Professional Documents
Culture Documents
XV1700PCRC
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-16-36
5PX-28197-11
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
XV1700PCR/XV1700PCRC. For complete service information procedures it is necessary to use this
Supplementary Service Manual together with the following manual.
XV1700P/XV1700PC SERVICE MANUAL: LIT-11616-15-37 (5PX-28197-10)
XV1700PCR/XV1700PCRC
SUPPLEMENTARY
SERVICE MANUAL
2002 by Yamaha Motor Corporation, U.S.A.
First Edition, July 2002
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.
LIT-11616-16-36
EAS00003
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. 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.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
_
EAS00004
WARNING
CAUTION:
NOTE:
EAS00007
EAS00009
GEN
INFO
SYMBOLS
The following symbols are not relevant to
every vehicle. Symbols 1 to 8 indicate the
subject of each chapter.
SPEC
CHK
ADJ
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Chassis
5 Engine
6 Fuel injection system
7 Electrical system
8 Troubleshooting
CHAS
FI
ENG
7
ELEC
TRBL
SHTG
T.
R.
E
J
K
B
L
M
LS
LT
G Engine oil
H Gear oil
I Molybdenum-disulfide oil
J Wheel-bearing grease
K Lithium-soap-based grease
L Molybdenum-disulfide grease
New
CONTENTS
SPECIFICATIONS ........................................................................................... 1
GENERAL SPECIFICATIONS ................................................................. 1
ENGINE SPECIFICATIONS .................................................................... 1
CHASSIS SPECIFICATIONS ................................................................... 1
ELECTRICAL SPECIFICATIONS ............................................................ 2
TIGHTENING TORQUES ......................................................................... 2
CHASSIS TIGHTENING TORQUES .................................................... 2
CABLE ROUTING .................................................................................... 3
PERIODIC CHECKS AND ADJUSTMENTS ................................................. 11
INTRODUCTION .................................................................................... 11
PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM ................................................ 11
GENERAL MAINTENANCE AND LUBRICATION CHART .................... 12
CHASSIS ................................................................................................ 14
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ............. 14
CHASSIS ....................................................................................................... 16
FRONT AND REAR BRAKES ................................................................ 16
REAR BRAKE MASTER CYLINDER ................................................. 16
REAR SHOCK ABSORBER AND SWINGARM ..................................... 18
ENGINE .......................................................................................................... 22
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ....................... 22
GENERATOR AND STARTER CLUTCH ............................................... 24
STATOR COIL ASSEMBLY ............................................................... 24
GENERAL SPECIFICATIONS/
ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Standard
Model code
5PX4 (USA)
5PX5 (California)
5PX6 (CDN)
Limit
----------
ENGINE SPECIFICATIONS
Item
Standard
Limit
-------
E
D
A
Width A
Max. runout C
Electrical
5PX (MITSUBISHI)
5A
392 ~ 588 kPa
(3.92 ~ 5.88 kg/cm2, 55.7 ~ 83.6 psi)
---0.04 mm
(0.0016 in)
---0.09 mm
(0.0035 in)
0.1 mm
(0.0039 in)
-------------
CHASSIS SPECIFICATIONS
Item
Front tire
Tire type
Size
Model (manufacturer)
Standard
Tubeless
120/70 ZR 18 M/C (59 W)
120/70 ZR 18 (59 W)
D220F ST G (DUNLOP)/
BT020F G (BRIDGESTONE)
Limit
----------
CHASSIS SPECIFICATIONS/
ELECTRICAL SPECIFICATIONS/TIGHTENING TORQUES
Item
SPEC
Standard
Limit
----------
ELECTRICAL SPECIFICATIONS
Item
Standard
Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
Charging system
System type
Model (manufacturer)
Nominal output
Stator coil resistance/color
Limit
J0447 (DENSO)
6 mm (0.24 in)
1.32 ~ 1.78
12 ~ 18 k
-------------
AC magneto
F5PX (YAMAHA)
14 V/31 A at 5,000 r/min
0.13 ~ 0.19 /WW
-------------
TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES
Item
Thread size
M10
M6
M6
M6
Tightening torque
Nm
mkg
ftlb
48
7
9
9
4.8
0.7
0.9
0.9
35
5.1
6.5
6.5
Remarks
LT
CABLE ROUTING
SPEC
EB206000
CABLE ROUTING
1 Brake hose
2 Clutch cable
3 Rectifier/regulator
4 Rectifier/regulator lead
5 Rear brake light switch lead
6 Horn lead
7 Stator coil assembly lead
6
3
4
CABLE ROUTING
1 Tachometer couplers
2 Right handlebar switch coupler and speedometer couplers
3 Main switch coupler
4 Left handlebar switch couplers
5 Left and right turn signal/position light connectors
SPEC
3
2
4
CABLE ROUTING
1 Throttle cable 1 and throttle cable 2
2 Clutch cable
3 Atmospheric pressure sensor
4 Spark plug cap (ignition coil 1-L spark plug lead)
5 Horn lead
6 Crankshaft position sensor lead
7 Horn 2
8 Sidestand switch lead
9 Starter motor lead
0 Spark plug cap (ignition coil 2-L spark plug lead)
A Rear brake light switch
SPEC
3
4
0
A
CABLE ROUTING
SPEC
Fasten the engine stop switch lead, crankshaft position sensor lead, and horn lead with a plastic locking
tie.
Fasten the starter motor lead and side stand switch lead with a plastic locking tie to the frame.
Fasten the starter motor lead, fuel tank drain hose, and fuel tank/air filter breather hose with a plastic band
to the frame.
Be sure not to pinch the fuel tank drain hose or the fuel tank/air filter breather hose.
Fasten the starter motor lead with a plastic locking tie.
Clamp the clutch cable between the locknut and washer with a plastic clamp.
To the engine.
Fasten the rear brake light switch with a plastic locking tie.
3
4
0
A
CABLE ROUTING
1 Ignition coil 1
2 Atmospheric pressure sensor lead
3 Ignition coil 2
4 Ignition coil 2 lead
5 Rear brake light switch coupler
6 Rectifier/regulator lead and horn lead
7 Linear control valve lead
8 Ignition coil 1 lead
9 Fuel return hose
0 Fuel inlet hose
SPEC
E
D
B
D
E
2
1
8
7
6
3
5
0
D-D
E-E
CABLE ROUTING
1 Oil temperature sensor
2 Fuel hose
3 Spark plug cap (ignition coil 1-R
spark plug lead)
4 Injector lead
5 Throttle position sensor lead
6 Intake air pressure sensor 1
7 Intake air temperature sensor
coupler
8 Intake air pressure sensor lead
8
6 7
45
3
1
9
0
SPEC
A
B
A
F
E
2
A-A
H
B-B
C-C
D-D
M
I
L
K
CABLE ROUTING
To the battery box.
Fasten the main wire harness and fuel hose with
a plastic locking tie to the frame.
Fasten the main wire harness and spark plug
lead #3 with a plastic locking tie to the frame.
Fasten the throttle position sensor lead, engine
temperature sensor lead, and injector lead with
a plastic locking tie to the fuel delivery pipe.
Fasten the main wire harness and spark plug
lead #3 with a plastic locking tie.
3
1
9
0
Fasten the main wire harness, intake air pressure sensor lead #2, ignition coil 1-R spark plug
lead, and intake air temperature sensor coupler
with a plastic locking tie.
Fasten the rear brake light switch lead and ignition coil lead #2 with a plastic band.
Fasten the main wire harness and intake vacuum hose with a plastic locking tie.
8
6 7
45
SPEC
A
B
A
F
E
2
A-A
H
B-B
C-C
D-D
M
I
L
K
CABLE ROUTING
To the injector sub lead.
To the engine temperature sensor.
10 ~ 30 mm (0.4 ~ 1.2 in)
Position the gray mark on the stator coil lead at
the center of the bolt, and then fasten it with a
plastic locking tie.
To the stator coil.
To the decompression solenoid and cylinder
identification sensor.
To the neutral switch.
3
1
9
0
8
6 7
45
SPEC
A
B
A
F
E
2
A-A
H
B-B
C-C
D-D
M
I
L
K
10
CHK
ADJ
EAS00036
ITEM
600 mi
4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi
(1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
or
1 month 6 months 12 months 18 months 24 months 30 months
ROUTINE
1 * Valve clearance
2 * Spark plugs
Check condition.
Adjust gap and clean.
Replace at 8,000 mi (13,000 km) or
12 months and thereafter every 8,000 mi
(13,000 km) or 12 months.
3 *
ODOMETER READINGS
Replace.
Replace.
4 * Fuel line
5 * Exhaust system
6 *
Electronic fuel
injection
Evaporative
Emission control
7 *
system (For
California only)
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
11
CHK
ADJ
ITEM
ROUTINE
TYPE
Engine oil
Change.
2 *
Replace.
4 * Front brake
5 * Rear brake
6 * Clutch
9 * Control cables
ODOMETER READINGS
600 mi
4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi
(1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
or
1 month 6 months 12 months 18 months 24 months 30 months
Replace
brake
fluid.
Replace
brake
fluid.
Lithium-soapbased grease
Check.
Change.
10 *
11
Lubricate.
Apply grease lightly.
12
Lubricate.
Apply grease lightly.
13 * Sidestand pivot
14 * Sidestand switch
15 * Front fork
16 * Steering bearings
Repack.
12
Repack.
ITEM
17 * Wheel bearings
18 *
Rear suspension
link pivots
19 * Drive belt
ROUTINE
TYPE
ODOMETER READINGS
600 mi
4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi
(1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
or
1 month 6 months 12 months 18 months 24 months 30 months
Lithium-soapbased grease
CHK
ADJ
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi
(7,000 km) or 6 months.
NOTE:
Air filters
This models air filters are equipped with disposable oil-coated paper elements, which must not
be cleaned with compressed air to avoid damaging them.
The air filter elements need to be replaced more frequently when riding in unusually wet or dusty
areas.
Hydraulic brake service
After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
_
13
CHK
ADJ
CHASSIS
EAS00156
WARNING
_
CAUTION:
_
Direction a
Spring preload is
increased (suspension
is harder).
Direction b
Spring preload is
decreased (suspension
is softer).
Adjusting positions a
Minimum: 52 mm (2.05 in)
Standard: 54 mm (2.13 in)
Maximum: 63 mm (2.48 in)
CAUTION:
_
14
CHK
ADJ
Rebound damping
CAUTION:
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
rebound damping
Direction a
Rebound damping is
increased (suspension
is harder).
Direction b
Rebound damping is
decreased (suspension
is softer).
Adjusting positions
Minimum: 20 clicks out*
Standard: 10 clicks out*
Maximum: 3 clicks out*
* from the fully turned-in position
15
CHAS
CHASSIS
FRONT AND REAR BRAKES
REAR BRAKE MASTER CYLINDER
7
6
8
LT
T.
R.
13
T.
R.
10
3 New
2
T.
R.
T.
R.
R.
Order
11
12
1
2
3
4
Job/Part
Removing the rear brake master
cylinder
Brake master cylinder cover
Union bolt
Copper washer
Brake hose
5
6
7
8
Qty
1
1
2
1
1
1
2
1
16
Remarks
Remove the parts in the order listed.
Refer to REMOVING THE
REAR BRAKE MASTER
CYLINDER and ASSEMDisconnect. BLING AND INSTALLING
THE REAR BRAKE MASTER CYLINDER in chapter 4. (Manual No.: 5PX28197-10)
Disconnect.
CHAS
7
6
8
LT
T.
R.
13
T.
R.
10
3 New
2
T.
R.
T.
R.
R.
Order
9
10
11
12
13
11
12
Job/Part
Cotter pin
Pin
Brake rod
Locknut
Brake master cylinder
Qty
1
1
1
1
1
Remarks
17
CHAS
T.
R.
T.
R.
T.
R.
14
11
13
LS
4 3
9
12
T.
R.
11
7
6
T.
R.
10
Order
1
2
3
4
5
6
7
Job/Part
Qty
Remarks
Removing the rear shock absorber
Remove the parts in the order listed.
and swingarm
Rear brake master cylinder bracket
Refer to FRONT AND REAR BRAKES
in chapter 4. (Manual No.: 5PX-28197-10)
Rear exhaust pipe
Refer to ENGINE in chapter 5. (Manual
No.: 5PX-28197-10)
Rear wheel
Refer to REAR WHEEL, BRAKE DISC,
AND REAR WHEEL PULLEY in chapter 4.
(Manual No.: 5PX-28197-10)
Adjusting bolt
2
Locknut
2
Lower drive belt cover plate
1
Spacer
1
Lower drive belt cover
1
Horn 2 coupler
1
Disconnect.
Horn 2
1
18
T.
R.
T.
CHAS
R.
T.
R.
14
11
13
LS
4 3
9
12
T.
11
R.
7
6
T.
R.
10
Order
8
9
10
11
12
13
14
Job/Part
Brake hose holder
Self-locking nut
Bolt (shock absorber-connecting armframe)
Cover (left and right)
Pivot shaft nut/washer
Pivot shaft
Rear shock absorber and swingarm
assembly
Qty
Remarks
2
Refer to REMOVING THE REAR
1
SHOCK ABSORBER AND SWINGARM
1
in chapter 4 (Manual No.: 5PX-28197-10)
and INSTALLING THE REAR SHOCK
ABSORBER AND SWINGARM in chap2
1/1 ter 4. (Manual No.: 5PX-28197-10)
1
1
For installation, reverse the removal
procedure.
19
CHAS
12
LS
T.
R.
13
T.
R.
15
LS
LS
10
9
10
11
4 6
14
15
11
1
5
LS
6
LS
13
LS
4
LS
T.
R.
LS
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Removing the rear shock absorber
and swingarm
Self-locking nut/washer/bolt
Self-locking nut/washer/bolt
Connecting arm
O-ring
Rear shock absorber
Spacer/O-ring
Self-locking nut/washer/bolt
Relay arm
Spacer/oil seal/bearing
Spacer/bearing
Spacer/bearing
Qty
Remarks
Remove the parts in the order listed.
1/1/1
1/1/1
2
4
1
1/2
1/2/1
1
1/2/1
1/2
1/1
Bolt
Bolt
Bolt
= 77 mm (3.03 in)
20
CHAS
12
LS
T.
R.
13
T.
R.
15
LS
LS
10
9
10
11
4 6
14
15
11
1
5
LS
6
LS
13
LS
4
LS
3
T.
R.
LS
Order
12
13
14
15
Job/Part
Swingarm
Dust cover
Spacer
Bearing
Qty
1
2
1
2
Remarks
21
ENG
ENGINE
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS
1
R.
R.
R.
T.
R.
12
13
(5)
T.
10
T.
T.
14
15 New
(4)
12
11
8 9
6
5
LT
T.
R.
R.
Order
Job/Part
Removing the engine left side cover
and camshaft sprocket cover
Seat/fuel tank/silencer air filter case
Qty
Muffler/exhaust pipes
Engine oil
1
2
3
4
5
2/2
4
1
1
1
22
Remarks
Remove the parts in the order listed.
Refer to SEAT AND SIDE COVERS,
FUEL TANK and SILENCER AIR FILTER CASE in chapter 3. (Manual No.:
5PX-28197-10)
Refer to ENGINE in chapter 5. (Manual
No.: 5PX-28197-10)
Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3 (Manual No.: 5PX-28197-10).
Disconnect. Refer to INSTALLING THE
CAMSHAFT SPROCKET
COVER AND ENGINE
LEFT SIDE COVER in
For califor- chapter 5. (Manual No.:
5PX-28197-10)
nia only.
ENG
R.
R.
R.
T.
R.
12
13
(5)
T.
10
T.
T.
14
15 New
(4)
12
11
8 9
6
5
LT
T.
R.
R.
Order
6
7
8
9
10
11
12
13
14
15
Job/Part
Engine left side cover
Rubber damper
Timing mark accessing screw
Crankshaft end cover
Decompression solenoid cover
Camshaft sprocket cover 1
Dowel pin
Cylinder identification sensor
Camshaft sprocket cover 2
Camshaft sprocket cover gasket
Qty
1
1
1
1
1
1
2
1
1
1
Remarks
23
ENG
EAS00341
T.
R.
T.
R.
2
1
T.
R.
11
2
1
6
1
10 12
9 New
LT
(9)
T.
R.
R.
Order
Job/Part
Removing the stator coil assembly
Muffler/exhaust pipes
Qty
Engine oil
1
2
3
4
5
6
7
3
2
1
2
1
1
1
24
Remarks
Remove the parts in the order listed.
Refer to ENGINE in chapter 5. (Manual
No.: 5PX-28197-10)
Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3. (Manual No.: 5PX-28197-10)
Disconnect.
Disconnect.
ENG
T.
R.
T.
R.
2
1
T.
R.
11
2
1
6
1
10 12
9 New
LT
(9)
T.
R.
R.
Order
8
9
10
11
12
Job/Part
Generator cover
Generator cover gasket
Dowel pin
Stator coil assembly lead holder
Stator coil assembly
Qty
1
1
2
1
1
Remarks
25
PRINTED IN U.S.A.
XV1700P
XV1700PC
SERVICEMANUAL
LIT-11616-15-37
5PX-28197-10
EAS00001
XV1700P/XV1700PC
SERVICE MANUAL
2001 by Yamaha Motor Corporation, U.S.A.
First edition, October 2001
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-15-37
EAS00003
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. 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.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
_
EAS00004
WARNING
CAUTION:
NOTE:
EAS00007
EAS00009
GEN
INFO
SYMBOLS
The following symbols are not relevant to
every vehicle. Symbols 1 to 8 indicate the
subject of each chapter.
SPEC
CHK
ADJ
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Chassis
5 Engine
6 Fuel injection system
7 Electrical system
8 Troubleshooting
CHAS
FI
ENG
7
ELEC
TRBL
SHTG
T.
R.
E
J
K
B
L
M
LS
LT
G Engine oil
H Gear oil
I Molybdenum-disulfide oil
J Wheel-bearing grease
K Lithium-soap-based grease
L Molybdenum-disulfide grease
New
EAS00013
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
FUEL INJECTION SYSTEM
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG
FI
ELECTRICAL SYSTEM
TROUBLESHOOTING
ELEC
TRBL
SHTG
CONTENTS
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION ..................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES ......................................................................................................1-2
OUTLINE ...................................................................................................1-2
FI SYSTEM ................................................................................................1-3
COMPONENTS .........................................................................................1-5
FUEL INJECTION SYSTEM ....................................................................1-17
FIRST IDLE CONTROL SYSTEM ...........................................................1-28
COMPONENTS .......................................................................................1-29
IMPORTANT INFORMATION........................................................................1-32
PREPARATION FOR REMOVAL AND DISASSEMBLY .........................1-32
REPLACEMENT PARTS .........................................................................1-32
GASKETS, OIL SEALS AND O-RINGS ..................................................1-32
LOCK WASHERS/PLATES AND COTTER PINS ...................................1-33
BEARINGS AND OIL SEALS ..................................................................1-33
CIRCLIPS ................................................................................................1-33
CHECKING THE CONNECTIONS ................................................................1-34
SPECIAL TOOLS ..........................................................................................1-35
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS.........................................................................2-1
ENGINE SPECIFICATIONS ...........................................................................2-2
CHASSIS SPECIFICATIONS ........................................................................2-13
ELECTRICAL SPECIFICATIONS .................................................................2-17
CONVERSION TABLE ..................................................................................2-20
GENERAL TIGHTENING TORQUE SPECIFICATIONS ...............................2-20
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION..............................................................................................3-1
PERIODIC MAINTENANCE CHART
FOR THE EMISSION CONTROL SYSTEM ...................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ............................3-2
SEAT AND SIDE COVERS .............................................................................3-4
HEADLIGHT AND METER ASSEMBLIES......................................................3-5
BATTERY ........................................................................................................3-6
FUEL TANK .....................................................................................................3-7
AIR FILTER CASE...........................................................................................3-8
SILENCER AIR FILTER CASE .......................................................................3-9
ENGINE..........................................................................................................3-11
ADJUSTING THE VALVE CLEARANCE.................................................3-11
SYNCHRONIZING THE THROTTLE BODIES ........................................3-15
ADJUSTING THE ENGINE IDLING SPEED ...........................................3-17
ADJUSTING THE THROTTLE CABLE FREE PLAY...............................3-18
CHECKING THE SPARK PLUGS ...........................................................3-20
CHECKING THE IGNITION TIMING .......................................................3-22
MEASURING THE COMPRESSION PRESSURE ..................................3-23
CHECKING THE ENGINE OIL LEVEL ....................................................3-26
CHANGING THE ENGINE OIL................................................................3-27
MEASURING THE ENGINE OIL PRESSURE ........................................3-31
CHECKING THE TRANSFER GEAR OIL LEVEL ...................................3-32
CHANGING THE TRANSFER GEAR OIL ...............................................3-33
ADJUSTING THE CLUTCH CABLE FREE PLAY ...................................3-35
CLEANING THE AIR FILTER ELEMENTS .............................................3-36
CHECKING THE THROTTLE BODY JOINTS.........................................3-37
CHECKING THE FUEL HOSES ..............................................................3-37
CHECKING THE CYLINDER HEAD BREATHER HOSE AND
OIL TANK BREATHER HOSE................................................................3-38
CHECKING THE EXHAUST SYSTEM ....................................................3-39
CHASSIS .......................................................................................................3-40
ADJUSTING THE FRONT BRAKE..........................................................3-40
ADJUSTING THE REAR BRAKE ............................................................3-41
CHECKING THE BRAKE FLUID LEVEL .................................................3-42
CHECKING THE FRONT BRAKE PADS ................................................3-43
CHECKING THE REAR BRAKE PADS...................................................3-43
ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-44
CHECKING THE FRONT AND REAR BRAKE HOSES ..........................3-44
BLEEDING THE HYDRAULIC BRAKE SYSTEM....................................3-45
ADJUSTING THE SHIFT PEDAL ............................................................3-47
ADJUSTING THE DRIVE BELT SLACK .................................................3-47
CHECKING AND ADJUSTING THE STEERING HEAD .........................3-50
CHECKING THE FRONT FORK .............................................................3-52
ADJUSTING THE FRONT FORK LEGS .................................................3-53
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ..................3-54
CHECKING THE TIRES ..........................................................................3-55
CHECKING THE WHEELS .....................................................................3-58
CHECKING AND LUBRICATING THE CABLES.....................................3-58
LUBRICATING THE LEVERS AND PEDALS .........................................3-59
LUBRICATING THE SIDESTAND ...........................................................3-59
LUBRICATING THE REAR SUSPENSION .............................................3-59
ELECTRICAL SYSTEM.................................................................................3-60
CHECKING AND CHARGING THE BATTERY .......................................3-60
CHECKING THE FUSES.........................................................................3-65
REPLACING THE HEADLIGHT BULB ....................................................3-68
ADJUSTING THE HEADLIGHT BEAM ...................................................3-69
INSTRUMENT FUNCTIONS..........................................................................3-70
ODOMETER AND TRIPMETER..............................................................3-70
ADJUSTING THE METER LIGHT ...........................................................3-71
ADJUSTING THE CLOCK .......................................................................3-71
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS ............................................................4-1
REMOVING THE FRONT WHEEL ............................................................4-4
CHECKING THE FRONT WHEEL ............................................................4-4
CHECKING THE BRAKE DISCS ..............................................................4-6
INSTALLING THE FRONT WHEEL ..........................................................4-7
ADJUSTING THE FRONT WHEEL STATIC BALANCE............................4-9
REAR WHEEL, BRAKE DISC, AND REAR WHEEL PULLEY.....................4-11
REMOVING THE REAR WHEEL ............................................................4-17
CHECKING THE REAR WHEEL .............................................................4-17
CHECKING THE REAR WHEEL DRIVE HUB ........................................4-18
CHECKING AND REPLACING THE REAR WHEEL PULLEY................4-18
ASSEMBLING THE REAR WHEEL ........................................................4-18
INSTALLING THE REAR WHEEL ...........................................................4-19
ADJUSTING THE REAR WHEEL STATIC BALANCE ............................4-22
FRONT AND REAR BRAKES.......................................................................4-23
FRONT BRAKE PADS ............................................................................4-23
REAR BRAKE PADS ...............................................................................4-24
REPLACING THE FRONT BRAKE PADS ..............................................4-25
REPLACING THE REAR BRAKE PADS .................................................4-27
FRONT BRAKE MASTER CYLINDER ....................................................4-30
REAR BRAKE MASTER CYLINDER ......................................................4-33
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-37
REMOVING THE REAR BRAKE MASTER CYLINDER..........................4-37
CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS ..4-37
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER..............................................................................4-38
ASSEMBLING AND INSTALLING THE REAR BRAKE
MASTER CYLINDER..............................................................................4-41
FRONT BRAKE CALIPERS ....................................................................4-43
REAR BRAKE CALIPER .........................................................................4-45
DISASSEMBLING THE FRONT BRAKE CALIPERS ..............................4-47
DISASSEMBLING THE REAR BRAKE CALIPER...................................4-48
CHECKING THE FRONT AND REAR BRAKE CALIPERS.....................4-49
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS .....4-50
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER ..........4-52
FRONT FORK................................................................................................4-55
REMOVING THE FRONT FORK LEGS ..................................................4-58
DISASSEMBLING THE FRONT FORK LEGS ........................................4-58
CHECKING THE FRONT FORK LEGS...................................................4-60
ASSEMBLING THE FRONT FORK LEGS ..............................................4-62
INSTALLING THE FRONT FORK LEGS.................................................4-67
HANDLEBAR.................................................................................................4-69
REMOVING THE HANDLEBAR ..............................................................4-71
CHECKING THE HANDLEBAR...............................................................4-71
INSTALLING THE HANDLEBAR.............................................................4-71
STEERING HEAD..........................................................................................4-75
REMOVING THE LOWER BRACKET .....................................................4-77
CHECKING THE STEERING HEAD .......................................................4-77
INSTALLING THE STEERING HEAD .....................................................4-78
REAR SHOCK ABSORBER AND SWINGARM ...........................................4-80
HANDLING THE REAR SHOCK ABSORBER ........................................4-84
DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER.............................................................................4-84
REMOVING THE REAR SHOCK ABSORBER AND SWINGARM..........4-85
CHECKING THE REAR SHOCK ABSORBER ........................................4-86
CHECKING THE RELAY ARM AND CONNECTING ARM .....................4-86
CHECKING THE SWINGARM ................................................................4-86
INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM ........4-87
DRIVE BELT AND DRIVE SPROCKET ........................................................4-89
REMOVING THE DRIVE BELT AND DRIVE SPROCKET......................4-90
CHECKING THE DRIVE BELT................................................................4-90
INSTALLING THE DRIVE BELT AND DRIVE SPROCKET ....................4-91
CHAPTER 5
ENGINE
ENGINE............................................................................................................5-1
INSTALLING THE ENGINE .......................................................................5-9
INSTALLING THE MUFFLER AND EXHAUST PIPES............................5-10
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ..............................5-11
REMOVING THE ROCKER ARMS, PUSH RODS AND
VALVE LIFTERS.....................................................................................5-16
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS.........5-16
CHECKING THE ROCKER ARM BASES ...............................................5-18
CHECKING THE PUSH RODS ...............................................................5-18
CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES..........5-18
BLEEDING A VALVE LIFTER .................................................................5-19
CHECKING THE PUSH ROD COVER ....................................................5-21
INSTALLING THE VALVE LIFTERS .......................................................5-21
INSTALLING THE ROCKER ARMS AND PUSH RODS .........................5-22
INSTALLING THE CYLINDER HEAD COVERS .....................................5-23
INSTALLING THE CAMSHAFT SPROCKET COVER AND
ENGINE LEFT SIDE COVER .................................................................5-23
CAMSHAFTS.................................................................................................5-25
REMOVING THE CAMSHAFTS ..............................................................5-27
CHECKING THE CAMSHAFTS ..............................................................5-28
CHECKING THE DECOMPRESSION SYSTEM .....................................5-30
CHECKING THE OIL DELIVERY PIPE ...................................................5-30
INSTALLING THE CAMSHAFTS ............................................................5-31
CYLINDER HEADS .......................................................................................5-34
REMOVING THE CYLINDER HEADS ....................................................5-36
CHECKING THE CYLINDER HEADS .....................................................5-36
CHECKING THE OIL DELIVERY PIPE ...................................................5-37
INSTALLING THE CYLINDER HEAD .....................................................5-37
VALVES AND VALVE SPRINGS .................................................................5-39
REMOVING THE VALVES ......................................................................5-40
CHECKING THE VALVES AND VALVE GUIDES...................................5-41
CHECKING THE VALVE SEATS ............................................................5-43
CHECKING THE VALVE SPRINGS ........................................................5-46
INSTALLING THE VALVES.....................................................................5-47
CYLINDERS AND PISTONS .........................................................................5-49
REMOVING THE CYLINDERS AND PISTONS ......................................5-50
CHECKING THE CYLINDERS AND PISTONS.......................................5-51
CHECKING THE PISTON RINGS ...........................................................5-52
CHECKING THE PISTON PINS ..............................................................5-53
INSTALLING THE PISTONS AND CYLINDERS.....................................5-54
CLUTCH.........................................................................................................5-56
CLUTCH COVER ....................................................................................5-56
CLUTCH ..................................................................................................5-59
REMOVING THE CLUTCH .....................................................................5-61
REMOVING THE PRIMARY DRIVE GEAR ............................................5-62
CHECKING THE FRICTION PLATES .....................................................5-62
CHECKING THE CLUTCH PLATES .......................................................5-62
CHECKING THE CLUTCH PLATE SPRING ...........................................5-63
CHECKING THE CLUTCH HOUSING ....................................................5-63
CHECKING THE CLUTCH BOSS ...........................................................5-63
CHECKING THE PRESSURE PLATE ....................................................5-64
CHECKING THE PULL LEVER SHAFT AND PULL ROD.......................5-64
CHECKING THE PRIMARY DRIVE ........................................................5-64
INSTALLING THE CRANKSHAFT POSITION SENSOR AND
PULL LEVER SHAFT .............................................................................5-64
INSTALLING THE PRIMARY DRIVE GEAR ...........................................5-65
INSTALLING THE CLUTCH ....................................................................5-66
SHIFT SHAFT AND STOPPER LEVER ........................................................5-70
CHECKING THE SHIFT SHAFT .............................................................5-71
CHECKING THE STOPPER LEVER.......................................................5-71
INSTALLING THE STOPPER LEVER AND SHIFT SHAFT ....................5-71
GENERATOR AND STARTER CLUTCH......................................................5-73
STATOR COIL ASSEMBLY ....................................................................5-73
GENERATOR AND STARTER CLUTCH ................................................5-75
REMOVING THE GENERATOR .............................................................5-76
CHECKING THE STARTER CLUTCH ....................................................5-76
INSTALLING THE GENERATOR ............................................................5-77
TRANSFER GEAR CASE .............................................................................5-79
FUEL PUMP ............................................................................................5-82
REMOVING THE FUEL PUMP ...............................................................5-83
INSTALL THE FUEL PUMP ....................................................................5-83
SUB FUEL TANK.....................................................................................5-84
REMOVING THE MIDDLE DRIVEN SHAFT ...........................................5-88
CHECKING THE MIDDLE DRIVE ...........................................................5-88
CHECKING THE OIL STRAINER............................................................5-89
CHECKING THE OIL PUMP ...................................................................5-89
CHECKING THE OIL PIPE......................................................................5-90
ASSEMBLING THE OIL PUMP ...............................................................5-90
INSTALLING THE TRANSFER GEAR CASE .........................................5-91
CRANKCASE ................................................................................................5-93
DISASSEMBLING THE CRANKCASE ....................................................5-96
CHECKING THE CRANKCASE ..............................................................5-97
CHECKING THE BEARINGS AND OIL SEALS ......................................5-98
CHECKING THE OIL DELIVERY PIPE ...................................................5-98
CHECKING THE ENGINE OIL PUMP DRIVE.........................................5-98
ASSEMBLING THE CRANKCASE ..........................................................5-99
ENGINE OIL PUMP .....................................................................................5-102
CHECKING THE OIL PUMP .................................................................5-105
CHECKING THE RELIEF VALVE .........................................................5-105
CHECKING THE OIL STRAINER..........................................................5-106
ASSEMBLING THE OIL PUMP .............................................................5-106
INSTALLING THE OIL PUMP ...............................................................5-107
INSTALLING THE OIL STRAINER........................................................5-108
CRANKSHAFT AND CONNECTING RODS ...............................................5-109
REMOVING THE CRANKSHAFT..........................................................5-110
REMOVING THE CONNECTING RODS...............................................5-110
CHECKING THE CRANKSHAFT AND CONNECTING RODS .............5-110
INSTALLING THE CONNECTING RODS .............................................5-116
INSTALLING THE CRANKSHAFT ........................................................5-118
TRANSMISSION..........................................................................................5-119
CHECKING THE SHIFT FORKS ...........................................................5-122
CHECKING THE SHIFT DRUM ASSEMBLY ........................................5-123
CHECKING THE TRANSMISSION .......................................................5-123
INSTALLING THE TRANSMISSION .....................................................5-124
INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY.....5-124
CHAPTER 6
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM ............................................................................6-1
WIRING DIAGRAM....................................................................................6-2
ECUS SELF-DIAGNOSTIC FUNCTION ...................................................6-4
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL
(FAIL-SAFE ACTION)...............................................................................6-8
TROUBLESHOOTING...............................................................................6-9
THROTTLE BODIES ...............................................................................6-37
CHECKING THE INJECTOR...................................................................6-41
CHECKING THE THROTTLE BODY ......................................................6-41
CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION...............................................6-42
CHAPTER 7
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS........................................................................7-1
ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND
COUPLERS ....................................................................................................7-3
CHECKING SWITCH CONTINUITY ................................................................7-8
CHECKING THE SWITCHES ........................................................................7-10
CHECKING THE BULBS AND BULB SOCKETS ........................................7-12
TYPES OF BULBS ..................................................................................7-12
CHECKING THE CONDITION OF THE BULBS......................................7-12
CHECKING THE CONDITION OF THE BULB SOCKETS......................7-14
CHECKING THE LEDs ............................................................................7-15
IGNITION SYSTEM........................................................................................7-16
CIRCUIT DIAGRAM ................................................................................7-16
TROUBLESHOOTING.............................................................................7-17
ELECTRIC STARTING SYSTEM ..................................................................7-22
CIRCUIT DIAGRAM ................................................................................7-22
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................7-23
TROUBLESHOOTING.............................................................................7-24
STARTER MOTOR ........................................................................................7-28
CHECKING THE STARTER MOTOR .....................................................7-31
ASSEMBLING THE STARTER MOTOR .................................................7-33
CHARGING SYSTEM ....................................................................................7-35
CIRCUIT DIAGRAM ................................................................................7-35
TROUBLESHOOTING.............................................................................7-36
CHAPTER 8
TROUBLESHOOTING
STARTING FAILURES ....................................................................................8-1
ENGINE .....................................................................................................8-1
FUEL SYSTEM ..........................................................................................8-1
ELECTRICAL SYSTEMS ..........................................................................8-2
INCORRECT ENGINE IDLING SPEED...........................................................8-2
ENGINE .....................................................................................................8-2
FUEL SYSTEM ..........................................................................................8-2
ELECTRICAL SYSTEMS ..........................................................................8-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE .................................8-3
ENGINE .....................................................................................................8-3
FUEL SYSTEM ..........................................................................................8-3
FAULTY GEAR SHIFTING ..............................................................................8-3
SHIFTING IS DIFFICULT ..........................................................................8-3
SHIFT PEDAL DOES NOT MOVE ............................................................8-3
JUMPS OUT OF GEAR .............................................................................8-3
FAULTY CLUTCH ...........................................................................................8-3
CLUTCH SLIPS .........................................................................................8-3
CLUTCH DRAGS ......................................................................................8-3
OVERHEATING ...............................................................................................8-4
ENGINE .....................................................................................................8-4
FUEL SYSTEM ..........................................................................................8-4
CHASSIS ...................................................................................................8-4
ELECTRICAL SYSTEMS ..........................................................................8-4
POOR BRAKING PERFORMANCE................................................................8-4
FAULTY FRONT FORK LEGS........................................................................8-4
LEAKING OIL ............................................................................................8-4
MALFUNCTION .........................................................................................8-4
UNSTABLE HANDLING..................................................................................8-5
FAULTY LIGHTING OR SIGNALING SYSTEM..............................................8-6
HEADLIGHT DOES NOT COME ON ........................................................8-6
HEADLIGHT BULB BURNT OUT ..............................................................8-6
TAIL/BRAKE LIGHT DOES NOT COME ON ............................................8-6
TAIL/BRAKE LIGHT LED BURNT OUT ....................................................8-6
TURN SIGNAL DOES NOT COME ON.....................................................8-6
TURN SIGNAL BLINKS SLOWLY .............................................................8-6
TURN SIGNAL REMAINS LIT ...................................................................8-6
TURN SIGNAL BLINKS QUICKLY ............................................................8-6
HORN DOES NOT SOUND ......................................................................8-6
MOTORCYCLE IDENTIFICATION
GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
EAS00018
MODEL LABEL
The model label 1 is affixed to the frame. This
information will be needed to order spare
parts.
