper side cowling Bottom cowling inner panel...
  • Page 140 GENERAL CHASSIS Removing the front cowling assembly Order Job/Parts to remove Q’ty Remarks Spacer Meter assembly coupler Disconnect. Air temperature sensor coupler Disconnect. Atmospheric pressure sensor coupler Disconnect. Meter assembly Meter bracket Air duct Air temperature sensor Atmospheric pressure sensor Headlight relay coupler Disconnect.
  • Page 141 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Left reflector assembly Right reflector assembly Left front brake hose holder Right front brake hose holder Left front brake caliper Right front brake caliper Front wheel axle pinch bolt Loosen.
  • Page 142 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure.

  • Page 143: Front Wheel

    FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.

  • Page 144: Assembling The Front Wheel

    FRONT WHEEL EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the front wheel static balance should be adjusted. • Adjust the front wheel static balance with the brake disc installed. 1. Remove: 4.

  • Page 145: Checking The Front Brake Discs

    FRONT WHEEL 3. Adjust: ET2C01002 CHECKING THE FRONT BRAKE DISCS • Front wheel static balance Refer to “CHECKING THE FRONT BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ DISCS” on page 4-23. a. Install a balancing weight “1” onto the rim exactly opposite the heavy spot “X”. EAS22000 INSTALLING THE FRONT WHEEL (FRONT NOTE:...
  • Page 146 FRONT WHEEL 5. Install: • Front wheel axle ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Front wheel axle bolt 6. Install: • Front wheel axle pinch bolts • Front brake calipers Front wheel axle Front brake caliper bolt 91 Nm (9.1 m·kg, 67 ft·lb) 35 Nm (3.5 m·kg, 26 ft·lb) Front wheel axle pinch bolt EWA13500 21 Nm (2.1 m·kg, 16 ft·lb)

  • Page 147: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel 22 Nm (2.2 m kg, 16 ft Ib) 27 Nm (2.7 m kg, 20 ft Ib) 110 Nm (11.0 m kg, 81 ft Ib) Order Job/Parts to remove Q’ty Remarks Rear brake caliper Drive chain adjusting locknut Loosen.
  • Page 148 REAR WHEEL Removing the rear brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar Dust cover Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Dust cover Collar For installation, reverse the removal proce- dure.
  • Page 149 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly pro- cedure. 4-14...

  • Page 150: Removing The Rear Wheel

    REAR WHEEL EAS22040 EAS22090 REMOVING THE REAR WHEEL CHECKING THE REAR WHEEL 1. Stand the vehicle on a level surface. 1. Check: EWA13120 • Rear wheel axle WARNING • Rear wheel • Wheel bearings Securely support the vehicle so that there •...

  • Page 151: Assembling The Rear Wheel

    REAR WHEEL EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1.
  • Page 152 REAR WHEEL 4. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-26. Drive chain slack 30.0–45.0 mm (1.18–1.77 in) 5. Install: • Rear brake caliper Rear brake caliper bolt (M12) 27 Nm (2.7 m·kg, 20 ft·lb) Rear brake caliper bolt (M8) 22 Nm (2.2 m·kg, 16 ft·lb) ®...

  • Page 153: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Reflector assembly Brake hose holder Front brake caliper Brake pad clip Brake pad pin Brake pad spring Front brake pad For installation, reverse the removal proce-...
  • Page 154 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. Brake fluid reservoir cap holder Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose...
  • Page 155 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Bleed screw Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-20...
  • Page 156 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. Reflector assembly Brake hose holder Front brake hose union bolt Copper washer Front brake hose...
  • Page 157 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Front brake pad Brake caliper piston Brake caliper piston seal Brake caliper piston dust seal Bleed screw For assembly, reverse the disassembly pro-...

  • Page 158: Introduction

    FRONT BRAKE EAS22220 c. Remove the brake caliper. INTRODUCTION d. Hold the dial gauge at a right angle against EWA14100 the brake disc surface. WARNING Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary.

  • Page 159: Replacing The Front Brake Pads

    FRONT BRAKE Brake disc bolt 2. Install: 18 Nm (1.8 m·kg, 13 ft·lb) • Brake pads ® LOCTITE • Brake pad spring NOTE: d. Measure the brake disc deflection. Always install new brake pads, and a brake e. If out of specification, repeat the adjust- pad spring as a set.

  • Page 160: Removing The Front Brake Calipers

    FRONT BRAKE • Copper washers “2” • Front brake hose “3” NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Brake pad pin • Brake pad clips •...

  • Page 161: Checking The Front Brake Calipers

    FRONT BRAKE b. Remove the brake caliper piston seals and EAS22410 brake caliper piston dust seals. ASSEMBLING THE FRONT BRAKE CALI- PERS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EWA13S1003 WARNING EAS22390 CHECKING THE FRONT BRAKE CALIPERS • Before installation, all internal brake com- ponents should be cleaned and lubricated Recommended brake component replace- with clean or new brake fluid.

  • Page 162: Removing The Front Brake Master Cylinder

    FRONT BRAKE ECA14170 the brake fluid and could cause vapor CAUTION: lock. When installing the brake hose onto the ECA13540 brake caliper “1”, make sure the brake pipe CAUTION: “a” touches the projection “b” on the brake Brake fluid may damage painted surfaces caliper.

  • Page 163: Checking The Front Brake Master Cylinder

    FRONT BRAKE Front brake master cylinder holder bolt 13 Nm (1.3 m·kg, 9.6 ft·lb) NOTE: • Install the brake master cylinder holder with the “UP” mark “a” facing up. • Align the mating surfaces of the brake master cylinder holder with the punch mark “b” on the handlebar.
  • Page 164 FRONT BRAKE 15.8˚ 3. Fill: 6. Check: • Brake fluid reservoir • Brake lever operation Soft or spongy feeling → Bleed the brake (with the specified amount of the recom- mended brake fluid) system. Refer to “BLEEDING THE HYDRAULIC Recommended fluid BRAKE SYSTEM”...

  • Page 165: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad insulator Rear brake pad Brake pad spring For installation, reverse the removal proce- dure.
  • Page 166 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. Brake fluid reservoir Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir hose Rear brake hose Right footrest assembly...
  • Page 167 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake hose joint Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-32...
  • Page 168 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. Rear brake hose union bolt Copper washer Rear brake hose Rear brake caliper For installation, reverse the removal proce- dure.
  • Page 169 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Brake pad shim Brake pad insulator Rear brake pad Brake pad spring Brake caliper piston Brake caliper piston seal Brake caliper piston dust seal Bleed screw For assembly, reverse the disassembly pro- cedure.

  • Page 170: Introduction

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 4.5 mm (0.18 in) WARNING 5. Adjust: Disc brake components rarely require dis- • Brake disc deflection assembly. Therefore, always follow these Refer to “CHECKING THE FRONT preventive measures: BRAKE DISCS” on page 4-23. •...

  • Page 171: Removing The Rear Brake Caliper

    REAR BRAKE Below the minimum level mark “a” → Add NOTE: the recommended brake fluid to the Always install new brake pads, brake pad insu- proper level. lators, brake pad shims, and a brake pad Refer to “CHECKING THE BRAKE spring as a set.

  • Page 172: Checking The Rear Brake Caliper

    REAR BRAKE • Brake caliper cylinder “2” Scratches/wear → Replace the brake cal- iper assembly. • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air.

  • Page 173: Installing The Rear Brake Caliper

    REAR BRAKE 4. Fill: Recommended fluid • Brake fluid reservoir DOT 4 (with the specified amount of the recom- mended brake fluid) EAS22670 INSTALLING THE REAR BRAKE CALIPER Recommended fluid 1. Install: DOT 4 • Rear brake caliper “1” (temporarily) EWA13090 WARNING •...

  • Page 174: Removing The Rear Brake Master Cylinder

    REAR BRAKE Soft or spongy feeling → Bleed the brake EAS22730 ASSEMBLING THE REAR BRAKE MASTER system. CYLINDER Refer to “BLEEDING THE HYDRAULIC EWA13520 BRAKE SYSTEM” on page 3-25. WARNING • Before installation, all internal brake com- EAS22700 REMOVING THE REAR BRAKE MASTER ponents should be cleaned and lubricated CYLINDER with clean or new brake fluid.
  • Page 175 REAR BRAKE EWA13090 6. Adjust: WARNING • Brake pedal position Refer to “ADJUSTING THE REAR DISC • Use only the designated brake fluid. BRAKE” on page 3-22. Other brake fluids may cause the rubber 7. Adjust: seals to deteriorate, causing leakage and •...

  • Page 176: Handlebars

    HANDLEBARS EAS22850 HANDLEBARS Removing the handlebars Order Job/Parts to remove Q’ty Remarks Left side panel/Left upper side cowling Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-4. Refer to “AIR INDUCTION SYSTEM”...
  • Page 177 HANDLEBARS Removing the handlebars Order Job/Parts to remove Q’ty Remarks Left coupler holder Main switch coupler Disconnect. Upper bracket Left handlebar Right handlebar For installation, reverse the removal proce- dure. 4-42...

  • Page 178: Removing The Handlebars

    HANDLEBARS EAS22870 NOTE: REMOVING THE HANDLEBARS • Install the brake master cylinder holder with 1. Stand the vehicle on a level surface. the “UP” mark “a” facing up. EWA13120 • Align the mating surfaces of the brake master WARNING cylinder holder with the punch mark “b” on Securely support the vehicle so that there the handlebar.
  • Page 179 HANDLEBARS • Left grip end “2” NOTE: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ There should be 1–3 mm (0.04–0.12 in) of a. Apply a thin coat of rubber adhesive onto clearance “a” between the throttle grip and the the end of the left handlebar. right grip end. b.

  • Page 180: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Side panels Refer to “GENERAL CHASSIS” on page 4-1. Front wheel Refer to “FRONT WHEEL” on page 4-6. Front fender Upper bracket pinch bolt Loosen.
  • Page 181 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Washer Damper adjusting rod Spacer Upper spring seat Fork spring Under spring seat Outer tube Dust seal Oil seal clip...

  • Page 182: Removing The Front Fork Legs

    FRONT FORK EAS22970 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: 2.

  • Page 183: Checking The Front Fork Legs

    FRONT FORK • Damper rod assembly NOTE: Loosen the nut using a proper tool that has a NOTE: thickness of 3 mm (0.12 in) or less. Remove the damper rod assembly with the damper rod holder “1”. Damper rod holder 90890-01506 d.

  • Page 184: Assembling The Front Fork Legs

    FRONT FORK Obstruction → Blow out all of the oil pas- ECA14210 CAUTION: sages with compressed air. • Damper adjusting rod Allow the damper rod assembly to slide Bends/damage → Replace. slowly down the inner tube “2” until it pro- ECA14200 trudes from the bottom of the inner tube.
  • Page 185 FRONT FORK EC2C01012 CAUTION: Make sure the numbered side of the oil seal faces bottom side. NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil. •...
  • Page 186 FRONT FORK Rod puller 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M10) 90890-01436 Universal damping rod bleeding tool set YM-A8703 13. Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.
  • Page 187 FRONT FORK Rod puller 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M10) 90890-01436 Universal damping rod bleeding tool set YM-A8703 Fork spring compressor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 90890-01441 a. Remove the rod puller attachment. YM-01441 b. Install the under spring seat. Rod holder c.

  • Page 188: Installing The Front Fork Legs

    FRONT FORK EWA13670 NOTE: WARNING Make sure the outer tube is flush with the top Always use a new cap bolt O-ring. of the upper bracket. EC2C01013 2. Tighten: CAUTION: • Lower bracket pinch bolts “1” and “2” When tightening the spring preload adjust- ing bolt “10”...
  • Page 189 FRONT FORK 4. Check: • Cable routing NOTE: Make sure the brake hose, throttle cables, clutch cable, and handlebar switch leads are routed properly. Refer to “CABLE ROUTING” on page 2-45. 5. Install: • Plastic locking tie “1” • Plastic locking tie “2” NOTE: •...

  • Page 190: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Front cowling assembly Refer to “GENERAL CHASSIS” on page 4-1. Front fork legs Refer to “FRONT FORK” on page 4-45. Handlebars Refer to “HANDLEBARS” on page 4-41. Fuel tank Refer to “FUEL TANK”...
  • Page 191 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Upper bearing Lower bearing Lower bearing inner race Lower bearing dust seal Upper bearing outer race Lower bearing outer race For installation, reverse the removal proce- dure. 4-56...

  • Page 192: Removing The Lower Bracket

    STEERING HEAD EAS23110 3. Replace: REMOVING THE LOWER BRACKET • Bearings 1. Stand the vehicle on a level surface. • Bearing races EWA13120 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a. Remove the bearing race from the steering Securely support the vehicle so that there head pipe “1”...
  • Page 193 STEERING HEAD NOTE: Recommended lubricant Route the right brake pipe “a” through the pro- Lithium-soap-based grease jections “b” of the front brake hose joint bracket. 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” •...

  • Page 194: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Exhaust pipe assembly brackets Refer to “ENGINE REMOVAL” on page 5-1. Rear wheel Refer to “REAR WHEEL” on page 4-12. Fuel tank Refer to “FUEL TANK”...

  • Page 195: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 EWA13120 HANDLING THE REAR SHOCK ABSORBER WARNING EWA13740 Securely support the vehicle so that there WARNING is no danger of it falling over. This rear shock absorber contains highly compressed nitrogen gas. Before handling NOTE: the rear shock absorber, read and make Place the vehicle on a suitable stand so that sure you understand the following informa-...

  • Page 196: Checking The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23240 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • 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. •...
  • Page 197 REAR SHOCK ABSORBER ASSEMBLY NOTE: Install the washer with the brim pointing back of the vehicle and the “UP” punch mark facing 4. Tighten: • Spacer bolt Spacer bolt 16 Nm (1.6 m·kg, 12 ft·lb) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 40 Nm (4.0 m·kg, 30 ft·lb)

  • Page 198: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-12. Refer to “REAR SHOCK ABSORBER Rear shock absorber ASSEMBLY” on page 4-59. Drive chain guide (drive sprocket side) Refer to “CHAIN DRIVE” on page 4-68. Drive chain adjusting locknut Drive chain puller Drive chain adjusting bolt...
  • Page 199 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Bearing Bearing Collar Collar Oil seal Bearing For installation, reverse the removal proce- dure. 4-64...

  • Page 200: Removing The Swingarm

    SWINGARM EAS23350 Refer to “REMOVING THE DRIVE REMOVING THE SWINGARM CHAIN” on page 4-69. 1. Stand the vehicle on a level surface. 4. Remove: EWA13120 • Swingarm pivot shaft ring nut “1” WARNING NOTE: Securely support the vehicle so that there Loosen the swingarm pivot shaft ring nut with is no danger of it falling over.

  • Page 201: Installing The Swingarm

    SWINGARM EWA13770 Installed depth of bearing “a” WARNING 0–1.0 mm (0–0.04 in) Do not attempt to straighten a bent pivot Installed depth of bearing “b” shaft. 4.0 mm (0.16 in) Installed depth of oil seal “c” 1.0 mm (0.04 in) 3.
  • Page 202 SWINGARM Drive chain slack 30.0–45.0 mm (1.18–1.77 in) 4. Install: • Swingarm pivot shaft ring nut “1” Swingarm pivot shaft ring nut 95 Nm (9.5 m·kg, 70 ft·lb) NOTE: • Lubricate the swingarm pivot ring nut threads and mating surfaces with lithium-soap-based grease.

  • Page 203: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain 10 Nm (1.0 m kg, 7.4 ft • • Order Job/Parts to remove Q’ty Remarks Left lower side cowling Refer to “GENERAL CHASSIS” on page 4-1. Left bottom cowling Refer to “GENERAL CHASSIS”...

  • Page 204: Removing The Drive Chain

    CHAIN DRIVE EAS23410 NOTE: REMOVING THE DRIVE CHAIN • When measuring a 15-link section of the 1. Stand the vehicle on a level surface. drive chain, make sure that the drive chain is EWA13120 taut. WARNING • Perform this procedure 2–3 times, at a differ- Securely support the vehicle so that there ent location each time.

  • Page 205: Checking The Drive Sprocket

    CHAIN DRIVE More than 1/4 tooth “a” wear → Replace • Do not soak the drive chain in kerosene for more than ten minutes, otherwise the the drive chain sprockets as a set. Bent teeth → Replace the drive chain O-rings can be damaged.
  • Page 206 CHAIN DRIVE 4-71...

  • Page 207: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-6 CAMSHAFTS....................5-7 REMOVING THE CAMSHAFTS .............5-9 CHECKING THE CAMSHAFTS .............5-9 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES........5-11 CHECKING THE TIMING CHAIN TENSIONER ........5-11 INSTALLING THE CAMSHAFTS ............5-12 CYLINDER HEAD..................5-15 REMOVING THE CYLINDER HEAD ............5-16 CHECKING THE CYLINDER HEAD ............5-16 INSTALLING THE CYLINDER HEAD ...........5-16 VALVES AND VALVE SPRINGS ..............5-18...
  • Page 208 CHECKING THE PRIMARY DRIVE GEAR ..........5-42 CHECKING THE PRIMARY DRIVEN GEAR........5-42 CHECKING THE PULL LEVER SHAFT AND PULL ROD....5-43 CHECKING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVE CHAIN ............5-43 INSTALLING THE CLUTCH..............5-43 SHIFT SHAFT .....................5-46 CHECKING THE SHIFT SHAFT ............5-47 CHECKING THE STOPPER LEVER............5-47 INSTALLING THE SHIFT SHAFT ............5-47 OIL PUMP ....................5-48...