1-1
FEATURES
GEN
INFO
FEATURES
OUTLINE
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature.
In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet that
is used in the respective chamber.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions.
45 6 7
8 9
2
1
B
H G
8 FE D
1-2
FEATURES
GEN
INFO
FI SYSTEM
The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the injector at only 2.55 kg/cm2 higher than the intake manifold pressure. Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage
opens, causing the fuel to be injected into the intake manifold only during the time the passage
remains open. Therefore, the longer the length of time the injector is energized (injection duration),
the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the injector
is energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, crankshaft position sensor, intake air pressure sensor, atmospheric
pressure sensor, intake temperature sensor, engine temperature sensor, and oil temperature sensor enable the ECU to determine the injection duration. The injection timing is determined through
the signals from the crankshaft position sensor and the cylinder identification sensor. As a result,
the volume of fuel that is required by the engine can be supplied at all times in accordance with the
driving conditions.
Illustration is for reference only.
2
1
#2 #1
5
4 7
6
0
1 Fuel pump
2 Pressure regulator
3 Fuel injector
4 Throttle body
5 Intake temperature sensor
6 Throttle position sensor
1-3
Fuel system
Air system
Control system
FEATURES
GEN
INFO
Control block
Sensor block
Actuator block
Component
Function
ECU
Throttle body
Pressure regulator
Speed sensor
Speed detection
Injector
Fuel injection
Fuel pump
Fuel feed
1-4
FEATURES
GEN
INFO
COMPONENTS
ECU (Electronic Control Unit)
The ECU is mounted underneath the seat, above the battery box. The main functions of the ECU
are ignition control, fuel control, self-diagnosis, and load control.
ECUs internal construction and functions
The main components and functions of the ECU can be broadly divided into the following four
items:
A. Power supply circuit
The power supply circuit obtains power from the battery (12 V) to supply the power (more than
5 V) that is required for operating the ECU.
B. Input interface circuits
The input interface circuits convert the signals output by all the sensors into digital signals,
which can be processed by the CPU, and input them into the CPU.
C. CPU (Central Processing Unit)
The CPU determines the condition of the sensors in accordance with the level of the signal that
is output by the respective sensor. Then, the signals are temporarily stored on the RAM in the
CPU. Based on those stored signals and the basic processing program on the ROM, the CPU
calculates the fuel injection duration, injection timing, and ignition timing, and then sends control commands to the respective output interface circuits.
D. Output interface circuits
The output interface circuits convert the control signals output by the CPU into actuating signals for the respective actuators in order to actuate them. They also output commands to the
indicator and relay output circuits as needed.
ECU
Input
interface circuit
Hall sensor
signal
(for cylinder
identification)
Pickup coil signal
(for identifying the
crankshaft position)
Switches
Waveform
shaping circuit
Battery
Power
supply
circuit
CPU
Output
interface circuit
Injector drive
output circuit
Injector
Waveform
shaping circuit
Lamp drive
output circuit
Indicating lamp
Relay drive
output circuit
Relay
Ignition coil
RAM/ROM
MEMORY
Sensors
A/D converter
input circuit
1-5
FEATURES
GEN
INFO
Ignition control
The ignition timing control uses the signals from the throttle position sensor (to detect the angle of
the throttle), and the crankshaft position sensor (to detect the speed of the engine) and the speed
sensor. This control establishes an ignition timing that suits the operating condition of the engine
through compensations made to the basic ignition timing control map. The ignition energizing
duration control establishes the energizing duration to suit the operating conditions by calculating
the energizing duration in accordance with the signal received from the crankshaft position sensor
and the battery voltage.
Fuel control
The fuel control function of the ECU controls the injection timing and injection duration. The injection timing control controls the injection timing during the starting of the engine and the injection
timing during the normal operation of the engine, based on the signals received from the crankshaft position sensor and the cylinder identification sensor. The injection duration control determines the duration of injection based on the signals received from the atmospheric pressure
sensors, temperature sensors, and the position sensors, to which compensations are made to suit
various conditions such as the weather, atmospheric pressure, starting, acceleration, and deceleration.
Load control
The ECU effects load control in the following manner:
1. Stopping the fuel pump and injectors when the motorcycle overturns
The ECU turns OFF the fuel injection system relay when the lean angle cut-off switch is tripped.
2. Operating the headlight illumination relay
The ECU controls the headlight relay in accordance with the engine speed as required by the
daytime illumination specification.
3. Operating the liner control valve
The ECU controls the liner control valve to increase the intake air volume for starting the engine
under cold conditions.
4. Operating the automatic decompression solenoid valve
The ECU controls the operation of the automatic decompression solenoid valve when the
engine is started.
1-6
FEATURES
GEN
INFO
Self-diagnosis function
The ECU is equipped with a self-diagnosis function to ensure that the engine control system is
operating normally. The ECU mode functions include a diagnosis mode in addition to the normal
mode.
Normal mode
To check for any blown bulbs, this mode illuminates a warning light while the main switch is
turned ON, and while the starter switch is being pressed.
If the starting disable warning is activated, this mode alerts the rider by blinking the warning light
while the start switch is being pressed.
If a malfunction occurs in the system, this mode provides an appropriate substitute characteristic
operation, and alerts the rider of the malfunction by illuminating a warning light. After the engine
is stopped, this mode displays a fault code on the clock LCD.
Diagnosis mode
In this mode, a diagnostic code is input into the ECU through the operation of the operating
switch on the meter, and the ECU displays the values output by the sensors or actuates the
actuators in accordance with the diagnostic code. Whether the system is operating normally can
be checked by observing the illumination of the warning light, the values displayed on the meter,
or the actuating state of the actuators.
1-7
FEATURES
GEN
INFO
Fuel pump
The fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps it
to the injector.
A filter that is provided in the fuel pump prevents any debris in the fuel tank from entering the fuel
system downstream of the pump.
The pump consists of a pump unit, electric motor, filter, and valves.
The pump unit is a Wesco type rotary pump that is connected to the motor shaft.
A relief valve is provided to prevent the fuel pressure from rising abnormally if the fuel hose
becomes clogged. This valve opens when the fuel pressure at the discharge outlet reaches
between 440 and 640 kpa, and returns the fuel to the fuel tank.
1 Fuel filter
2 Fuel inlet strainer
3 Fuel inlet
4 Fuel outlet
5 Air vent pipe
1-8
FEATURES
GEN
INFO
Pressure regulator
It regulates the fuel pressure that is applied to the injectors that supply fuel to the cylinders in order
to maintain a constant pressure.
The fuel that is delivered by the fuel pump fills the fuel chamber through the fuel inlet of the regulator
and exerts pressure on the diaphragm in the direction for opening the valve.
A spring that is provided in the spring chamber exerts pressure on the diaphragm in the direction for
closing the valve, in contrast to the pressure of the fuel. Thus, the valve cannot open unless the fuel
pressure overcomes the spring force.
By the atmospheric pressure applied to the spring chamber and when the fuel pressure exceeds the
sum of the atmospheric pressure and spring force, the diaphragm opens the valve, allowing fuel to
return to the fuel tank from the return hose.
Therefore, the fuel pressure applied to the injectors by the pressure regulator is controlled by the
atmospheric pressure and the spring force to maintain the fuel pressure in accordance to the
changes of the atmospheric pressure.
2
3
7
4
6
5
1 Spring chamber
2 Spring
3 Diaphragm
4 Fuel inlet
5 Fuel outlet
6 Fuel chamber
7 Valve
8 Atmospheric pressure
sensor
1-9
Spring pressure
Fuel pressure
GEN
INFO
FEATURES
Fuel injector
Upon receiving injection signals from the ECU, the fuel injector injects fuel. In the normal state, the
core is pressed downward by the force of the spring, as illustrated. The needle that is integrated
with the bottom of the core keeps the fuel passage closed.
When the current flows to the coil in accordance with the signal from the ECU, the core is drawn
upward, allowing the flange that is integrated with the needle to move to the spacer. Since the distance of the movement of the needle is thus kept constant, the opening area of the fuel passage
also becomes constant. Because the pressure difference of the fuel to the intake manifold pressure
is kept constant by the pressure regulator, the fuel volume varies in proportion to the length of time
the coil is energized. The injector that has been recently adopted has a four-hole type injection orifice that enhances the atomization of fuel and improves combustion efficiency.
3
4
5
6
1 Fuel
2 Coil
3 Core
4 Spacer
5 Needle
6 Inject
7 Flange
1 - 10
FEATURES
GEN
INFO
X5P
10
00
IT
2 3
#1
#2
1 Pickup rotor
2 Identification of cylinder #1 (82 BTDC)
3 Ignition of cylinder #1 (10 BTDC)
4 Identification of cylinder #2
5 Ignition of cylinder #2
Direction of rotation
Compression stroke of cylinder #1 (10 BTDC)
Crankshaft position sensor
Compression
Combustion
Exhaust
Intake
1 - 11
GEN
INFO
FEATURES
#1
#2
1 - 12
FEATURES
GEN
INFO
5.0
4.0
3.88
3.0
2
2.0
1.0
0.68 V
1 Moving contact
2 Resistor board
3 Spring
17
97
Output voltage
Idling output position
Full close
Full open
1 - 13
GEN
INFO
FEATURES
4
2
3
7
6
0
A
(V)
4.00
B
C
1.842
0.789
D
P
1 EMI shield
2 Sensor unit
3 Through condenser
4 Hybrid IC
5 Cap
6 Silicon diaphragm
7 Vacuum chamber
8 Solder
9 Silicon chip
0 Gold wire
20
46
101
A Lead pin
Output voltage
B Stem
Input pressure
C Pressure induction pipe
D Atmospheric pressure,
intake air pressure
1 - 14
FEATURES
GEN
INFO
67.0
1
10.0
0.99
-20(-4)
1 Connector
2 Terminal
3 Tube
4 Thermistor
0(32)
20(68)
5 Holder
Resistance k
Temperature C (F)
2
6.0
3
0.34
4
5
1 Connector
2 Terminal
3 Tube
4 Thermistor
-20(-4)
0(32)
20(68)
5 Holder
Resistance k
Temperature C (F)
1 - 15
FEATURES
GEN
INFO
65
65
ON
ON
V
4.0
1.0
20 40 60 80
65
1 Shaft
2 Float
3 Magneto
4 IC unit
Output voltage
High level
Low level
Cut-off switch tilt angle
Fuel injection system relay OFF
1 - 16
GEN
INFO
FEATURES
RPM
Injection duration
Cranking
Warm-up
Idle
Acceleration
Constant
Deceleration
1 - 17
Start
After start
Basic injection duration
Voltage compensation duration
FEATURES
GEN
INFO
Deceleration
Starting
After starting
Basic injection duration
Voltage compensation duration
Correction volume
1 - 18
FEATURES
GEN
INFO
Atmospheric
pressure
Engine rpm
Basic injection
quantity
Degree of
opening of
throttle
Battery voltage
Injection
command
Compensation
Engine
temperature
Intake air
temperature
The fuel is cut off under conditions that do not require fuel, in order to stop the injection.
Composition of final injection duration
1
4
5
3
1 Injection at start *1
2 After-start enrichment *2
3 Warm-up enrichment *3
4 Acceleration compensation *5
5 Fuel cut-off Deceleration
compensation *5
6 Basic injection duration
1 - 19
Acceleration
Constant
Deceleration
Start
After start
FEATURES
GEN
INFO
Check item
Sensor used
Engine temperature
After-start enrichment *2
Engine temperature
Warm-up enrichment *3
Engine temperature
Intake temperature
Acceleration compensation/
deceleration compensation *5
Throttle position
Engine temperature
After-start injection:
1 - 20
FEATURES
GEN
INFO
To determine the injection timing, the ECU calculates the injection timing through the use of the 3D
control map provided in the ECU, which is based on the throttle position and the engine speed.
The injection duration is based on the basic injection duration (obtained through the throttle position,
intake air pressure, and engine speed) to which injection duration compensation (based on the signals from various sensors such as the intake temperature sensor, atmospheric pressure sensor) is
added to determine the final injection duration. As a result, fuel is supplied to the cylinders.
Normal synchronous injection
#1
#2
1 Injector #1
2 Injector #2
3 Identification of cylinder #1
4 Identification of cylinder #2
1 - 21
Combustion
Exhaust
Intake
Compression
FEATURES
Fuel injection control during normal driving
1 - 22
GEN
INFO
FEATURES
GEN
INFO
2
1
0
(C)
Injection duration
Engine temperature
Extended duration
45
1
2
1 Injector #1
2 Injector #2
3 Starting asynchronous injection
4 Identification of cylinder #1
5 Identification of cylinder #2
1 - 23
FEATURES
GEN
INFO
After-start enrichment
After-start enrichment provides enrichment compensation during a prescribed duration following the
starting (firing) of the engine. While the amount of fuel enrichment is determined by the after-start
enrichment coefficient, the coefficient varies by the engine temperature. Although the engine temperature determines the initial starting enrichment coefficient, the coefficient subsequently changes
in accordance with the damping factor. The enrichment ratio is the highest immediately after the
engine is started, and diminishes gradually. The enrichment of fuel in this manner ensures a stable
engine operation immediately after the engine is started.
Changes in compensation coefficient and compensation injection duration
Engine speed
Stopped
Cranking
Initial starting enrichment
coefficient (determined by
engine temperature)
1 - 24
Long
Injection
duration
After-start enrichment
Basic injection
duration
Short
Duration
Compensation injection
duration
FEATURES
GEN
INFO
Warm-up enrichment
When the engine temperature is low, a warm-up coefficient is applied in accordance with the signals
from the engine temperature sensor in order to effect fuel enrichment. Because the engine temperature determines the coefficient, the coefficient changes with the fluctuations in the engine temperature. The coefficient increases with the decrease in the engine temperature, and decreases with the
increase in the engine temperature. The ratio of fuel enrichment also changes with the changes in
the coefficient.
Small
Enrichment
coefficient
Large
Long
Injection
duration
Short
1.0
60
Warm-up enrichment
Basic injection duration
Duration
(C)
Engine temperature
Low
High
1 - 25
FEATURES
GEN
INFO
Acceleration enrichment
Acceleration enrichment is provided in accordance with the signals from the throttle position sensor.
As the rider operates the accelerator to accelerate the motorcycle from a constant speed, the throttle position sensor actuates in unison with the accelerator. The ECU interprets that acceleration has
taken place through the throttle position sensor signal and executes acceleration enrichment. The
enrichment volume is determined by the acceleration enrichment coefficient. The coefficient
increases with the changes in the throttle position sensor, which also increases the actual enrichment volume. The enrichment volume is executed in accordance with the acceleration enrichment
coefficient when the movement of the throttle position sensor has met the acceleration condition as
defined by the ECU. Thereafter, the enrichment volume is regulated by the coefficient that changes
in accordance with the damping rate.
(Acceleration injection duration = basic injection duration acceleration compensation coefficient)
Changes in compensation coefficient and compensation injection duration
Changes in acceleration
compensation coefficient
Acceleration enrichment volume
Large
Long
Changes in
throttle position
sensor angle
Injection
duration
Small
Short
Duration
Starting of acceleration
Compensation injection duration
1 - 26
FEATURES
GEN
INFO
Deceleration control
Deceleration control is effected in accordance with the signals from the throttle position sensor. As
the rider operates the accelerator to decelerate the motorcycle that is in motion, the throttle position
sensor actuates in unison with the accelerator. When the engine speed is greater than a prescribed
value with the throttle fully closed (thus applying engine braking), the ECU executes a deceleration
fuel cut-off. The injection of fuel to all the cylinders is stopped when fuel cut-off control is executed,
thus improving fuel economy.
Engine speed
Duration
Fuel cut-off control (stopping fuel injection)
Basic injection duration
Basic injection duration
Over-revolution control
The over-revolution control of the ECU operates the ignition control and fuel cut-off control when the
engine speed becomes greater than the specified value. The over-revolution control first operates
the ignition control to reduce the ignition of each cylinder to keep the engine speed from rising. If the
engine speed increases after the ignition control is activated, the fuel cut-off control is activated. The
fuel cut-off control is first activated in cylinder #1, then in cylinder #2 as the engine speed increases
further.
In addition, specified engine speeds are set at each gear position, therefore, over-revolution control
can be achieved more accurately.
1 - 27
FEATURES
GEN
INFO
1 - 28
FEATURES
GEN
INFO
COMPONENTS
Linear control valve
The linear control valve sends air from the silencer box to the intake manifold to increase the intake
air volume.
The linear control valve consists of a stepper motor that operates the valve, a valve unit that is
attached to the motor, and a main body that distributes the intake air. The stepper motor has been
adopted to deduce malfunctions during operation and for high-precision control. The main body
contains air passages, which are opened and closed by the motor, which operates the valve. In
addition, a pipe to introduce air from the silencer air filter case and air pipes to distribute air to each
cylinder are installed on the linear control valve.
The stepper motor used in the XV1700 rotates exactly 15 degrees per step (1 pulse input). With
each step, the valve moves approximately 0.041 mm. The stepper motor is set to make a total of
146 steps, thus the total range of the valve, from fully closed to fully open, is approximately 6.08
mm.
The linear control valve is operated when the engine is started and adjusts its opening to accommodate the temperature of the engine. When the engine is started, the control data transfers from the
engine temperature to the engine oil temperature and adjusts the valve opening to accommodate
the engine oil temperature. When the engine oil temperature reaches 80 C (176 F) or higher, the
valve fully closes to stop the intake air volume from increasing.
In addition, the linear control valve fully closes when the main switch is turned off, but maintains its
current position if the engine is stopped with the engine stop switch or if the engine stalls. When the
engine is restarted, control starts at the maintained position.
1 Valve
To intake manifold - cylinder #1
From silencer air filter case
To intake manifold - cylinder #2
1 - 29
GEN
INFO
FEATURES
Instrument panel
Function indication
The indications of the self-diagnosis function can be checked and inspection operations can be performed through the use of the tachometer on the instrument panel.
Based on the signals received from the sensors, the ECU inputs the signals into the tachometer.
Then, the conditions of the sensors appear on the clock and trip/odometer display of the tachometer.
1. ECU transmission data and meter display
Mode
Common to all
modes
Normal mode
Meter indication
Tripmeter
Indicator lamp
Trip LCD
Clock LCD
Indicator lamp
Clock LCD
DIAG mode
Display description
4 digits including decimals
ON/OFF
Shows trouble code in numbers
Engine temperature
Shows diagnostic code in
numbers
Shows data for sensors
Note: If the exchange of data between the ECU and the meters is abnormal, the clock LCD shows
error Er-1~4. The clock LCD reverts to showing the time after the error has been corrected.
2
1
1 Tachometer
2 Clock
3 Odometer/tripmeter/fuel reserve tripmeter
4 RESET button
5 SELECT button
6 Speedometer assembly
7 Engine trouble warning light
1 - 30
FEATURES
GEN
INFO
Normal mode
Turn ON the main switch.
* The self-diagnostic function starts a system check.
System normal
Normal meter display
1
2
1 Clock
2 Odometer/tripmeter/fuel reserve tripmeter
3 RESET button
4 SELECT button
1 - 31
Malfunction detection
A fault code number
appears on the clock
LCD.
The engine trouble
warning light illuminates.
IMPORTANT INFORMATION
GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recommended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EAS00022
1 - 32
IMPORTANT INFORMATION
GEN
INFO
EAS00023
EAS00024
CAUTION:
_
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
4 Shaft
1 - 33
GEN
INFO
EAS00026
2.
Check:
lead
coupler
connector
Moisture Dry with an air blower.
Rust/stains Connect and disconnect several times.
3. Check:
all connections
Loose connection Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.
_
4.
Connect:
lead
coupler
connector
NOTE:
Make sure all connections are tight.
_
5. Check:
continuity (with the pocket tester)
Pocket tester
YU-03112
NOTE:
If there is no continuity, clean the terminals.
When checking the wire harness, perform
steps (1) to (3).
As a quick remedy, use a contact revitalizer
available at most part stores.
_
1 - 34
SPECIAL TOOLS
GEN
INFO
EAS00027
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 inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
Tool name/Function
Mity vac
YB-35956
This tool used to measure the vacuum
pressure.
Alternator rotor puller
YM-01080-A
This tool is used to remove the generator rotor.
Damper rod holder
YM-01423
YM-01434
This tool is used to support the damper
adjusting rod.
Rod puller
Rod puller
YM-01437
These tools are used to pull up the front
fork damper rod.
Fork spring compressor
YM-01441
This tool is used to disassemble or
assemble the front fork legs.
Fork seal driver
YM-01442
This tool is used to install the front forks
oil seal and dust seal.
1 - 35
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Valve spring compressor set
YM-04019
This tool is used to remove or install the
valve assemblies.
Bearing driver
YM-04058
This tool is needed when installing the
crankshaft journal bearing.
Valve guide remover (6)
YM-04064-A
This tool is used to remove or install the
valve guides.
Valve guide installer (6)
YM-04065-A
This tool is used to install the valve
guides.
Valve guide reamer (6)
YM-04066
This tool is used to rebore the new
valve guides.
Bearing remover and installer
YM-28898
This tool is needed when removing or
installing the crankshaft journal bearing.
Timing light
YM-33277-A
This tool is used to check the ignition
timing.
Belt tension gauge
YM-03170
This tool is used to measure the drive
belt slack.
1 - 36
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Dynamic spark tester
YM-34487
This tool is used to check the ignition
system components.
Valve adjuster
YM-8035
This tool is used to adjust the valve
clearance.
Universal clutch holder
YM-91042
YS-01880-A
YU-01304
This tool is used to remove the piston
pins.
Micrometer (75 ~ 100 mm)
YU-03009
This tool is used to measure the piston
skirt diameter.
Cylinder bore gauge (50 ~ 100 mm)
YU-03017
This tool is used to measure the cylinder bore.
Pocket tester
YU-03112
This tool is used to check the electrical
system.
1 - 37
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Carburetor synchronizer
YU-08030
This gauge is needed for throttle bodies
synchronization.
Compression gauge
YU-33223
Compression gauge
adapter
YU-33223-3
YU-33975
This tool is used to loosen or tighten the
steering stem ring nuts.
Oil filter wrench
YU-38411
This tool is needed to loosen or tighten
the oil filter cartridge.
Inductive tachometer
YU-8036-A
This tool is used for check engine
speed.
Quick Gasket
ACC-11001-05-01
Gauge
YU-03153
Oil pressure adaptor E
YM-03129
YM-03176
This tool is needed to measure fuel
pressure.
1 - 38
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
Tool name/Function
Pivot shaft wrench
YM-01485
This tool is needed to loosen or tighten
the spacer bolt.
1 - 39
GEN
INFO
Illustration
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Weight
Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
Gross vehicle weight ratio (GVWR)
Bias weight (dry) front
Bias weight (dry) rear
Maximum load (total of cargo, rider,
passenger, and accessories)
Standard
Limit
5PX1 (USA)
5PX2 (California)
5PX3 (CDN)
----------
----------------------
-------------------
2-1
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item
Engine
Engine type
Displacement
Cylinder arrangement
Bore stroke
Compression ratio
Engine idling speed
CO%
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Minimum compression pressure
Maximum compression pressure
Engine dry weight
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Engine oil
Lubrication system
Recommended oil
Quantity
Total amount
Engine
Oil tank
Without oil filter cartridge replacement
With oil filter cartridge replacement
Oil pressure (hot)
Relief valve opening pressure
Oil temperature
Standard
Limit
-------------------------
1,200 kPa
(12.0 kg/cm2, 171 psi) at 200 r/min
1,000 kPa (10.0 kg/cm2, 145 psi)
1,400 kPa (14.0 kg/cm2, 203 psi)
108 kg (238 lb)
----
-------
-------
Dry sump
Yamalube 4 (20W40) or SAE 20W40 type
SE motor oil (40 F/5 C or above)
(Non-Friction modified)
-------
-------------
-------------
2-2
----------
1
2
ENGINE SPECIFICATIONS
Item
Transfer gear oil
Recommended oil
Total amount
Periodic oil replacement
Oil filter
Oil filter type
Bypass valve opening pressure
SPEC
Standard
SAE 80 API GL-4 hypoid gear oil
0.49 L (0.43 Imp qt, 0.52 US qt)
0.4 L (0.35 Imp qt, 0.42 US qt)
----------
Cartridge (paper)
80 ~ 120 kPa
(0.8 ~ 1.2 kg/cm2, 11.3 ~ 17.1 psi)
-------
Limit
Trochoid
0.07 ~ 0.12 mm (0.0028 ~ 0.0047 in)
Outer rotor to oil pump housing clear- 0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in)
ance
Bypass valve opening pressure
80 ~ 120 kPa
(0.8 ~ 1.2 kg/cm2, 11.3 ~ 17.1 psi)
Relief valve opening pressure
600 kPa (6.0 kg/cm2, 85 psi)
Oil pressure (hot)
60 kPa (0.6 kg/cm2, 8.5 psi) at 900 r/min
Starting system type
Electric starter
Electric fuel injection
Model
IMP-732
Manufacturer
NIPPON INJECTOR
Quantity
2
Spark plugs
Model
DPR7EA-9/X22EPR-U9
Manufacturer
NGK/DENSO
Quantity
4
Spark plug gap
0.8 ~ 0.9 mm (0.0315 ~ 0.0354 in)
Cylinder heads
Volume
98.6 ~ 103.6 cm3 (6.02 ~ 6.32 cu.in)
Max. warpage
----
2-3
---0.17 mm
(0.0067 in)
0.13 mm
(0.0051 in)
0.16 mm
(0.0063 in)
---0.17 mm
(0.0067 in)
0.16 mm
(0.0063 in)
------------------------------------0.03 mm
(0.0012 in)
ENGINE SPECIFICATIONS
Item
Camshafts
Drive system
Crankcase hole inside diameter
Camshaft cover hole inside diameter
Camshaft journal diameter
(crankcase side)
Camshaft journal diameter
(camshaft cover side)
Camshaft to crankcase clearance
Camshaft to camshaft cover clearance
Camshaft intake cam dimensions
SPEC
Standard
Limit
Gear drive
25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in)
28.000 ~ 28.021 mm (1.1024 ~ 1.1032 in)
24.937 ~ 24.950 mm (0.9818 ~ 0.9823 in)
-------------
----
-------
Measurement A
Measurement B
Camshaft exhaust cam dimensions
Measurement A
Measurement B
2-4
ENGINE SPECIFICATIONS
Item
Standard
SPEC
Limit
C
D
A
Head Diameter
Face Width
Seat Width
Margin Thickness
-------
-------
2-5
2.0 mm
(0.079 in)
2.0 mm
(0.079 in)
0.4 mm
(0.016 in)
0.4 mm
(0.016 in)
ENGINE SPECIFICATIONS
Item
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve stem-to-valve guide clearance
Intake
Exhaust
Valve stem runout
SPEC
Standard
5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in)
5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in)
PB 6
V557W
2-6
Limit
5.945 mm
(0.2341 in)
5.920 mm
(0.2331 in)
6.05 mm
(0.2382 in)
6.05 mm
(0.2382 in)
0.08 mm
(0.0031 in)
0.1 mm
(0.0039 in)
0.01 mm
(0.0004 in)
-------
36.26 mm
(1.43 in)
36.26 mm
(1.43 in)
-------------------
ENGINE SPECIFICATIONS
Item
Compressed spring force
(installed)
Intake
Exhaust
Spring tilt
Standard
Intake
----
Exhaust
----
Outer springs
Free length
Intake
Exhaust
Spring rate-intake (K1)
Spring rate-intake (K2)
Spring rate-exhaust (K1)
Spring rate-exhaust (K2)
Installed length (valve closed)
Intake
Exhaust
Compressed spring force
(installed)
Intake
Exhaust
SPEC
Limit
-------
2.5/2.4 mm
(2.5/0.094 in)
2.5/2.4 mm
(2.5/0.094 in)
Counterclockwise
Counterclockwise
-------
41.26 mm
(1.62 in)
41.26 mm
(1.62 in)
-------------
-------
139 ~ 161 N
(13.9 ~ 16.1 kg, 30.6 ~ 35.5 lb)
139 ~ 161 N
(13.9 ~ 16.1 kg, 30.6 ~ 35.5 lb)
----
2-7
----
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Limit
Spring tilt
Intake
----
Exhaust
----
Valve lifters
Valve lifter outside diameter
Valve lifter case inside diameter
Valve lifter-to-valve lifter case clearance
Valve push rods
Valve push rod 1 length
Valve push rod 2 length
Valve push rod runout
Cylinders
Material
Sleeve type
Bore
Max. taper
Max. out of round
2.5/2.4 mm
(2.5/0.094 in)
2.5/2.4 mm
(2.5/0.094 in)
Clockwise
Clockwise
-------
22.9680 ~ 22.9744 mm
(0.9043 ~ 0.9045 in)
23.000 ~ 23.021 mm (0.9055 ~ 0.9063 in)
0.0256 ~ 0.0530 mm (0.0010 ~ 0.0021 in)
----
----------
-------
Aluminum alloy
---Ceramic composite plated
---97.000 ~ 97.010 mm (3.8189 ~ 3.8193 in)
------0.05 mm
(0.00197 in)
---0.05 mm
(0.00197 in)
2-8
ENGINE SPECIFICATIONS
Item
Standard
Pistons
Piston-to-cylinder clearance
SPEC
Limit
0.15 mm
(0.006 in)
96.960 ~ 96.975 mm (3.8173 ~ 3.8179 in)
----
Diameter D
H
D
Height H
Piston pin bore (in the piston)
Diameter
5 mm (0.20 in)
----
Offset
Piston pins
Outside diameter
Ring type
Dimensions (B T)
End gap (installed)
Barrel
1.2 3.8 mm (0.047 0.150 in)
0.30 ~ 0.45 mm (0.012 ~ 0.018 in)
Plating/coating
Chrome plated/parkerizing
2-9
------0.65 mm
(0.026 in)
0.12 mm
(0.0047 in)
----
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Limit
2nd ring
B
T
Ring type
Dimensions (B T)
End gap (installed)
Taper
1.2 3.8 mm (0.047 0.150 in)
0.30 ~ 0.45 mm (0.012 ~ 0.018 in)
Plating/coating
Oil ring
Parkerizing
------0.8 mm
(0.031 in)
0.12 mm
(0.0047 in)
----
B
T
Dimensions (B T)
End gap (installed)
Plating/coating
Connecting rods
Crankshaft pin-to-big end bearing
clearance
Bearing color code
Connecting rod length
Crankshaft
C
----------
----
-------
E
D
A
Width A
Max. runout C
2 - 10
---0.04 mm
(0.0016 in)
---0.09 mm
(0.0035 in)
0.1 mm
(0.0039 in)
ENGINE SPECIFICATIONS
Item
Clutch
Clutch type
Clutch release method
Clutch release method operation
Operation
Clutch cable free play (at the end of
the clutch lever)
Friction plates
Thickness
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
Min. length
Clutch housing thrust clearance
Clutch housing radial clearance
Primary reduction gear backlash tolerance
Primary drive gear backlash Number
Primary driven gear backlash Number
SPEC
Standard
Limit
----------------
2.8 mm
(0.110 in)
----
------0.2 mm
(0.008 in)
7 mm (0.276 in)
1
----
------6.5 mm
(0.256 in)
----------
2 - 11
-------
ENGINE SPECIFICATIONS
Item
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
Max. main axle runout
Max. drive axle runout
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Shift fork thickness
Air filter type
Fuel pump
Pump type
Model (manufacturer)
Output pressure
Throttle bodies
Model (manufacturer) quantity
Throttle cable free play (at the flange
of the throttle grip)
ID mark
Throttle valve size
SPEC
Standard
Constant mesh, 5-speed
Spur gear
72/47 (1.532)
Belt drive
35/32 70/32 (2.393)
Left-foot operation
38/16 (2.375)
30/19 (1.579)
29/25 (1.160)
29/31 (0.935)
24/30 (0.800)
-------
Guide bar
---6.26 ~ 6.39 mm (0.2465 ~ 0.2516 in)
Wet element
Limit
---------------------------------0.08 mm
(0.003 in)
0.08 mm
(0.003 in)
---0.025 mm
(0.001 in)
-------
Electrical
5PX (MITSUBISHI)
392 ~ 588 kPa
(3.92 ~ 5.88 kg/cm2, 55.7 ~ 83.6 psi)
----------
AC40-B204 (MIKUNI) 2
4 ~ 6 mm (0.16 ~ 0.24 in)
-------
----------
2 - 12
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item
Frame
Frame type
Caster angle
Trail
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Rear wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb)
90 kg (198 lb) ~ Maximum load*
High-speed riding
Standard
Limit
Double cradle
29.5
130 mm (5.12 in)
----------
Cast wheel
----
18 M/C MT 3.50
18 MT 3.50
Aluminum
135 mm (5.31 in)
----
----
------1 mm
(0.04 in)
0.5 mm
(0.02 in)
----
Cast wheel
----
17 M/C MT 6.00
17 MT 6.00
Aluminum
110 mm (4.33 in)
----
----
------1 mm
(0.04 in)
0.5 mm
(0.02 in)
----
Tubeless
120/70 ZR 18 M/C (59 W)
120/70 ZR 18 (59 W)
D220FST (DUNLOP)/
BT020FG (BRIDGESTONE)
----------
2 - 13
CHASSIS SPECIFICATIONS
Item
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb)
90 kg (198 lb) ~ Maximum load*
High-speed riding
Standard
Tubeless
200/50 ZR 17 M/C (75 W)
200/50 ZR 17 (75 W)
D220ST (DUNLOP)/
BT020R (BRIDGESTONE)
Limit
----------
Max. deflection
----
SPEC
14 mm (0.55 in)
27 mm (1.06 in) and 30.2 mm (1.19 in)
2 - 14
---------------4.5 mm
(0.18 in)
0.1 mm
(0.004 in)
0.5 mm
(0.02 in)
-------
CHASSIS SPECIFICATIONS
Item
Standard
Rear brake
Brake type
Single-disc brake
Operation
Right-foot operation
Brake pedal free play (P)
0 mm (0 in)
Brake pedal position
80 mm (3.2 in)
(from the top of the rider footrest to
the top of the brake pedal)
Recommended fluid
DOT 4
Brake discs
Diameter thickness
282 6 mm (11.10 0.24 in)
Min. thickness
----
SPEC
Limit
-------------
------5.5 mm
(0.22 in)
0.15 mm
(0.006 in)
0.8 mm
(0.03 in)
Max. deflection
----
-------
----------
Telescopic fork
Coil spring/oil damper
135 mm (5.31 in)
----------
291 mm
(11.46 in)
----------------
Suspension oil 01
476 cm3 (16.8 Imp oz, 16.1 US oz)
100 mm (3.94 in)
----------
41 mm (1.61 in)
----
2 - 15
CHASSIS SPECIFICATIONS
Item
Rear suspension
Suspension type
Rear shock absorber assembly type
Rear shock absorber assembly travel
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Standard spring preload gas/air pressure
Swingarm
Free play (at the end of the swingarm)
Radial
Axial
Drive belt
Model (manufacturer)
Drive belt slack (on a sidestand)
Drive belt slack (on a suitable stand)
SPEC
Standard
Swingarm (link suspension)
Coil spring/gas-oil damper
50 mm (1.97 in)
188 mm (7.4 in)
172 mm (6.77 in)
137 N/mm (13.7 kg/mm, 782.27 lb/in)
0 ~ 50 mm (0 ~ 1.97 in)
No
1,000 kPa (10 kg/cm2, 142 psi)
----
Limit
---------183 mm
(7.2 in)
----------------
1 mm
(0.04 in)
1 mm
(0.04 in)
----
UBD-0568
6 ~ 8 mm (0.24 ~ 0.31 in)
7 ~ 9 mm (0.28 ~ 0.35 in)
2 - 16
----------
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
Standard
System voltage
12 V
Ignition system
Ignition system type
Transistorized coil ignition (digital)
Ignition timing
10 BTDC at 900 r/min
Advancer type
Electric
Crankshaft position sensor
248 ~ 372 /GyB
resistance/color
Transistorized coil ignition unit model F8T914 (MITSUBISHI)
(manufacturer)
Ignition coils
Model (manufacturer)
J0447 (DENSO)
Minimum ignition spark gap
6 mm (0.24 in)
Primary coil resistance
1.31 ~ 1.79
Secondary coil resistance
12 ~ 18 k
Spark plug caps
Material
Resin
Resistance
10 k
Charging system
System type
AC magneto
Model (manufacturer)
F5PX/YAMAHA
Nominal output
14 V/31 A at 5,000 r/min
Stator coil resistance/color
0.12 ~ 0.20 /WW
Rectifier/regulator
Regulator type
Semiconductor, short circuit
Model (manufacturer)
FH001 (SHINDENGEN)
No-load regulated voltage
14.1 ~ 14.9 V
Rectifier capacity
35 A
Withstand voltage
200 V
Battery
Battery type (manufacturer)
GT14B-4 (GS)
Battery voltage/capacity
12 V/12 AH
Specific gravity
1.320
Ten hour rate amperage
1.2 A
Headlight type
Halogen bulb
Indicator light
(voltage/wattage quantity)
Meter light
LED 13
Neutral indicator light
LED 1
Turn signal indicator light
LED 2
Fuel indicator light
LED 1
High beam indicator light
LED 1
Engine trouble warning light
LED 1
2 - 17
Limit
----------------------------------------------------------------------------------
-------------------
ELECTRICAL SPECIFICATIONS
Item
Bulbs (voltage/wattage quantity)
Headlight
Licence plate light
Tail/brake light
Front turn signal/position light
Rear turn signal light
Speedometer light
Tachometer light
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Armature coil resistance
Brushes
Overall length
Spring force
Commutator diameter
Mica undercut
Starter relay
Model (manufacturer)
Amperage
Coil resistance
Starting circuit cut-off relay
Model/manufacturer
Coil resistance
Horn
Horn type
Model (manufacturer) quantity
Max. amperage
Performance
Coil resistance
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Hazard flasher device
Turn signal blinking frequency
Wattage
Standard
SPEC
Limit
12 V 60 W/55 W 1
12 V 5 W 2
LED
12 V 23 W/8 W 2
12 V 23 W 2
LED 1
LED 1
----------------------
Constant mesh
----
5PX (YAMAHA)
0.9 kW
0.0081 ~ 0.0099
----------
5 mm
(0.2 in)
---27.5 mm
(1.08 in)
----
MS5F-631 (JIDECO)
180 A
4.18 ~ 4.62
----------
G8R-30Y-S/OMRON
162 ~ 198
-------
Eddy
YP-12 (NIKKO) 2
2A
95 ~ 115 db/2 m
0.94 ~ 0.98
----------------
Semi-transistor
FB257H (DENSO)
Yes
Yes
75 ~ 95 cycles/min.