  • Page 210: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe assembly 8 Nm (0.8 m kg, 5.9 ft • • 7 Nm (0.7 m kg, 5.2 ft • • 8 Nm (0.8 m kg, 5.9 ft • • 45 Nm (4.5 m kg, 33 ft •...
  • Page 211 ENGINE REMOVAL Removing the exhaust pipe assembly 8 Nm (0.8 m kg, 5.9 ft • • 7 Nm (0.7 m kg, 5.2 ft • • 8 Nm (0.8 m kg, 5.9 ft • • 45 Nm (4.5 m kg, 33 ft •...
  • Page 212 ENGINE REMOVAL Disconnecting the leads and hoses 10 Nm (1.0 m kg, 7.4 ft • • 10 Nm (1.0 m kg, 7.4 ft • • 70 Nm (7.0 m kg, 52 ft • • 10 Nm (1.0 m kg, 7.4 ft •...
  • Page 213 ENGINE REMOVAL Disconnecting the leads and hoses 10 Nm (1.0 m kg, 7.4 ft • • 10 Nm (1.0 m kg, 7.4 ft • • 70 Nm (7.0 m kg, 52 ft • • 10 Nm (1.0 m kg, 7.4 ft •...
  • Page 214 ENGINE REMOVAL Removing the engine 45 Nm (4.5 m kg, 33 ft • • 64 Nm (6.4 m kg, 47 ft • • 45 Nm (4.5 m kg, 33 ft • • 64 Nm (6.4 m kg, 47 ft • •...

  • Page 215: Installing The Engine

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Engine “1” • Engine mounting bolt (rear lower side) “2” • Engine mounting bolt (rear upper side) “3” • Engine mounting collars (inside) “4” 12 11 • Engine mounting collar (center) “5” •...

  • Page 216: Camshafts

    CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 8 Nm (0.8 m kg, 5.9 ft • • 12 Nm (1.2 m kg, 8.9 ft • • 13 Nm (1.3 m kg, 9.6 ft • • Order Job/Parts to remove Q’ty Remarks Radiator Refer to “RADIATOR”...
  • Page 217 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kg, 7.4 ft • • 12 Nm (1.2 m kg, 8.9 ft • • 24 Nm (2.4 m kg, 18 ft • • 10 Nm (1.0 m kg, 7.4 ft • • Order Job/Parts to remove Q’ty...

  • Page 218: Removing The Camshafts

    CAMSHAFTS EAS23810 ECA13720 REMOVING THE CAMSHAFTS CAUTION: 1. Remove: To prevent damage to the cylinder head, • Pickup rotor cover camshafts or camshaft caps, loosen the Refer to “PICKUP ROTOR” on page 5-29. camshaft cap bolts in stages and in a criss- 2.
  • Page 219 CAMSHAFTS 3. Measure: Camshaft lobe dimensions • Camshaft runout Intake A Out of specification → Replace. 33.725–33.875 mm (1.3278– 1.3337 in) Camshaft runout limit Limit 0.030 mm (0.0012 in) 33.675 mm (1.3258 in) Intake B 25.225–25.325 mm (0.9931– 0.9970 in) Limit 25.175 mm (0.9911 in) Exhaust A...

  • Page 220: Checking The Timing Chain, Camshaft Sprockets, And Timing Chain Guides

    CAMSHAFTS Camshaft cap bolt 10 Nm (1.0 m·kg, 7.4 ft·lb) d. Remove the camshaft caps and then mea- ® sure the width of the Plastigauge “1”. a. 1/4 tooth b. Correct 1. Timing chain roller 2. Camshaft sprocket 3. Check: •...

  • Page 221: Installing The Camshafts

    CAMSHAFTS NOTE: Prior to installing the timing chain tensioner rod, drain the engine oil from the timing chain tensioner housing. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the timing chain tensioner springs, timing chain tensioner spring seat, and tim- ing chain tensioner rod “1”. b.
  • Page 222 CAMSHAFTS 2. Install: • Timing chain “1” • Exhaust camshaft “2” • Intake camshaft “3” (with the camshaft sprockets temporarily tightened) NOTE: • Make sure the match marks “a” on the cam- shaft sprockets are aligned with the cylinder head edge “b”. 4.
  • Page 223 CAMSHAFTS 6. Rotate the crankshaft a few times to release the timing chain tensioner rod. 9. Measure: • Valve clearance Out of specification → Adjust. NOTE: Refer to “ADJUSTING THE VALVE If the engine is not disassembled, set the CLEARANCE” on page 3-4. engine stop switch to “...

  • Page 224: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Camshafts Refer to “CAMSHAFTS” on page 5-7. Coolant temperature sensor Cylinder head Cylinder head gasket Dowel pin For installation, reverse the removal proce- dure.

  • Page 225: Removing The Cylinder Head

    CYLINDER HEAD Mineral deposits/rust → Eliminate. EAS24120 REMOVING THE CYLINDER HEAD 3. Measure: 1. Remove: • Cylinder head warpage • Cylinder head bolts Out of specification → Resurface the cyl- • Cylinder head nuts inder head. NOTE: Warpage limit • Loosen the nuts, cap nuts, and bolts in 0.05 mm (0.0020 in) decreasing numerical order (refer to the numbers in the illustration).
  • Page 226 CYLINDER HEAD Cylinder head nut (1st) 25 Nm (2.5 m·kg, 18 ft·lb) Cylinder head nut (final) 42 Nm (4.2 m·kg, 31 ft·lb) • Cylinder head cap nuts “8”, “9” Cylinder head cap nut (1st) 30 Nm (3.0 m·kg, 22 ft·lb) Cylinder head cap nut (final) 60 Nm (6.0 m·kg, 44 ft·lb) •...
  • Page 227 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-15. Valve lifter Valve pad Valve cotter Upper spring seat Intake valve spring Exhaust valve spring Intake valve Exhaust valve...

  • Page 228: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 • Valve cotters “1” REMOVING THE VALVES NOTE: The following procedure applies to all of the Remove the valve cotters by compressing the valves and related components. valve spring with the valve spring compressor NOTE: “1”...
  • Page 229 VALVES AND VALVE SPRINGS • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 (0.0004– b. Install the new valve guide with the valve 0.0015 in) guide installer “2”...

  • Page 230: Checking The Valve Seats

    VALVES AND VALVE SPRINGS NOTE: Valve guide remover (ø4.5) • When installing a new valve, always replace 90890-04116 the valve guide. Valve guide remover (4.5 mm) • If the valve is removed or replaced, always YM-04116 replace the valve stem seal. Valve guide installer (ø4.5) 90890-04117 Valve guide installer (4.5 mm)
  • Page 231 VALVES AND VALVE SPRINGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. ECA13790 CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face.

  • Page 232: Checking The Valve Springs

    VALVES AND VALVE SPRINGS h. Install the valve into the cylinder head. 2. Measure: i. Press the valve through the valve guide • Compressed valve spring force “a” Out of specification → Replace the valve and onto the valve seat to make a clear impression.

  • Page 233: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 3. Install: • Lower spring seat “1” • Valve stem seal “2” • Valve “3” • Valve spring “4” • Upper spring seat “5” (into the cylinder head) NOTE: • Make sure each valve is installed in its origi- nal place.
  • Page 234 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. ECA13800 CAUTION: Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve lifter (with the recommended lubricant) Recommended lubricant Engine oil...

  • Page 235: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the generator and starter clutch Order Job/Parts to remove Q’ty Remarks Side cowling assembly Refer to “GENERAL CHASSIS” on page 4-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-11.

  • Page 236: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH Damage/wear → Replace. EAS24490 REMOVING THE GENERATOR 2. Check: 1. Remove: • Starter clutch idle gear • Generator rotor bolt “1” • Starter clutch gear • Washer Burrs/chips/roughness/wear → Replace NOTE: the defective part(s). While holding the generator rotor “2” with the 3.

  • Page 237: Installing The Generator

    GENERATOR AND STARTER CLUTCH Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) EAS24500 INSTALLING THE GENERATOR 1. Install: • Generator rotor • Washer • Generator rotor bolt NOTE: • Clean the tapered portion of the crankshaft and the generator rotor hub.

  • Page 238: Pickup Rotor

    PICKUP ROTOR EAS24520 PICKUP ROTOR Removing the pickup rotor 35 Nm (3.5 m kg, 26 ft • • 15 Nm (1.5 m kg, 11 ft • • 12 Nm (1.2 m kg, 8.9 ft • • 10 Nm (1.0 m kg, 7.4 ft •...

  • Page 239: Removing The Pickup Rotor

    When installing the pickup rotor, align the groove “a” in the crankshaft with the projection 3. Apply: “b” on the pickup rotor. • Sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 5-30...
  • Page 240 PICKUP ROTOR 5-31...

  • Page 241: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kg, 7.4 ft • • Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Air filter case Refer to “AIR FILTER CASE” on page 7-4. Fuel tank Refer to “FUEL TANK”...
  • Page 242 ELECTRIC STARTER Disassembling the starter motor 7 Nm (0.7 m kg, 5.2 ft • • Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Lock washer Oil seal Bearing Washer set Starter motor yoke Armature assembly Gasket Washer set Brush holder (along with the brushes) Starter motor rear cover For assembly, reverse the disassembly pro-...

  • Page 243: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 600 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “1” Armature coil Out of specification → Replace the Commutator resistance “1” starter motor.

  • Page 244: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing • Oil seal Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Starter motor yoke “1” NOTE: Align the tab “a” on the brush holder with the slot “b”...

  • Page 245: Clutch

    CLUTCH EAS25060 CLUTCH Removing the clutch cover 12 Nm (1.2 m kg, 8.9 ft • • 12 Nm (1.2 m kg, 8.9 ft • • 12 Nm (1.2 m kg, 8.9 ft • • Order Job/Parts to remove Q’ty Remarks Side cowling assembly Refer to “GENERAL CHASSIS”...
  • Page 246 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever shaft Oil seal Bearing Bearing For installation, reverse the removal proce- dure. 5-37...
  • Page 247 CLUTCH Removing the clutch 115 Nm (11.5 m kg, 85 ft • • 12 Nm (1.2 m kg, 8.9 ft • • 25 Nm (2.5 m kg, 18 ft • • 8 Nm (0.8 m kg, 5.9 ft • • Order Job/Parts to remove Q’ty...
  • Page 248 CLUTCH Removing the clutch 115 Nm (11.5 m kg, 85 ft • • 12 Nm (1.2 m kg, 8.9 ft • • 25 Nm (2.5 m kg, 18 ft • • 8 Nm (0.8 m kg, 5.9 ft • • Order Job/Parts to remove Q’ty...

  • Page 249: Removing The Clutch

    CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: • Oil strainer Refer to “OIL PUMP” on page 5-48. • Water pump Refer to “WATER PUMP” on page 6-8. • Friction plates • Clutch plates NOTE: Be sure to mark the friction plates and clutch EAS25100 plates or note the position of each part so that CHECKING THE FRICTION PLATES...

  • Page 250: Checking The Clutch Springs

    CLUTCH Clutch plate “1” Thickness gauge Part No. Thickness 90890-03180 Feeler gauge set 168-16325-00 1.6 mm (0.063 in) YU-26900-9 3J2-16324-00 2.0 mm (0.079 in) STD 168-16324-00 2.3 mm (0.091 in) Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in) Clutch plate “2” Warpage limit Part No.

  • Page 251: Checking The Clutch Housing

    CLUTCH EAS25150 EAS25170 CHECKING THE CLUTCH HOUSING CHECKING THE PRESSURE PLATE 1. Check: 1. Check: • Clutch housing dogs • Pressure plate “1” Damage/pitting/wear → Deburr the clutch Cracks/damage → Replace. housing dogs or replace the clutch hous- • Bearing “2” Damage/wear →...

  • Page 252: Checking The Pull Lever Shaft And Pull Rod

    CLUTCH onto the oil pump driven sprocket while installing the clutch housing onto the main axle. • Make sure that the oil pump drive chain passes through the oil pump drive chain guide. EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1.
  • Page 253 CLUTCH a projection on the friction plate with the punch mark “a” on the clutch housing. 4. Tighten: • Clutch boss nut “1” 7. Install: Clutch boss nut • Pressure plate “1” 115 Nm (11.5 m·kg, 85 ft·lb) NOTE: Align the punch marks “a” in the pressure plate NOTE: with one of the three punch marks “b”...
  • Page 254 CLUTCH Refer to “ADJUSTING THE CLUTCH • Clutch cover gasket LEVER FREE PLAY” on page 3-14. • Clutch cover “1” Clutch cover bolt 12 Nm (1.2 m·kg, 8.9 ft·lb) NOTE: • Position the pull rod so that the teeth “a” face towards the rear of the vehicle.

  • Page 255: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kg, 16 ft • • Order Job/Parts to remove Q’ty Remarks Shift arm Refer to “ENGINE REMOVAL” on page 5-1. Clutch housing Refer to “CLUTCH” on page 5-36. Circlip Washer Shift shaft...

  • Page 256: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stop- per lever.

  • Page 257: Oil Pump

    OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump 12 Nm (1.2 m kg, 8.9 ft • • 12 Nm (1.2 m kg, 8.9 ft • • 12 Nm (1.2 m kg, 8.9 ft • • 43 Nm (4.3 m kg, 32 ft 10 Nm (1.0 m kg, 7.4 ft...
  • Page 258 OIL PUMP Removing the oil pan and oil pump 12 Nm (1.2 m kg, 8.9 ft • • 12 Nm (1.2 m kg, 8.9 ft • • 12 Nm (1.2 m kg, 8.9 ft • • 43 Nm (4.3 m kg, 32 ft 10 Nm (1.0 m kg, 7.4 ft...
  • Page 259 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump housing Oil pump driven sprocket For assembly, reverse the disassembly pro- cedure. 5-50...

  • Page 260: Removing The Oil Pan

    OIL PUMP EAS24930 REMOVING THE OIL PAN Inner-rotor-to-outer-rotor-tip 1. Remove: clearance • Oil level switch lead holder Less than 0.12 mm (less than • Bottom cowling brackets 0.0047 in) • Oil pan Limit • Oil pan gasket 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-hous- NOTE: ing clearance...

  • Page 261: Checking The Oil Pipes

    OIL PUMP EAS24980 EAS25050 CHECKING THE OIL PIPES INSTALLING THE OIL PAN The following procedure applies to all of the oil 1. Install: delivery pipes. • Oil pan gasket 1. Check: • Oil pan • Ventilation chamber oil drain pipe •...

  • Page 262: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase 8 Nm (0.8 m kg, 5.9 ft • • 8 Nm (0.8 m kg, 5.9ft • • 20 Nm (2.0 m kg, 15 ft • • 12 Nm (1.2 m kg, 8.9 ft • •...
  • Page 263 CRANKCASE Separating the crankcase 8 Nm (0.8 m kg, 5.9 ft • • 8 Nm (0.8 m kg, 5.9ft • • 20 Nm (2.0 m kg, 15 ft • • 12 Nm (1.2 m kg, 8.9 ft • • 12 Nm (1.2 m kg, 8.9 ft •...

  • Page 264: Disassembling The Crankcase

    • M6 × 30 mm bolt: “29” 2. Apply: • Sealant 24 23 22 (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.
  • Page 265 CRANKCASE 5. Install: Crankcase bolt (M8 × 115 mm, • Lower crankcase “1” M8 × 85 mm) (onto the upper crankcase “2”) 1st: 20 Nm (2.0 m·kg, 14 ft·lb) ECA13980 *2nd: 12 Nm (1.2 m·kg, 8.9 CAUTION: ft·lb) Before tightening the crankcase bolts, 3rd: 45°–55°...
  • Page 266 CONNECTING RODS AND PISTONS EAS24370 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 1st 15 Nm (1.5 m kg, 11 ft • • 2nd Specified angle 175 -185 Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-53. Connecting rod cap Big end lower bearing Piston pin clip...

  • Page 267: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS26030 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: • Connecting rod cap “1” NOTE: Identify the position of each connecting rod so that it can be reinstalled in its original place. 4.

  • Page 268: Checking The Piston Rings

    CONNECTING RODS AND PISTONS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cylinder. Then, find the average of the mea- surements. Bore b. 10 mm (0.39 in) from the bottom edge of 67.000–67.010 mm (2.6378–...

  • Page 269: Checking The Piston Pins

    CONNECTING RODS AND PISTONS Piston ring Top ring End gap (installed) 0.25–0.35 mm (0.0098–0.0138 Limit 0.60 mm (0.0236 in) 2nd ring End gap (installed) 0.70–0.80 mm (0.0276–0.0315 2. Install: • Piston ring Limit (into the cylinder) 1.15 mm (0.0453 in) NOTE: Oil ring Level the piston ring into the cylinder with the...

  • Page 270: Checking The Connecting Rods

    CONNECTING RODS AND PISTONS a. Clean the big end bearings, crankshaft Piston pin bore inside diameter pins, and the inside of the connecting rods 15.002–15.013 mm (0.5906– halves. 0.5911 in) b. Install the big end upper bearing into the Limit connecting rod and the big end lower bear- 15.043 mm (0.5922 in) ing into the connecting rod cap.

  • Page 271: Installing The Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS 2 1 1 2 2 1 1 1 1 e. Tighten the connecting rod nuts. Refer to “INSTALLING THE CONNECTING RODS AND PISTONS” on page 5-62. f. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS AND PISTONS”...
  • Page 272 CONNECTING RODS AND PISTONS 90˚ 90˚ 45˚ 2. Install: a. Top ring • Piston “1” b. Upper oil ring rail (onto the respective connecting rod “2”) c. Oil ring expander • Piston pin “3” d. 2nd ring • Piston pin clips “4” e.
  • Page 273 CONNECTING RODS AND PISTONS • While compressing the piston rings one hand, install the connecting rod assembly into the cylinder with the other hand. • Make sure the “Y” marks “a” on the connect- ing rods face towards the left side of the crankshaft.

  • Page 274: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-53. Refer to “CONNECTING RODS AND PIS- Connecting rod caps TONS” on page 5-57. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Oil nozzle For installation, reverse the removal proce- dure.