23 W 2 + 3.4 W
-------------------
2 - 18
ELECTRICAL SPECIFICATIONS
Item
Headlight relay
Model/manufacturer
Coil resistance
Fuel injection system relay
Model/manufacturer
Coil resistance
Throttle position sensor
Resistance
Output voltage (at idle)
Circuit breaker
Circuit breaker type
Fuses (amperage quantity)
Main fuse
Fuel injection system fuse
Headlight fuse
Signaling system fuse
Ignition fuse
ECU fuse
Decompression solenoid fuse
Backup fuse (odometer and clock)
Reserve fuse
Engine temperature sensor
Model/manufacturer
Resistance
SPEC
Standard
Limit
ACM33211 M04/MATSUSHITA
86.4 ~ 105.6
-------
G8R-30Y-S/OMRON
162 ~ 198
-------
4 ~ 6 k/L-B
0.605 ~ 0.755 V
-------
Fuse
----
30 A 1
15 A 1
15 A 1
10 A 1
10 A 1
10 A 1
15 A 1
7.5 A 1
30 A, 15 A, 10 A, 7.5 A 1
----------------------------
5PX/DENSO
895.38 ~ 1,098.02 at 100 C (212 F)
-------
2 - 19
CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS
SPEC
EAS00028
EAS00030
CONVERSION TABLE
MULTIPLIER
IMPERIAL
** mm
0.03937
** in
2 mm
0.03937
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
mkg
Tightening torque mkg
cmkg
cmkg
Multiplier
Imperial unit
7.233
86.794
0.0723
0.8679
ftlb
inlb
ftlb
inlb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km/hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume/
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP lip.)
cu.in
qt (IMP liq.)
gal (IMP liq.)
kg/mm
kg/cm2
Centigrade
(C)
55.997
14.2234
9/5+32
lb/in
psi (lb/in2)
Fahrenheit (F)
Misc.
This chart specifies tightening torques for standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special 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.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Components should be at room temperature.
2 - 20
B
(bolt)
General tightening
torques
Nm
mkg
ftlb
10 mm
6 mm
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item
Spark plug
Front cylinder head cover
Rear cylinder head cover
Front rocker arm base
Front rocker arm base
Rear rocker arm base
Rear rocker arm base
Cylinder head
Cylinder head
Engine temperature sensor
Cylinder head (exhaust pipe)
Camshaft driven gear
Camshaft driven gear
Camshaft cover
Decompression solenoid
Camshaft sprocket cover 1
Camshaft sprocket cover 1
Camshaft sprocket cover 2
Engine left side cover
Rocker arm adjusting screw
Valve lifter case
Engine oil checking bolt
Front cylinder camshaft end cover
Engine oil drain bolt (crankcase)
Engine oil drain bolt (oil tank)
Oil filter cartridge
Oil filter bolt
Oil filter bracket
Oil delivery pipe
Oil delivery pipe
(cylinder head-to-crankcase)
Oil delivery pipe
(cylinder head-to-crankcase)
Oil strainer
Engine oil pump assembly
Oil pump housing cover
Dipstick
Fastener
Thread
Qty
size
Tightening torque
Nm
mkg
ftlb
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Nut
Stud bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
Union bolt
Bolt
Bolt
M12
M6
M6
M8
M6
M8
M6
M12
M10
M12
M8
M14
M10
M6
M4
M6
M6
M6
M6
M7
M6
M5
M5
M14
M14
M20
M20
M6
M6
4
14
14
2
4
2
4
8
4
1
4
1
1
6
2
2
1
5
6
4
4
3
2
1
1
1
1
4
4
18
10
10
24
10
24
10
60
39
20
15
52
30
10
7
7
10
10
10
20
10
4
5
43
43
17
70
10
10
1.8
1.0
1.0
2.4
1.0
2.4
1.0
6.0
3.9
2.0
1.5
5.2
3.0
1.0
0.7
0.7
1.0
1.0
1.0
2.0
1.0
0.4
0.5
4.3
4.3
1.7
7.0
1.0
1.0
13
7.2
7.2
17
7.2
17
7.2
43
28
14
11
37
22
7.2
5.1
5.1
7.2
7.2
7.2
14
7.2
2.9
3.6
31
31
12
50
7.2
7.2
Union bolt
M10
21
2.1
15
Union bolt
M8
18
1.8
13
Bolt
Bolt
Screw
M6
M6
M4
M33
2
3
4
1
10
10
2
2
1.0
1.0
0.2
0.2
7.2
7.2
1.4
1.4
2 - 21
Remarks
E
E
TIGHTENING TORQUES
Item
Intake manifold
Throttle body joint
Pressure regulator
Intake vacuum hose bracket
Intake air pressure sensor bracket 2
A.I.S. bracket
Resonator
Air cut-off valve assembly
Air cut-off valve assembly
Air filter case
Air filter case clamp
Front exhaust pipe
Rear exhaust pipe
Rear exhaust pipe joint cover
Rear exhaust pipe joint
Muffler
Muffler
Muffler clamp
Crankcase (cylinder head)
Crankcase (cylinder head)
Crankcase (transfer gear case)
Right crankcase
Right crankcase
Left crankcase
Crankshaft position sensor
Crankshaft position sensor lead
holder
Stator coil assembly
Stator coil assembly
Starter clutch
Generator cover
Generator rotor
Generator shaft
Generator shaft end cover
Crankshaft position sensor rotor
Clutch cover
Fastener
Thread
Qty
size
SPEC
Tightening torque
Nm
mkg
ftlb
Bolt
Screw
Bolt
Bolt
Bolt
Bolt
Screw
Bolt
Bolt
Bolt
Screw
Nut
Bolt
Screw
Nut
Bolt
Bolt
Bolt
Stud bolt
Stud bolt
Stud bolt
Bolt
Bolt
Bolt
Screw
M6
M4
M5
M6
M6
M5
M5
M8
M6
M6
M4
M8
M8
M6
M8
M10
M8
M8
M12
M10
M8
M8
M6
M6
M6
4
2
2
1
1
4
2
1
2
2
1
2
2
2
2
1
2
2
8
4
1
3
3
15
2
10
1.0
7.2
4
0.4
2.9
7
0.7
5.1
10
1.0
7.2
10
1.0
7.2
4
0.4
2.9
2
0.2
1.4
24
2.4
17
10
1.0
7.2
7
0.7
5.1
3
0.3
2.2
20
2.0
14
24
2.4
17
7
0.7
5.1
20
2.0
14
53
5.3
38
20
2.0
14
12
1.2
8.7
See NOTE *1.
See NOTE *2.
See NOTE *3.
24
2.4
17
10
1.0
7.2
10
1.0
7.2
7
0.7
5.1
Screw
M6
0.7
5.1
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
M6
M6
M8
M6
M12
M8
M6
M12
M6
3
1
6
11
1
1
2
1
11
7
10
24
10
130
28
10
100
10
0.7
1.0
2.4
1.0
13.0
2.8
1.0
10.0
1.0
5.1
7.2
17
7.2
94
20
7.2
72
7.2
Clutch boss
Nut
M20
85
8.5
61
Bolt
Bolt
M6
M6
M8
6
1
1
8
12
18
0.8
1.2
1.8
5.8
8.7
13
Nut
M22
100
10.0
72
2 - 22
Remarks
E
E
E
LT
LT
LT
LT
LT
LT
Use a lock
washer.
Use a lock
washer.
TIGHTENING TORQUES
Item
Fastener
Thread
Qty
size
SPEC
Tightening torque
Nm
mkg
ftlb
Cover
Cover
Oil tank left cover
Oil tank left cover
Oil strainer
Transfer gear case
Transfer gear case cover
Transfer gear oil checking bolt
Transfer gear oil pump cover
Transfer gear oil pump
Drive sprocket case
Drive sprocket case
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
M8
M6
M6
M6
M6
M8
M8
M6
M6
M6
M10
M10
2
5
16
3
1
4
1
1
2
3
3
5
24
10
10
10
10
30
30
8
10
10
50
50
2.4
1.0
1.0
1.0
1.0
3.0
3.0
0.8
1.0
1.0
5.0
5.0
17
7.2
7.2
7.2
7.2
22
22
5.8
7.2
7.2
36
36
Drive sprocket
Nut
M22
100
10.0
72
Bolt
Bolt
Nut
Bolt
Screw
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
M6
M6
M8
M8
M6
M5
M6
M6
M6
M5
M8
M12
M8
M6
M5
1
1
2
1
1
1
1
2
1
2
1
1
3
1
3
7
12
12
22
12
4
10
4
10
5
15
20
20
10
9
0.7
1.2
1.2
2.2
1.2
0.4
1.0
0.4
1.0
0.5
1.5
2.0
2.0
1.0
0.9
5.1
8.7
8.7
16
8.7
2.9
7.2
2.9
7.2
3.6
11
14
14
7.2
6.5
Remarks
Use a lock
washer.
LT
LT
NOTE:
*1:Do not tighten the engine temperature sensor and oil temperature sensor beyond the specified
torques.
*2:When installing the crankcase stud bolts (cylinder head), make sure that their installed length is
141.5 mm (5.57 in).
*3:When installing the crankcase stud bolts (transfer gear case), make sure that their installed
length is 69.3 mm (2.73 in).
2 - 23
TIGHTENING TORQUES
SPEC
Thread size
2 - 24
Tightening torque
Nm
mkg
ftlb
M8
M8
M28
26
23
115
2.6
2.3
11.5
19
17
85
M8
28
2.8
20
M30
M6
M4
M6
M8
M6
M12
M6
M10
4
7
2
7
7
23
7
40
10
32
0.4
0.7
0.2
0.7
0.7
2.3
0.7
4.0
1.0
3.2
2.9
5.1
1.4
5.1
5.1
17
5.1
29
7.2
23
M18
18
1.8
13
M10
48
4.8
35
M10
M12
M12
M10
M12
M10
M12
48
105
88
53
98
48
88
4.8
10.5
8.8
5.3
9.8
4.8
8.8
35
75
64
38
71
35
64
M10
63
6.3
45
M10
M10
M8
M6
M18
M12
M12
M10
M12
M6
M6
53
53
20
7
125
59
59
40
59
7
7
5.3
5.3
2.0
0.7
12.5
5.9
5.9
4.0
5.9
0.7
0.7
38
38
14
5.1
90
43
43
29
43
5.1
5.1
Remarks
See NOTE.
TIGHTENING TORQUES
Item
Thread size
2 - 25
SPEC
Tightening torque
Nm
mkg
ftlb
M10
M8
M6
M6
M8
M6
M8
M6
M6
M6
M6
M6
M6
M10
M12
M12
M10
M10
M6
40
23
7
10
19
10
16
4
13
7
7
7
7
63
122
88
48
48
10
4.0
2.3
0.7
1.0
1.9
1.0
1.6
0.4
1.3
0.7
0.7
0.7
0.7
6.3
12.2
8.8
4.8
4.8
1.0
29
17
5.1
7.2
7.2
7.2
11
2.9
9.4
5.1
5.1
5.1
5.1
45
88
64
35
35
7.2
M8
23
2.3
17
M8
M6
M10
M8
M18
M8
M18
M10
M10
M6
M8
M7
M12
M10
M8
M6
M8
23
7
30
16
72
23
150
40
27
18
6
6
95
30
16
13
16
23
2.3
0.7
3.0
1.6
7.2
2.3
15.0
4.0
2.7
1.8
0.6
0.6
9.5
3.0
1.6
1.3
1.6
2.3
17
5.1
22
11
52
17
110
29
19
13
4.3
4.3
68
22
11
9.4
11
17
Remarks
LT
TIGHTENING TORQUES
Item
Thread size
M6
M8
M8
M8
M6
SPEC
Tightening torque
Nm
mkg
ftlb
40
8
16
16
19
12
4.0
0.8
1.6
1.6
1.9
1.2
29
5.8
11
11
13
8.7
Remarks
NOTE:
1. First, tighten the ring nut approximately 52 Nm (5.2 m kg, 37 ft lb) by using the torque wrench,
then loosen the ring nut completely.
2. Retighten the ring nut to specification.
2 - 26
SPEC
EAS00031
2 - 27
Lubricant
LS
LS
E
M
E
E
E
E
E
M
E
E
M
E
E
E
E
E
E
E
E
E
E
M
E
M
E
E
LS
LS
LS
Sealant
(Quick Gasket)
Sealant
(Quick Gasket)
Sealant
(Quick Gasket)
SPEC
EAS00032
CHASSIS
Lubrication point
Steering bearings and bearing races (upper and lower)
Steering bearing cover
Steering head pipe lower oil seal
Front wheel oil seal (right and left)
Rear wheel oil seal
Rear wheel drive hub mating surface
Rear brake pedal shaft
Shift pedal
Rear footrest pivot
Sidestand sliding surface
Tube guide (throttle grip) inner surface
Brake lever pivot bolt, contact surface
Clutch lever pivot bolt, contact surface
Swingarm pivot shaft
Swingarm pivot bearing
Swingarm pivot oil seal
Relay arm bearing (inner)
Rear shock absorber bearing (inner)
Connecting rod bearing (inner)
2 - 28
Lubricant
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
SPEC
Pressure feed
Connecting rod
Valve stem
end
Rocker
arm
Crankshaft journal
(left)
Crank pin
Push
rod
Valve
lifter
Rear
camshaft
Push
rod
Valve
lifter
Front
camshaft
Front cylinder
Valve stem
end
Rocker
arm
Piston
Connecting rod
Crank pin
Crankshaft journal
(camshaft cover side)
Crankshaft journal
(right)
Clutch
Main axle gears
Bypass valve
Main axle
Oil pump
Check ball
Relief valve
Oil tank
Rotor 2
Rotor 1
Oil strainer
Drain bolt
2 - 29
Oil strainer
Drain bolt
SPEC
2
1
4
3
4
2 - 30
3
3
2 - 31
SPEC
SPEC
1
2
2 - 32
SPEC
2 - 33
SPEC
2 - 34
SPEC
2 - 35
CABLE ROUTING
SPEC
EB206000
CABLE ROUTING
1 Brake hose
2 Clutch cable
3 Rectifier/regulator
4 Rectifier/regulator lead
5 Rear brake light switch lead
6 Horn lead
7 Stator coil assembly lead
6
3
4
2 - 36
CABLE ROUTING
1 Clutch cable
2 Left handlebar switch lead
3 Right handlebar switch lead
4 Throttle cable 1
5 Throttle cable 2
6 Brake hose
SPEC
2 - 37
CABLE ROUTING
1 Throttle cables
2 Clutch cable
3 Atmospheric pressure sensor
4 Spark plug cap (ignition coil 1-L spark plug lead)
5 Horn lead
6 Crankshaft position sensor lead
7 Horn 2
8 Sidestand switch lead
9 Starter motor lead
0 Spark plug cap (ignition coil 2-L spark plug lead)
SPEC
3
4
0
5
2 - 38
CABLE ROUTING
SPEC
Fasten the engine stop switch lead, crankshaft position sensor lead, and horn lead with a plastic locking
tie.
Fasten the starter motor lead, and side stand switch lead with a plastic locking tie to the frame.
Fasten the starter motor lead, fuel tank drain hose, and fuel tank/air filter breather hose with a plastic band
to the frame.
Be sure not to pinch the fuel tank drain hose or the fuel tank/air filter breather hose.
Fasten the starter motor lead with the plastic clamp.
Clamp the clutch cable between the locknut and washer with a plastic clamp.
To the engine.
3
4
0
5
2 - 39
SPEC
CABLE ROUTING
1 Ignition coil 1
2 Atmospheric pressure sensor lead
3 Ignition coil 2
4 Ignition coil 2 lead
5 Rear brake light switch coupler
6 Rectifier/regulator lead and horn lead
7 Linear control valve lead
8 Ignition coil 1 lead
9 Fuel return hose
0 Fuel inlet hose
D
B
D
A
2
1
8
7
6
3
5
2 - 40
0
D-D
SPEC
CABLE ROUTING
1 Tail/brake light lead
2 Fuel pump lead
3 Sidestand switch lead
4 Starter motor lead
3
B
A-A
2 - 41
SPEC
CABLE ROUTING
Fasten the decompression solenoid lead, speed sensor lead, cylinder identification sensor lead, sidestand
switch lead, crankshaft position sensor lead, neutral switch lead, and fuel pump lead with a plastic band.
Position the gray mark on the starter motor lead at the center of the bolt. Fit the starter motor lead and sidestand switch lead into the groove in the frame, and then fasten them with a plastic locking tie.
10 ~ 30 mm (0.4 ~ 1.2 in)
3
B
A-A
2 - 42
SPEC
CABLE ROUTING
1 Fuse box
2 ECU lead
3 Battery
4 Starter motor lead
5 ECU ground lead
6 Fuel tank/air filter breather hose
7 Fuel tank/air filter drain hose
8 Regulator lead
9 Horn lead
0 Rear brake light switch lead
A Cut-off relay
B Turn signal relay
C Headlight relay
Clamp the fuel tank/air filter breather hose, and
fuel tank/air filter drain hose with a plastic clamp.
45 ~ 60 degrees
15 ~ 30 degrees
A
D
C
C
B
B
1
2
1
4 6
B-B
9 8
A
C-C
3
A-A
2 - 43
CABLE ROUTING
1 Roll over valve
2 Fuel tank breather hose
3 Fuel hose joint 1
4 Fuel hose
5 Fuel inlet hose
6 Fuel outlet hose
7 Fuel hose joint 2
8 Fuel hose
9 Fuel pump coupler
0 Sub fuel tank
SPEC
3
4
6
7
8
9
0
A
B
A
4
A
A-A
2 - 44
CABLE ROUTING
1 Oil temperature sensor
2 Fuel hose
3 Spark plug cap (ignition coil 1-R
spark plug lead)
4 Injector lead
5 Throttle position sensor lead
6 Intake air pressure sensor 1
7 Intake air temperature sensor
coupler
8 Intake air pressure sensor lead
8
6 7
45
3
9
0
B
A
A
B
A
F
E
2
A-A
H
B-B
SPEC
M
I
C-C
L
K
2 - 45
CABLE ROUTING
To the battery box.
Fasten the main wire harness, and fuel hose
with a plastic locking tie to the frame.
Fasten the main wire harness, and spark plug
lead #3 with a plastic locking tie to the frame.
Fasten the throttle position sensor lead, engine
temperature sensor lead, and injector lead with
a plastic locking tie to the fuel delivery pipe.
Fasten the main wire harness, and spark plug
lead #3 with a plastic locking tie.
9
0
Fasten the main wire harness, intake air pressure sensor lead #2, ignition coil 1-R spark plug
lead, and intake air temperature sensor coupler
with a plastic locking tie.
Fasten the rear brake light switch lead, and ignition coil lead #2 with a plastic band.
Fasten the main wire harness, and intake vacuum hose with a plastic locking tie.
8
6 7
45
A
A
B
A
F
E
2
A-A
H
B-B
SPEC
M
I
C-C
L
K
2 - 46
CABLE ROUTING
To the injector sub lead.
To the engine temperature sensor.
10 ~ 30 mm (0.4 ~ 1.2 in)
Position the gray mark on the stator coil lead at
the center of the bolt, and then fasten it with a
plastic locking tie.
To the stator coil.
To the decompression solenoid, and cylinder
identification sensor.
To the neutral switch.
9
0
8
6 7
45
A
A
B
A
F
E
2
A-A
H
B-B
SPEC
M
I
C-C
L
K
2 - 47
CABLE ROUTING
1 Ignition coil 2-R spark plug lead
2 Ignition coil 1-R spark plug lead
3 Main wire harness
4 Negative battery ground lead
5 Fuse box
6 Main fuse coupler
7 Positive battery lead
SPEC
8 ECU
9 Fuel hose
0 Ignition coil 1-L spark plug lead
A Ignition coil 2-L spark plug lead
40 ~ 60 mm (1.6 ~ 2.4 in)
1
A
0
2
9
4
5
8
6
7
2 - 48
CABLE ROUTING
1 Canister (California only)
2 Canister purge hose (California only)
3 Intake vacuum hose
4 Liner control valve inlet hose
5 Liner control valve outlet hose
6 Throttle position sensor
7 Fuel hose
8 Throttle stop screw
9 Fuel inlet hose
SPEC
0 Pressure regulator
A A.I.S. vacuum hose
B Silencer air filter case drain hose
2
1
3
4
B
5
A
7
6
0
7
9
8
2 - 49
CABLE ROUTING
SPEC
1
5
2
A-A
1
1
5
B
6
8
3 C
B-B
2
1
C
2 - 50
CHK
ADJ
EAS00036
1 *
2 *
ITEM
ODOMETER READINGS
600 mi
4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi
(1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
or
1 month 6 months 12 months 18 months 24 months 30 months
ROUTINE
Valve clearance
(See page 3-11.)
Spark plugs
(See page 3-20.)
Check condition.
Adjust gap and clean.
Replace at 8,000 mi (13,000 km) or
12 months and thereafter every 8,000 mi
(13,000 km) or 12 months.
Replace.
Replace.
4 *
Fuel line
(See page 3-37.)
5 *
Exhaust system
(See page 3-39.)
Electrical Fuel
6 * Injection System
(See page 3-15.)
Evaporative
Emission control
7 *
system (For
California only)
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
3-1
CHK
ADJ
ITEM
ROUTINE
TYPE
Engine oil
(See page 3-27.)
Change.
2 *
Replace.
3 *
Front brake
4 *
(See page 3-40.)
Rear brake
5 *
(See page 3-41.)
Clutch
(See page 3-35.)
7 *
8 *
Control cables
(See page 3-58.)
Lithium-soapbased grease
6 *
ODOMETER READINGS
600 mi
4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi
(1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
or
1 month 6 months 12 months 18 months 24 months 30 months
Replace
brake
fluid.
Replace
brake
fluid.
Check.
Change.
Repack.
10
Lubricate.
Apply grease lightly.
11
Lubricate.
Apply grease lightly.
12 *
Sidestand pivot
(See page 3-59.)
13 *
Sidestand switch
(See page 3-59.)
14 *
Front fork
(See page 3-52.)
15 *
Steering bearings
(See page 3-50.)
Repack.
16 *
Wheel bearings
(See page 4-4.)
3-2
1
2
3
ITEM
Rear suspension
17 * link pivots
(See page 4-86.)
18 *
Drive belt
(See page 3-47.)
ROUTINE
Lubricate.
Apply grease lightly.
Check belt tension.
Adjust if necessary.
TYPE
ODOMETER READINGS
600 mi
4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi
(1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
or
1 month 6 months 12 months 18 months 24 months 30 months
Lithium-soapbased grease
CHK
ADJ
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi
(7,000 km) or 6 months.
NOTE:
Air filters
This models air filters are equipped with disposable oil-coated paper elements, which must not
be cleaned with compressed air to avoid damaging them.
The air filter elements need to be replaced more frequently when riding in unusually wet or dusty
areas.
Hydraulic brake service
After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
_
3-3
CHK
ADJ
EAS00038
1
T.
R.
T.
R.
R.
T.
R.
R.
5
T.
R.
Order
1
2
3
4
5
6
Job/Part
Removing the seat and side covers
Seat
Cover
Tool kit
Left side cover 1
Left side cover 2
Right side cover
Qty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
For installation, reverse the removal
procedure.
3-4
CHK
ADJ
T.
R.
T.
R.
T.
R.
R.
2
3
1
Order
1
2
3
4
5
Job/Part
Removing the headlight and meter
assemblies
Headlight lens unit
Wire harness (in the headlight body)
Headlight body
Tachometer assembly
Speedometer assembly
Qty
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Disconnect.
3-5
BATTERY
CHK
ADJ
BATTERY
1
4
3
5
2
Order
1
2
3
4
5
6
Job/Part
Removing the battery
Seat
ECU
Battery cover
Negative battery lead
Positive battery lead
Battery
Belt
Qty
Remarks
Remove the parts in the order listed.
Refer to SEAT AND SIDE COVERS.
1
1
1
1
1
1
For installation, reverse the removal
procedure.
3-6
FUEL TANK
CHK
ADJ
FUEL TANK
T.
R.
5
3
4
T.
R.
(4)
Order
1
2
3
4
5
6
Job/Part
Removing the fuel tank
Seat
Air induction system cover
Air duct
Fuel hose joint 1
Fuel hose joint 2
Fuel tank breather hose
Fuel tank
Qty
1
1
1
1
2
1
Remarks
Remove the parts in the order listed.
Refer to SEAT AND SIDE COVERS.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
3-7
CHK
ADJ
EAS00043
T.
R.
T.
R.
2
(4)
1
4
Order
1
2
3
4
Job/Part
Removing the air filter case
Fuel tank
Air filter case
Air filter case cover
Air filter element
Air filter check hose
Qty
Remarks
Remove the parts in the order listed.
Refer to FUEL TANK.
1
1
1
1
For installation, reverse the removal
procedure.
3-8
CHK
ADJ
EAS00043
(4)
1
T.
R.
T.
R.
13
16
14
12
5
15
10
17
11
4
T.
R.
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the silencer air filter case
Air filter case
Silencer air filter case cover
Silencer air filter element
Silencer air filter case bracket
Cylinder head breather hose
Resonator
Silencer air filter case drain hose
Atmospheric pressure sensor coupler
Intake air temperature sensor coupler
Qty
1
1
1
1
1
1
1
1
3-9
Remarks
Remove the parts in the order listed.
Refer to AIR FILTER CASE.
Disconnect.
Disconnect.
Disconnect.
(4)
1
T.
R.
T.
R.
13
CHK
ADJ
16
14
12
5
15
10
17
11
4
T.
R.
Order
9
10
11
12
13
14
15
16
17
Job/Part
Intake air pressure sensor 1 coupler
Liner control valve inlet hose
Clamp screw
Atmospheric pressure sensor bracket
Atmospheric pressure sensor
Intake air pressure sensor 1
Intake air pressure sensor 1 bracket
Intake air temperature sensor
Silencer air filter case
Qty
Remarks
1
Disconnect.
1
Disconnect.
2
Loosen.
1
1
1
1
1
1
For installation, reverse the removal
procedure.
3 - 10
CHK
ADJ
EAS00047
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
The valve clearance is automatically
adjusted by the hydraulic valve lifter. However, there are times that the valve clearance
is needed to be adjusted manually. If this is
the case, adjust the clearance of the two
maladjusted or worn valves, of a rocker arm,
with the adjusting screw.
_
1
3
2.
3.
3 - 11
Disconnect:
spark plug caps 1
cylinder head breather hose 2
oil tank breather hose 3
Remove:
spark plugs
cylinder head covers (upper)
gaskets
dowel pins
CHK
ADJ
4. Remove:
engine left side cover 1
1
5. Remove:
timing mark accessing screw 1
crankshaft end cover 2
6. Remove:
decompression solenoid cover 1
camshaft sprocket cover 2
7. Measure:
valve clearance
Out of specification Adjust.
Valve clearance (cold)
Intake valve
0 ~ 0.04 mm (0 ~ 0.0016 in)
Exhaust valve
0 ~ 0.04 mm (0 ~ 0.0016 in)
3 - 12
CHK
ADJ
d
c
3 - 13
CHK
ADJ
8. Adjust:
valve clearance
1
2
Adjusting
screw side
Slip side
Direction a
Valve clearance is
increased.
Valve clearance is
decreased.
Direction b
Valve clearance is
decreased.
Valve clearance is
increased.
3
a
T.
Locknut
20 Nm (2.0 m kg, 14 ft lb)
R.
9. Install:
all moved parts
NOTE:
For installation, reverse the removal procedure. Note the following points.
****
3 - 14
CHK
ADJ
EAS00051
2. Remove:
seat
Refer to SEAT AND SIDE COVERS.
fuel tank
Refer to FUEL TANK.
air filter case
Refer to AIR FILTER CASE.
3.
4.
Remove:
hose 1
hose 2
Install:
carburetor synchronizer
inductive tachometer
(onto the spark plug lead of cylinder #1)
Carburetor synchronizer
YU-08030
Inductive tachometer
YU-8036-A
3 - 15
CHK
ADJ
7. Adjust:
throttle body synchronization
CAUTION:
Do not use the throttle valve adjusting
screws to adjust the throttle body synchronization.