  • Page 275: Removing The Crankshaft Journal Bearings

    CRANKSHAFT EAS26040 3. Measure: REMOVING THE CRANKSHAFT JOURNAL • Crankshaft-journal-to-crankshaft-journal- BEARINGS bearing clearance 1. Remove: Out of specification → Replace the crank- • Crankshaft journal lower bearings shaft journal bearings. (from the lower crankcase) • Crankshaft journal upper bearings Journal oil clearance (using (from the upper crankcase) ®...
  • Page 276 CRANKSHAFT • Crankshaft journal bearings (J –J NOTE: • The numbers “A” stamped into the crank- shaft web and the numbers “B” stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. • J –J refer to the bearings shown in the crankshaft illustration.

  • Page 277: Installing The Crankshaft

    CRANKSHAFT Bearing color code 0.White 1.Blue 2.Black 3.Brown 4.Green EAS26200 INSTALLING THE CRANKSHAFT 1. Install: • Crankshaft journal upper bearings (into the upper crankcase) • Crankshaft journal lower bearings (into the lower crankcase) NOTE: • Align the projections “a” on the crankshaft journal bearings “1”...

  • Page 278: Transmission

    TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 Nm (1.2 m kg, 8.9 ft • • 10 Nm (1.0 m kg, 7.4 ft • • 10 Nm (1.0 m kg, 7.4 ft • • Order Job/Parts to remove Q’ty Remarks...
  • Page 279 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd/4th pinion gear Circlip Washer 5th pinion gear Collar Bearing housing Bearing Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure.
  • Page 280 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer 2nd wheel gear...
  • Page 281 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks For assembly, reverse the disassembly pro- cedure. 5-72...

  • Page 282: Removing The Transmission

    TRANSMISSION ET2C01014 REMOVING THE TRANSMISSION 1. Remove: • Main axle assembly “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the main axle assembly bearing housing bolts “2” 2. Check: • Shift fork guide bar Roll the shift fork guide bar on a flat sur- face.

  • Page 283: Checking The Transmission

    TRANSMISSION • Shift drum bearing “2” 3. Check: Damage/pitting → Replace the shift drum • Transmission gears Blue discoloration/pitting/wear → assembly. Replace the defective gear(s). • Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). EAS26300 CHECKING THE TRANSMISSION 1.

  • Page 284: Installing The Transmission

    TRANSMISSION NOTE: Face the seal side of the bearing to the outside and install it close to the right side end of the crankcase. 2. Install: • Main axle assembly “1” NOTE: Stake the main axle assembly bearing housing bolts “2” at a cutout “a” in the main axle assem- bly bearing housing “3”.
  • Page 285 TRANSMISSION 4. Install: • Shift fork-R “1” • Shift fork-L “2” • Shift fork guide bar • Springs • Shift drum retainers “3” • Bearing • Oil seal • Circlip “4” • Drive axle assembly “5” Shift drum retainer bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) ®...
  • Page 286 TRANSMISSION 5-77...

  • Page 287: Cooling System

    COOLING SYSTEM RADIATOR....................6-1 CHECKING THE RADIATOR..............6-2 INSTALLING THE RADIATOR ..............6-2 OIL COOLER ....................6-4 CHECKING THE OIL COOLER..............6-5 INSTALLING THE OIL COOLER ............6-5 THERMOSTAT ....................6-6 CHECKING THE THERMOSTAT............6-7 INSTALLING THE THERMOSTAT ............6-7 WATER PUMP ....................6-8 DISASSEMBLING THE WATER PUMP..........6-10 CHECKING THE WATER PUMP ............6-10 ASSEMBLING THE WATER PUMP............6-11 INSTALLING THE WATER PUMP ............6-12...
  • Page 288 RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Lower side cowlings/Bottom cowlings Refer to “GENERAL CHASSIS” on page 4-1. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-19. Coolant reservoir breather hose Coolant reservoir hose Coolant reservoir Radiator fan motor coupler Disconnect.

  • Page 289: Checking The Radiator

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.
  • Page 290 RADIATOR b. Apply 100 kPa (14.50 psi) (1.0 kg/cm ) of pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 291: Oil Cooler

    OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-11. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-19. Exhaust pipe assembly Refer to “ENGINE REMOVAL”...

  • Page 292: Checking The Oil Cooler

    OIL COOLER EAS26420 Refer to “CHANGING THE COOLANT” on CHECKING THE OIL COOLER page 3-19. 1. Check: • Crankcase • Oil cooler (with the specified amount of the recom- Cracks/damage → Replace. mended engine oil) 2. Check: Refer to “CHANGING THE ENGINE OIL” •...

  • Page 293: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Air filter case Refer to “AIR FILTER CASE” on page 7-4. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-19. Coolant temperature sensor coupler Disconnect. Thermostat outlet hose Thermostat cover Thermostat For installation, reverse the removal proce-...

  • Page 294: Checking The Thermostat

    THERMOSTAT EAS26450 • Thermostat cover CHECKING THE THERMOSTAT Cracks/damage → Replace. 1. Check: • Thermostat EAS26480 Does not open at 71–85 °C (159.8–185.0 INSTALLING THE THERMOSTAT °F) → Replace. 1. Install: • Thermostat NOTE: Install the thermostat with its breather hole “a” facing up.

  • Page 295: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump Order Job/Parts to remove Q’ty Remarks It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Right bottom cowling Refer to “GENERAL CHASSIS”...
  • Page 296 WATER PUMP Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Water pump cover Gasket Circlip Impeller shaft (along with the impeller) Water pump seal Bearing Oil seal O-ring For installation, reverse the removal proce- dure.

  • Page 297: Disassembling The Water Pump

    WATER PUMP EAS26520 DISASSEMBLING THE WATER PUMP 1. Remove: • Circlip • Impeller shaft 2. Remove: • Water pump seal “1” NOTE: Remove the water pump seal from the outside of the water pump housing. 5. Remove: • Rubber damper holder “1” •...

  • Page 298: Assembling The Water Pump

    ASSEMBLING THE WATER PUMP 90890-04058 1. Install: Bearing driver 40 mm YM-04058 • Oil seal “1” Yamaha bond No. 1215 (Three (into the water pump housing “2”) Bond No.1215®) NOTE: 90890-85505 • Before installing the oil seal, apply tap water or coolant onto its out surface.

  • Page 299: Installing The Water Pump

    WATER PUMP ECA14090 Refer to “CHANGING THE COOLANT” CAUTION: on page 3-19. 3. Check: Make sure the rubber damper and rubber • Cooling system damper holder are flush with the impeller. Leaks → Repair or replace the faulty part. Impeller shaft tilt limit 0.15 mm (0.006 in) 1.
  • Page 300 WATER PUMP 6-13...

  • Page 301: Fuel System

    FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP...............7-2 CHECKING THE FUEL PUMP BODY ............7-2 CHECKING THE FUEL PUMP OPERATION .........7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK...............7-3 AIR FILTER CASE ..................7-4 REMOVING THE FUEL HOSE (PRIMARY INJECTOR FUEL RAIL SIDE AND SECONDARY INJECTOR FUEL RAIL SIDE)....7-6 REMOVING THE AIR FILTER CASE .............7-6 CHECKING THE SECONDARY INJECTORS ........7-6...

  • Page 302: Fuel Tank

    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank and fuel pump Order Job/Parts to remove Q’ty Remarks Rider seat/Fuel tank bracket Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank side cover Except for california Fuel tank breather hose Disconnect.

  • Page 303: Fuel Tank

    FUEL TANK EAS26630 • Do not touch the base section of the fuel REMOVING THE FUEL TANK sender. 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. EAS26670 2. Remove: CHECKING THE FUEL PUMP BODY •...

  • Page 304: Installing The Fuel Tank

    FUEL TANK ET2C01010 NOTE: INSTALLING THE FUEL TANK Attach the fuel hose connector cover “1” to the 1. Connect: fuel hose connector “2” from the bottom. Make • Fuel tank breather hose (fuel tank to hose sure that parts “a” are firmly attached to the joint) “1”...
  • Page 305 AIR FILTER CASE ET2C01003 AIR FILTER CASE Removing the air filter case and secondary injectors Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Crankcase breather hose Disconnect. Sub-wire harness coupler Disconnect. Intake funnel servo motor coupler Fuel hose (secondary injector fuel rail side) Disconnect.

  • Page 306: Air Filter Case

    AIR FILTER CASE Removing the air filter case and secondary injectors Order Job/Parts to remove Q’ty Remarks Air induction system hose (air filter case to air Disconnect. cut-off valve) Intake funnel servo motor For installation, reverse the removal proce- dure.

  • Page 307: Removing The Fuel Hose (Primary Injector Fuel Rail Side And Secondary Injector Fuel Rail Side)

    AIR FILTER CASE ET2C01005 REMOVING THE FUEL HOSE (PRIMARY INJECTOR FUEL RAIL SIDE AND SECOND- ARY INJECTOR FUEL RAIL SIDE) 1. Remove: • Fuel hose (primary injector fuel rail side and secondary injector fuel rail side) EW2C01008 WARNING Cover fuel hose connections with a cloth when disconnecting them.

  • Page 308: Installing The Intake Funnel

    AIR FILTER CASE ECA4C81020 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ CAUTION: a. Activate the diagnostic mode and select the diagnostic code number “34”. • Make sure that the intake funnel smoothly Refer to “FUEL INJECTION SYSTEM” on moves to the contacting surface between page 8-33. upper stopper and lower seating position b.
  • Page 309 AIR FILTER CASE • To install the fuel hose onto the secondary injector fuel rail, slide the fuel hose connector cover “1” on the end of the hose in the direc- tion of the arrow shown.
  • Page 310 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle body assembly Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-4. Canister purge hose (throttle boby-#4 to 3-way joint) Canister purge hose (throttle boby-#2 to 3-way joint)

  • Page 311: Throttle Bodies

    THROTTLE BODIES Removing the throttle body assembly Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-4. Refer to “AIR INDUCTION SYSTEM” on Air induction system cover page 7-15.
  • Page 312 THROTTLE BODIES Removing the primary injectors Order Job/Parts to remove Q’ty Remarks Intake air pressure sensor coupler Disconnect. Cylinder-#1 primary injector coupler Disconnect. Cylinder-#2 primary injector coupler Disconnect. Cylinder-#3 primary injector coupler Disconnect. Cylinder-#4 primary injector coupler Disconnect. Sub-wire harness Intake air pressure sensor hose Intake air pressure sensor Primary injector fuel rail...

  • Page 313: Checking The Primary Injectors

    THROTTLE BODIES EAS26980 EAS27010 CHECKING THE PRIMARY INJECTORS CHECKING THE FUEL PRESSURE 1. Check: 1. Check: • Injectors • Fuel pressure Damage → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the rider seat. EAS26990 Refer to “GENERAL CHASSIS” on page 4- CHECKING THE THROTTLE BODIES 1.

  • Page 314: Adjusting The Throttle Position Sensor (For Throttle Valves)

    THROTTLE BODIES Fuel pressure Digital circuit tester 324.0 kPa (47.0 psi) (3.24 kg/ 90890-03174 cm²) Model 88 Multimeter with tachometer Faulty → Replace the fuel pump. YU-A1927 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ e. Measure the throttle position sensor volt- age. ET2C01007 ADJUSTING THE THROTTLE POSITION f.

  • Page 315: Installing The Throttle Body Joints

    THROTTLE BODIES Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 c. Measure the throttle position sensor volt- age. d. Adjust the throttle position sensor angle so that the voltage is within the specified range. Output voltage 0.630–0.730 V e.

  • Page 316: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-15...
  • Page 317 AIR INDUCTION SYSTEM 1. Lower air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to cylinder head cover) 5. Reed valve assembly 6.
  • Page 318 AIR INDUCTION SYSTEM Removing the air cut-off valve Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “AIR FILTER CASE” on page 7-4. Air induction system cover Air induction system solenoid coupler Disconnect.
  • Page 319 AIR INDUCTION SYSTEM Removing the reed valves Order Job/Parts to remove Q’ty Remarks Reed valve cover Reed valve assembly Reed valve plate For installation, reverse the removal proce- dure. 7-18...

  • Page 320: Checking The Air Induction System

    AIR INDUCTION SYSTEM Cracks/damage → Replace. EAS27060 CHECKING THE AIR INDUCTION SYSTEM 2. Check: • Reed valve Air injection • Reed valve stopper The air induction system burns unburned • Reed valve seat exhaust gases by injecting fresh air (second- Cracks/damage →...

  • Page 321: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM..................8-1 CIRCUIT DIAGRAM................8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION .....8-3 TROUBLESHOOTING ................8-5 ELECTRIC STARTING SYSTEM..............8-7 CIRCUIT DIAGRAM................8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-9 TROUBLESHOOTING ................8-11 CHARGING SYSTEM .................8-13 CIRCUIT DIAGRAM................8-13 TROUBLESHOOTING ................8-15 LIGHTING SYSTEM ...................8-17 CIRCUIT DIAGRAM................8-17 TROUBLESHOOTING ................8-19 SIGNALING SYSTEM.................8-21 CIRCUIT DIAGRAM................8-21 TROUBLESHOOTING ................8-23...
  • Page 322 CHECKING THE IGNITION COILS ............8-92 CHECKING THE CRANKSHAFT POSITION SENSOR .......8-93 CHECKING THE LEAN ANGLE SENSOR ...........8-93 CHECKING THE STARTER MOTOR OPERATION......8-93 CHECKING THE STATOR COIL............8-94 CHECKING THE RECTIFIER/REGULATOR ........8-94 CHECKING THE HORN ...............8-95 CHECKING THE OIL LEVEL SWITCH ..........8-95 CHECKING THE FUEL SENDER ............8-96 CHECKING THE SPEED SENSOR .............8-96 CHECKING THE RADIATOR FAN MOTORS ........8-97...

  • Page 324: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 325 IGNITION SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 17.Sidestand switch 22.ECU (engine control unit) 23.Spark plug 24.Cylinder-#1 ignition coil 25.Cylinder-#2 ignition coil 26.Cylinder-#3 ignition coil 27.Cylinder-#4 ignition coil 40.Crankshaft position sensor 47.Lean angle sensor...

  • Page 326: Engine Stopping Due To Sidestand Operation

    IGNITION SYSTEM ET2C01023 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
  • Page 327 IGNITION SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. ECU (engine control unit) 9. Sidestand switch 10.Relay unit (diode) 11.Neutral switch 12.Engine ground...

  • Page 328: Troubleshooting

    IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Air filter case 4. Side cowlings 5. Bottom cowlings NG→ 1.
  • Page 329 IGNITION SYSTEM 8. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-81. OK↓ 9. Check the neutral switch. NG→ Refer to “CHECKING THE Replace the neutral switch. SWITCHES” on page 8-81. OK↓...

  • Page 330: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 331 ELECTRIC STARTING SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 8. Starter relay 10.Starter motor 11.Engine ground 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 17.Sidestand switch 64.Engine stop switch 65.Start switch 70.Clutch switch...

  • Page 332: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 333 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.

  • Page 334: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Air filter case 4. Side cowlings 5. Thermostat NG→ 1. Check the fuses. (Main and ignition) Replace the fuse(s).
  • Page 335 ELECTRIC STARTING SYSTEM 8. Check the main switch. NG→ Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-81. OK↓ 9. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-81. OK↓...

  • Page 336: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-13...
  • Page 337 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 6. Main fuse 7. Battery 11.Engine ground 8-14...

  • Page 338: Troubleshooting

    CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Bottom cowlings NG→ 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUSES” on page 8-85.
  • Page 339 CHARGING SYSTEM 8-16...

  • Page 340: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-17...
  • Page 341 LIGHTING SYSTEM 3. Main switch 6. Main fuse 7. Battery 11.Engine ground 22.ECU (engine control unit) 57.High beam indicator light 60.Meter light 68.Dimmer switch 77.Headlight (low beam) 78.Headlight (high beam) 79.License plate light 81.Tail/brake light 82.Headlight relay (on/off) 83.Headlight relay (dimmer) 85.Headlight fuse 8-18...

  • Page 342: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light, taillight, license plate light, auxiliary light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2.
  • Page 343 LIGHTING SYSTEM 8. Check the headlight relay (dimmer). NG→ Refer to “CHECKING THE Replace the headlight relay (dimmer). RELAYS” on page 8-89. OK↓ 9. Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to “CIRCUIT DIAGRAM” on system’s wiring.

  • Page 344: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21...
  • Page 345 SIGNALING SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 13.Relay unit 16.Neutral switch 19.Fuel sender 22.ECU (engine control unit) 42.Coolant temperature sensor 46.Speed sensor 49.Fuel level warning light 50.Oil level warning light 51.Neutral indicator light 52.Tachometer 53.Shift timing indicator light 54.Multi-function meter...

  • Page 346: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or indicator light. • The horn fails to sound. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3.
  • Page 347 SIGNALING SYSTEM 2. Check the horn. NG→ Refer to “CHECKING THE HORN” Replace the horn. on page 8-95. OK↓ 3. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-21.
  • Page 348 SIGNALING SYSTEM 4. Check the turn signal/hazard relay. NG→ Refer to “CHECKING THE TURN Replace the turn signal/hazard relay. SIGNAL/HAZARD RELAY” on page 8-90. OK↓ 5. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring.
  • Page 349 SIGNALING SYSTEM 2. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-21. OK↓ This circuit is OK. The fuel level warning light fails to come. NG→ 1.
  • Page 350 SIGNALING SYSTEM 2. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-21. OK↓ Replace the meter assembly. The shift timing indicator light fails to come. NG→ 1.
  • Page 351 SIGNALING SYSTEM 8-28...

  • Page 352: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-29...
  • Page 353 COOLING SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 22.ECU (engine control unit) 42.Coolant temperature sensor 86.Radiator fan motor relay 87.Right radiator fan motor fuse 88.Left radiator fan motor fuse 89.Right radiator fan motor 90.Left radiator fan motor 8-30...