Vacuum pressure at engine idling
speed
50 kPa (375 mm Hg, 14.8 in Hg)
NOTE:
The difference in vacuum pressure between
the two throttle bodies should not exceed
1.33 kPa (10 mm Hg, 0.4 in Hg).
_
8. Check:
engine idling speed
Out of specification Adjust.
9. Stop the engine and remove the measuring
equipment.
10.Adjust:
throttle cable free play
Refer to ADJUSTING THE THROTTLE
CABLE FREE PLAY.
Throttle cable free play (at the
flange of the throttle grip)
4 ~ 6 mm (0.16 ~ 0.24 in)
11.Install:
air filter case
Refer to AIR FILTER CASE.
fuel tank
Refer to FUEL TANK.
seat
Refer to SEAT AND SIDE COVERS.
3 - 16
CHK
ADJ
EAS00053
Direction a
Direction b
5. Adjust:
throttle cable free play
Refer to ADJUSTING THE THROTTLE
CABLE FREE PLAY.
Throttle cable free play (at the
flange of the throttle grip)
4 ~ 6 mm (0.16 ~ 0.24 in)
3 - 17
CHK
ADJ
EAS00058
1. Check:
throttle cable free play a
Out of specification Adjust.
Throttle cable free play (at the
flange of the throttle grip)
4 ~ 6 mm (0.16 ~ 0.24 in)
2. Adjust:
throttle cable free play
NOTE:
When the throttle is opened, the accelerator
cable 1 is pulled.
3 - 18
CHK
ADJ
NOTE:
Apply locking agend (LOCKTITE) to the
threads of the locknut 2.
e. Loosen the locknut 4 on the accelerator
cable.
f. Turn the adjusting nut 5 in direction a or
b until the specified throttle cable free play
is obtained.
Direction a
Direction b
Handlebar side
a. Loosen the locknut 6.
b. Turn the adjusting nut 7 in direction c or
d until the specified throttle cable free play
is obtained.
Direction c
Direction d
WARNING
_
3 - 19
CHK
ADJ
EAS00059
3. Remove:
spark plug
CAUTION:
_
4. Check:
spark plug type
Incorrect Change.
Spark plug type (manufacturer)
DPR7EA-9 (NGK)
X22EPR-U9 (DENSO)
3 - 20
CHK
ADJ
5. Check:
electrode 1
Damage/wear Replace the spark plug.
insulator 2
Abnormal color Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
spark plug gap a
(with a wire thickness gauge)
Out of specification Regap.
Spark plug gap
0.8 ~ 0.9 mm (0.0315 ~ 0.0354 in)
T.
R.
8. Install:
spark plug
NOTE:
Before installing the spark plug, clean the
spark plug and gasket surface.
_
9. Connect:
spark plug cap
10.Install:
silencer air filter case
Refer to SILENCER AIR FILTER CASE.
air filter case
Refer to AIR FILTER CASE.
fuel tank
Refer to FUEL TANK.
seat
Refer to SEAT AND SIDE COVERS.
3 - 21
CHK
ADJ
EAS00061
1. Remove:
engine left side cover 1
2. Remove:
timing mark accessing screw 1
3. Connect:
timing light 1
inductive tachometer 2
(onto the spark plug lead of cylinder #1)
Timing light
YM-33277-A
Inductive tachometer
YU-8036-A
4. Check:
ignition timing
a. Start the engine, warm it up for several minutes, and then let it run at the specified
engine idling speed.
Engine idling speed
850 ~ 950 r/min
b. Check that the mark a is within the
required firing range b on the timing.
Incorrect firing range Check the ignition
system.
NOTE:
The ignition timing is not adjustable.
_
3 - 22
6.
CHK
ADJ
Install:
timing mark accessing screw
Install:
engine left side cover
EAS00065
1. Measure:
valve clearance
Out of specification Adjust.
Refer to ADJUSTING THE VALVE
CLEARANCE.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Remove:
seat
Refer to SEAT AND SIDE COVERS.
fuel tank
Refer to FUEL TANK.
air filter case
Refer to AIR FILTER CASE.
silencer air filter case
Refer to SILENCER AIR FILTER CASE.
4. Remove:
camshaft sprocket cover
Refer to ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS in chapter 5.
decompression solenoid
Refer to CAMSHAFTS in chapter 5.
5. Install:
camshaft sprocket cover
Refer to ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS in chapter 5.
6. Disconnect:
spark plug cap
3 - 23
CHK
ADJ
7. Remove:
spark plug
CAUTION:
_
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it
from falling into the cylinders.
8. Install:
compression gauge set 14/18 mm 1
compression gauge adapter 12 mm 2
Compression gauge set 14/18 mm
YU-33223
Compression gauge adapter
12 mm
YU-33223-3
3 - 24
CHK
ADJ
Diagnosis
Higher than
without oil
Same as without
oil
T.
10.Install:
spark plug
18 Nm (1.8 m kg, 13 ft lb)
11.Connect:
spark plug cap
12.Remove:
camshaft sprocket cover
Refer to ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS in chapter 5.
13.Install:
decompression solenoid
Refer to CAMSHAFTS in chapter 5.
camshaft sprocket cover
Refer to ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS in chapter 5.
14.Install:
silencer air filter case
Refer to SILENCER AIR FILTER CASE.
air filter case
Refer to AIR FILTER CASE.
fuel tank
Refer to FUEL TANK.
seat
Refer to SEAT AND SIDE COVERS.
R.
3 - 25
CHK
ADJ
EAS00071
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Remove:
seat
Refer to SEAT AND SIDE COVERS.
4. Remove:
dipstick 1
5. Check:
engine oil level
The engine oil level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark Add the
recommended engine oil to the proper level.
NOTE:
Do not screw the dipstick in when inspecting
the oil level.
Recommended oil
Yamalube 4 (20W40) or
SAE 20W40 type SE motor oil
CAUTION:
_
3 - 26
CHK
ADJ
6. Install:
dipstick
7. Start the engine, warm it up for several minutes, and then turn it off.
8. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
_
9. Install:
seat
Refer to SEAT AND SIDE COVERS.
EAS00073
3 - 27
CHK
ADJ
CAUTION:
_
Make sure the O-ring 3 is positioned correctly in the groove of the oil filter cartridge.
c. Tighten the new oil filter cartridge to specification with an oil filter wrench.
T.
R.
6. Check:
engine oil drain bolt gasket
Damage Replace.
7. Install:
engine oil drain bolts
(along with the gasket)
T.
R.
3 - 28
CHK
ADJ
8. Fill:
oil tank
(with the specified amount of the recommended engine oil)
Quantity
Total amount
5.0 L (4.40 Imp qt, 5.29 US qt)
Without oil filter cartridge
replacement
3.7 L (3.26 Imp qt, 3.91 US qt)
With oil filter cartridge
replacement
4.1 L (3.61 Imp qt, 4.33 US qt)
NOTE:
Pour the engine oil in several stages.
First, pour in 2.5 L of oil and then start the
engine and rev it 3 to 5 times. Stop the
engine, and then pour in the remainder of the
specified amount.
_
CAUTION:
When starting the engine make sure the
dipstick is securely fitted into the oil tank.
3 - 29
CHK
ADJ
10.Install:
dipstick
11.Start the engine, warm it up for several minutes, and then turn it off.
12.Check:
engine
(for engine oil leaks)
13.Check:
engine oil level
Refer to CHECKING THE ENGINE OIL
LEVEL.
14.Check:
engine oil pressure
T.
R.
3 - 30
CHK
ADJ
EAS00077
CAUTION:
_
3. Remove:
oil gallery bolt 1
WARNING
_
4. Install:
oil pressure gauge 1
oil pressure adaptor E
Pressure gauge
YU-03153
Oil pressure adaptor E
YM-03129
3 - 31
CHK
ADJ
5. Measure:
engine oil pressure
(at the following conditions)
Engine oil pressure
40 ~ 80 kPa
(0.4 ~ 0.8 kg/cm2,
5.688 ~ 11.376 psi)
Engine speed
Approx. 900 r/min
Engine oil temperature
70 ~ 90 C (158 ~ 194 F)
Engine oil pressure
Possible causes
Below specification
Above specification
6. Install:
oil gallery bolt
T.
R.
2.
Remove:
muffler
rear exhaust pipe
front exhaust pipe
Refer to ENGINE in chapter 5.
3. Remove:
checking bolt 1
3 - 32
CHK
ADJ
4. Check:
transfer gear oil level
The transfer gear oil level should be up to
the brim 2 of the hole.
Below the brim Add the recommended
transfer gear oil to the proper level.
Recommended oil
SAE80API GL-4 Hypoid gear
oil
CAUTION:
Do not allow foreign materials to enter the
transfer case.
R.
Install:
checking bolt
8 Nm (0.8 m kg, 5.8 ft lb)
Install:
front exhaust pipe
rear exhaust pipe
muffler
Refer to ENGINE in chapter 5.
T.
5.
6.
3 - 33
CHK
ADJ
6. Install:
transfer gear oil drain bolt
T.
R.
7. Fill:
transfer gear case
(with the specified amount of the recommended transfer gear oil)
Quantity
Total amount
0.49 L (0.43 Imp qt, 0.52 US qt)
Periodic oil replacement
0.4 L (0.35 Imp qt, 0.42 US qt)
8.
9.
Install:
straight plug
Check:
transfer gear oil level
Refer to CHECKING THE TRANSFER
GEAR OIL LEVEL.
10.Install:
front exhaust pipe
rear exhaust pipe
muffler
Refer to ENGINE in chapter 5.
3 - 34
CHK
ADJ
EAS00078
Handlebar side
a. Pull the boot 1 off.
b. Loosen the locknut 2.
c. Turn the adjusting bolt 3 in direction a or
b until the specified clutch cable free play
is obtained.
Direction a
Direction b
Engine side
a. Loosen the locknut 4.
b. Turn the adjusting bolt 5 in direction c or
d until the specified clutch cable free play
is obtained.
Direction c
Direction d
3 - 35
CHK
ADJ
EAS00088
CAUTION:
_
Never operate the engine without the air filter 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 tuning, leading to poor
engine performance and possible overheating.
5. Install:
air filter case
Refer to AIR FILTER CASE.
fuel tank
Refer to FUEL TANK.
seat
Refer to SEAT AND SIDE COVERS.
3 - 36
CHK
ADJ
EAS00094
2. Check:
throttle body joint 1
Cracks/damage Replace.
3. Install:
silencer air filter case
Refer to SILENCER AIR FILTER CASE.
air filter case
Refer to AIR FILTER CASE.
fuel tank
Refer to FUEL TANK.
seat
Refer to SEAT AND SIDE COVERS.
EAS00096
3 - 37
CHK
ADJ
2. Check:
fuel hose 1
Cracks/damage Replace.
Loose connection Connect properly.
3. Install:
air induction system cover
Refer to FUEL TANK.
EAS00098
2. Check:
oil tank breather hose 1
cylinder head breather hose 2
Cracks/damage Replace.
Loose connection Connect properly.
CAUTION:
_
3 - 38
CHK
ADJ
EAS00099
93 3
5
1
3
6
T.
R.
3 - 39
CHK
ADJ
EAS00108
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Check:
brake lever free play a
Out of specification Adjust.
Brake lever free play (at the end
of the brake lever)
2 ~ 5 mm (0.08 ~ 0.20 in)
2. Adjust:
brake lever free play
Direction b
WARNING
_
CAUTION:
_
3 - 40
CHK
ADJ
EAS00110
2. Adjust:
brake pedal position
Direction a
Direction b
WARNING
_
d
c. Tighten the locknut 1 to specification.
T.
Locknut
16 Nm (1.6 m kg, 11 ft lb)
R.
WARNING
_
3 - 41
CHK
ADJ
CAUTION:
_
3. Adjust:
rear brake light switch
Refer to ADJUSTING THE REAR BRAKE
LIGHT SWITCH.
EAS00115
2. Check:
brake fluid level
Below the minimum level mark a Add
the recommended brake fluid to the proper
level.
WARNING
a
3 - 42
CHK
ADJ
CAUTION:
_
EAS00120
3 - 43
CHK
ADJ
EAS00128
1. Check:
rear brake light operation timing
Incorrect Adjust.
2. Adjust:
rear brake light operation timing
Direction b
EAS00131
3 - 44
CHK
ADJ
4. Check:
brake hose
Brake fluid leakage Replace the damaged hose.
Refer to FRONT AND REAR BRAKES in
chapter 4.
Front
Rear
EAS00134
WARNING
_
3 - 45
CHK
ADJ
1. Bleed:
hydraulic brake system
Front (right)
Front (left)
Rear
T.
Bleed screw
6 Nm (0.6 m kg, 4.3 ft lb)
R.
WARNING
_
3 - 46
CHK
ADJ
EAS00137
1. Measure:
installed shift rod length a
Incorrect Adjust.
Installed shift rod length
368 ~ 372 mm (14.49 ~ 14.65 in)
2. Adjust:
installed shift rod length a
Direction c
EAS00138
CAUTION:
_
3 - 47
CHK
ADJ
WARNING
_
3. Check:
drive belt slack a
Out of specification Adjust.
Drive belt slack
On the sidestand
6 ~ 8 mm at 4.5 kg
(0.24 ~ 0.31 in at 10 lbs)
On a suitable stand
7 ~ 9 mm at 4.5 kg
(0.28 ~ 0.35 in at 10 lbs)
NOTE:
The level marks of the level window on the
lower drive belt cover are in units of 5 mm
(0.20 in). Use them as a standard for measuring the drive belt slack.
Measure the drive belt slack when the drive
belt has been pushed with 4.5 kg (10 lbs) of
pressure using a belt tension gauge 1.
_
3 - 48
CHK
ADJ
4. Adjust:
drive belt slack
NOTE:
Place the motorcycle on the suitable stand so
that the rear wheel is elevated.
_
Right
Left
a
2
Direction a
Direction b
NOTE:
To maintain the proper wheel alignment, adjust
both sides evenly.
b
1
2
e. Tighten the locknuts to specification.
Locknut
16 Nm (1.6 m kg, 11 ft lb)
T.
R.
T.
R.
3 - 49
CHK
ADJ
EAS00146
WARNING
_
2. Check:
steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness Adjust the steering
head.
3. Remove:
tachometer
speedometer assembly
Refer to HEADLIGHT AND METER
ASSEMBLIES.
4. Loosen:
upper bracket pinch bolts 1
5. Remove:
steering stem nut 2
washer
upper bracket 3
3 - 50
CHK
ADJ
6. Adjust:
steering head
1
2
3
4
Spanner wrench
YU-33975
5
T.
R.
WARNING
_
T.
R.
1
2
3
3 - 51
CHK
ADJ
Install:
upper bracket
washer
steering stem nut
T.
R.
8. Tighten:
upper bracket pinch bolt
T.
R.
9. Install:
speedometer
tachometer
Refer to HEADLIGHT
ASSEMBLIES.
AND
METER
EAS00149
WARNING
_
2. Check:
inner tube
Damage/scratches Replace.
oil seal
Oil leakage Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement Repair.
Refer to FRONT FORK in chapter 4.
3 - 52
CHK
ADJ
EAS00152
WARNING
_
CAUTION:
_
Direction a
Spring preload is
increased (suspension
is harder).
Direction b
Spring preload is
decreased (suspension
is softer).
Adjusting positions
Minimum: 8
Standard: 5
Maximum: 1
3 - 53
CHK
ADJ
EAS00156
WARNING
_
CAUTION:
_
Direction a
Spring preload is
increased (suspension
is harder).
Direction b
Spring preload is
decreased (suspension
is softer).
Adjusting positions a
Minimum: 40.5 mm (1.59 in)
Standard: 42.5 mm (1.67 in)
Maximum: 51.5 mm (2.03 in)
CAUTION:
_
3 - 54
CHK
ADJ
EAS00166
WARNING
_
Cold tire
pressure
Front
Rear
250 kPa
(2.5 kgf/cm2,
36 psi)
250 kPa
(2.5 kgf/cm2,
36 psi)
250 kPa
90 kg ~ maxi(2.5 kgf/cm2,
mum load*
36 psi)
290 kPa
(2.9 kgf/cm2,
42 psi)
250 kPa
(2.5 kgf/cm2,
36 psi)
250 kPa
(2.5 kgf/cm2,
36 psi)
Up to 90 kg
load*
High-speed
riding
WARNING
_
3 - 55
CHK
ADJ
2. Check:
tire surfaces
Damage/wear Replace the tire.
Minimum tire tread depth
1.0 mm (0.04 in)
1 Tire tread depth
2 Sidewall
3 Wear indicator
WARNING
_
Tube wheel
Tubeless wheel
Tube or tubeless
tire
3 - 56
CHK
ADJ
Front tire
Manufacturer
Model
Size
BRIDGESTONE
120/70 ZR 18
M/C (59 W)
BT020FG
120/70 ZR 18
(59 W)
DUNLOP
120/70 ZR 18
M/C (59 W)
D220FST
120/70 ZR 18
(59 W)
Rear tire
Manufacturer
BRIDGESTONE
DUNLOP
Model
Size
BT020R
200/50 ZR 17
M/C (75 W)
200/50 ZR 17
(75 W)
D220ST
200/50 ZR 17
M/C (75 W)
200/50 ZR 17
(75 W)
WARNING
_
3 - 57
CHK
ADJ
EAS00168
WARNING
_
EAS00170
WARNING
_
3 - 58
CHK
ADJ
EAS00171
EAS00172
EAS00174
3 - 59
CHK
ADJ
EAS00178
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE
BATTERY
WARNING
_
CAUTION:
_
3 - 60
CHK
ADJ
NOTE:
Since MF batteries are sealed, it is not possible to check the charge state of the battery by
measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to
be checked by measuring the voltage at the
battery terminals.
_
1. Remove:
seat
Refer to SEAT AND SIDE COVERS.
2. Disconnect:
battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
3.
4.
Remove:
battery
Check:
battery charge
NOTE:
The charge state of an MF battery can be
checked by measuring its open-circuit voltage (i.e., the voltage when the positive battery terminal is disconnected).
No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
_
3 - 61
CHK
ADJ
5. Charge:
battery
(refer to the appropriate charging method
illustration)
WARNING
_
CAUTION:
_
Ambient
temperature
20 C (68 F)
3 - 62
CHK
ADJ
Charger
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
Ammeter
NOTE:
YES
YES
NO
Leave the battery unused for more than 30 minutes before measuring its
open-circuit voltage.
12.8 V Charging is complete.
12.0 ~ 12.7 V Recharging is required.
Under 12.0 V Replace the battery.
3 - 63
CHK
ADJ
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
YES
NO
NOTE:
Set the charging time to a maximum of 20 hours.
Charger
Leave the battery unused for more than 30
minutes before measuring its open-circuit
voltage.
12.8 V Charging is complete.
12.0 ~ 12.7 V Recharging is required.
Under 12.0 V Replace the battery.
Voltmeter
CAUTION:
3 - 64
Ammeter
CHK
ADJ
6. Install:
battery
Refer to BATTERY.
7. Connect:
battery leads
(to the battery terminals)
CAUTION:
8. Check:
battery terminals
Dirt Clean with a wire brush.
Loose connection Connect properly.
9. Lubricate:
battery terminals
Recommended lubricant
Dielectric grease
10.Install:
seat
Refer to SEAT AND SIDE COVERS.
EAS00181
CAUTION:
_
3 - 65
CHK
ADJ
1. Remove:
seat
Refer to SEAT AND SIDE COVERS.
2. Check:
fuse
Pocket tester
YU-03112
b. If the pocket tester indicates , replace
the fuse.
3 - 66
CHK
ADJ
3. Replace:
blown fuse
Amperage
rating
Qty
Main
30 A
Headlight
15 A
Signaling system
10 A
Ignition
10 A
Fuel injection
system
15 A
ECU
10 A
Decompression
solenoid
15 A
Backup (odometer
and clock)
7.5 A
Reserve
30 A
Reserve
15 A
Reserve
10 A
Reserve
7.5 A
WARNING
_
4. Install:
seat
Refer to SEAT AND SIDE COVERS.
3 - 67
CHK
ADJ
EAS00182
2.
3.
Disconnect:
headlight coupler 1
Remove:
headlight bulb holder cover 2
4.
5.
Detach:
headlight bulb holder 1
Remove:
headlight bulb 2
WARNING
_
CAUTION:
_
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be
adversely affected. If the headlight bulb
gets soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
3 - 68
CHK
ADJ
7. Attach:
headlight bulb holder
8. Install:
headlight bulb holder cover
9. Connect:
headlight coupler
10.Install:
headlight lens unit
screws
EAS00184
Headlight beam is
raised.
Direction b
2. Adjust:
headlight beam (horizontally)
Direction b
3 - 69
INSTRUMENT FUNCTIONS
CHK
ADJ
INSTRUMENT FUNCTIONS
ODOMETER AND TRIPMETER
1 Tachometer
2 Clock
3 Odometer/trip meter/fuel reserve trip meter
4 RESET button
5 SELECT button
Pushing the SELECT button switches the display between the odometer mode ODO and
the tripmeter modes TRIP 1 and TRIP 2 in
the following order:
ODO TRIP 1 TRIP 2 ODO
If the fuel level warning light comes on, the
odometer display will automatically change to
the fuel reserve tripmeter mode TRIP F and
start counting the distance traveled from that
point. In that case, pushing the SELECT button switches the display between the various
tripmeter and odometer modes in the following
order:
TRIP F TRIP 1 TRIP 2 ODO
TRIP F
To reset a tripmeter, select it by pushing the
SELECT button, and then push the RESET
button for at least one second. If you do not
reset the fuel reserve tripmeter manually, it will
reset itself automatically and the display will
return to the prior mode after refueling and
traveling 5 km (3 mi).
3 - 70
INSTRUMENT FUNCTIONS
CHK
ADJ
EAS00187
1. Adjust:
clock
3 - 71
CHAS
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS
1
T.
R.
3
2
4
1
T.
R.
T.
R.
6
T.
R.
LT
(6)
T.
R.
T.
R.
8
LT
(6)
10
8
T.
R.
Order
9
10
Job/Part
Qty
Remarks
Removing the front wheel and brake
Remove the parts in the order listed.
discs
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
_
1
2
3
4
5
6
7
2
2
2
2
2
1
1
4-1
CHAS
T.
R.
3
2
4
1
T.
R.
T.
R.
6
T.
R.
LT
(6)
T.
R.
T.
R.
8
LT
(6)
10
8
T.
R.
Order
8
9
10
Job/Part
Collar (left and right)
Front wheel
Brake disc (left and right)
9
10
Qty
Remarks
2
Refer to INSTALLING THE FRONT
1
WHEEL.
2
For installation, reverse the removal
procedure.
4-2
CHAS
LS
New 1
LS
Order
1
2
3
Job/Part
Disassembling the front wheel
Oil seal (left and right)
Wheel bearing (left and right)
Spacer
Qty
1 New
Remarks
Remove the parts in the order listed.
2
2
1
For assembly, reverse the disassembly
procedure.
4-3
CHAS
EAS00521
WARNING
_
2. Remove:
left brake caliper
right brake caliper
NOTE:
Do not apply the brake lever when removing
the brake calipers.
_
3. Elevate:
front wheel
NOTE:
Place the motorcycle on a suitable stand so
that the front wheel is elevated.
_
EAS00525
WARNING
_
4-4
CHAS
3. Measure:
radial wheel runout 1
lateral wheel runout 2
Over the specified limits Replace.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4. Check:
wheel bearings
Front wheel turns roughly or is loose
Replace the wheel bearings.
oil seals
Damage/wear Replace.
5. Replace:
wheel bearings
oil seals New
2
New 1
New
CAUTION:
_
4-5
CHAS
EAS00531
3. Measure:
brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification Replace.
Brake disc thickness limit
(minimum)
Front: 4.5 mm (0.18 in)
Rear: 5.5 mm (0.22 in)
4-6
CHAS
4. Adjust:
brake disc deflection
T.
R.
EAS00544
T.
NOTE:
Apply locking agent (LOCTITE 648) to the
threads of the brake disc bolts.
Tighten the brake disc bolts in stages and in
a crisscross pattern.
4-7
CHAS
2. Lubricate:
wheel axle
oil seal lips
Recommended lubricant
Lithium-soap-based grease
3.
4.
Install:
collars
front wheel
front wheel axle
Tighten:
front wheel axle 1
T.
R.
T.
R.
CAUTION:
_
Install:
spacer
front fork guard (left and right)
front fork guard bolts
T.
R.
NOTE:
When installing the front fork guards, make
sure that there is not dirt between the guard
and the front fork.
_
6. Install:
brake calipers
T.
R.
WARNING
_
4-8
CHAS
EAS00549
1.
2.
Remove:
balancing weight(s)
Find:
front wheels heavy spot
NOTE:
Place the front wheel on a suitable balancing
stand.
_
4-9
CHAS
3. Adjust:
front wheel static balance
4. Check:
front wheel static balance
4 - 10
CHAS
EAS00550
T.
R.
R.
1
T.
R.
T.
R.
Order
1
2
3
Job/Part
Removing the rear fender
Seat
Tail sub-wire harness coupler
Rear fender assembly
Rear fender bracket (left and right)
Qty
1
1
2
Remarks
Remove the parts in the order listed.
Refer to SEAT AND SIDE COVERS in
chapter 3.
Disconnect.
Refer to INSTALLING THE
REAR WHEEL.
For installation, reverse the removal
procedure.
4 - 11
CHAS
T.
R.
T.
R.
T.
R.
16
1
11
10
8
9
2
12
13
15
T.
R.
T.
R.
15
14
Order
Job/Part
Removing the rear wheel
Qty
Remarks
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
_
1
2
3
4
5
6
7
1
1
1
1
2
2/2
2
4 - 12
CHAS
T.
R.
T.
R.
T.
R.
16
1
11
10
8
9
2
12
13
15
T.
R.
T.
R.
15
14
Order
8
9
10
11
12
13
14
15
16
Job/Part
Locknut (left and right)
Adjusting bolt (left and right)
Wheel axle nut
Right adjusting plate
Left adjusting plate
Rear wheel axle
Rear wheel
Collar (left and right)
Brake caliper bracket
Qty
Remarks
2
Loosen.
2
Loosen.
1
1
Refer to REMOVING THE
1
REAR WHEEL and INSTALLING THE REAR WHEEL.
1
1
2
1
For installation, reverse the removal
procedure.
4 - 13
CHAS
EAS00556
Order
1
2
3
4
5
6
7
Job/Part
Removing the brake disc and rear
wheel pulley
Brake disc cover
Brake disc
Rear wheel pulley
Oil seal
Circlip
Rear wheel drive hub
Circlip
Qty
1
1
1
1
1
1
1
4 - 14
Remarks
Remove the parts in the order listed.
Order
8
9
10
11
12
13
Job/Part
Collar
Bearing
Collar
Bearing
Rear wheel drive hub damper
Rear wheel
Qty
1
1
1
1
6
1
CHAS
Remarks
4 - 15
CHAS
EAS00560
Order
1
2
3
4
5
Job/Part
Disassembling the rear wheel
Oil seal
Bearing
Spacer
Bearing
Rear wheel
Qty
1
1
1
2
1
Remarks
Remove the parts in the order listed.
Refer to ASSEMBLING THE REAR
WHEEL.
4 - 16
CHAS
EAS00561
WARNING
_
2. Remove:
brake caliper
NOTE:
Do not depress the brake pedal when removing the brake caliper.
_
3.
4.
Loosen:
locknuts
adjusting nuts
Remove:
wheel axle nut
wheel axle
rear wheel
NOTE:
Push the rear wheel forward and remove the
drive belt from the rear wheel pulley.
_
EAS00565
4 - 17
CHAS
EAS00567
EAS00568
T.
R.
NOTE:
Tighten the self-locking nuts in stages and in a
crisscross pattern.
_
4 - 18
CHAS
EAS00572
2. Install:
rear wheel drive hub dampers 1
3. Install:
rear wheel drive hub assembly 1
4. Install:
rear wheel pulley 1
T.
R.
NOTE:
Tighten the self-locking nuts in stages and in a
crisscross pattern.
Install the rear wheel pulley with its wider
spokes situated on top of the rear wheel
spokes.
5. Install:
brake disc
brake disc cover
NOTE:
Apply locking agent (LOCTITE 648) to the
threads of the brake disc bolts.
Tighten the brake disc bolts in stages and in
a crisscross pattern.
4 - 19
CHAS
Install:
brake caliper bracket 1
washer
brake caliper bracket bolt 2
NOTE:
Temporarily tighten the brake caliper bracket
bolt.
7.
Install:
collars
rear wheel
adjusting plates
rear wheel axle
washer
wheel axle nut
NOTE:
Temporarily tighten the wheel axle nut.
8. Adjust:
drive belt slack
Refer to ADJUSTING THE DRIVE BELT
SLACK in chapter 3.
9. Tighten:
wheel axle nut
T.
R.
R.
10.Install:
brake pad springs
brake pad shims
brake pads
pin boots
11.Install:
brake caliper 1
T.
R.
4 - 20
CHAS
12.Install:
upper drive belt cover plate 1
T.
R.
R.
13.Install:
rear fender bracket 1
T.
R.
14.Install:
rear fender assembly 1
15.Connect:
tail sub-wire harness coupler 2
16.Install:
seat
Refer to SEAT AND SIDE COVERS in
chapter 3.
4 - 21
CHAS
EAS00575
1. Adjust:
rear wheel static balance
Refer to FRONT WHEEL AND BRAKE
DISCS.
4 - 22
CHAS
EAS00577
T.
R.
T.
R.
5
5
6
3
4
2
Order
1
2
3
4
5
6
Job/Part
Removing the front brake pads
Qty
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
2
2
1
1
2
2
For installation, reverse the removal
procedure.
4 - 23
CHAS
EAS00578
T.
R.
5
4
4
1
5
T.
R.
Order
1
2
3
4
5
Job/Part
Removing the rear brake pads
Brake caliper retaining bolt
Brake caliper
Brake pad
Brake pad shim
Brake pad spring
Qty
Remarks
Remove the parts in the order listed.
2
1
2
2
2
For installation, reverse the removal
procedure.
4 - 24
CHAS
EAS00579
CAUTION:
_
EAS00580
1
1
2
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
_
1. Remove:
brake caliper bolts 1
brake caliper 2
4 - 25
1
1
CHAS
Remove:
brake pad clips 1
brake pad pin 2
brake pad spring 3
2
3
3. Remove:
brake pads 1
(along with the brake pad shims)
brake pad shims
4. Measure:
brake pad wear limit a
Out of specification Replace the brake
pads as a set.
Brake pad wear limit
0.5 mm (0.02 in)
5. Install:
brake pad shims
(onto the brake pads)
brake pads
brake pad spring
NOTE:
Always install new brake pads and a new
brake pad spring as a set.
_
T.
R.
4 - 26
Bleed screw
6 Nm (0.6 m kg, 4.3 ft lb)
CHAS
6. Install:
brake caliper
brake caliper bolts
T.
R.
7. Check:
brake fluid level
Below the minimum level mark a Add
the recommended brake fluid to the proper
level.
Refer to CHECKING THE BRAKE FLUID
LEVEL in chapter 3.
8. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
EAS00583
1. Remove:
brake caliper retaining bolts 1
brake caliper 2
4 - 27
CHAS
2. Remove:
brake pads 1
(along with the brake pad shims)
brake pad springs
3. Measure:
brake pad wear limit a
Out of specification Replace the brake
pads as a set.
4. Install:
brake pad springs
brake pad shims
(onto the brake pads)
brake pads
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
_
4 3
3
T.
Bleed screw
6 Nm (0.6 m kg, 4.3 ft lb)
R.
4 - 28
CHAS
5. Install:
brake caliper retaining bolt 1
6. Check:
brake fluid level
Below the minimum level mark a Add
the recommended brake fluid to the proper
level.
Refer to CHECKING THE BRAKE FLUID
LEVEL in chapter 3.
7. Check:
brake pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
4 - 29
CHAS
EAS00584
Order
1
2
3
4
5
6
Job/Part
Removing the front brake master
cylinder
Brake fluid
Rear view mirror (right)
Brake master cylinder reservoir cap
Brake master cylinder reservoir
diaphragm holder
Brake master cylinder reservoir
diaphragm
Brake lever
Brake lever spring
Qty
Remarks
Remove the parts in the order listed.
Drain.
1
1
1
1
1
1
4 - 30
Order
7
8
9
10
11
12
13
Job/Part
Front brake light switch connector
Union bolt
Brake hose
Copper washer
Brake master cylinder holder
Brake master cylinder
Front brake light switch
CHAS
Qty
Remarks
2
Disconnect. Refer to REMOVING THE
1
FRONT BRAKE MASTER
1
Disconnect. CYLINDER and ASSEMBLING AND INSTALLING
2
THE FRONT BRAKE MAS1
TER CYLINDER.
1
1
For installation, reverse the removal
procedure.
4 - 31
CHAS
EAS00585
Order
1
2
3
4
Job/Part
Disassembling the front brake
master cylinder
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder
Qty
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER.
For assembly, reverse the disassembly
procedure.
4 - 32
CHAS
EAS00586
2
3
4
5
1
6
T.
R.
Order
1
2
3
4
5
6
Job/Part
Removing the brake fluid reservoir
Brake fluid
Brake fluid reservoir cover
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir
Brake fluid reservoir hose
Qty
Remarks
Remove the parts in the order listed.
Drain.
1
1
1
1
1
1
For installation, reverse the removal
procedure.
4 - 33
CHAS
7
6
T.
R.
13
5
T.
R.
10
3 New
2
T.
R.
T.
R.
R.
Order
11
12
1
2
3
4
Job/Part
Removing the rear brake master
cylinder
Brake master cylinder cover
Union bolt
Copper washer
Brake hose
5
6
7
8
Qty
1
1
2
1
1
1
2
1
4 - 34
Remarks
Remove the parts in the order listed.
Refer to REMOVING THE
REAR BRAKE MASTER
CYLINDER and ASSEMDisconnect. BLING AND INSTALLING
THE REAR BRAKE MASTER CYLINDER.
Disconnect.
CHAS
7
6
T.
R.
13
T.
R.
10
3 New
2
T.
R.
T.
R.
R.
Order
9
10
11
12
13
11
12
Job/Part
Cotter pin
Pin
Brake rod
Locknut
Brake master cylinder
Qty
1
1
1
1
1
Remarks
4 - 35
CHAS
EAS00587
1
2 New
4
3
Order
1
2
3
4
5
6
7
Job/Part
Disassembling the rear brake
master cylinder
Dust boot
Circlip
Brake master cylinder kit
Circlip
Brake hose joint
O-ring
Brake master cylinder
Qty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
4 - 36
CHAS
EAS00588
1.
Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
_
EAS00589
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
EAS00592
Front
Rear
4 - 37
2. Check:
brake master cylinder kit
Damage/scratches/wear Replace.
CHAS
Front
Rear
1
2
3. Check:
rear brake fluid reservoir 1
Cracks/damage Replace.
rear brake fluid reservoir diaphragm 2
Cracks/damage Replace.
4. Check:
front brake master cylinder reservoir 1
Cracks/damage Replace.
front brake master cylinder reservoir diaphragm 2
Damage/wear Replace.
5. Check:
brake hoses
Cracks/damage/wear Replace.
EAS00598
WARNING
_
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake
components.
Recommended brake fluid
DOT 4
4 - 38
CHAS
1. Install:
brake master cylinder
brake master cylinder holder 1
T.
R.
NOTE:
Install the brake master cylinder holder with
the UP mark facing up.
Align the end of the brake master cylinder
holder with the punch mark a on the handlebar.
First, tighten the upper bolt, then the lower
bolt.
_
Install:
copper washers New
brake hose
union bolt
32 Nm (3.2 m kg, 23 ft lb)
T.
R.
2.
WARNING
_
3. Fill:
brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
4 - 39
CHAS
WARNING
_
CAUTION:
_
5. Check:
brake fluid level
Below the minimum level mark a Add
the recommended brake fluid to the proper
level.
Refer to CHECKING THE BRAKE FLUID
LEVEL in chapter 3.
6. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
4 - 40
CHAS
EAS00608
1 New
T.
WARNING
_
CAUTION:
_
2. Fill:
brake fluid reservoir
(to the maximum level mark)
Recommended brake fluid
DOT 4
WARNING
_
CAUTION:
_
4 - 41
CHAS
3. Bleed:
brake system
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
4. Check:
brake fluid level
Below the minimum level mark a Add
the recommended brake fluid to the proper
level.
Refer to CHECKING THE BRAKE FLUID
LEVEL in chapter 3.
5. Adjust:
brake pedal position a
Refer to ADJUSTING THE REAR BRAKE
in chapter 3.
Brake pedal position (from the
top of the rider footrest to the top
of the brake pedal)
80 mm (3.2 in)
6. Adjust:
rear brake light operation timing
Refer to ADJUSTING THE REAR BRAKE
LIGHT SWITCH in chapter 3.
4 - 42
CHAS
EAS00613
T.
R.
5
2 New
1
T.
R.
Order
Job/Part
Removing the front brake calipers
Qty
1
2
3
4
5
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper bolt
Brake caliper
1
2
1
2
1
4 - 43
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Refer to FRONT WHEEL AND BRAKE
DISCS.
Drain.
Refer to DISASSEMBLING THE FRONT
Disconnect. BRAKE CALIPERS and
ASSEMBLING AND
INSTALLING THE FRONT
BRAKE CALIPERS.
For installation, reverse the removal
procedure.
CHAS
EAS00615
T.
7 New
R.
6
New 7
New 7
6
2
New 7
5
3
4
4
5
Order
Job/Part
Disassembling the front brake
calipers
Qty
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
1
2
3
4
5
6
7
8
2
1
1
2
2
4
8
1
4 - 44
CHAS
EAS00616
T.
R.
1
3
New 2
5
4
4
8
1
2
3
4
5
Job/Part
Removing the rear brake caliper
Union bolt
Copper washer
Brake hose
Brake caliper retaining bolt
Brake caliper
6
7
8
Brake pad
Brake pad shim
Brake pad spring
Qty
1
2
1
2
1
R.
Order
T.
Remarks
Remove the parts in the order listed.
Refer to DISASSEMBLING THE REAR BRAKE
Disconnect. CALIPER and ASSEMBLING AND INSTALLING
THE REAR BRAKE CALIPER.
2
2
2
For installation, reverse the removal
procedure.
4 - 45
CHAS
EAS00617
T.
R.
2 New
1
Order
1
2
3
Job/Part
Disassembling the rear brake
caliper
Brake caliper piston
Brake caliper piston seal
Bleed screw
Qty
1
2
1
Remarks
Remove the parts in the order listed.
Refer to DISASSEMBLING THE REAR
BRAKE CALIPER.
For assembly, reverse the disassembly
procedure.
4 - 46
CHAS
EAS00625
1.
Remove:
union bolt 1
copper washers 2
brake hose
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
_
2. Remove:
brake caliper pistons 1
brake caliper piston seals 2
WARNING
_
4 - 47
CHAS
EAS00627
1.
Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
_
3
2
2. Remove:
brake caliper piston
brake caliper piston seals
WARNING
_
4 - 48
CHAS
EAS00633
If necessary
Piston seals
Brake hoses
Brake fluid
1. Check:
brake caliper pistons 1
Rust/scratches/wear Replace the brake
caliper pistons.
brake caliper cylinders 2
Scratches/wear Replace the brake caliper assembly.
brake caliper body
Cracks/damage Replace the brake caliper assembly.
brake fluid delivery passages
(brake caliper body)
Obstruction Blow out with compressed
air.
WARNING
_
2
Front
Rear
2. Check:
rear brake caliper bracket 1
Cracks/damage Replace.
4 - 49
CHAS
EAS00638
WARNING
_
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4
T.
1. Install:
brake caliper 1
(temporarily)
copper washers 2 New
brake hose 3
union bolt 4
32 Nm (3.2 m kg, 23 ft lb)
R.
WARNING
_
CAUTION:
_
4 - 50
CHAS
Install:
brake pads
brake pad spring
brake caliper bolt
T.
R.
R.
4. Fill:
brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
_
CAUTION:
_
4 - 51
CHAS
6. Check:
brake fluid level
Below the minimum level mark a Add
the recommended brake fluid to the proper
level.
Refer to CHECKING THE BRAKE FLUID
LEVEL in chapter 3.
7. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
EAS00642
WARNING
_
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4
4 - 52
R.
2 New
1. Install:
brake caliper 1
(temporarily)
copper washers 2 New
brake hose 3
union bolt 4
30 Nm (3.0 m kg, 22 ft lb)
T.
CHAS
WARNING
_
CAUTION:
_
2.
3.
Remove:
brake caliper
Install:
brake pad springs
brake pad
brake caliper
brake caliper retaining bolts
T.
R.
4 - 53
CHAS
4. Fill:
brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
_
CAUTION:
_
5. Bleed:
brake system
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
6. Check:
brake fluid level
Below the minimum level mark a Add
the recommended brake fluid to the proper
level.
Refer to CHECKING THE BRAKE FLUID
LEVEL in chapter 3.
7. Check:
brake pedal operation
Soft or spongy feeling Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
4 - 54
FRONT FORK
CHAS
EAS00647
FRONT FORK
T.
R.
T.
R.
3
2
4
5
T.
R.
T.
R.
1
T.
R.
Order
Job/Part
Removing the front fork legs
Qty
Front wheel
1
2
3
4
5
6
Front fender
Upper bracket pinch bolt
Cap bolt
Turn signal light bracket pinch bolt
Lower bracket pinch bolt
Front fork leg
1
2
1
1
2
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
Refer to FRONT WHEEL AND BRAKE
DISCS.
Loosen.
Refer to REMOVING THE
Loosen.
FRONT FORK LEGS and
Loosen.
INSTALLING THE FRONT
Loosen.
FORK LEGS.
For installation, reverse the removal
procedure.
4 - 55
FRONT FORK
CHAS
EAS00648
Order
1
2
3
4
5
6
7
8
Job/Part
Disassembling the front fork legs
Cap bolt
O-ring
Spacer
Nut
Spring seat
Fork spring
Outer tube
Dust seal
Qty
1
1
1
1
1
1
1
1
4 - 56
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
FRONT FORK
Order
9
0
A
B
C
D
E
Job/Part
Oil seal clip
Oil seal
Washer
Damper rod assembly bolt
Copper washer
Damper rod assembly
Inner tube
CHAS
Qty
Remarks
1
1
1
Refer to DISASSEMBLING THE FRONT
1 FORK LEGS and ASSEMBLING THE
FRONT FORK LEGS.
1
1
1
For assembly, reverse the disassembly
procedure.
4 - 57
FRONT FORK
CHAS
EAS00649
WARNING
_
2.
Loosen:
upper bracket pinch bolts 1
cap bolt 2
turn signal light bracket pinch bolt 3
lower bracket pinch bolts 4
WARNING
_
3. Remove:
front fork leg
4
EAS00655
4 - 58
FRONT FORK
CHAS
NOTE:
Use the side of the rod holder that is marked
B.
_
WARNING
_
2. Drain:
fork oil
NOTE:
Stroke the damper rod 1 several times while
draining the fork oil.
_
3.
Remove:
dust seal
oil seal clip 1
oil seal
washer
(with a flat-head screwdriver)
CAUTION:
_
4 - 59
FRONT FORK
CHAS
4. Remove:
damper rod assembly bolt
copper washer
NOTE:
While holding the damper rod with the damper
rod holder 1, loosen the damper rod assembly bolt.
_
EAS00657
WARNING
_
2. Measure:
spring free length a
Out of specification Replace.
Spring free length
296 mm (11.65 in)
<Limit>: 291 mm (11.46 in)
4 - 60
FRONT FORK
CHAS
3. Check:
damper rod 1
Damage/wear Replace.
Obstruction Blow out all of the oil passages with compressed air.
CAUTION:
_
4. Check:
cap bolt O-ring
Damage/wear Replace.
4 - 61
FRONT FORK
CHAS
EAS00660
WARNING
_
1. Install:
damper rod assembly 1
CAUTION:
_
2. Tighten:
damper rod assembly bolt 1
T.
R.
NOTE:
While holding the damper rod assembly with
the damper rod holder 2, tighten the damper
rod assembly bolt.
_
4 - 62
FRONT FORK
3.
CHAS
Install:
dust seal 1
oil seal clip 2
oil seal 3
washer 4
CAUTION:
_
4. Install:
outer tube
(onto the inner tube)
5. Install:
washer
oil seal 1
(with the fork seal driver 2)
Fork seal driver
YM-01442
6. Install:
oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the
outer tubes groove.
_
4 - 63
FRONT FORK
CHAS
7. Install:
dust seal 1
(with the fork seal driver 2)
8. Install:
rod puller 1
(onto the damper rod 2)
Rod puller
YM-01437
CAUTION:
_
4 - 64
FRONT FORK
CHAS
14.Measure:
front fork leg oil level a
Out of specification Correct.
Front fork leg oil level (from the
top of the outer tube and damper
rod, with the outer tube fully compressed, and without the spring)
100 mm (3.94 in)
4 - 65
FRONT FORK
CHAS
15.Install:
nut 1
fork spring 2
spring seat 3
spacer 4
cap bolt 5
T.
R.
4 - 66
Nut
15 Nm (1.5 m kg, 11 ft lb)
FRONT FORK
CHAS
CAUTION:
_
16.Install:
cap bolt
(onto the outer tube)
NOTE:
Temporary tighten the cap bolt.
_
EAS00662
2. Tighten:
lower bracket pinch bolts 1
T.
R.
R.
T.
cap bolt 3
23 Nm (2.3 m kg, 17 ft lb)
upper bracket pinch bolts 4
R.
T.
R.
WARNING
_
4 - 67
FRONT FORK
CHAS
3. Adjust:
spring preload
Refer to ADJUSTING THE FRONT FORK
LEGS in chapter 3.
4 - 68
HANDLEBAR
CHAS
EAS00664
HANDLEBAR
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the handlebar
Rear view mirror (left and right)
Plastic clamp
Front brake light switch connector
Brake master cylinder holder
Brake master cylinder
Right handlebar switch
Throttle cable holder
Throttle cable
Throttle grip
Clutch switch coupler
Qty
2
6
2
1
1
1
1
2
1
1
4 - 69
Remarks
Remove the parts in the order listed.
Disconnect.
HANDLEBAR
Order
11
12
Job/Part
Left handlebar switch
Handlebar grip
13
14
15
16
17
Clutch cable
Clutch lever holder
Upper handlebar holder
Handlebar
Lower handlebar holder
CHAS
Qty
Remarks
1
1
Refer to REMOVING THE HANDLEBAR.
Refer to INSTALL1
Disconnect.
ING THE HANDLE1
BAR.
2
1
2
For installation, reverse the removal
procedure.
4 - 70
HANDLEBAR
CHAS
EAS00666
WARNING
_
2. Remove:
handlebar grip 1
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
_
EAS00668
WARNING
_
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
EAS00670
WARNING
_
2. Install:
washers
lower handlebar holders 1
NOTE:
Temporarily tighten the nuts 2.
_
4 - 71
HANDLEBAR
CHAS
3. Install:
handlebar 1
upper handlebar holders 2
T.
R.
CAUTION:
_
4. Tighten:
lower handlebar holder nuts
T.
R.
5. Install:
clutch lever holder
NOTE:
Align the slit of clutch lever holder with the
punch mark a on the handlebar.
_
6. Install:
clutch cable
NOTE:
Lubricate the end of the clutch cable with a thin
coat of lithium soap base grease.
_
4 - 72
HANDLEBAR
CHAS
7. Install:
left handlebar switch
NOTE:
Align the end a of the left handlebar switch
with the punch mark b on the handlebar.
_
8. Connect:
clutch switch coupler
9. Install:
handlebar grip
WARNING
_
10.Install:
throttle grip
11.Connect:
throttle cable
12.Install:
right handlebar switch
NOTE:
Align the projection a on the right handlebar
switch with the hole b in the handlebar.
_
4 - 73
HANDLEBAR
CHAS
13.Install:
brake master cylinder
brake master cylinder holder
T.
R.
NOTE:
Install the brake master cylinder holder with
the UP mark facing up.
Align the end of the brake master cylinder
holder with the punch mark a in the handlebar.
First, tighten the upper bolt, then the lower
bolt.
_
14.Connect:
front brake light switch connectors
15.Install:
plastic clamps
NOTE:
Refer to CABLE ROUTING in chapter 2.
_
16.Adjust:
clutch cable free play
Refer to ADJUSTING THE CLUTCH
CABLE FREE PLAY in chapter 3.
Clutch cable free play (at the end
of the clutch lever)
10 ~ 15 mm (0.39 ~ 0.59 in)
17.Adjust:
throttle cable free play
Refer to ADJUSTING THE THROTTLE
CABLE FREE PLAY in chapter 3.
Throttle cable free play (at the
flange of the throttle grip)
4 ~ 6 mm (0.16 ~ 0.24 in)
4 - 74
CHAS
STEERING HEAD
EAS00676
STEERING HEAD
T.
R.
R.
T.
R.
R.
LS
1
2
8
9
10
11
15
16
LS
7
12
17
7
4
17
13
14
LS
5
T.
R.
Order
Job/Part
Removing the lower bracket
Handlebar/handlebar holders
Meter assemblies
Qty
Front wheel
1
2
3
4
5
6
7
1
1
1
1
2
1
2
4 - 75
Remarks
Remove the parts in the order listed.
Refer to HANDLEBAR.
Refer to HEADLIGHT AND METER
ASSEMBLIES in chapter 3.
Refer to FRONT WHEEL AND BRAKE
DISCS.
Refer to FRONT FORK.
Refer to INSTALLING THE STEERING
HEAD.
CHAS
STEERING HEAD
T.
R.
R.
T.
R.
R.
LS
1
2
8
9
10
11
15
16
LS
7
12
17
7
4
17
13
14
LS
5
T.
R.
Order
8
9
10
11
12
13
14
15
16
17
Job/Part
Lock washer
Upper ring nut
Rubber washer
Lower ring nut
Lower bracket
Lower bearing
Lower bearing cover
Upper bearing cover
Upper bearing
Bearing outer race
Qty
Remarks
1
1
1
1
Refer to REMOVING THE LOWER
Refer to INSTALLBRACKET.
ING THE STEER1
ING HEAD.
1
1
1
1
1
For installation, reverse the removal
procedure.
4 - 76
STEERING HEAD
CHAS
EAS00677
WARNING
_
WARNING
_
EAS00681
2. Check:
bearings
bearing races
Damage/pitting Replace.
4 - 77
STEERING HEAD
CHAS
3. Replace:
bearings
bearing races
CAUTION:
_
4. Check:
upper bracket
lower bracket
(along with the steering stem)
Bends/cracks/damage Replace.
EAS00683
4
3
1
2.
4 - 78
Install:
lower ring nut 1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to CHECKING AND ADJUSTING
THE STEERING HEAD in chapter 3.
STEERING HEAD
CHAS
3. Install:
upper bracket
steering stem nut
NOTE:
Temporarily tighten the steering stem nut.
_
4. Install:
front fork legs
Refer to FRONT FORK.
NOTE:
Temporarily tighten the lower bracket pinch
bolts.
_
5. Tighten:
steering stem nut
T.
R.
4 - 79
CHAS
T.
R.
T.
R.
T.
R.
14
11
13
LS
9
12
T.
R.
11
7
6
T.
R.
10
Order
1
2
3
4
5
6
7
Job/Part
Qty
Remarks
Removing the rear shock absorber
Remove the parts in the order listed.
and swingarm
Rear brake master cylinder bracket
Refer to FRONT AND REAR BRAKES.
Rear exhaust pipe
Refer to ENGINE in chapter 5.
Rear wheel
Refer to REAR WHEEL, BRAKE DISC,
AND REAR WHEEL PULLEY.
Adjusting bolt
2
Locknut
2
Lower drive belt cover plate
1
Spacer
1
Lower drive belt cover
1
Horn 2 coupler
1
Disconnect.
Horn 2
1
4 - 80
T.
R.
T.
CHAS
R.
T.
R.
14
11
13
LS
9
12
T.
11
R.
7
6
T.
R.
10
Order
8
9
10
11
12
13
14
Job/Part
Brake hose holder
Self-locking nut
Bolt (shock absorber-connecting armframe)
Cover (left and right)
Pivot shaft nut/washer
Pivot shaft
Rear shock absorber and swingarm
assembly
Qty
Remarks
2
1
Refer to REMOVING THE REAR
1
SHOCK ABSORBER AND SWINGARM
and INSTALLING THE REAR SHOCK
ABSORBER AND SWINGARM.
2
1/1
1
1
For installation, reverse the removal
procedure.
4 - 81
CHAS
12
LS
T.
R.
13
T.
R.
15
LS
LS
10
9
10
11
4 6
14
15
11
1
5
LS
6
LS
13
LS
4
LS
T.
R.
LS
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Removing the rear shock absorber
and swingarm
Self-locking nut/washer/bolt
Self-locking nut/washer/bolt
Connecting arm
O-ring
Rear shock absorber
Spacer/O-ring
Self-locking nut/washer/bolt
Relay arm
Spacer/oil seal/bearing
Spacer/bearing
Spacer/bearing
Qty
Remarks
Remove the parts in the order listed.
1/1/1
1/1/1
2
4
1
1/2
1/2/1
1
1/2/1
1/2
1/1
Bolt
Bolt
Bolt
= 77 mm (3.03 in)
4 - 82
CHAS
12
LS
T.
R.
13
T.
R.
15
LS
LS
10
9
10
11
4 6
14
15
11
1
5
LS
6
LS
13
LS
4
LS
3
T.
R.
LS
Order
12
13
14
15
Job/Part
Swingarm
Dust cover
Spacer
Bearing
Qty
1
2
1
2
Remarks
4 - 83
CHAS
EAS00686
WARNING
_
EAS00689
WARNING
_
4 - 84
CHAS
EAS00703
WARNING
_
2. Remove:
bolt (shock absorber-connecting armframe) 1
NOTE:
When removing the bolt (shock absorber-connecting arm-frame) 1, hold the swingarm so
that it does not drop down.
_
3. Measure:
swingarm free play
swingarm vertical movement
T.
R.
b. Measure the swingarm side play by moving the swingarm from side to side.
c. If the swingarm side play is out of specification, check the spacers, bearings, washers,
and dust covers.
Swingarm side play (at the end of
the swingarm)
1 mm (0.04 in)
d. Check the swingarm vertical movement
by moving the swingarm up and down.
If swingarm vertical movement is not
smooth or if there is binding, check the
spacers, bearings, washers, and dust covers.
4 - 85
CHAS
EAS00696
2. Check:
pivot shaft
Roll the pivot shaft on a flat surface.
Bends Replace.
WARNING
_
4 - 86
CHAS
Wash:
pivot shaft
dust covers
spacer
bearings
Recommended cleaning solvent
Kerosine
4.
Check:
dust covers
spacer
oil seals
Damage/wear Replace.
bearings
Damage/pitting Replace.
EAS00711
1
3
a
2. Install:
bearings 1, 2, 3
(to relay arm)
Installed depth a
4.5 mm (0.18 in)
Installed depth b
1.0 mm (0.04 in)
Installed depth c
2.0 mm (0.08 in)
c
b
4 - 87
CHAS
3. Install:
bolt (shock absorber-connecting armframe) 1
NOTE:
When installing the bolt (shock absorber-connecting arm-frame), hold the swingarm so that
it does not drop down.
_
4. Adjust:
drive belt slack
Refer to ADJUSTING THE DRIVE BELT
SLACK in chapter 3.
4 - 88
CHAS
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the drive belt and drive
sprocket
Rear wheel
Rear shock absorber and swingarm
assembly
Drive sprocket cover
Slider
Dowel pin
Transfer gear case bracket
Drive belt
Drive sprocket nut
Lock washer
Drive sprocket
Qty
Remarks
Remove the parts in the order listed.
Refer to REAR WHEEL, BRAKE DISC,
AND REAR WHEEL PULLEY.
Refer to REAR SHOCK ABSORBER
AND SWINGARM.
1
2
2
1
1
1
1
1
For installation, reverse the removal
procedure.
4 - 89
CHAS
2. Loosen:
drive sprocket nut 1
NOTE:
When loosening the drive sprocket nut, press
down on the brake pedal so the drive sprocket
does not move.
_
2. Check:
drive belt
CAUTION:
To protect the drive belt from damage,
handle it with care.
The drive belt can not be bent smaller
than 127 mm (5 in) a.
The removed drive belt can not be twisted
inside out.
4 - 90
CHAS
3. Check:
drive sprocket
rear wheel pulley
Bent teeth Replace the drive belt and
pulleys as a set.
2. Install:
drive belt
CAUTION:
_
3. Install:
rear shock absorber and swingarm
assembly
Refer to REAR SHOCK ABSORBER AND
SWINGARM.
rear wheel
Refer to REAR WHEEL, BRAKE DISC,
AND REAR WHEEL PULLEY.
4. Tighten:
drive sprocket nut
T.
R.
NOTE:
When tightening the drive sprocket nut, press
down on the brake pedal so the drive sprocket
does not move.
_
4 - 91
ENG
ENGINE
EAS00188
ENGINE
ENGINE
T.
T.
R.
R.
T.
R.
T.
R.
1
T.
R.
(2)
(2)
(2)
(3)
(2)
3
(2)
1
2
3
4
5
Job/Part
Removing the muffler and exhaust
pipes
Muffler
Rear exhaust pipe
Front exhaust pipe
Gasket
Gasket
Qty
R.
Order
T.
Remarks
Remove the parts in the order listed.
1
1
1
2
2
For installation, reverse the removal
procedure.
5-1
ENG
ENGINE
2
5
LT
1
R.
R.
T.
T.
3
2
T.
R.
T.
R.
Order
Job/Part
Removing the oil filter bracket and
horn
Seat/side covers
Qty
Remarks
Remove the parts in the order listed.
Refer to SEAT AND SIDE COVERS in
chapter 3.
Refer to FUEL TANK in chapter 3.
Refer to AIR FILTER CASE in
chapter 3.
Refer to SILENCER AIR FILTER CASE
in chapter 3.
Refer to FUEL INJECTION SYSTEM in
chapter 6.
Refer to AIR INDUCTION SYSTEM in
chapter 6.
Refer to STARTER MOTOR in
chapter 7.
Fuel tank
Air filter case
Silencer air filter case
Throttle bodies/intake manifold
Air induction system parts
Starter motor
5-2
4
5
ENG
ENGINE
LT
1
R.
R.
T.
T.
3
2
T.
R.
T.
R.
Order
Job/Part
Engine oil/oil filter cartridge
Qty
1
1
5-3
Remarks
Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3.
Refer to SUB FUEL TANK.
Drain.
Refer to CHANGING THE TRANSFER
GEAR OIL in chapter 3.
Refer to TRANSFER GEAR CASE.
Refer to ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS.
Refer to GENERATOR AND STARTER
CLUTCH.
ENG
ENGINE
LT
1
R.
R.
T.
T.
3
2
T.
R.
T.
R.
Order
3
4
5
6
7
8
Job/Part
Rectifier/regulator coupler
Stator coil assembly coupler
Rectifier/regulator
Rectifier/regulator bracket
Horn 2
Lean angle cut-off switch
Qty
Remarks
1
Disconnect.
1
Disconnect.
1
1
1
1
For installation, reverse the removal
procedure.
5-4
ENGINE
ENG
8
6
2
1
7
1
3
T.
R.
12
9
T.
R.
10
Order
1
2
3
4
5
6
7
8
9
10
11
12
11
Job/Part
Disconnecting the leads and hoses
Spark plug caps
Cylinder head breather hose
Oil tank breather hose
Clutch cable
Plastic clamp
Decompression solenoid coupler
Crankshaft position sensor coupler
Cylinder identification coupler
Engine temperature sensor coupler
Neutral switch cover
Neutral switch
Speed sensor
Qty
Remarks
Disconnect the parts in the order listed.
4
1
1
1
1
2
1
1
1
1
1
1
For connecting, reverse the disconnection procedure.
5-5
ENGINE
ENG
2
5
3
8
7
T.
R.
4
6
1
2
3
4
5
6
7
8
Job/Part
Removing the ignition coil and
linear control valve
Hose bracket
Wire harness bracket
Ignition coil connector
Ignition coil 1
Ignition coil 2
Linear control valve coupler
Linear control valve
Linear control valve bracket
R.
Order
T.
Qty
1
1
4
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Disconnect.
Disconnect.
5-6
ENGINE
ENG
1
11
13
T.
R.
3
.
R.
R.
11
T.
12
14
R.
16
9
10
8
15
6
T.
R.
T.
R.
T.
R.
18
17
Job/Part
Removing the engine
R.
Order
T.
Qty
Remarks
Remove the parts in the order listed.
NOTE:
Place a suitable stand under the frame
and engine.
_
1
2
3
4
5
6
7
8
9
10
2
2
1
1
1
4
2
4
3
1
5-7
ENGINE
ENG
1
11
13
T.
R.
3
.
R.
R.
11
T.
12
14
R.
16
9
10
8
15
6
T.
R.
T.
R.
T.
R.
18
17
Job/Part
Rear engine bracket nut
Rear engine bracket bolt
Rear engine bracket (left)
Rear engine bracket (right)
Spacer bolt
Lower rear mounting bolt
Lower front mounting bolt
Engine
R.
Order
11
12
13
14
15
16
17
18
T.
Qty
Remarks
2
2
1
1
Refer to INSTALLING THE
1
Loosen. ENGINE.
1
1
1
For installation, reverse the removal
procedure.
5-8
ENGINE
ENG
EAS00192
F
7 G
8
0 E
G
D
3
T.
R.
5
1
H
NOTE:
Tighten the spacer bolt 1 to specification
with a pivot shaft wrench 4.
When tightened, the spacer bolt 1 should be
flat against the engine surface.
H
A
3.
Install:
self-locking nut 5, 6
rear engine bracket (left) 7
rear engine bracket (right) 8
upper rear mounting bolt 9
self-locking nut 0
front engine bracket A
front mounting bolt B
self-locking nut C
upper engine bracket D
upper mounting bolts E
NOTE:
Do not fully tighten the bolts and nuts.
_
4. Tighten:
upper mounting bolts E
T.
R.
R.
5. Tighten:
self-locking nut 5
T.
R.
self-locking nut 6
T.
R.
T.
nuts G
53 Nm (5.3 m kg, 38 ft lb)
self-locking nut 0
R.
T.
R.
self-lock nuts H
T.
R.
self-locking nut C
T.
R.
5-9
ENGINE
6.
ENG
Connect:
oil tank breather hose 1
cylinder head breather hose 2
spark plug caps 3
NOTE:
Refer to CABLE ROUTING in chapter 2.
3
1
Install:
muffler
bolt 1
bolts 2
T.
R.
T.
R.
2.
3. Tighten:
exhaust pipe nuts
T.
R.
R.
clamp bolts 1
T.
R.
5 - 10
ENG
R.
R.
T.
T.
T.
R.
11
12
(5)
13
14 New
(4)
11
10
7 8
6
5
T.
R.
R.
Order
Job/Part
Removing the engine left side cover
and camshaft sprocket cover
Seat/fuel tank/silencer air filter case
Qty
Muffler/exhaust pipes
Engine oil
1
2
3
4
5
2/2
4
1
1
1
5 - 11
Remarks
Remove the parts in the order listed.
Refer to SEAT AND SIDE COVERS,
FUEL TANK and SILENCER AIR FILTER CASE in chapter 3.
Refer to ENGINE.
Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3.
Disconnect.
Refer to INSTALLING THE
CAMSHAFT SPROCKET
COVER AND ENGINE
For califor- LEFT SIDE COVER.
nia only.
ENG
R.
R.
T.
T.
T.
R.
11
12
(5)
13
14 New
(4)
11
10
7 8
6
5
T.
R.
R.
Order
6
7
8
9
10
11
12
13
14
15
Job/Part
Engine left side cover
Rubber damper
Timing mark accessing screw
Crankshaft end cover
Decompression solenoid cover
Camshaft sprocket cover 1
Dowel pin
Cylinder identification sensor
Camshaft sprocket cover 2
Camshaft sprocket cover gasket
Qty
Remarks
1
1
1
1
Refer to INSTALLING THE CAMSHAFT
1
SPROCKET COVER AND ENGINE
1
LEFT SIDE COVER.
2
1
1
1
For installation, reverse the removal
procedure
5 - 12
ENG
1
4 3
54
2
34
4
5
3
5
5 5
5
7
5
New 8
8 New
9
9
T.
R.
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing cylinder head covers
Ignition coil/rectifier/regulator/
liner control valve
Cylinder head breather hose
Oil tank breather hose
Bolt
Bolt
Bolt
Rear cylinder head cover
Front cylinder head cover
Cylinder head cover gasket
Dowel pin
Qty
1
1
4
12
12
1
1
2
4
Remarks
Remove the parts in the order listed.
Refer to ENGINE.
= 60 mm (2.36 in)
= 50 mm (1.97 in)
= 40 mm (1.57 in)
Refer to INSTALLING THE CYLINDER
HEAD COVERS.
For installation, reverse the removal
procedure
5 - 13
ENG
T.
R.
E
T.
R.
10
11
8
9
10
11
10
11
8
10
11
7
E
T.
R.
3
2
5 New
New 5
6
6
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Removing the push rods and rocker
arms
Push rod 1
Push rod 2
Rear rocker arm base
Front rocker arm base
Rocker arm base gasket
Dowel pin
Rocker arm shaft
Rocker arm 1
Rocker arm 2
Locknut
Adjusting screw
Qty
3
1
1
1
2
4
4
2
2
2
2
Remarks
Remove the parts in the order listed.
= 288.5 mm (11.358 in) blue painting
= 290.5 mm (11.437 in) yellow painting
5 - 14
ENG
T.
R.
4
T.
R.
2
1
1
E
3
7
2
3
2
Order
1
2
3
4
5
6
7
Job/Part
Removing the valve lifters
Push rod cover
O-ring
Seal
Air filter bracket
Rear valve lifter case
Front valve lifter case
Valve lifter
Qty
2
4
2
1
1
1
4
5 - 15
Remarks
Remove the parts in the order listed.
ENG
d
c
2. Remove:
rocker arm bases
(with the rocker arms)
3. Remove:
valve lifters
NOTE:
Make a note of the position of each valve lifter
so that they can be installed in the correct
place.
CAUTION:
Do not lay the removed valve lifter on its
side.
5 - 16
ENG
2. Check:
rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches Replace or check the lubrication system.
3. Measure:
rocker arm inside diameter a
Out of specification Replace.
Rocker arm inside diameter
18.000 ~ 18.018 mm
(0.7087 ~ 0.7094 in)
4. Measure:
rocker arm shaft outside diameter a
Out of specification Replace.
Rocker arm shaft outside
diameter
17.976 ~ 17.991 mm
(0.7077 ~ 0.7083 in)
5. Calculate:
rocker arm to rocker arm shaft clearance
NOTE:
Calculate the clearance by subtracting the
rocker arm shaft outside diameter from the
rocker arm inside diameter.
Above 0.08 mm (0.003 in) Replace the
defective part(s).
Rocker arm to rocker arm shaft
clearance
0.009 ~ 0.042 mm
(0.0004 ~ 0.0017 in)
5 - 17
ENG
2. Measure:
push rod runout
Out of specification Replace.
Push rod runout
0.3 mm (0.012 in)
2. Check:
valve lifter case 1
Damage/wear Replace the valve lifter
case.
O-ring 2
Damage/wear Replace the O-ring.
5 - 18
ENG
3. Measure:
valve lifter outside diameter a
Out of specification Replace.
Valve lifter outside diameter
22.9680 ~ 22.9744 mm
(0.9043 ~ 0.9045 in)
4. Measure:
valve lifter case inside diameter a
Out of specification Replace.
Valve lifter case inside diameter
23.000 ~ 23.021 mm
(0.9055 ~ 0.9063 in)
5. Calculate:
valve lifter-to-valve lifter case clearance
NOTE:
Calculate the clearance by subtracting the
valve lifter case outside diameter.
Above 0.072 mm (0.0028 in) Replace the
defective part(s).
Valve lifter-to-valve lifter case
clearance
0.0256 ~ 0.0530 mm
(0.0010 ~ 0.0021 in)
5 - 19
ENG
1. Bleed:
valve lifter
CAUTION:
Do not pump the valve lifter excessively.
Kerosene is highly flammable.
1 Kerosene
2 Valve lifter
CAUTION:
Be sure to install the valve lifter in its
appropriate position.
c.
d.
e.
f.
NOTE:
The crankshaft can be rotated smoothly when
the spark plugs are removed.
WARNING
Be careful since the engine is hot.
g. With piston #1 at TDC, count the indicated
number of gear teeth and place marks 2
through 5 on the camshaft driven gear as
shown. When these marks align between
the centers of the camshaft drive and driven
gears, the corresponding valve lifter is at its
highest point.
1 Piston #1 TDC punch mark
2 Cylinder #2 intake valve at its highest point
3 Cylinder #1 exhaust valve at its highest point
4 Cylinder #1 intake valve at its highest point
5 Cylinder #2 exhaust valve at its highest point
5 - 20
ENG
5 - 21
ENG
New
3. Install:
rocker arm bass
(with rocker arms)
push rods
NOTE:
Be sure to correctly install the push rods
between the rocker arms and valve lifters as
shown. The illustration is viewed from the
right side of the motorcycle.