  • Page 354: Troubleshooting

    COOLING SYSTEM EAS27320 TROUBLESHOOTING NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings 1. Check the fuses. NG→ (Main, ignition and radiator fan motor) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-85.
  • Page 355 COOLING SYSTEM 8-32...

  • Page 356: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-33...
  • Page 357 FUEL INJECTION SYSTEM 3. Main switch 4. Ignition fuse 5. Backup fuse (odometer and clock) 6. Main fuse 7. Battery 9. Fuel injection system fuse 11.Engine ground 12.ETV fuse 13.Relay unit 14.Starting circuit cut-off relay 15.Fuel pump relay 16.Neutral switch 17.Sidestand switch 18.Fuel pump 20.Throttle position sensor (for throttle cable...

  • Page 358: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 359: Self-Diagnostic Function Table

    FUEL INJECTION SYSTEM EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.
  • Page 360 FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable to unable to code No. start drive Atmospheric pressure Atmospheric pressure sensor: sensor Able Able open or short circuit detected. (open or short circuit) No normal signal is received from sensor Able Able the O...
  • Page 361 FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable to unable to code No. start drive Error in writing the An error is detected while reading amount of CO adjust- or writing on EEPROM (CO adjust- Able Able ment on EEPROM ment value).

  • Page 362: Troubleshooting Method

    FUEL INJECTION SYSTEM EAS27400 The engine operation is not normal but the TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1. Check the operation of following sensors engine trouble warning light comes on. and actuators in the Diagnostic mode.

  • Page 363: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS27420 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.
  • Page 364 FUEL INJECTION SYSTEM Fault code table Fault Diagnostic code Symptom Probable cause of malfunction code No. No normal signals are • Open or short circuit in sub-wire-harness 1. received from the cylinder • Open or short circuit in wire harness. identification sensor when •...
  • Page 365 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. Coolant temperature sen- • Defective coolant temperature sensor. sor: open or short circuit • Malfunction in ECU. detected. • Improperly installed coolant temperature sensor.
  • Page 366 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. No normal signals are • Open circuit in wire harness. received from the speed • Malfunction in speed sensor. sensor. • Malfunction in ECU. Neutral switch: • Open circuit in wire harness. open or short circuit •...
  • Page 367 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Non-registered data has • Improper connection in wire harness. Er-4 been received from the • Malfunction in meter. — meter. • Malfunction in ECU. Sensor operation table Diag- nostic Item...
  • Page 368 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Throttle position sensor (for throttle valves) signal 2 • Fully closed position 9–23 Check with throttle valve fully closed. • Fully opened position 94–108 Check with throttle valve fully opened. Throttle position sensor (for throttle cable pulley) signal •...
  • Page 369 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction history code erasure • No history — • History exists • Displays the total number of To erase the history, set the malfunctions, including the engine stop switch from current malfunction, that “...
  • Page 370 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the cylinder-#4 igni- tion coil five times at one-sec- Check the spark five times. Cylinder-#4 ignition coil ond intervals. • Connect an ignition Illuminates the engine trou- checker. ble warning light. Actuates the intake funnel (up position down position for Check the operating sound...
  • Page 371 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the secondary injec- tor #4 five times at one-sec- Check the operating sound Secondary injector #4 ond intervals. of the secondary injector #4 Illuminates the engine trou- five times. ble warning light.

  • Page 372: Troubleshooting Details

    FUEL INJECTION SYSTEM EAS27460 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the meter display according to the reinstatement method.
  • Page 373 FUEL INJECTION SYSTEM No normal signals are received from the crankshaft posi- Fault code No. Symptom tion sensor. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the tion sensor.
  • Page 374 FUEL INJECTION SYSTEM Intake air pressure sensor: open or short circuit Fault code No. Symptom detected. Diagnostic code No. Intake air pressure sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Reinstated •...
  • Page 375 FUEL INJECTION SYSTEM Throttle position sensor (for throttle valves): open or Fault code No. Symptom short circuit detected. Throttle position sensor (for throttle valves) signal 1 Diagnostic code No. Throttle position sensor (for throttle valves) signal 2 Item/components and probable Reinstatement Order Check or maintenance job...
  • Page 376 FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor circuit: open or short circuit detected. Diagnostic code No. EXUP servo motor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Reinstated •...
  • Page 377 FUEL INJECTION SYSTEM Open circuit is detected in the input lead from the side- Fault code No. Symptom stand switch to the ECU. Diagnostic code No. Sidestand switch Item/components and probable Reinstatement Order Check or maintenance job cause method Connections •...
  • Page 378 FUEL INJECTION SYSTEM Coolant temperature sensor: open or short circuit Fault code No. Symptom detected. Diagnostic code No. Coolant temperature sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Reinstated •...
  • Page 379 FUEL INJECTION SYSTEM Atmospheric pressure sensor: open or short circuit Fault code No. Symptom detected. Diagnostic code No. Atmospheric pressure sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Reinstated •...
  • Page 380 FUEL INJECTION SYSTEM Latch up detected. Fault code No. Symptom No normal signal is received from the lean angle sensor. Diagnostic code No. Lean angle sensor Item/components and probable Reinstatement Order Check or maintenance job cause method The vehicle has overturned. Raise the vehicle upright.
  • Page 381 FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. Symptom #2 ignition coil. Diagnostic code No. Cylinder-#2 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Cranking the •...
  • Page 382 FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. Symptom #3 ignition coil. Diagnostic code No. Cylinder-#3 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Cranking the •...
  • Page 383 FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. Symptom #4 ignition coil. Diagnostic code No. Cylinder-#4 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Cranking the •...
  • Page 384 FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit detected in a primary injector. Primary injector #1 Primary injector #2 Diagnostic code No. Primary injector #3 Primary injector #4 Item/components and probable Reinstatement Order Check or maintenance job cause method Connections •...
  • Page 385 FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit detected in a secondary injector. Secondary injector #1 Secondary injector #2 Diagnostic code No. Secondary injector #3 Secondary injector #4 Item/components and probable Reinstatement Order Check or maintenance job cause method Connections •...
  • Page 386 FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Reinstated •...
  • Page 387 FUEL INJECTION SYSTEM A. No normal signals are received from the speed sensor. Fault code No. Symptom B. Open circuit is detected in the neutral switch. Speed sensor Diagnostic code No. Neutral switch Item/components and probable Reinstatement Order Check or maintenance job cause method Installed state of speed sensor.
  • Page 388 FUEL INJECTION SYSTEM A. No normal signals are received from the speed sensor. Fault code No. Symptom B. Open circuit is detected in the neutral switch. Speed sensor Diagnostic code No. Neutral switch Item/components and probable Reinstatement Order Check or maintenance job cause method Installed state of neutral switch.
  • Page 389 FUEL INJECTION SYSTEM Power supply to the injectors and fuel pump is not nor- Fault code No. Symptom mal. Diagnostic code No. Fuel system voltage (battery voltage) Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •...
  • Page 390 FUEL INJECTION SYSTEM An error is detected while reading or writing on EEPROM Fault code No. Symptom (CO adjustment value). Diagnostic code No. EEPROM fault cylinder No. Item/components and probable Reinstatement Order Check or maintenance job cause method Malfunction in ECU. •...
  • Page 391 FUEL INJECTION SYSTEM Throttle position sensor (for throttle cable pulley): open or short circuit detected. Fault code No. Symptom Throttle position sensor (for throttle cable pulley): cou- pler connection is loose. Throttle position sensor (for throttle cable pulley) signal Diagnostic code No. Throttle position sensor (for throttle cable pulley) signal Item/components and probable Reinstatement...
  • Page 392 FUEL INJECTION SYSTEM Throttle servo motor: open or short circuit detected. Fault code No. Symptom Defective throttle servo motor. Malfunction in ECU (servo motor driving system). Throttle position sensor (for throttle valves) signal 1 Diagnostic code No. Throttle position sensor (for throttle valves) signal 2 Item/components and probable Reinstatement Order...
  • Page 393 FUEL INJECTION SYSTEM No signals are received from the ECU within the speci- Fault code No. Er-2 Symptom fied duration. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •...
  • Page 394 FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •...
  • Page 395 FUEL INJECTION SYSTEM 8-72...

  • Page 396: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-73...
  • Page 397 FUEL PUMP SYSTEM 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 9. Fuel injection system fuse 11.Engine ground 13.Relay unit 15.Fuel pump relay 18.Fuel pump 22.ECU (engine control unit) 64.Engine stop switch 8-74...

  • Page 398: Troubleshooting

    FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings NG→ 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 399 FUEL PUMP SYSTEM 8-76...