Rear cylinder
Front cylinder
1 Intake side rocker arm
2 Exhaust side rocker arm
3 Intake valve lifter
4 Exhaust valve lifter
5 Push rod 2 = 288.5 mm (11.358 in) blue painting
= 290.5 mm (11.437 in) yellow
6 Push rod 1
painting
5 - 22
ENG
T.
R.
2. Install:
cylinder head cover 1
T.
R.
5 - 23
ENG
2. Install:
canister (for California only)
NOTE:
Refer to CABLE ROUTING in chapter 2.
3.
4.
Install:
spark plugs
Connect:
spark plug caps
NOTE:
Refer to CABLE ROUTING in chapter 2.
Forward
1 Ignition coil 1 - L spark plug lead
2 Ignition coil 1 - R spark plug lead
3 Ignition coil 2 - L spark plug lead
4 Ignition coil 2 - R spark plug lead
5. Adjust:
installed shift rod length
Refer to ADJUSTING THE SHIFT PEDAL
in chapter 3.
5 - 24
ENG
CAMSHAFTS
EAS00196
CAMSHAFTS
12
13
11 New
10
T.
R.
(6)
14
12
7
3
2
8
6
5
T.
R.
T.
R.
R.
Order
1
2
3
4
5
6
Job/Part
Removing the camshafts
Valve lifters
Decompression solenoid
Long decompression push rod
Short decompression push rod
Front cylinder camshaft end cover
Camshaft drive gear
Straight key
Qty
1
1
1
1
1
1
5 - 25
Remarks
Remove the parts in the order listed.
Refer to ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS.
92 mm (3.6 in)
78 mm (3.1 in)
Refer to REMOVING THE CAMSHAFTS and INSTALLING THE CAMSHAFTS.
ENG
CAMSHAFTS
12
13
11 New
10
T.
R.
(6)
14
12
7
3
2
8
6
5
T.
R.
T.
R.
R.
Order
7
8
9
10
11
12
13
14
Job/Part
Camshaft driven gear
Straight key
Oil delivery pipe
Camshaft cover
Camshaft cover gasket
Dowel pin
Front cylinder camshaft
Rear cylinder camshaft
Qty
Remarks
1
1
1
Refer to REMOVING THE CAM1
SHAFTS and INSTALLING THE CAM1
SHAFTS.
2
1
1
For installation, reverse the removal
procedure.
5 - 26
CAMSHAFTS
ENG
2. Loosen:
camshaft driven gear nut 1
NOTE:
Place a folded copper washer 2 between
the teeth of the camshaft drive gear and
camshaft driven gear in order to lock them.
Do not damage the teeth of the camshaft
drive and camshaft driven gears.
_
3.
Remove:
front cylinder camshaft end cover
camshaft drive gear 1
camshaft driven gear 2
straight keys
NOTE:
Cover the crankcase hole with a clean rag 3
to prevent the straight keys from falling into the
crankcase.
_
4. Remove:
oil delivery pipe 1
camshaft cover 2
(along with the camshafts)
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
_
5 - 27
CAMSHAFTS
ENG
EAS00204
2. Measure:
cam dimensions a and b
Out of specification Replace the camshaft.
Camshaft lobe dimension limit
Intake camshaft
a 38.231 ~ 38.331 mm
(1.5052 ~ 1.5091 in)
b 32.013 ~ 32.113 mm
(1.2604 ~ 1.2643 in)
Exhaust camshaft
a 38.232 ~ 38.332 mm
(1.5052 ~ 1.5091 in)
b 31.995 ~ 32.095 mm
(1.2596 ~ 1.2636 in)
3. Measure:
camshaft journal diameter (crankcase side)
a
Out of specification Replace the camshaft.
Camshaft journal diameter
(crankcase side)
24.937 ~ 24.950 mm
(0.9818 ~ 0.9823 in)
4. Measure:
camshaft journal diameter (camshaft cover
side) b
Out of specification Replace the camshaft.
Camshaft journal diameter
(camshaft cover side)
27.967 ~ 27.980 mm
(1.1011 ~ 1.1016 in)
5 - 28
CAMSHAFTS
ENG
5. Measure:
crankcase hole inside diameter c
Out of specification Replace the crankcase.
Crankcase hole inside diameter
25.000 ~ 25.021 mm
(0.9843 ~ 0.9851 in)
6. Measure:
camshaft cover hole inside diameter d
Out of specification Replace the camshaft cover.
Camshaft cover hole inside
diameter
28.000 ~ 28.021 mm
(1.1024 ~ 1.1032 in)
7. Calculate:
camshaft-to-crankcase clearance
Out of specification Replace the defective part(s).
NOTE:
Calculate the clearance by subtracting the
crankcase side camshaft journal diameter
(crankcase side) from the crankcase hole
inside diameter.
Camshaft to crankcase clearance
0.050 ~ 0.084 mm
(0.0020 ~ 0.0033 in)
8. Calculate:
camshaft to camshaft cover clearance
Out of specification Replace the defective part(s).
NOTE:
Calculate the clearance by subtracting the
camshaft journal diameter (camshaft cover
side) from the camshaft cover hole inside
diameter.
Camshaft to camshaft cover
clearance
0.020 ~ 0.054 mm
(0.0008 ~ 0.0021 in)
5 - 29
CAMSHAFTS
ENG
9. Check:
camshaft drive gears
camshaft driven gears
Chips/pitting/roughness/wear Replace
the defective part(s).
2. Check:
decompression push rods
Bends/damage Replace.
5 - 30
CAMSHAFTS
ENG
2. Install:
dowel pins 1
camshaft cover gasket 2
New
3. Install:
camshaft cover 1
(along with the camshafts)
oil delivery pipe 2
NOTE:
Tighten the camshaft cover bolts in stages and
in a crisscross pattern.
_
5 - 31
CAMSHAFTS
ENG
4. Install:
front cylinder camshaft end cover 1
NOTE:
Align the projection a on the front cylinder
camshaft end cover with the hole b on the
front cylinder camshaft.
Finger tighten the place bolts.
_
5.
Install:
straight keys
camshaft drive gear 1
camshaft driven gear 2
NOTE:
Cover the crankcase hole with a clean rag 3
to prevent the straight keys from falling into
the crankcase.
Align the punch mark a on the camshaft
drive gear 1 with the punch mark b on the
camshaft driven gear 2.
Insert a cross-headed screwdriver into one of
the holes in the outer camshaft driven gear
and rotate the gear until the teeth of both
driven gears are aligned. The teeth of both
camshaft driven gears must be aligned for
installation.
_
5 - 32
CAMSHAFTS
ENG
6. Tighten:
camshaft driven gear nut 1
T.
R.
NOTE:
Place a folded copper washer 2 between
the teeth of the camshaft drive gear and
camshaft driven gear in order to lock them.
Do not damage the teeth of the camshaft
drive and camshaft driven gear.
After tightening the camshaft driven gear nut,
remove the copper washer to clean the teeth
of the camshaft drive gear and camshaft
driven gear.
_
7. Tighten:
camshaft drive gear bolt 1
T.
R.
R.
NOTE:
Place a folded copper washer 3 between
the teeth of the camshaft drive gear and
camshaft driven gear in order to lock them.
Do not damage the teeth of the camshaft
drive and camshaft driven gear.
After tightening the camshaft drive gear bolt,
remove the copper washer to clean the teeth
of the camshaft drive gear and camshaft
driven gear.
_
5 - 33
CYLINDER HEADS
ENG
EAS00221
CYLINDER HEADS
T.
R.
T.
R.
T.
R.
T.
R.
10
5
3 New
New 7
New
New 3
2
T.
R.
T.
R.
4 New
T.
R.
6
New 7
Order
Job/Part
Removing the cylinder heads
Throttle bodies/intake manifolds
Qty
1
1
4
2
5 - 34
Remarks
Remove the parts in the order listed.
Refer to THROTTLE BODIES in chapter 6.
Refer to AIR CUT-OFF VALVE ASSEMBLY AND AIR INDUCTION SYSTEM
HOSES in chapter 6.
Refer to ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS.
Refer to INSTALLING THE CYLINDER
HEAD.
CYLINDER HEADS
ENG
T.
R.
T.
R.
T.
R.
T.
R.
10
5
3 New
New 7
New 3
2
T.
R.
T.
R.
New
4 New
T.
R.
6
New 7
Order
5
6
7
8
9
10
Job/Part
Rear cylinder head
Front cylinder head
Cylinder head gasket
Dowel pin
Rear exhaust pipe joint cover
Rear exhaust pipe joint
Qty
Remarks
1
Refer to REMOVING THE CYLIN1
DER HEADS.
Refer to INSTALL2
ING THE CYLIN4
DER HEAD.
1
1
For installation, reverse the removal
procedure.
5 - 35
CYLINDER HEADS
ENG
EAS00228
2. Check:
cylinder head
Damage/scratches Replace.
3. Measure:
cylinder head warpage
Out of specification Resurface the cylinder head.
Maximum cylinder head warpage
0.03 mm (0.0012 in)
5 - 36
CYLINDER HEADS
ENG
EAS00232
3. Tighten:
cylinder head nuts (M12: 1 ~ 4)
T.
R.
R.
NOTE:
Lubricate the cylinder head nuts with engine
oil.
Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.
_
5.
Install:
copper washers New
oil delivery pipe 1
oil delivery pipe bolts (M10)
T.
R.
R.
5 - 37
CYLINDER HEADS
ENG
6. Install:
washer
engine temperature sensor 1
T.
R.
5 - 38
ENG
1
1
2
New 7
2
7 New
3
3
8
7 New
4
4
8
3
8
2
New 7
4
3
8
5 6
E
M
M
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the valves and valve
springs
Cylinder head
Valve cotter
Upper spring seat
Outer valve spring
Inner valve spring
Intake valve
Exhaust valve
Valve stem seal
Lower spring seat
Qty
Remarks
Remove the parts in the order listed.
The following procedure applies to both
cylinders.
Refer to CYLINDER HEADS.
8
4
4
4
2
2
4
4
5 - 39
ENG
EAS00238
1. Check:
valve sealing (for leakage)
Leakage at the valve seat Check the
valve face, valve seat, and valve seat width.
Refer to CHECKING THE VALVE SEATS.
NOTE:
There should be no leakage at the valve seat
1.
_
2. Remove:
valve cotters
NOTE:
Remove the valve cotters by compressing the
valve springs with the valve spring compressor
set 1.
_
5 - 40
ENG
Remove:
upper spring seat 1
outer valve spring 2
inner valve spring 3
valve 4
valve stem seal 5
lower spring seat 6
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
_
EAS00239
5 - 41
ENG
2. Replace:
valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 C (212 F) in an oven.
_
3. Eliminate:
carbon deposits
(from the valve face and valve seat)
4. Check:
valve face
Pitting/wear Grind the valve face.
valve stem end
Mushroom shape or diameter larger than
the body of the valve stem Replace the
valve.
5 - 42
ENG
5. Measure:
valve margin thickness a
Out of specification Replace the valve.
Valve margin thickness
0.7 ~ 1.3 mm (0.0276 ~ 0.0512 in)
6. Measure:
valve stem runout
Out of specification Replace the valve.
NOTE:
When installing a new valve, always replace
the valve guide.
If the valve is removed or replaced, always
replace the oil seal.
_
EAS00240
5 - 43
ENG
3. Measure:
valve seat width a
Out of specification Replace the cylinder
head.
Valve seat width
Intake
0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
Exhaust
0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been
removed.
_
5 - 44
ENG
4. Lap:
valve face
valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
_
CAUTION:
_
5 - 45
ENG
EAS00241
2. Measure:
compressed valve spring force a
Out of specification Replace the valve
spring.
b Installed length
3. Measure:
valve spring tilt a
Out of specification Replace the valve
spring.
Spring tilt limit
Intake and exhaust inner valve
spring
2.4 mm (0.094 in)
Intake and exhaust outer valve
spring
2.4 mm (0.094 in)
5 - 46
ENG
EAS00246
2. Lubricate:
valve stem 1
oil seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3.
Install:
lower spring seat 1
valve stem seal 2
valve 3
inner valve spring 4
outer valve spring 5
upper spring seat 6
(into the cylinder head)
NOTE:
Install the valve springs with the larger pitch a
facing up.
_
b Smaller pitch
5 - 47
ENG
4. Install:
valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve springs with the valve spring compressor
set 1.
_
CAUTION:
_
6. Install:
cylinder head
Refer to CYLINDER HEADS.
5 - 48
ENG
New 3
8
9
8
9
10
10
4
E
E
5 New
1
5
New
5
New
5 New
6
7
New 3
4
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the cylinders and pistons
Cylinder heads
Front cylinder
Rear cylinder
Cylinder gasket
Dowel pin
Piston pin clip
Piston pin
Piston
Top ring
2nd ring
Oil ring
Qty
1
1
2
4
4
2
2
2
2
2
Remarks
Remove the parts in the order listed.
Refer to CYLINDER HEADS.
5 - 49
ENG
EAS00254
CAUTION:
_
Remove:
top ring
2nd ring
oil ring
NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
_
5 - 50
ENG
EAS00258
Cylinder bore C
97.000 ~ 97.010 mm
(3.8189 ~ 3.8193 in)
Taper limit T
Out of round R
C = maximum of D1 ~ D6
T = maximum of D1 or D2 - maximum of
D5 or D6
R = maximum of D1, D3 or D5 - minimum
of D2, D4 or D6
b. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
c. Measure piston skirt diameter P with the
micrometer.
Micrometer (75 ~ 100 mm)
YU-03009
a 5 mm (0.20 in) from the bottom edge of the piston
5 - 51
ENG
Piston size P
Standard
96.960 ~ 96.975 mm
(3.8173 ~ 3.8179 in)
EAS00263
5 - 52
ENG
2. Install:
piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
_
a 10 mm (0.39 in)
3. Measure:
piston ring end gap
Out of specification Replace the piston
ring.
NOTE:
The oil ring expander spacers end gap cannot
be measured. If the oil ring rails gap is excessive, replace all three piston rings.
_
EAS00266
5 - 53
ENG
3. Measure:
piston pin bore diameter (in the piston) b
Out of specification Replace the piston
pin.
Piston pin bore diameter (in the
piston)
22.004 ~ 22.015 mm
(0.8663 ~ 0.8667 in)
<Limit>: 22.045 mm (0.8679 in)
4. Calculate:
piston-pin-to-piston-pin-bore clearance
Out of specification Replace the piston
pin and piston as a set.
Piston-pin-to-piston clearance =
Piston pin bore diameter (in the piston)
b - Piston pin outside diameter a
Piston-pin-to-piston pin bore
clearance
0.004 ~ 0.024 mm
(0.00016 ~ 0.00094 in)
<Limit>: 0.074 mm (0.0029 in)
EAS00268
5 - 54
Install:
piston 1
piston pin 2
piston pin clips 3
ENG
New
NOTE:
Apply engine oil onto the piston pin.
Make sure the arrow mark a on the piston
faces towards the front of the motorcycle.
Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent the clip from falling into the crankcase.
_
3.
4.
Install:
dowel pins 1
cylinder gasket 2 New
Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
New 2
5. Offset:
piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
Forward
6. Install:
cylinder 1
NOTE:
While compressing the piston rings with one
hand, install the cylinder with the other hand.
_
5 - 55
ENG
CLUTCH
EAS00273
CLUTCH
CLUTCH COVER
T.
R.
4
2
1
9
3
5
6
9
(5)
New 8
(7)
7
(4)
T.
R.
Order
Job/Part
Removing the clutch cover
Left side cover
Qty
1
2
3
4
Clutch cable
Pull lever
Pull lever spring
Crankshaft position sensor lead
1
1
1
1
5 - 56
Remarks
Remove the parts in the order listed.
Refer to SEAT AND SIDE COVERS in
chapter 3.
Refer to SUB FUEL TANK.
Refer to ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS.
Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3.
Disconnect.
Refer to INSTALLING THE
CLUTCH.
Disconnect.
ENG
CLUTCH
T.
R.
4
2
1
9
3
5
6
9
(5)
New 8
(7)
7
(4)
T.
R.
Order
5
6
7
8
9
Job/Part
Shift arm
Clutch cable holder
Clutch cover
Clutch cover gasket
Dowel pin
Qty
Remarks
1
1
Refer to REMOVRefer to INSTALLING THE CLUTCH.
1
ING THE CLUTCH.
1
1
For installation, reverse the removal
procedure.
5 - 57
CLUTCH
ENG
T.
R.
LT
5
5
5
2
LT
LT
LS
3
4
4
1
3
LS
Order
1
2
3
4
5
6
Job/Part
Removing the pull lever shaft and
crankshaft position sensor
Pull lever
Pull lever spring
Circlip
Pull lever shaft
Oil seal
Bearing
Crankshaft position sensor lead holder
Crankshaft position sensor
Qty
1
1
1
1
2
3
3
1
5 - 58
Remarks
Remove the parts in the order listed.
ENG
CLUTCH
EAS00274
CLUTCH
18 19
20
17
16
T.
R.
15
14
24
13
9 12 New
11
9
9
10
8
23
22 21
New
LT
T.
R.
5
4
T.
R.
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Removing the clutch
Generator cover
Clutch spring plate retainer
Clutch spring plate
Clutch spring plate seat
Pressure plate
Pull rod
Friction plate 2
Clutch plate
Cushion spring
Friction plate 1
Lock washer
Wire circlip
Clutch plate
(6)
Qty
1
1
1
1
1
6
7
2
3
1
1
1
5 - 59
Remarks
Remove the parts in the order listed.
Refer to GENERATOR AND STARTER
CLUTCH.
Green painting
Black painting
Refer to REMOVING THE CLUTCH.
ENG
CLUTCH
18 19
20
17
16
T.
R.
15
14
24
13
9 12 New
11
9
9
10
8
23
22 21
New
LT
T.
R.
5
4
T.
R.
Order
13
14
15
16
17
18
19
20
21
22
23
24
Job/Part
Clutch damper spring
Clutch damper spring seat
Clutch boss
Thrust washer
Clutch housing
Circlip
Oil pump drive gear
Dowel pin
Spacer
Crankshaft position sensor rotor
(6)
Qty
Remarks
1
Refer to REMOV1
ING THE CLUTCH.
1
1
1
1
Refer to INSTALL1
ING THE CLUTCH.
1
1
1
Refer to REMOVING THE PRIMARY
DRIVE GEAR.
1
1
For installation, reverse the removal
procedure.
5 - 60
CLUTCH
ENG
EAS00277
4.
Remove:
clutch boss nut 1
lock washer 2
clutch boss assembly 3
NOTE:
There is a built-in damper between the clutch
boss and the clutch plate. It is not necessary to
remove the wire circlip 4 and disassemble the
built-in damper unless there is serious clutch
chattering.
_
5 - 61
CLUTCH
ENG
EAS00279
EAS00280
EAS00281
5 - 62
CLUTCH
ENG
2. Measure:
clutch plate warpage
(with a surface plate and thickness gauge
1)
Out of specification Replace the clutch
plates as a set.
Clutch plate warpage limit
0.2 mm (0.008 in)
EAS00283
EAS00284
2. Check:
bearing
Damage/wear Replace the bearing and
clutch housing.
EAS00285
5 - 63
CLUTCH
ENG
EAS00286
EAS00287
EAS00292
5 - 64
CLUTCH
ENG
2. Install:
crankshaft position sensor
T.
R.
R.
NOTE:
Apply locking agent (LOCTITE) to the
threads of the crankshaft position sensor bolts
and crankshaft position sensor lead holder
bolts.
_
EAS00303
R.
CAUTION:
The timing marks on the crankshaft position sensor rotor must face outside.
NOTE:
While holding the generator rotor 6 with the
primary sheave holder 7, tighten the crankshaft position sensor rotor bolt.
_
5 - 65
CLUTCH
ENG
EAS00293
2. Install:
clutch housing 1
thrust washer 2
NOTE:
Lubricate the clutch housing bearings with
engine oil.
Make sure that the primary driven gear teeth
and primary drive gear teeth mesh correctly.
Make sure that the oil pump drive gear teeth
and oil pump driven gear teeth mesh correctly.
_
3. Install:
clutch boss assembly 1
NOTE:
If the wire circlip 2 has been removed, carefully install a new one.
Install the clutch damper spring 3 with the
OUTSIDE mark facing out.
_
5 - 66
CLUTCH
4.
ENG
Install:
clutch boss 1
lock washer New
clutch boss nut 2
T.
R.
NOTE:
While holding the clutch boss with the universal clutch holder 3, tighten the clutch boss
nut.
_
6. Lubricate:
friction plates
clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
7.
Install:
friction plates
clutch plates
cushion springs
NOTE:
First, install a friction plate and then alternate
between a clutch plate and a friction plate.
Apply molybdenum disulfide grease onto the
bearing and pull rod teeth.
Align the two embossed mark a on the
clutch housing with the two semicircular slots
b in the friction plates.
_
5 - 67
CLUTCH
ENG
8. Install:
pressure plate 1
NOTE:
Align the punch mark a in the pressure plate
with the punch mark b in the clutch boss.
_
9.
Install:
clutch spring plate seat 1
clutch spring plate 2
clutch spring plate retainer 3
T.
R.
NOTE:
Tighten the clutch spring plate retainer bolts in
stages and in a crisscross pattern.
_
10.Install:
dowel pins 1
clutch cover gasket 2
New
11.Install:
clutch cover 1
clutch cable holder 2
T.
R.
NOTE:
Tighten the clutch cover bolts in stages and in
a crisscross pattern.
_
12.Connect:
crankshaft position sensor coupler
NOTE:
Refer to CABLE ROUTING in chapter 2.
_
5 - 68
CLUTCH
ENG
13.Install:
shift arm 1
T.
R.
NOTE:
Align the mark a in the shift shaft with the slot
in the shift arm.
_
T.
14.Install:
pull lever spring
pull lever
12 Nm (1.2 m kg, 8.7 ft lb)
NOTE:
If there is no free play in the clutch, install the
pull lever to the pull lever shaft in order to get
the distance a between the pull lever and
clutch cable holder to 31.3 mm (1.23 in).
R.
15.Connect:
clutch cable 1
16.Adjust:
clutch cable free play
Refer to ADJUSTING THE CLUTCH
CABLE FREE PLAY in chapter 3.
5 - 69
ENG
EAS00327
LS
1
3
2
6
5
4
7
LT
T.
LT
R.
R.
Order
1
2
3
4
5
6
7
Job/Part
Removing the shift shaft and
stopper lever
Engine oil
Clutch housing
Shift shaft
Circlip
Shift shaft spring
Shift shaft spring stopper
Washer
Stopper lever
Stopper lever spring
Qty
Remarks
Remove the parts in the order listed.
Drain.
Refer to CLUTCH.
1
2
1
1
1
1
1
5 - 70
ENG
EAS00328
EAS00330
EAS00331
R.
2. Install:
washer
shift shaft spring stopper 1
T.
R.
NOTE:
Apply locking agent (LOCTITE) to the
threads of shift shaft spring stopper.
_
5 - 71
ENG
Install:
shift shaft spring
circlips
shift shaft 1
NOTE:
Install the end of the shift shaft spring onto the
shift shaft spring stopper 2.
_
5 - 72
ENG
EAS00341
T.
R.
T.
R.
2
1
T.
R.
11
2
1
6
1
10 12
9 New
LT
(9)
T.
R.
R.
Order
1
2
3
4
5
6
7
Job/Part
Removing the stator coil assembly
Muffler/exhaust pipes
Engine oil
Qty
3
2
1
2
1
1
1
5 - 73
Remarks
Remove the parts in the order listed.
Refer to ENGINE.
Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3.
Disconnect.
Disconnect.
ENG
T.
R.
T.
R.
2
1
T.
R.
11
2
1
6
1
10 12
9 New
LT
(9)
T.
R.
R.
Order
8
9
10
11
12
Job/Part
Generator cover
Generator cover gasket
Dowel pin
Stator coil assembly lead holder
Stator coil assembly
Qty
1
1
2
1
1
Remarks
5 - 74
ENG
EAS00343
Order
1
2
3
4
5
6
7
Job/Part
Removing the generator rotor
Starter clutch idle gear shaft #2
Starter clutch idle gear shaft #1
Starter clutch idle gear #2
Starter clutch idle gear #1
Generator rotor
Woodruff key
Starter clutch gear
Qty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
5 - 75
ENG
EAS00347
2. Remove:
generator rotor bolt 1
washer
NOTE:
While holding the generator rotor 2 with the
primary sheave holder 3, loosen the generator rotor bolt.
_
3. Remove:
generator rotor 1
(with the alternator rotor puller 2)
Alternator rotor puller
YM-01080-A
EAS00348
5 - 76
ENG
2. Check:
starter clutch operation
EAS00354
2. Tighten:
generator rotor bolt 1
T.
R.
NOTE:
While holding the generator rotor 2 with the
primary sheave holder 3, tighten the generator rotor bolt.
_
5 - 77
ENG
3. Apply:
sealant
(onto the stator coil assembly lead grommet)
Quick Gasket
ACC-11001-05-01
4. Install:
stator coil assembly 1
T.
R.
R.
NOTE:
Apply locking agent (LOCTITE) to the
threads of the stator coil assembly bolts.
_
5.
Connect:
stator coil assembly coupler
horn 1 connectors
rear brake light switch coupler 1
NOTE:
Refer to CABLE ROUTING in chapter 2.
_
5 - 78
ENG
R.
R.
6 New
R.
R.
T.
T.
T.
T.
13
8 New
4
12
10 New
LT
LT
11
4
(5)
T.
R.
T.
R.
T.
R.
R.
Order
Job/Part
Removing the transfer gear case
cover
Muffler/exhaust pipes
Engine oil
Qty
Drive sprocket
Oil pipe #1
Oil pipe #2
Cover
Remarks
Remove the parts in the order listed.
Refer to ENGINE.
Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3.
Drain.
Refer to CHANGING THE TRANSFER
GEAR OIL in chapter 3.
Refer to DRIVE BELT AND DRIVE
SPROCKET in chapter 4.
1
2
3
1
1
1
5 - 79
R.
R.
6 New
R.
R.
T.
T.
T.
T.
ENG
13
8 New
4
12
10 New
LT
LT
11
4
(5)
T.
R.
T.
R.
T.
R.
R.
Order
4
5
6
7
8
9
10
11
12
13
Job/Part
Dowel pin
Transfer gear oil pump
Transfer gear oil pump gasket
Transfer gear case cover
Transfer gear case cover gasket
Oil strainer
Lock washer
Primary chain
Middle drive gear
Middle driven shaft
Qty
4
1
1
1
1
1
1
1
1
1
Remarks
5 - 80
Order
1
2
3
4
5
6
7
Job/Part
Disassembling the transfer gear
case oil pump
Oil pump cover
Pin
Pin
Oil pump shaft
Oil pump inner rotor
Oil pump outer rotor
Oil pump housing
Qty
ENG
Remarks
Remove the parts in the order listed.
1
2
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
5 - 81
ENG
FUEL PUMP
8
T.
R.
(6)
10
9
New
New
3
2
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the fuel pump
Seat/cover
Fuel tank
Throttle stop screw bracket
Fuel hose joint bracket
Fuel hose joint
Fuel hose
Fuel inlet hose
Hose holder
Fuel outlet hose
Fuel pump coupler
Fuel pump cover
Fuel pump
Qty
1
1
1
2
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to SEAT AND SIDE COVERS in
chapter 3.
Refer to FUEL TANK in chapter 3.
Disconnect.
5 - 82
ENG
CAUTION:
Do not drop the fuel pump or give it a
strong shock.
Do not touch the base section of the fuel
sender.
T.
5 - 83
ENG
T.
R.
2
4
9
3
5
1
T.
R.
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the sub fuel tank
Fuel pump
Battery
Battery negative lead
Starter motor lead
Battery positive lead
Starter relay coupler
Relay assembly
Plastic locking tie
Battery box
Sub fuel tank bracket
Sub fuel tank
Qty
1
1
1
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to FUEL PUMP.
Refer to BATTERY in chapter 3.
Disconnect.
Disconnect.
5 - 84
ENG
T.
R.
(5)
3
1
8
12
9 New
5
7
11
13
12
11
2
10
(4)
(4)
T.
R.
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the transfer gear case
Seat/right side cover
Oil tank breather hose
Oil temperature sensor coupler
Oil tank cover
Dipstick
Dipstick joint
Drive sprocket case
Dowel pin
Spacer
Qty
1
1
1
1
1
1
2
1
5 - 85
Remarks
Remove the parts in the order listed.
Refer to SEAT AND SIDE COVERS in
chapter 3.
Disconnect.
ENG
T.
R.
(5)
3
1
8
12
9 New
5
7
11
13
12
11
2
10
(4)
(4)
T.
R.
Order
9
10
11
12
13
Job/Part
Oil seal
Transfer gear case
Dowel pin
Bearing
Bearing housing
Qty
1
1
2
2
1
Remarks
5 - 86
T.
R.
6 8
ENG
7 New
T.
R.
3 New
(9)
(7)
T.
R.
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembling the oil tank
Oil temperature sensor
Oil tank left cover
Oil tank left cover gasket
Dowel pin
Oil strainer
Oil tank right cover
Oil tank right cover gasket
Dowel pin
Oil pipe
Oil tank
Qty
Remarks
Remove the parts in the order listed.
1
1
1
2
1
1
1
2
1
1
For assembly, reverse the disassembly
procedure.
5 - 87
ENG
3.
Remove:
primary chain 1
middle drive gear 2
middle driven shaft 3
NOTE:
Remove the primary chain, middle drive gear
and middle driven shaft at the same time.
2. Check:
primary chain 1
Damage/stiffness Replace the primary
chain, middle drive gear and middle driven
shaft as a set.
5 - 88
ENG
2. Measure:
inner rotor-to-outer rotor tip clearance a
outer rotor-to-oil pump housing clearance
b
Out of specification Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
3. Check:
oil pump operation
Unsmooth Repair or replace the defective part(-s).
5 - 89
ENG
EAS00375
Install:
oil pump housing 1
oil pump outer rotor 2
oil pump inner rotor 3
oil pump shaft 4
pin 5
NOTE:
When installing the oil pump shaft, align the
pin in the oil pump shaft with the groove in
the oil pump inner rotor.
Align the arrow a on the pump outer rotor
with the arrow b on the oil pump inner rotor.
_
3. Install:
pins 1
oil pump cover 2
T.
R.
NOTE:
Apply locking agent (LOCTITE) to the
threads of the oil pump cover screws.
_
5 - 90
ENG
4. Check:
oil pump operation
Refer to CHECKING THE OIL PUMP.
New
2.
Install:
oil strainer 1
dowel pins 2
transfer gear case cover gasket 3
New
1
2
3. Install:
transfer gear case cover 1
10 Nm (1.0 m kg, 7.2 ft lb)
T.
R.
R.
5 - 91
T.
nut 2
ENG
4. Install:
lock washer New
middle drive gear nut 1
T.
R.
6. Remove:
drive sprocket nut
7. Install:
transfer gear oil pump gasket
transfer gear oil pump 1
New
T.
R.
NOTE:
Apply locking agent (LOCTITE) only to the
threads of the transfer gear oil pump bolts (M6
25 mm) bolts 2.
_
5 - 92
CRANKCASE
ENG
CRANKCASE
Order
Job/Part
Separating the crankcase
Engine
Camshafts
Pistons
Shift shaft
Qty
Generator rotor
1
2
3
1
1
1
5 - 93
Remarks
Remove the parts in the order listed.
Refer to ENGINE.
Refer to CAMSHAFTS.
Refer to CYLINDERS AND PISTONS.
Refer to SHIFT SHAFT AND STOPPER
LEVER.
Refer to GENERATOR AND STARTER
CLUTCH.
CRANKCASE
Order
4
5
6
7
8
Job/Part
Engine oil pump driven gear
Left crankcase
Dowel
Joint pipe
Right crankcase
Qty
1
1
2
1
1
ENG
Remarks
5 - 94
CRANKCASE
Order
1
2
3
Job/Part
Removing the baffle plate and
bearings
Crankshaft
Transmission
Baffle plate
Oil seal
Bearing
Qty
ENG
Remarks
Remove the parts in the order listed.
Refer to CRANKSHAFT AND CONNECTING RODS.
Refer to TRANSMISSION.
1
1
4
For installation, reverse the removal
procedure.
5 - 95
CRANKCASE
ENG
EAS00386
1. Remove:
generator shaft bolt 1
NOTE:
While the holding the generator rotor 2 with
the primary sheave holder 3, loosen the generator shaft bolt.
_
2. Remove:
crankcase bolts
holder
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical
order (refer to the numbers in the illustration).
The numbers embossed on the crankcase
indicate the crankcase tightening sequence.
_
Right crankcase
Left crankcase
M8 100 mm bolts: 1, 2
M8 80 mm bolt: 3
M6 105 mm bolt: K
M6 85 mm bolts: 9, C
M6 75 mm bolts: D, E
M6 60 mm bolts: 4 ~ 7
M6 40 mm bolts: 8, 0 ~ B, F ~ J
5 - 96
CRANKCASE
ENG
3. Turn:
shift drum segment
NOTE:
Turn the shift drum segment 1 to the position
shown in the illustration. In this position, the
shift drum segments teeth will not contact the
crankcase during crankcase separation.
_
4. Remove:
right crankcase
CAUTION:
_
EAS00399
5 - 97
CRANKCASE
ENG
EAS00401
5 - 98
CRANKCASE
ENG
EAS00416
2. Install:
dowel pins 1
joint pipe 2
3. Install:
left crankcase
(onto the right crankcase)
NOTE:
Turn the shift drum segment 1 to the position shown in the illustration. In this position,
the shift drum segments teeth will not contact the crankcase during crankcase installation.
Tap lightly on the left crankcase with a softface hammer.
_
5 - 99
CRANKCASE
ENG
4. Install:
holder
crankcase bolts
NOTE:
Lubricate the bolt threads with engine oil.
Tighten each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern.
Tighten the bolts in numerical order (refer to
the numbers in the illustration).
_
Left crankcase
Right crankcase
M8 100 mm bolts: 1, 2
M8 80 mm bolt: 3
M6 105 mm bolt: K
M6 85 mm bolts: 9, C
M6 75 mm bolts: D, E
M6 60 mm bolts: 4 ~ 7
M6 40 mm bolts: 8, 0 ~ B, F ~ J
T.
R.
Bolt 1 ~ 3
24 Nm (2.4 m kg, 17 ft lb)
Bolt 4 ~ K
10 Nm (1.0 m kg, 7.2 ft lb)
5. Apply:
engine oil
(onto the crankshaft pins bearings and oil
delivery holes)
6. Check:
crankshaft and transmission operation
Rough movement Repair.