  • Page 400: Electrical Components

    ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-77...
  • Page 401 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Battery 5. Fuse box (backup, ETV, spare) 6. Main fuse 7. Fuel injection system fuse 8. Starter relay 9. Neutral switch 10.EXUP servo motor 11.Rear brake light switch 12.O sensor 13.Sidestand switch...
  • Page 402 ELECTRICAL COMPONENTS 8-79...
  • Page 403 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Atmospheric pressure sensor 3. Intake funnel servo motor 4. Coolant temperature sensor 5. Fuel pump 6. ECU (engine control unit) 7. Lean angle sensor 8. Relay unit 9. Turn signal/hazard relay 10.Crankshaft position sensor 11.Intake air pressure sensor 12.Throttle servo motor 13.Throttle position sensor (for throttle cable...

  • Page 404: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-81...
  • Page 405 ELECTRICAL COMPONENTS 1. Clutch switch 2. Main switch 3. Dimmer switch 4. Horn switch 5. Turn signal switch 6. Sidestand switch 7. Front brake light switch 8. Engine stop switch 9. Start switch 10.Neutral switch 11.Rear brake light switch 8-82...
  • Page 406 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 407: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EAS27990 Checking the condition of the bulbs CHECKING THE BULBS AND BULB SOCK- The following procedure applies to all of the bulbs. NOTE: 1. Remove: Do not check any of the lights that use LEDs. • Bulb EW2C01001 Check each bulb and bulb socket for damage WARNING or wear, proper connections, and also for conti-...

  • Page 408: Checking The Fuses

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Checking the condition of the bulb sockets b. If the pocket tester indicates “∞”, replace The following procedure applies to all of the the fuse.

  • Page 409: Checking And Charging The Battery

    ELECTRICAL COMPONENTS 4. Install: NOTE: • Left upper side cowling Since MF batteries are sealed, it is not possi- • Rider seat ble to check the charge state of the battery by Refer to “GENERAL CHASSIS” on page measuring the specific gravity of the electro- 4-1.
  • Page 410 ELECTRICAL COMPONENTS b. Check the charge of the battery, as shown • Do not use a high-rate battery charger in the charts and the following example. since it forces a high-amperage current into the battery quickly and can cause Example battery overheating and battery plate Open-circuit voltage = 12.0 V damage.
  • Page 411 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Charging method using a variable-current Charging method using a constant voltage (voltage) charger charger a. Measure the open-circuit voltage prior to a. Measure the open-circuit voltage prior to charging. charging. NOTE: NOTE: Voltage should be measured 30 minutes after Voltage should be measured 30 minutes after the engine is stopped.

  • Page 412: Checking The Relays

    ELECTRICAL COMPONENTS 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3” and “4”) Relay unit (starting circuit cut-off relay) 8. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection →...

  • Page 413: Checking The Turn Signal/Hazard Relay

    ELECTRICAL COMPONENTS Headlight relay (on/off) 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3” and “4”) ET2C01021 CHECKING THE TURN SIGNAL/HAZARD RELAY 1. Check: 1. Positive battery terminal • Turn signal/hazard relay input voltage 2.

  • Page 414: Checking The Relay Unit (Diode)

    ELECTRICAL COMPONENTS Turn signal/hazard relay output Continuity Positive tester probe → sky voltage DC 12 V blue “1” Negative tester probe → black/ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ yellow “2” a. Connect the pocket tester (DC 20 V) to the No continuity turn signal/hazard relay terminal as shown. Positive tester probe →...

  • Page 415: Checking The Ignition Coils

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Secondary coil resistance a. Disconnect the relay unit coupler from the 5.01–6.78 kΩ wire harness. b. Connect the pocket tester (Ω × 1) to the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ relay unit terminal as shown. a. Connect the pocket tester (Ω × 1k) to the c.

  • Page 416: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS b. Turn the main switch to “ON” and engine • Lean angle sensor stop switch to “ ”. (from the bracket) c. Measure the ignition spark gap “a”. 2. Check: d. Crank the engine by pushing the start •...

  • Page 417: Checking The Stator Coil

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Positive tester probe → a. Connect the positive battery terminal “1” white “1” and starter motor lead “2” with a jumper • Negative tester probe → lead “3”. white “3” EWA13810 WARNING • Positive tester probe → •...

  • Page 418: Checking The Horn

    ELECTRICAL COMPONENTS 2. Check: • Horn sound Faulty sound → Adjust or replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a battery (12 V) to the horn. b. Turn the adjusting screw in direction “a” or “b” until the horn sound is obtained. c. Start the engine and let it run at approxi- mately 5000 r/min.

  • Page 419: Checking The Fuel Sender

    ELECTRICAL COMPONENTS Maximum level position “B” • Positive tester probe → connector (white) “1” • Negative tester probe → body earth “2” b. Measure the fuel sender resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28240 CHECKING THE SPEED SENSOR 1. Check: • Speed sensor output voltage b.

  • Page 420: Checking The Radiator Fan Motors

    ELECTRICAL COMPONENTS EAS28250 CHECKING THE RADIATOR FAN MOTORS Pocket tester 1. Check: 90890-03112 • Radiator fan motor Analog pocket tester Faulty/rough movement → Replace. YU-03112-C ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the radiator fan motor coupler from the wire harness. b. Connect the battery (DC 12 V) as shown. •...

  • Page 421: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS Out of specification → Replace the throt- Resistance tle position sensor (for throttle cable pul- 2.0–3.0 kΩ ley). ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Resistance a. Connect the pocket tester (Ω × 1k) to the 2.0–3.0 kΩ throttle position sensor (for throttle valves) terminal as shown.

  • Page 422: Checking The Air Induction System Solenoid

    ELECTRICAL COMPONENTS • Do not smoke, and keep away from open EAS28370 CHECKING THE AIR INDUCTION SYSTEM flames, sparks, or any other source of SOLENOID fire. 1. Check: • If you do accidentally spill gasoline, wipe • Air induction system solenoid resistance it up immediately with dry rags.

  • Page 423: Checking The Cylinder Identification Sensor

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Pocket tester a. Connect the pocket tester (DC 20 V) to the 90890-03112 atmospheric pressure sensor coupler as Analog pocket tester shown. YU-03112-C Pocket tester • Positive tester probe → 90890-03112 Analog pocket tester white/black “1” • Negative tester probe → YU-03112-C black/blue “2”...

  • Page 424: Checking The Air Temperature Sensor

    ELECTRICAL COMPONENTS b. Immerse the air temperature sensor “1” in a container filled with water “2”. NOTE: Make sure that the air temperature sensor ter- minals do not get wet. c. Place a thermometer “3” in the water. d. Slowly heat the water, then let it cool down to the specified temperature.

  • Page 425: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED ..........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING ..............9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ...................9-2 OVERHEATING ..................9-2 OVERCOOLING ..................9-3 POOR BRAKING PERFORMANCE ............9-3 FAULTY FRONT FORK LEGS ..............9-3 UNSTABLE HANDLING................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........9-4...

  • Page 426: Troubleshooting

    TROUBLESHOOTING EAS28450 • Discharged battery TROUBLESHOOTING • Faulty battery 2. Fuse(s) EAS28460 • Blown, damaged or incorrect fuse GENERAL INFORMATION • Improperly installed fuse NOTE: 3. Spark plug(s) The following guide for troubleshooting does • Incorrect spark plug gap not cover all the possible causes of trouble. It •...

  • Page 427: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •...

  • Page 428: Overcooling

    TROUBLESHOOTING • Incorrect oil viscosity • Leaking brake fluid • Inferior oil quality • Faulty brake caliper kit • Faulty brake caliper seal Cooling system • Loose union bolt 1. Coolant • Damaged brake hose • Low coolant level • Oil or grease on the brake disc 2.

  • Page 429: Faulty Lighting Or Signaling System

    TROUBLESHOOTING • Leaking oil or gas • Incorrect connection • Damaged or faulty wire harness Tire(s) • Improperly grounded circuit • Uneven tire pressures (front and rear) • Faulty battery • Incorrect tire pressure • Blown, damaged or incorrect fuse •...

  • Page 430: Wiring Diagram

    EAS28740 55. Engine trouble warning light Black/Red WIRING DIAGRAM 56. Coolant temperature warning Black/White light YZFR6X(C) Black/Yellow 57. High beam indicator light 1. AC magneto Br/B Brown/Black 58. Left turn signal indicator light 2. Rectifier/regulator Br/G Brown/Green 59. Right turn signal indicator light 3.
  • Page 432 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 433 YZFR6X(C) WIRING DIAGRAM R/L R/B G/B O/G R/B O Gy/R Gy/R Br/Y R/L Br/Y Y/L R/G Br/W Br/W G/W B/W O/B B/L Gy/G Br/R Br/R Gy/G Sb/W Br/B Br/B Sb/W B/R Y/B R/W Y/B B Ch Dg Sb/W Sb/W P/W L HEADLIGHT HEADLIGHT HEADLIGHT...
  • Page 434 YZFR6X(C) WIRING DIAGRAM HEADLIGHT HEADLIGHT HEADLIGHT WIRE HARNESS SUB-WIRE HARNESS WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS 3 SUB-WIRE HARNESS 2 SUB-WIRE HARNESS 1 FREE PUSH...

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Yzfr6x 2008R6 2008

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