Install:
engine oil pump driven gear 1
engine oil pump driven gear stopper 2
oil delivery pipe 3
bolts 4
10 Nm (1.0 m kg, 7.2 ft lb)
T.
7.
R.
8. Install:
generator rotor
Refer to GENERATOR AND STARTER
CLUTCH.
5 - 100
CRANKCASE
ENG
9. Install:
washer
generator shaft bolt 1
T.
R.
NOTE:
Apply locking agent (LOCTITE) to the
threads of the generator shaft bolt.
While holding the generator rotor 2 with the
primary sheave holder 3, tighten the generator shaft bolt.
_
5 - 101
ENG
EAS00356
Order
1
2
Job/Part
Removing the engine oil pump
Crankcase
Oil strainer
Engine oil pump assembly
Qty
Remarks
Remove the parts in the order listed.
Separate.
Refer to CRANKCASE
1
1
For installation, reverse the removal
procedure.
5 - 102
Order
1
2
3
4
5
6
7
8
9
0
A
Job/Part
Disassembling the engine oil pump
Spring retainer
Spring
Relief valve
Oil pump housing cover 1
Pin
Spring
Collar
Ball
Oil pump outer rotor 1
Oil pump inner rotor 1
Pin
Qty
1
1
1
1
2
1
1
1
1
1
1
5 - 103
ENG
Remarks
Remove the parts in the order listed.
Order
B
C
D
E
F
G
H
I
Job/Part
Oil pump housing cover 2
Pin
Oil pump shaft
Pin
Oil pump inner rotor 2
Oil pump outer rotor 2
Oil seal
Oil pump housing
Qty
1
2
1
1
1
1
2
1
ENG
Remarks
5 - 104
ENG
EAS00363
2. Measure:
inner-rotor-to-outer-rotor-tip clearance a
outer-rotor-to-oil-pump-housing clearance
b
Out of specification Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0 ~ 0.12 mm (0 ~ 0.0047 in)
Outer-rotor-to-oil-pump-housing
clearance (feed pump)
0.03 ~ 0.08 mm
(0.0012 ~ 0.0031 in)
Outer-rotor-to-oil-pump-housing
clearance (scavenging pump)
0.06 ~ 0.11 mm
(0.0024 ~ 0.0043 in)
3. Check:
oil pump operation
Rough movement Repeat steps (1) and
(2) or replace the defective part(s).
EAS00365
5 - 105
ENG
Check:
ball 1
collar 2
spring 3
oil seal 4
Damage/wear Replace the defective
part(s).
EAS00368
EAS00375
5 - 106
ENG
Install:
oil pump housing 1
oil seals 2
oil pump outer rotor 2 3
oil pump inner rotor 2 4
pin 5
oil pump shaft 6
pins 7
oil pump housing cover 2 8
pin 9
oil pump inner rotor 1 0
oil pump outer rotor 1 A
ball B
collar C
spring D
pins E
oil pump housing cover 1 F
T.
2.
R.
T.
R.
relief valve G
spring H
spring retainer I
T.
R.
NOTE:
When installing the inner rotor, align the pin in
the oil pump shaft with the groove in the inner
rotor.
_
3. Check:
oil pump operation
Refer to CHECKING THE OIL PUMP.
EAS00376
T.
CAUTION:
_
5 - 107
ENG
EAS00378
R.
NOTE:
The arrow mark on the oil strainer cover must
point towards the rear of the engine.
_
5 - 108
ENG
Order
1
2
3
4
5
6
Job/Part
Removing the crankshaft and
connecting rods
Crankcase
Crankshaft
Generator shaft
Connecting rod cap
Big end lower bearing
Connecting rod
Big end upper bearing
Qty
Remarks
Remove the parts in the order listed.
Separate.
Refer to CRANKCASE.
1
1
2
2
2
2
For installation, reverse the removal
procedure.
5 - 109
ENG
EAS00385
EAS00391
EAS00398
5 - 110
ENG
2.
Check:
crankshaft journal surfaces
crankshaft pin surfaces
bearing surfaces
Scratches/wear Replace the crankshaft.
generator shaft drive gear 1
Damage/wear Replace the crankshaft.
3. Measure:
crankshaft-pin-to-big-end-bearing clearance
Out of specification Replace the big end
bearings.
Crankshaft-pin-to-big-end-bearing clearance
0.037 ~ 0.074 mm
(0.0015 ~ 0.0029 in)
The following procedure applies to all of the
connecting rods.
CAUTION:
_
5 - 111
ENG
WARNING
Replace the connecting rod bolts with
new ones.
Clean the connecting rod bolts.
NOTE:
The tightening procedure of the connecting rod
bolts is angle controlled, therefore tighten the
bolts using the following procedure.
f. Tighten the connecting rod bolts to the
specified torque.
T.
R.
T.
R.
WARNING
When the bolts are tightened more than the
specified angle, do not loosen the bolt and
then retighten it.
Replace the bolt with a new one and perform the procedure again.
5 - 112
ENG
CAUTION:
Do not use a torque wrench to tighten the
bolt to the specified angle.
Tighten the bolt until it is the specified
angle.
NOTE:
When using a hexagonal bolt note that the
angle from one corner to another is 60.
h. Remove the connecting rod and big end
bearings.
Refer to REMOVING THE CONNECTING
RODS.
i. Measure the compressed Plastigauge
width e on each crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select
replacement big end bearings.
5 - 113
P1
P2
ENG
4. Select:
big end bearings (P1 ~ P2)
NOTE:
The numbers a stamped into the crankshaft
web and the numbers b on the connecting
rods are used to determine the replacement
big end bearing sizes.
P1 ~ P2 refer to the bearings shown in the
crankshaft illustration.
_
5 - 114
blue
black
brown
green
yellow
ENG
5. Measure:
crankshaft journal diameter a
Out of specification Replace the crankshaft.
Crankshaft journal diameter
49.968 ~ 49.980 mm
(1.9672 ~ 1.9677 in)
NOTE:
Measure the diameter of each crankshaft journal at two places.
6. Measure:
crankshaft journal bearing inside diameter
a
Out of specification Replace the crankcase assembly.
Crankshaft journal bearing inside
diameter
50.010 ~ 50.028 mm
(1.9689 ~ 1.9696 in)
NOTE:
Measure the inside diameter of each crankshaft journal bearing at two places.
5 - 115
ENG
7. Calculate:
crankshaft journal-to-crankshaft journal
bearing clearance
Out of specification Replace the crankshaft and crankshaft journal bearings as a
set.
NOTE:
Calculate the clearance by subtracting the
crankshaft journal diameter from the crankshaft journal bearing inside diameter.
Crankshaft journal-to-crankshaft
journal bearing clearance
0.030 ~ 0.060 mm
(0.0012 ~ 0.0024 in)
EAS00403
2.
Lubricate:
crankshaft pins
big end bearings
connecting rod inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
5 - 116
ENG
Install:
big end bearings
connecting rods
connecting rod caps
(onto the crankshaft pins)
NOTE:
Align the projections a on the big end bearings with the notches b in the connecting
rods and connecting rod caps.
Be sure to reinstall each big end bearing in
its original place.
Make sure the projection c on the connecting rods face towards the left side of the
crankshaft.
Make sure the characters d on both the connecting rod and connecting rod cap are
aligned.
_
4. Tighten:
connecting rod bolts 1
WARNING
Replace the connecting rod bolts with
new ones.
Clean the connecting rod bolts.
NOTE:
The tightening procedure of the connecting rod
bolts is angle controlled, therefore tighten the
bolts using the following procedure.
T.
R.
T.
R.
5 - 117
ENG
WARNING
When the bolts are tightened more than the
specified angle, do not loosen the bolt and
then retighten it.
Replace the bolt with a new one and perform the procedure again.
CAUTION:
Do not use a torque wrench to tighten the
bolt to the specified angle.
Tighten the bolt until it is the specified
angle.
NOTE:
When using a hexagonal bolt note that the
angle from one corner to another is 60.
EAS00408
2. Install:
crankshaft assembly
CAUTION:
_
5 - 118
TRANSMISSION
ENG
EAS00419
TRANSMISSION
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the transmission, shift
drum assembly, and shift forks
Crankcase
Shift fork guide bar
Shift fork L
Shift fork R
Shift fork C
Shift drum assembly
Drive axle assembly
Main axle assembly
Spacer
Qty
Remarks
Remove the parts in the order listed.
Separate.
Refer to CRANKCASE.
2
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
5 - 119
TRANSMISSION
Order
1
2
3
4
5
6
7
8
Job/Part
Disassembling the main axle
assembly
Circlip
Washer
5th pinion gear
2nd/3rd pinon gear
Circlip
Washer
4th pinon gear
Main axle/1st pinon gear
Qty
ENG
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
5 - 120
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
0
A
B
Job/Part
Disassembling the drive axle
assembly
5th wheel gear
Circlip
Washer
2nd wheel gear
Circlip
Washer
1st wheel gear
4th wheel gear
Circlip
Washer
3rd wheel gear
Drive axle
Qty
ENG
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
5 - 121
TRANSMISSION
ENG
EAS00421
2. Check:
shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends Replace.
WARNING
_
3. Check:
shift fork movement
(along the shift fork guide bar)
Rough movement Replace the shift forks
and shift fork guide bar as a set.
5 - 122
TRANSMISSION
ENG
EAS00422
EAS00425
3. Check:
transmission gears
Blue discoloration/pitting/wear Replace
the defective gear(s).
transmission gear dogs
Cracks/damage/rounded edges Replace
the defective gear(s).
5 - 123
TRANSMISSION
ENG
4. Check:
transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect Reassemble the transmission
axle assemblies.
5. Check:
transmission gear movement
Rough movement Replace the defective
part(s).
6. Check:
circlips
Bends/damage/looseness Replace.
EAS00428
EAS00426
5 - 124
TRANSMISSION
ENG
2. Check:
transmission
Rough movement Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.
_
5 - 125
FI
8 Spark plug
9 Relay unit
0 ECU
A Battery
B Fuel pump
C Lean angle cut-off switch
D Oil temperature sensor
E Decompression solenoid
F Crankshaft position sensor
G Cylinder identification sensor
H Ignition coil
1
2
4 5
3
7
4
2
6
A
B
H
F E
6-1
ON
OFF
L/Y
Br/L R
Br/L L/B L/B
L/Y
6-2
Br/L
Br/L
Br/L
R/B
(GRAY)
R Br/L
L/Y L/B
W
W
W
WWW
W
W
W
R/Y
R/W
Br
R/B
Br/B
Ch
Dg
B L Y
(BLACK)
(BLACK)
Br
(BLACK)
R/B
Br
(BLACK)
R R
(BLACK)
(BLACK)
R/W
R/W L
B A B
R/W B/R Y
Br B/G L/W1
(BLACK)
G G/Y
W
G/Y G
L Y
Br
R/G
R/B
Dg
Ch
Y L B
L
B
L A
Y
L
R/W B/R
Gy/R
B/G
L/W1
L Y/G B/L
(BLACK)
(BLACK)
L
B/L
P
L
B/L
P/Y
L
B/L
P/W
B
Y
L
L/Y
Br/B
R/L
B/L
Gy
B/Y L/Y
(BLACK)
R/Y
R/Y
G/L
R/L
Br
P
(BLACK)
L
W/B
B/L
B/Y
B/L
Y/G
Sb
Lg
B Gy
B/Y
W L
B
(BLACK)
P B/L L
(GRAY)
P/Y B/L L
(BLACK)
P/W B/L L
(BLACK)
L Y B
Gy B/L
L/W1
L B/R
L W/B
B/L
Y G
G/L
Y/B
G
B
(L)
N
(R)
B/W
Br
Br/W
B/L
L
W/Y
(BLUE)
B L/G
B B
(BLUE)
Ch
Ch
Ch
Ch
Dg
Br/W
Br/W
Br
Y/R
Y/R
R/Y R/Y
Y/B
L/G
L/R
B B
(BLACK)
W L
B
Br
(BLACK)
W B
(BLACK)
Br B
(BLACK)
L W/Y
B/L
Sb
B/L Br/W
B/L
L/R
Br/B L
(BLUE)
Y G L/Y
Dg Ch B/Y
Br
Y/R B
Dg
Dg
Dg
Br/W P B
R/Y
Y/R
Br/W
B/Y
R/L
L/R
B/G
Y/G
R/B
Br/W
Br
W
P/W
P/Y
P
L/W
Gy
R/W
L/B
B/L
Y
L
W/B
W/Y
Dg
(BLUE)
B P Br/W
Y/R
G/L
B3 R/W
B3
L/Y G Y
B/Y Ch Dg
B/R
L Ch
Gy
G
Y/B
Lg
G/R
Y/L
Y/R
R/G
P/L
W/G
Br/L
B/O
B/W
(BLACK)
R/G
P/L
W/G
Br/L
Dg
Ch
Br
R/B
R/B
Y Ch
Lg Dg
(GREEN)
Ch Y Br
Dg Lg B
(GREEN)
Br
B
\
]
B G
Gy B Gy
Lg
B/L
G/R
Gy/R
W/G R/G
L
Y W/Y P P/W P/Y Br/W B/R W/B
R/W L/B G Gy Lg B3 B/W B/O
B/L Y/B L/R W Gy Y/R R/L Y/R L/W B3 B/Y B/G
R/W Y/L R/B Br
Br/L P/L G/R Y/G
Gy
G G
B B
(BLACK)
B/R
W Gy
W G
L/R Gy
B/L G/R
(BLUE)
R P
O Br/Y
(RED)
(GRAY)
G/R
L/R
B/L
P
R
O
Br/Y
Lg
Gy
(DARK GRAY)
(BLACK)
Gy/R Lg
G/R B/L
B/W
B/R
B/O
L/R Gy
B/L G/R
(BLUE)
R P
O Br/Y
(RED)
G/R
L/R
B/L
P
R
O
Br/Y
Y/L
R/G
Br
L
Gy
R/G G
(BLUE)
Gy L/R
G/R B/L
(RED)
P R
Br/Y O
G R/G
Br L
B Y/L
L Br
Y/L B
FI
WIRING DIAGRAM
6-3
FI
FI
6-4
FI
Engine trouble warning light indication and FI system operating conditions (normal mode)
Warning light
indication
ECUs operating
condition
FI operating condition
ON and OFF *1
Blinking *2
Operation stopped
Continuous ON
Detecting malfunction
OFF *3
Light
OFF
Light ON for
1.4 seconds
Unable
Light
OFF
*2
Warning control when unable to start engine
This control is effected when any one of the
conditions listed below is present and the
starter switch is turned ON:
a. Battery voltage below the specified value
(defective Fuel injection system relay,
engine stop switch turned OFF, or drained
battery)
b. One of the fault codes listed below has
been detected (self-diagnostic code 12, 19,
30, 41, or 50 is output):
(12: faulty crankshaft position sensor signal)
(19: open circuit in sidestand input line)
(30: a fall has been detected)
(41: open or short circuit in lean angle cutoff switch)
(50: ECU memory check error)
Initialize
6-5
FI
*3
Function to check for blown warning light bulb
The engine trouble warning light illuminates 1
for 1.4 seconds after the main switch has been
turned ON and while the starter switch is
being pressed. If the warning light does not
illuminate under these conditions, a problem
may have possibly occurred, such as a blown
warning light bulb. Therefore, take an appropriate corrective action by referring to the troubleshooting section.
Determining the area of the malfunction through the self-diagnostic fault code number
The possible location of the system in which a problem may be occurring can be determined by
observing the self-diagnostic fault code number that appears on the tachometer and cross-referencing it on the fault code number table. When used in conjunction with the troubleshooting details, and
by checking the possible items one by one, you will be able to identify the cause of the problem in
order to carry out an accurate repair work.
Warning of the occurrence of a malfunction appears on the tachometer.
Determine the area of the problem by referring to the self-diagnostic fault code number.
Turn off the main switch.
Repair the problem area by referring to the troubleshooting details.
Turn ON the main switch in order to revert to normal operation, and erase the fault code from
memory. (Once a fault code is detected by the ECU, it remains stored in the ECU memory even
after the main switch has been turned OFF.)
6-6
FI
11
Symptom
No normal signals are received
from the cylinder identification
sensor.
Able/
unable to
start
Able/
unable to
drive
No.
Symptom
Able/
unable to
start
Able/
unable to
drive
Able
Able
Able
Able
Able
Able
Able
Able
Unable
Unable
Able
Able
Able
Able
Unable
Unable
Able
Able
Able
Able
26
Unable
Unable
27
Able
Able
28
12
13
14
Able
Able
29
15
Able
Able
30
16
Able
Able
37
19
Unable
Unable
38
20
22
23
25
Able
Able
41
Able
Able
42
Able
Able
43
Able
Able
50
Unable
Unable
Able
Able
6-7
FI
Item
Fail-safe action
Able/unable to
start
Able/unable to
drive
Able
Able
Unable
Unable
Able
Able
Able
Able
Unable
Unable
Able
Able
Able
Able
Able
Able
Able
Able
Able
Able
Cylinder identification
sensor
15
16
Sidestand switch
(open circuit in wire to
ECU)
-- (No start)
19
Atmospheric pressure
sensor or intake air pressure sensor
20
22
23
Atmospheric pressure
sensor
27
28
29
Decompression thermostat
Able
Able
37
--
Able
Able
38
Decompression solenoid
--
Able
Able
30
41
Unable
Unable
42
Able
Able
43
Able
Able
50
--
Unable
Unable
11
12
13
14
25
26
6-8
FI
TROUBLESHOOTING
Diagnosis mode troubleshooting 1 (self-diagnostic malfunction detected)
By entering a diagnostic code in the ECU through the use of the SELECT and RESET buttons on
the tachometer, the sensor output values can be displayed and the actuators can be operated in
accordance with the code that has been entered.
The technician determines whether or not the operation is normal by verifying the values displayed
on the tachometer or the operating conditions of the actuators. These modes can be used to detect
and check the problems that are otherwise difficult to detect in the diagnosis mode.
Basic operation procedure
Operation preparation
Verify the self-diagnostic fault code number that is displayed on the meter.
Based on the self-diagnostic fault code number, select the applicable sensor or actuator from the
diagnostic code table.
If a diagnostic code is available, proceed with the operation procedure given below in order to
verify the operating conditions of the applicable sensor or actuator.
Operation procedure (make sure to turn OFF the main switch upon completing the operation preparation)
Setting the ECU in the diagnosis mode
1. While keeping the SELECT and RESET
buttons pressed simultaneously, turn ON
the main switch 1 (keep them pressed for
8 seconds or more).
* Letters dIAG appear on the clock LCD.
ON
OFF
TRIP
0D0
km
mile
TRIP
0D0
SELECT
6-9
km
mile
RESET
FI
6 - 10
TRIP
0D0
km
mile
SELECT
RESET
SELECT
(01 70)
TRIP
0D0
SELECT
km
mile
RESET
RESET
(01 70)
6 - 11
FI
FI
Symptom
No normal signals are received from
the cylinder identification sensor.
03
03
02
03
01
01
14
15
16
19
20
22
Diagnostic code
11
13
03
02
05
6 - 12
01
03
02
20
Symptom
FI
Diagnostic code
02
02
03
02
03
01
10
11
55
Overturned.
Malfunction in ECU.
08
10
54
55
08
07
21
43
The ECU is unable to monitor the battery voltage (an open circuit in the
monitor line to the ECU).
50
Faulty ECU memory. When this malfunction is detected, the code number
might not appear on the meter.
23
25
26
27
28
29
30
37
38
41
42
6 - 13
FI
Item
Description of action
Throttle angle
0 ~ 125 degrees
Fully closed position (15 ~ 20)
Fully open position (95 ~ 100)
Atmospheric pressure
Pressure difference 1
Displays the pressure difference 1 (atmospheric pressure intake air pressure 1).
Engine stop switch is on.
* Generate the pressure difference by cranking the engine
with the starter, without actually starting the engine.
10 ~ 200 mmHg
Pressure difference 2
Same as above
Intake temperature
Displays the accumulation of the vehicle pulses that are generated when the tire is spun.
08
09
0 ~ 18.7 V
Normally, approximately 12.0 V
Engine temperature
Sidestand switch
Stand retracted: ON
Stand extended: OFF
Neutral switch
Neutral: ON
In gear: OFF
Displays the faulty cylinder that has been detected by a selfdiagnostic fault code.
If multiple malfunctions have been detected, the same data
is transmitted 128 times, then different data is transmitted
repeatedly.
Malfunction history
code display
Displays the codes of the history of the self-diagnosis malfunctions (i.e., a code of a malfunction that occurred once
and which has been corrected).
If multiple malfunctions have been detected, the same data
is transmitted 128 times, then different data is transmitted
repeatedly.
11 ~ 55
(00) Displays when there is no
malfunction.
01
02
03
04
05
07
10
11
20
21
60
61
6 - 14
FI
Item
Malfunction history
code erasure
00 ~ 21
(00) Displays when there is no
malfunction.
Control number
00 ~ 255
62
70
Description of action
6 - 15
FI
Item
Ignition coil #1
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates ignition
coils #1 for five times every second and illuminates the engine
trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Ignition coil #2
Same as above
Injector #1
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the injector five times every second and illuminates the engine trouble
warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Injector #2
Same as above
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the fuel
injection system relay five times every second and illuminates
the engine trouble warning light (the light is OFF when the
relay is ON, and the light is ON when the relay is OFF).
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Headlight relay
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the linear
control valve four times every 5 seconds and illuminates the
engine trouble warning light (fully closed 2 seconds, fully open
2 seconds).
Decompression solenoid
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the
decompression solenoid five times every 5 seconds and illuminates the engine trouble warning light (ON 2 seconds, OFF
3 seconds).
NOTE: Be sure to turn the start switch to ON, otherwise the
above mentioned operation will not be possible.
30
31
36
37
50
52
54
55
Description of action
6 - 16
FI
OK
Not OK
Faulty engine
Refer to chapter 5 to
check and repair the
engine.
Not OK
Check the condition of the engine.
OK
No codeis displayed
Repairs are complete.
6 - 17
FI
Troubleshooting details
Troubleshooting the self-diagnostic fault code
Code No.
11
Symptom
Reinstatement
method
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
Reinstated by
starting the engine
and operating it at
idle.
Code No.
12
Symptom
Reinstatement
method
Reinstated by
cranking the
engine.
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
6 - 18
13
Symptom
FI
Reinstatement
method
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
6 - 19
14
Symptom
FI
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
1.Common to 1, 2, and 3:
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
Reinstated by
starting the engine
and operating it at
idle.
Reinstated by
starting the engine
and operating it at
idle.
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
3-2.Throttle position sensor lead wire open circuit output voltage check
(B/L - Y)
Black/Blue - Yellow
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
6 - 20
Reinstated by
starting the engine,
operating it at idle,
and then by racing
it.
15
Symptom
FI
Reinstatement
method
4.Throttle position sensor lead wire open circuit output voltage check
(B/L - Y)
Black/Blue - Yellow
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
6 - 21
16
Symptom
FI
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
1.Common to 1 and 2:
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
Reinstated by
starting the engine,
operating it at idle,
and then racing it.
4.Throttle position sensor lead wire open circuit output voltage check
(B/L - Y)
Black/Blue - Yellow
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
6 - 22
19
FI
Symptom
Open circuit is detected in the input line from the sidestand switch to the
ECU.
Used diagnostic code No. 20 (sidestand switch)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
1.Open or short circuit in wiring harness or
Repair or replace if there is an open or short If the transmission
sub lead.
circuit.
is in gear, it is rein(Between ECU and sidestand)
stated by retracting
2.Connected state of connector
If there is a malfunction, repair it and connect it the sidestand.
If the transmission
Inspect the coupler for any pins that may
securely.
is in neutral, it is
have pulled out.
Main wiring harness ECU coupler
reinstated by
Check the locking condition of the coupler.
(No. 43 pin, black)
reconnecting the
(Alarm coupler)
wiring.
ECU coupler illustration
(Indicate No. 43 pin)
3.Defective sidestand switch
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
Code No.
22
Symptom Open or short circuit detected from the intake temperature sensor.
Used diagnostic code No. 05 (intake temperature sensor)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
1.Installed state of sensor
Check the installed area for looseness or
Reinstated by turnpinching.
ing the main switch
2.Open or short circuit in wiring harness or
Repair or replace if there is an open or short ON.
sub lead.
circuit.
Main wiring harness
Black/Blue - Black/Blue
Brown/White - Brown/White
3.Connected state of connector
If there is a malfunction, repair it and connect it
Inspect the coupler for any pins that may
securely.
have pulled out.
Intake temperature sensor coupler
Check the locking condition of the coupler.
Main wiring harness ECU coupler
4.Defective intake temperature sensor.
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
6 - 23
23
Symptom
FI
Reinstatement
method
1.Installed state of atmospheric pressure sen- Check the installed area for looseness or
sor
pinching.
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
Code No.
25
Symptom
Reinstatement
method
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
6 - 24
26
Symptom
FI
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
1.Common to 1, 2, and 3:
Connected state of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
Reinstated by
starting the engine
and operating it at
idle.
Reinstated by
starting the engine
and operating it at
idle.
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
3-2.Throttle position sensor lead wire open circuit output voltage check
(B/L - Y)
Black/Blue - Yellow
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
6 - 25
Reinstated by
starting the engine,
operating it at idle,
and then by racing
it.
FI
Code No.
27
Symptom Open or short circuit is detected from the oil temperature sensor.
Used diagnostic code No. 10 (oil temperature sensor)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
1.Installed state of sensor
Check the installed area for looseness or
Reinstated by turnpinching.
ing the main switch
2.Open or short circuit in wiring harness or
Repair or replace if there is an open or short ON.
sub lead.
circuit.
Main wiring harness
Black/Blue - Black/Blue
White - White
3.Connected state of connector
If there is a malfunction, repair it and connect it
Inspect the coupler for any pins that may
securely.
have pulled out.
Oil temperature sensor coupler
Check the locking condition of the coupler.
Main wiring harness ECU coupler
4.Defective oil temperature sensor.
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
Code No.
28
Symptom Open or short circuit is detected from the engine temperature sensor.
Used diagnostic code No. 11 (engine temperature sensor)
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
1.Installed state of sensor
Check the installed area for looseness or
Reinstated by turnpinching.
ing the main switch
2.Open or short circuit in wiring harness or
Repair or replace if there is an open or short ON.
sub lead.
circuit.
Main wiring harness
Black - Black
Brown - Brown
3.Connected state of connector
If there is a malfunction, repair it and connect it
Inspect the coupler for any pins that may
securely.
have pulled out.
Engine temperature sensor coupler
Check the locking condition of the coupler.
Main wiring harness ECU coupler
4.Defective engine temperature sensor.
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
6 - 26
29
Symptom
Code No.
30
Symptom
FI
Reinstated by turning
the main switch
Check the installed area for looseness or
ON
(however, the
pinching.
engine cannot be
If there is a malfunction, repair it and connect it restarted unless
securely.
the main switch is
Lean angle cut-off switch coupler
first turned OFF).
Main wiring harness ECU coupler
Replace if defective.
Reinstatement
method
6 - 27
FI
Code No.
37
Used diagnostic code
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
Reinstatement
method
Perform diagnostic code 54 to
check the operation of the linear
control valve.
6 - 28
41
Symptom
FI
Reinstatement
method
Replace if defective.
Code No.
42
Symptom
Inspection operation item and probable cause Operation item and countermeasure
Reinstatement
method
Reinstated by
starting the engine,
and inputting the
vehicle speed signals by operating
the motorcycle at a
low speed of 20 to
30 km/h.
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
Replace if defective.
Refer to TRANSMISSION in chapter 5.
Replace if defective.
Refer to CHECKING THE SWITCHES in
chapter 7.
6 - 29
43
Symptom
FI
Reinstatement
method
1.Malfunction in ECU
Reinstated by
starting the engine
and operating it at
idle.
Replace if defective.
Refer to FUEL INJECTION SYSTEM in
chapter 7.
If there is no malfunction with the fuel injection
system relay, replace the ECU.
Code No.
50
Symptom
Faulty ECU memory. (When this malfunction is detected in the ECU, the
fault code number might not appear on the meter.)
Reinstatement
method
1.Malfunction in ECU
6 - 30
FI
The engine trouble warning light does not illuminate when the start switch is pressed.
Open or short circuit in start switch
Open or short circuit in wiring harness
Open circuit in warning light bulb
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1 indicated on
the left.
Open or short circuit in start switch
Inspect the handlebar switch for continuity.
Refer to CHECKING THE SWITCHES in chapter 7.
Defective: replace
Open or short circuit in wiring harness
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
Open circuit in warning light bulb
Inspect the bulb for continuity.
Defective: replace
6 - 31
FI
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the are of the malfunction has
been narrowed down in the inspection method 1 given on the
left.
Symptom
Probable malfunction area
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Open or short circuit in injector
Open or short circuit in wiring harness
6 - 32
FI
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1.
Symptom
Probable malfunction area
Clock LCD displays Er-1. (No signals are received from the ECU.)
Open or short circuit in communication line
Malfunction in meter
Malfunction in ECU
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1 given on the
left.
Inspect ECU coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
Inspect meter coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
6 - 33
FI
Clock LCD displays Er-2. (No signals are received from the ECU within the specified duration.)
Improper operation of communication line
Malfunction in meter
Malfunction in ECU
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1 given on the
left.
Inspect ECU coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
Inspect meter coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
Symptom
Probable malfunction area
Clock LCD displays Er-3. (Data from the ECU cannot be received correctly.)
Improper operation of communication line
Malfunction in meter
Malfunction in ECU
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1 given on the
left.
Inspect ECU coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
Inspect meter coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
Symptom
Probable malfunction area
Clock LCD displays Er-4. (Non-registered data has been received from the meter.)
Improper operation of communication line
Malfunction in meter
Malfunction in ECU
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1 given on the
left.
Inspect ECU coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
Inspect meter coupler
Inspect the wiring harness and couplers for continuity.
Defective: repair or replace
6 - 34
FI
Sidestand switch does not function (the engine does not stop when the stand is extended).
Short circuit in the input line to ECU
Malfunction in the starter circuit cut-off relay
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1 given on the
left.
6 - 35
FI
Engine trouble warning light blinks while the start switch is being pressed (to warn that the engine
is unable to start).
Inspection method 1
Inspection by diagnosis mode
Inspection method 2
Inspection of a malfunction that cannot be identified in the
diagnosis mode, and in case the area of the malfunction has
been narrowed down in the inspection method 1.
6 - 36
FI
7
3
5
6
4
2
3
R.
Order
T.
Job/Part
Removing the throttle bodies
Seat
Qty
1
1
4
1
6 - 37
Remarks
Remove the parts in the order listed.
Refer to SEAT AND SIDE COVERS in
chapter 3.
Refer to FUEL TANK in chapter 3.
Refer to AIR FILTER CASE in chapter
3.
Refer to SILENCER AIR FILTER CASE
in chapter 3.
Disconnect.
Disconnect.
Disconnect.
FI
7
3
5
6
4
2
3
Job/Part
Throttle stop screw
Throttle body joint screw
Throttle bodies
Throttle cable
Throttle position sensor
R.
Order
5
6
7
8
9
T.
Qty
Remarks
1
2
1
2
Disconnect.
1
Refer to FUEL INJECTION SYSTEM in
chapter 7.
For installation, reverse the removal
procedure.
6 - 38
FI
4
1
5
(2)
3
3
6 New
New 6
2
T.
R.
Order
1
2
3
4
5
6
(2)
Job/Part
Removing the intake manifolds
Engine temperature sensor coupler
Injection sub-wire harness coupler
Fuel hose
Linear control valve outlet hose
Intake manifolds
Gasket
Qty
1
1
2
2
1
2
Remarks
Remove the parts in the order listed.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
6 - 39
FI
T.
R.
New
New
4
5
New
New
1
2
7
3
6
Order
1
2
3
4
5
6
7
Job/Part
Removing the injectors
Cylinder #1-injector coupler
Cylinder #2-injector coupler
Injector sub-wire harness
Fuel pipe
Injector joint 1
Injector joint 2
Injector
Qty
1
1
1
1
1
1
2
Remarks
Remove the parts in the order listed.
Disconnect.
Disconnect.
6 - 40
FI
CAUTION:
The throttle bodies should not be disassembled unnecessarily.
2. Check:
fuel passages
Obstruction Clean.
6 - 41
FI
5
3
Mity vac
YB-35956
Pressure gauge
YU-03153
Fuel pressure adapter
YM-03176
g. Start the engine.
h. Measure the fuel pressure.
Fuel pressure
328 kPa (3.28 kg/cm2, 3.28 psi)
i. Use the vacuum pressure pump gauge set
to adjust the fuel pressure in relation to the
vacuum pressure as described below.
NOTE:
The vacuum pressure should not exceed
100 kPa (1 mmHg).
Increase the vacuum pressure
Fuel pressure is decreased
Decrease the vacuum pressure
Fuel pressure is increased
Faulty Replace the pressure regulator.
6 - 42
FI
EAS00507
EAS00508
6 - 43
FI
T.
R.
T.
R.
2
2
4
7
6
Order
1
2
3
4
5
6
7
Job/Part
Removing the air cut-off valve
assembly and hoses
Fuel hose joint 1/air duct
Fuel hose joint
Fuel hose
A.I.S. vacuum hose
Resonator hose
Reed valve case to front cylinder head
hose
Reed valve case to rear cylinder head
hose
Air cut-off valve assembly
Qty
1
2
1
1
1
Remarks
Remove the parts in the order listed.
Refer to FUEL TANK in chapter 3.
Disconnect.
1
1
For installation, reverse the removal
procedure.
6 - 44
FI
REED VALVES
T.
R.
3
6
Order
1
2
3
4
5
6
Job/Part
Removing the reed valves
Air cut-off valve assembly/hoses
A.I.S. vacuum hose
Reed valve cover
Reed valve assembly
Reed valve case
Pressure regulator
A.I.S. bracket
Qty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
For installation, reverse the removal
procedure.
6 - 45
FI
EAS00510
6 - 46
ELECTRICAL COMPONENTS
ELEC
EAS00729
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
1 Ignition coil 2
2 Ignition coil 1
3 Intake air pressure sensor 2
4 Front brake light switch
5 Main switch
6 Intake air pressure sensor 1
7 Clutch switch
8 Atmospheric pressure sensor
9 ECU
0 Battery
A Fuel pump
B Horn 2
C Decompression solenoid
D Sidestand switch
E Crankshaft position sensor
F Starter motor
G Horn 1
H Rectifier/regulator
5
6
4
9
0
6
A
7
G
F
C
E
D
7-1
ELECTRICAL COMPONENTS
1 Intake air temperature sensor
2 Linear control valve
3 Throttle position sensor
4 Engine temperature sensor
5 Spark plugs
6 Fuse box
7 Main fuse
8 Starter relay
9 Turn signal relay
0 Headlight relay
A Relay unit
B Speed sensor
C Lean angle cut-off switch
D Oil temperature sensor
E Neutral switch
F Stator coil assembly
G Rear brake light switch
H Cylinder identification sensor
ELEC
8
5
A
G
B
E
7-2
ELEC
1 Rear turn signal light (left) connectors and license plate light connectors
2 Rear turn signal light (right) connectors
3 Tail/brake light coupler
7-3
9 Starter motor
0 Starter motor lead
A Rectifier/regulator coupler
B Stator coil assembly coupler
C Horn 1 connectors
D Horn 1
E Rectifier/regulator
F Linear control valve coupler
3 4
E
D
7
CB
ELEC
0 9
7-4
ELEC
1 ECU coupler
2 ECU
3 Tail sub-wire harness coupler, decompression solenoid couplers, cylinder identification coupler, crankshaft
position sensor coupler, speed sensor coupler, neutral switch connector and sidestand switch coupler
4 Fuel pump coupler
5 Horn 2
6 Horn 2 coupler
7 Lean angle cut-off switch coupler
8 Lean angle cut-off switch
1
2
3
8
7
7-5
ELEC
4
5
6
C
A
0
A
9
6
8
7-6
4 5 6
2
1
F
8
E
9
D
ELEC
7-7
ELEC
EAS00730
CAUTION:
_
Never insert the tester probes into the coupler terminal slots 1. Always insert the
probes from the opposite end of the coupler, taking care not to loosen or damage
the leads.
Pocket tester
YU-03112
NOTE:
Before checking for continuity, set the pocket
tester to 0 and to the 1 range.
When checking for continuity, switch back
and forth between the switch positions a few
times.
_
b
R Br/L L/Y L/B
ON
OFF
R Br/L
L/Y L/B
NOTE:
7-8
ELEC
EAS00731
Y R/Y G
Y G L/Y
Dg Ch B/Y
(BLUE)
ON
OFF
R Br/L
L/Y L/B
P B
Rr/W P B
R/Y
Y/R
Ch Br/W Dg B Y/R
(L)
N
(R)
4
B/Y L/Y
(BLACK)
R/W R/B
L/W B
G/Y
Br
G/Y R/B R/W
L/W B Br
(BLACK)
B
Sb
B B
(BLUE)
7 - 10
B B
(BLUE)
7 - 11
ELEC
ELEC
EAS00732
TYPES OF BULBS
The bulbs used on this motorcycle are shown
in the illustration on the left.
Bulbs A and B are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by
turning them counterclockwise.
Bulbs C is used for turn signal and tail/
brake lights and can be removed from the
socket by pushing and turning the bulb
counterclockwise.
Bulbs D and E are used for meter and indicator lights and can be removed from their
respective socket by carefully pulling them
out.
7 - 12
ELEC
WARNING
_
CAUTION:
_
a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2, and check the continuity.
b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3, and check the continuity.
c. If either of the readings indicate no continuity, replace the bulb.
7 - 13
ELEC
7 - 14
Dg Lg B
Br
Ch Y
Br
Dg Lg B
1
Ch Y
ELEC
WARNING
_
7 - 15
ON
OFF
R Br/L
L/Y
Br/L R
Br/L L/B L/B
L/Y
7 - 16
Br/L
Br/L
Br/L
R/B
(GRAY)
L/Y L/B
W
W
W
WWW
W
W
W
R/Y
R/W
Br
R/B
Br/B
Ch
Dg
B L Y
(BLACK)
(BLACK)
Br
(BLACK)
R/B
Br
(BLACK)
R R
(BLACK)
(BLACK)
R/W
R/W L
B A B
R/W B/R Y
Br B/G L/W1
(BLACK)
G G/Y
W
G/Y G
L Y
Br
R/G
R/B
Dg
Ch
Y L B
L
B
L A
Y
L
R/W B/R
Gy/R
B/G
L/W1
L Y/G B/L
(BLACK)
(BLACK)
L
B/L
P
L
B/L
P/Y
L
B/L
P/W
B
Y
L
L/Y
Br/B
R/L
B/L
Gy
B/Y L/Y
(BLACK)
R/Y
R/Y
G/L
R/L
Br
P
(BLACK)
L
W/B
B/L
B/Y
B/L
Y/G
Sb
Lg
B Gy
B/Y
W L
B
(BLACK)
P B/L L
(GRAY)
P/Y B/L L
(BLACK)
P/W B/L L
(BLACK)
L Y B
Gy B/L
L/W1
L B/R
L W/B
B/L
Y G
G/L
Y/B
G
B
(L)
N
(R)
B/W
Br
Br/W
B/L
L
W/Y
(BLUE)
B L/G
B B
(BLUE)
Ch
Ch
Ch
Ch
Dg
Br/W
Br/W
Br
Y/R
Y/R
R/Y R/Y
Y/B
L/G
L/R
B B
(BLACK)
W L
B
Br
(BLACK)
W B
(BLACK)
Br B
(BLACK)
L W/Y
B/L
Sb
B/L Br/W
B/L
L/R
Br/B L
(BLUE)
Y G L/Y
Dg Ch B/Y
Br
Y/R B
Dg
Dg
Dg
Br/W P B
R/Y
Y/R
Br/W
B/Y
R/L
L/R
B/G
Y/G
R/B
Br/W
Br
W
P/W
P/Y
P
L/W
Gy
R/W
L/B
B/L
Y
L
W/B
W/Y
Dg
B P Br/W
Y/R
G/L
(BLUE)
B3 R/W
B3
L/Y G Y
B/Y Ch Dg
B/R
L Ch
Gy
G
Y/B
Lg
G/R
Y/L
Y/R
R/G
P/L
W/G
Br/L
B/O
B/W
(BLACK)
R/G
P/L
W/G
Br/L
Dg
Ch
Br
R/B
R/B
Y Ch
Lg Dg
(GREEN)
Ch Y Br
Dg Lg B
(GREEN)
Br
B
\
]
B G
Gy B Gy
Lg
B/L
G/R
Gy/R
W/G R/G
L
Y W/Y P P/W P/Y Br/W B/R W/B
R/W L/B G Gy Lg B3 B/W B/O
B/L Y/B L/R W Gy Y/R R/L Y/R L/W B3 B/Y B/G
R/W Y/L R/B Br
Br/L P/L G/R Y/G
Gy
G G
B B
(BLACK)
B/R
W Gy
W G
L/R Gy
B/L G/R
(BLUE)
R P
O Br/Y
(RED)
(GRAY)
G/R
L/R
B/L
P
R
O
Br/Y
Lg
Gy
(DARK GRAY)
(BLACK)
Gy/R Lg
G/R B/L
B/W
B/R
B/O
Gy
R/G G
P R
Br/Y O
G R/G
L/R Gy
B/L G/R
(BLUE)
R P
O Br/Y
(RED)
G/R
L/R
B/L
P
R
O
Br/Y
Y/L
R/G
Br
L
Br L
B Y/L
(RED)
Gy L/R
G/R B/L
(BLUE)
L Br
Y/L B
3 Main switch
X
4 Battery
Y
6 Main fuse
9 Relay unit
C Neutral switch
D Sidestand switch
E Crankshaft position sensor
K Lean angle cut-off switch
P ECU
R Ignition coil
S Spark plug
u Engine stop switch
{ Ignition fuse
IGNITION SYSTEM
ELEC
EAS00735
IGNITION SYSTEM
CIRCUIT DIAGRAM
IGNITION SYSTEM
EAS00737
ELEC
EAS00738
TROUBLESHOOTING
Check:
1. main and ignition fuses
2. battery
3. spark plugs
4. ignition spark gap
5. spark plug cap resistance
6. ignition coil resistance
7. crankshaft position sensor resistance
8. main switch
9. engine stop switch
10.neutral switch
11.sidestand switch
12.lean angle cut-off switch voltage
13.relay unit (diode)
14.wiring connections
(of the entire ignition system)
YES
NO
Replace the fuse(s).
EAS00739
2. Battery
Check the condition of the battery.
Refer to CHECKING AND CHARGING
THE BATTERY in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20 C (68 F)
NOTE:
Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. silencer air filter case
4. side covers
5. ignition coils
6. headlight lens unit
7. horn 2
Troubleshoot with the following special
tool(s).
YES
NO
Clean the battery
terminals.
Recharge
or
replace the battery.
EAS00741
3. Spark plugs
The following procedure applies to all of the
spark plugs.
Check the condition of the spark plug.
Check the spark plug type.
Measure the spark plug gap.
Refer to CHECKING THE SPARK
PLUGS in chapter 3.
Standard spark plug
DPR7EA-9 (NGK)
X22EPR-U9 (DENSO)
Spark plug gap
0.8 ~ 0.9 mm (0.0315 ~ 0.0354 in)
7 - 17
IGNITION SYSTEM
Is the spark plug in good condition, is it of
the correct type, and is its gap within specification?
YES
NO
Re-gap or replace
the spark plug.
EAS00743
ELEC
EAS00745
YES
Replace the
plug cap.
NO
The ignition system
is OK.
7 - 18
spark
ELEC
IGNITION SYSTEM
EAS00747
NO
YES
NO
Replace the crankshaft position sensor.
7 - 19
IGNITION SYSTEM
ELEC
EAS00749
8. Main switch
NO
YES
Replace
switch.
the
main
EAS00750
NO
Replace the right
handlebar switch.
EAS00751
10.Neutral switch
a
ON
ON
NO
b
Replace the neutral
switch.
NO
EAS00752
11.Sidestand switch
NO
Replace the
stand switch.
side-
7 - 20
IGNITION SYSTEM
EAS00760
ELEC
EAS00754
14.Wiring
Continuity
No continuity
321
Br/B L
L/R
NOTE:
When you switch the testers positive and
negative probes, the readings in the above
chart will be reversed.
_
NO
Replace the starting
circuit cut-off relay.
7 - 21
NO
Properly connect or
repair the ignition
systems wiring.
3 Main switch
4 Battery
6 Main fuse
7 Starter relay
8 Starter motor
9 Relay unit
0 Starting circuit cut-off relay
C Neutral switch
D Sidestand switch
P ECU
T Decompression solenoid
j Clutch switch
u Engine stop switch
v Start switch
{ Ignition fuse
} Decompression solenoid
fuse
ON
OFF
L/Y
Br/L R
Br/L L/B L/B
L/Y
7 - 22
Br/L
Br/L
Br/L
R/B
(GRAY)
R Br/L
L/Y L/B
W
W
W
WWW
W
W
W
R/Y
R/W
Br
R/B
Br/B
Ch
Dg
B L Y
(BLACK)
(BLACK)
Br
(BLACK)
R/B
Br
(BLACK)
(BLACK)
G G/Y
W
G/Y G
B A B
(BLACK)
R/W
(BLACK)
R/W L
R/W B/R Y
Br B/G L/W1
R R
L Y
Br
R/G
R/B
Dg
Ch
Y L B
L
B
L A
R/W B/R
Gy/R
B/G
L/W1
L Y/G B/L
(BLACK)
(BLACK)
L
B/L
P
L
B/L
P/Y
L
B/L
P/W
B
Y
L
L/Y
Br/B
R/L
B/L
Gy
B/Y L/Y
(BLACK)
R/Y
R/Y
G/L
R/L
Br
P
(BLACK)
L
W/B
B/L
B/Y
B/L
Y/G
Sb
Lg
B Gy
B/Y
W L
B
(BLACK)
P B/L L
(GRAY)
P/Y B/L L
(BLACK)
P/W B/L L
(BLACK)
L Y B
Gy B/L
L/W1
L B/R
L W/B
B/L
Y/B
Y G
G/L
Y/B
G
B
(L)
N
(R)
B/W
Br
Br/W
B/L
L
W/Y
(BLUE)
B L/G
B B
(BLUE)
Ch
Ch
Ch
Ch
Dg
Br/W
Br/W
Br
Y/R
Y/R
R/Y R/Y
L/G
L/R
B B
(BLACK)
W L
B
Br
(BLACK)
W B
(BLACK)
Br B
(BLACK)
L W/Y
B/L
Sb
B/L Br/W
B/L
L/R
Br/B L
(BLUE)
Y G L/Y
Dg Ch B/Y
Br
Y/R B
Dg
Dg
Dg
Br/W P B
R/Y
Y/R
Br/W
B/Y
R/L
L/R
B/G
Y/G
R/B
Br/W
Br
W
P/W
P/Y
P
L/W
Gy
R/W
L/B
B/L
Y
L
W/B
W/Y
Dg
B P Br/W
Y/R
G/L
(BLUE)
B3 R/W
B3
L/Y G Y
B/Y Ch Dg
B/R
L Ch
Gy
G
Y/B
Lg
G/R
Y/L
Y/R
R/G
P/L
W/G
Br/L
B/O
B/W
(BLACK)
R/G
P/L
W/G
Br/L
Dg
Ch
Br
R/B
R/B
Y Ch
Lg Dg
(GREEN)
Ch Y Br
Dg Lg B
(GREEN)
Br
B
\
]
B G
Gy B Gy
Lg
B/L
G/R
Gy/R
W/G R/G
L
Y W/Y P P/W P/Y Br/W B/R W/B
R/W L/B G Gy Lg B3 B/W B/O
B/L Y/B L/R W Gy Y/R R/L Y/R L/W B3 B/Y B/G
R/W Y/L R/B Br
Br/L P/L G/R Y/G
Gy
G G
B B
(BLACK)
B/R
W Gy
W G
L/R Gy
B/L G/R
(BLUE)
R P
O Br/Y
(RED)
(GRAY)
G/R
L/R
B/L
P
R
O
Br/Y
Lg
Gy
(DARK GRAY)
(BLACK)
Gy/R Lg
G/R B/L
B/W
B/R
B/O
ELEC
EAS00755
CIRCUIT DIAGRAM
ELEC
EAS00756
7 - 23
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
Check:
1. main, ignition and decompression solenoid
fuses
2. battery
3. starter motor
4. relay unit (starting circuit cut-off relay)
5. relay unit (diode)
6. starter relay
7. main switch
8. engine stop switch
9. neutral switch
10.sidestand switch
11.clutch switch
12.start switch
13.decompression solenoid
14.wiring connections
(of the entire starting system)
YES
3. Starter motor
Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
lead 3.
NOTE:
Before troubleshooting, remove the following
part(s):
1. seat
2. headlight lens unit
Troubleshoot with the following special
tool(s).
_
Pocket tester
YU-03112
EAS00738
WARNING
NO
NO
Repair or replace the
starter motor.
7 - 24
YES
Replace
unit.
the
Br/B L
ELEC
relay
43 12
EAS00760
Br/B L
L/R
NOTE:
When you switch the testers positive and
negative probes, the readings in the above
chart will be reversed.
_
YES
Replace
unit.
7 - 25
the
relay
ELEC
EAS00750
6. Starter relay
YES
NO
Replace the right
handlebar switch.
EAS00751
9. Neutral switch
Check the neutral switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the neutral switch OK?
YES
Does the starter relay have continuity
between red and black?
NO
YES
NO
Replace the neutral
switch.
EAS00752
10.Sidestand switch
Check the sidestand switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the sidestand switch OK?
7. Main switch
YES
Replace the
stand switch.
NO
YES
NO
side-
EAS00763
11.Clutch switch
Replace
switch.
the
main
NO
Replace the clutch
switch.
7 - 26
ELEC
EAS00764
Decompression solenoid
resistance
1.2 at 20 C (68 F)
12.Start switch
Check the start switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the start switch OK?
NO
YES
YES
Replace the right
handlebar switch.
NO
Replace the decompression solenoid.
13.Decompression solenoid
EAS00766
14.Wiring
Check the entire starting systems wiring.
Refer to CIRCUIT DIAGRAM.
Is the starting systems wiring properly
connected and without defects?
YES
Replace the ECU.
Measure the
resistance.
decompression
solenoid
Decompression solenoid
resistance (thermistor)
70 at 25 C (77 F)
NOTE:
The resistance value for the thermistor
changes when the temperature changes;
therefore, measure the decompression solenoid resistance at the specified temperature.
_
7 - 27
NO
Properly connect or
repair the starting
systems wiring.
STARTER MOTOR
ELEC
EAS00767
STARTER MOTOR
T.
R.
Order
1
2
Job/Part
Removing the starter motor
Starter motor lead
Starter motor assembly
Qty
Remarks
Remove the parts in the order listed.
1
1
For installation, reverse the removal
procedure.
7 - 28
STARTER MOTOR
ELEC
LS
2
New
48
D New
E
F
A
0
D
New
C
9
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembling the starter motor
Circlip
Starter motor gear
Starter motor rear cover
Lock washer
Washer set
Oil seal
Bearing
Circlip
Starter motor front cover
Brush
Qty
1
1
1
1
1
1
1
1
1
2
7 - 29
Remarks
Remove the parts in the order listed.
STARTER MOTOR
ELEC
LS
2
New
48
D New
E
F
A
0
D
New
C
9
Order
A
B
C
D
E
F
Job/Part
Brush holder (along with the brushes)
Brush seat (along with the brushes)
Bearing
Gasket
Armature assembly
Starter motor yoke
Qty
Remarks
1
1
1
Refer to ASSEMBLING THE STARTER
MOTOR.
2
1
1
For assembly, reverse the disassembly
procedure.
7 - 30
STARTER MOTOR
ELEC
EAS00770
2. Measure:
commutator diameter a
Out of specification Replace the starter
motor.
Commutator wear limit
27.5 mm (1.08 in)
3. Measure:
mica undercut a
Out of specification Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.
Mica undercut
1.5 mm (0.06 in)
NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
_
7 - 31
STARTER MOTOR
ELEC
4. Measure:
armature assembly resistances (commutator and insulation)
Out of specification Replace the starter
motor.
5. Measure:
brush length a
Out of specification Replace the brushes
as a set.
Brush length wear limit
5 mm (0.2 in)
6. Measure:
brush spring force
Out of specification Replace the brush
springs as a set.
Brush spring force
7.36 ~ 11.04 N (736 ~ 1,104 gf)
7. Check:
gear teeth
Damage/wear Replace the gear.
8. Check:
bearing
oil seal
Damage/wear Replace the defective
part(s).
7 - 32
STARTER MOTOR
ELEC
EAS00772
NOTE:
Align the slot a on the brush seat with the tab
b in the starter motor front cover.
2. Install:
brush holder (along with the brushes) 1
3. Install:
armature assembly 1
4.
Install:
gasket New
starter motor yoke 1
circlip
NOTE:
Align the tab a on the brush holder with the
slot b in the starter motor yoke.
_
5.
7 - 33
Install:
bearing
oil seal
washer set
lock washer 1
STARTER MOTOR
a
6.
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the starter
motor rear cover.
1 New
7.
Install:
gasket 1 New
starter motor cover 2
bolts
ELEC
3
2
7 - 34
Install:
O-rings 1 New
starter motor gear 2
circlip 3
ELEC
CHARGING SYSTEM
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
9
A
Lg
L B/R
Br/B
0
G/Y G
Ch
Dg
B L Y
Dg
Ch
Y L B
(BLACK)
Br/B L
L
(BLACK)
L/W1
G G/Y
B/Y
Sb
L/R
Sb
R/L
L/
B
B
W
W
W
W
W
W
B
B
R/G
R
Gy
(BLACK)
(GRAY)
5
B
WWW
G
R/L
R
R R
R/W L
Gy B/L
L W/Y
B/L
B Gy
W L
B
R/B
B/L
3
R Br/L
ON
OFF
L/Y L/B
B
L/Y
Br/L
L/B
Br/L R
L/B L/Y
(BLACK)
R/W
R/B
B
B
L
B/L
P/W
P/W B/L L
B
B
Y
L
L Y B
(BLACK)
(GRAY)
L
B/L
P/Y
P/Y B/L L
B/L
B/L Br/W
B
(BLA
(BLACK)
P B/L L
(BLACK)
Br/B
L
B/L
P
N
B
Br B
~
R/B
L W/B
B/L
W L
B
(BLACK)
(BLACK)
R/B
L
W/B
B/L
(BLACK)
W B
L
L Y/G B/L
(BLACK)
Y/G
B/L
}
Gy/R
|
Br
Br/L
{
Br/L
Br
Br
P
(BLACK)
R/W
z
Br/L
R/Y
R/Y R/Y
s
R/W B/R Y
Br B/G L/W1
R/W B/R
Br
L/W1
R/Y
(BLACK)
Y/B
L/Y
G/L
B/Y
t
B
h
Y/B
(BLACK)
Br
(BLACK)
R/Y
G/L
B/Y L/Y
(BLACK)
Y
Br
B/G
Y
(BLACK)
A
Y
L A
L
Y
B
7 - 35
L Y
Y
L
B
1 Generator
2 Rectifier/regulator
4 Battery
6 Main fuse
Y G
G
CHARGING SYSTEM
EAS00774
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil resistance
5. wiring connections
(of the entire charging system)
YES
NOTE:
Before troubleshooting, remove the following
part(s):
1. seat
2. battery compartment
Troubleshoot with the following special
tool(s).
_
3. Charging voltage
Connect the inductive tachometer to the
spark plug lead of cylinder #1.
Connect the pocket tester (DC 20 V) to the
battery as shown.
Inductive tachometer
YU-8036-A
Pocket tester
YU-03112
EAS00738
1. Main fuse
Check the main fuse for continuity.
Refer to CHECKING THE FUSES in
chapter 3.
Are the main fuse OK?
YES
NO
Replace the fuse.
7 - 36
CHARGING SYSTEM
Is the charging voltage within specification?
NO
ELEC
EAS00779
5. Wiring
Check the wiring connections of the entire
charging system.
Refer to CIRCUIT DIAGRAM.
Is the charging systems wiring properly
connected and without defects?
YES
The charging circuit
is OK.
EAS00776
YES
NO
2
3
W
NO
Replace the stator
coil assembly.
7 - 37
Properly connect or
repair the charging
systems wiring.
ON
OFF
L/Y
Br/L R
Br/L L/B L/B
L/Y
7 - 38
Br/L
Br/L
Br/L
R/B
(GRAY)
R Br/L
L/Y L/B
W
W
W
WWW
W
W
W
R/Y
R/W
Br
R/B
Br/B
Ch
Dg
B L Y
(BLACK)
(BLACK)
Br
(BLACK)
R/B
Br
(BLACK)
R R
(BLACK)
(BLACK)
R/W
R/W L
B A B
R/W B/R Y
Br B/G L/W1
(BLACK)
G G/Y
W
G/Y G
L Y
Br
R/G
R/B
Dg
Ch
Y L B
L
B
L A
Y
L
R/W B/R
Gy/R
B/G
L/W1
L Y/G B/L
(BLACK)
(BLACK)
L
B/L
P
L
B/L
P/Y
L
B/L
P/W
B
Y
L
L/Y
Br/B
R/L
B/L
Gy
B/Y L/Y
(BLACK)
R/Y
R/Y
G/L
R/L
Br
P
(BLACK)
L
W/B
B/L
B/Y
B/L
Y/G
Sb
Lg
B Gy
B/Y
W L
B
(BLACK)
P B/L L
(GRAY)
P/Y B/L L
(BLACK)
P/W B/L L
(BLACK)
L Y B
Gy B/L
L/W1
L B/R
L W/B
B/L
Y G
G/L
Y/B
G
B
(L)
N
(R)
B/W
Br
Br/W
B/L
L
W/Y
(BLUE)
B L/G
B B
(BLUE)
Ch
Ch
Ch
Ch
Dg
Br/W
Br/W
Br
Y/R
Y/R
R/Y R/Y
Y/B
L/G
L/R
B B
(BLACK)
W L
B
Br
(BLACK)
W B
(BLACK)
Br B
(BLACK)
L W/Y
B/L
Sb
B/L Br/W
B/L
L/R
Br/B L
(BLUE)
Y G L/Y
Dg Ch B/Y
Br
Y/R B
Dg
Dg
Dg
Br/W P B
R/Y
Y/R
Br/W
B/Y
R/L
L/R
B/G
Y/G
R/B
Br/W
Br
W
P/W
P/Y
P
L/W
Gy
R/W
L/B
B/L
Y
L
W/B
W/Y
Dg
(BLUE)
B P Br/W
Y/R
G/L
B3 R/W
B3
L/Y G Y
B/Y Ch Dg
B/R
L Ch
Gy
G
Y/B
Lg
G/R
Y/L
Y/R
R/G
P/L
W/G
Br/L
B/O
B/W
(BLACK)
R/G
P/L
W/G
Br/L
Dg
Ch
Br
R/B
R/B
Y Ch
Lg Dg
(GREEN)
Ch Y Br
Dg Lg B
(GREEN)
Br
B
\
]
B G
Gy B Gy
Lg
B/L
G/R
Gy/R
W/G R/G
L
Y W/Y P P/W P/Y Br/W B/R W/B
R/W L/B G Gy Lg B3 B/W B/O
B/L Y/B L/R W Gy Y/R R/L Y/R L/W B3 B/Y B/G
R/W Y/L R/B Br
Br/L P/L G/R Y/G
Gy
G G
B B
(BLACK)
B/R
W Gy
W G
L/R Gy
B/L G/R
(BLUE)
R P
O Br/Y
(RED)
(GRAY)
G/R
L/R
B/L
P
R
O
Br/Y
Lg
Gy
(DARK GRAY)
(BLACK)
Gy/R Lg
G/R B/L
B/W
B/R
B/O
L/R Gy
B/L G/R
(BLUE)
R P
O Br/Y
(RED)
G/R
L/R
B/L
P
R
O
Br/Y
Y/L
R/G
Br
L
Gy
R/G G
(BLUE)
Gy L/R
G/R B/L
(RED)
P R
Br/Y O
G R/G
Br L
B Y/L
L Br
Y/L B
3 Main switch
4 Battery
6 Main fuse
P ECU
X Tachometer
Y Tachometer light
] Speedometer
c High beam indicator light
d Speedometer light
h Headlight relay
Rk Dimmer switch
n
Front turn signal/position
S
light (left
R
o Front turn signal/position
S
light (right
r Headlight
w Tail/brake light
x License plate light
z Headlight fuse
| Signaling system fuse
LIGHTING SYSTEM
ELEC
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
LIGHTING SYSTEM
EAS00781
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
Any of the following fail to light: headlight, high beam indicator light, taillight,
position light, license plate light or meter
light.
Check:
1. main, headlight and signaling system fuses
2. battery
3. main switch
4. dimmer switch
5. headlight relay
6. wiring connections
(of the entire lighting system)
NOTE:
Before troubleshooting, remove the following
part(s):
1. seat
2. headlight lens unit
Troubleshoot with the following special
tool(s).
3. Main switch
Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the main switch OK?
NO
YES
Pocket tester
YU-03112
Replace
switch.
EAS00738
NO
YES
the
main
EAS00784
4. Dimmer switch
NO
NO
The dimmer switch is
faulty. Replace the
left handlebar switch.
7 - 39
LIGHTING SYSTEM
ELEC
EAS00788
5. Headlight relay
Remove the headlight relay from the wire
harness.
Connect the pocket tester ( 1) and battery (12 V) to the headlight relay terminal
as shown.
Check the headlight relay for continuity.
3
4
1
Y/B
R/Y
G/L
R/Y
NO
YES
NO
YES
NO
Replace the speedometer assembly.
EAS00787
6. Wiring
Check the entire lighting systems wiring.
Refer to CIRCUIT DIAGRAM.
Is the lighting systems wiring properly
connected and without defects?
YES
Check the condition
of each of the lighting
systems circuits.
Refer to CHECKING THE LIGHTING
SYSTEM.
NO
Properly connect or
repair the lighting
systems wiring.
7 - 40
LIGHTING SYSTEM
Headlight
Positive tester probe
yellow 1 or green 2
Negative tester probe black 3
ELEC
EAS00789
NO
YES
Dg Lg B
Ch Y
Br
Ch Y
Br
Dg Lg B
4
Set the main switch to ON.
Set the dimmer switch to
or
.
Measure the voltage (DC 12 V) of yellow
1 or green 2 on the headlight coupler,
and yellow 4 on the speedometer assembly coupler.
Is the voltage within specification?
YES
This circuit is OK.
2. Voltage
Connect the pocket tester (DC 20 V) to the
tachometer and speedometer assembly
couplers as shown.
Tachometer assembly coupler
NO
The wiring circuit
from the main switch
to the headlight coupler is faulty and
must be repaired.
Y/L
Br
Br
Y/L
Tachometer light
Positive tester probe brown 1
Negative tester probe black 2
Speedometer light
Positive tester probe brown 3
Negative tester probe black 4
7 - 41
2
1
ELEC
LIGHTING SYSTEM
2. Voltage
Connect the pocket tester (DC 20 V) to the
tail/brake light assembly coupler (tail subwire harness side) as shown.
Dg Lg B
Ch Y
Br
Ch Y
Br
Dg Lg B
EAS00790
L
B
YES
Replace the tail/
brake light assembly.
YES
Y
B
NO
YES
This circuit is OK.
EAS00791
NO
Replace the tail/
brake light assembly.
NO
Replace the license
plate
light
bulb,
socket or both.
7 - 42
LIGHTING SYSTEM
NO
YES
1
L
2. Voltage
ELEC
2. Voltage
1
YES
This circuit is OK.
NO
Ch
L
B
B
L
Dg
Ch
L
B
Dg
2
Set the main switch to ON.
Measure the voltage (DC 12 V) of blue 1
on the front turn signal/position light connectors (wire harness side).
Is the voltage within specification?
EAS00791
YES
This circuit is OK.
7 - 43
NO
The wiring circuit
from the main switch
to the front turn signal/position light connectors is faulty and
must be repaired.
ON
OFF
L/Y
Br/L R
Br/L L/B L/B
L/Y
7 - 44
Br/L
Br/L
Br/L
R/B
(GRAY)
R Br/L
L/Y L/B
W
W
W
WWW
W
W
W
R/Y
R/W
Br
R/B
Br/B
Ch
Dg
B L Y
(BLACK)
(BLACK)
Br
(BLACK)
R/B
Br
(BLACK)
R R
(BLACK)
(BLACK)
R/W
R/W L
B A B
R/W B/R Y
Br B/G L/W1
(BLACK)
G G/Y
W
G/Y G
L Y
Br
R/G
R/B
Dg
Ch
Y L B
L
B
L A
Y
L
R/W B/R
Gy/R
B/G
L/W1
L Y/G B/L
(BLACK)
(BLACK)
L
B/L
P
L
B/L
P/Y
L
B/L
P/W
B
Y
L
L/Y
Br/B
R/L
B/L
Gy
B/Y L/Y
(BLACK)
R/Y
R/Y
G/L
R/L
Br
P
(BLACK)
L
W/B
B/L
B/Y
B/L
Y/G
Sb
Lg
B Gy
B/Y
W L
B
(BLACK)
P B/L L
(GRAY)
P/Y B/L L
(BLACK)
P/W B/L L
(BLACK)
L Y B
Gy B/L
L/W1
L B/R
L W/B
B/L
Y G
G/L
Y/B
G
B
(L)
N
(R)
B/W
Br
Br/W
B/L
L
W/Y
(BLUE)
B L/G
B B
(BLUE)
Ch
Ch
Ch
Ch
Dg
Br/W
Br/W
Br
Y/R
Y/R
R/Y R/Y
Y/B
L/G
L/R
B B
(BLACK)
W L
B
Br
(BLACK)
W B
(BLACK)
Br B
(BLACK)
L W/Y
B/L
Sb
B/L Br/W
B/L
L/R
Br/B L
(BLUE)
Y G L/Y
Dg Ch B/Y
Br
Y/R B
Dg
Dg
Dg
Br/W P B
R/Y
Y/R
Br/W
B/Y
R/L
L/R
B/G
Y/G
R/B
Br/W
Br
W
P/W
P/Y
P
L/W
Gy
R/W
L/B
B/L
Y
L
W/B
W/Y
Dg
(BLUE)
B P Br/W
Y/R
G/L
B3 R/W
B3
L/Y G Y
B/Y Ch Dg
B/R
L Ch
Gy
G
Y/B
Lg
G/R
Y/L
Y/R
R/G
P/L
W/G
Br/L
B/O
B/W
(BLACK)
R/G
P/L
W/G
Br/L
Dg
Ch
Br
R/B
R/B
Y Ch
Lg Dg
(GREEN)
Ch Y Br
Dg Lg B
(GREEN)
Br
B
\
]
B G
Gy B Gy
Lg
B/L
G/R
Gy/R
W/G R/G
L
Y W/Y P P/W P/Y Br/W B/R W/B
R/W L/B G Gy Lg B3 B/W B/O
B/L Y/B L/R W Gy Y/R R/L Y/R L/W B3 B/Y B/G
R/W Y/L R/B Br
Br/L P/L G/R Y/G
Gy
G G
B B
(BLACK)
B/R
W Gy
W G
L/R Gy
B/L G/R
(BLUE)
R P
O Br/Y
(RED)
(GRAY)
G/R
L/R
B/L
P
R
O
Br/Y
Lg
Gy
(DARK GRAY)
(BLACK)
Gy/R Lg
G/R B/L
B/W
B/R
B/O
L/R Gy
B/L G/R
(BLUE)
R P
O Br/Y
(RED)
G/R
L/R
B/L
P
R
O
Br/Y
Y/L
R/G
Br
L
Gy
R/G G
(BLUE)
Gy L/R
G/R B/L
(RED)
P R
Br/Y O
G R/G
Br L
B Y/L
L Br
Y/L B
SIGNALING SYSTEM
ELEC
EAS00793
SIGNALING SYSTEM
CIRCUIT DIAGRAM
SIGNALING SYSTEM
3 Main switch
4 Battery
5 Backup fuse (odometer and clock)
6 Main fuse
9 Relay unit
B Fuel pump
C Neutral switch
P ECU
X Tachometer
[ Engine trouble warning light
\ Neutral indicator light
] Speedometer
_ Fuel level warning light
a Left turn signal indicator light
b Right turn signal indicator light
e Turn signal relay
f Horn 1
g Horn 2
l Horn switch
m Turn signal switch
n Front turn signal/position light (left)
o Front turn signal/position light (right)
p Rear turn signal light (right)
q Rear turn signal light (left)
t Front brake light switch
w Tail/brake light
y Rear brake light switch
| Signaling system fuse
7 - 45
ELEC
SIGNALING SYSTEM
EAS00794
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
Check:
1. main, signaling system and backup fuses
2. battery
3. main switch
4. wiring connections
(of the entire signaling system)
YES
NOTE:
Before troubleshooting, remove the following
part(s):
1. seat
2. headlight lens unit
Troubleshoot with the following special
tool(s).
EAS00749
3. Main switch
Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the main switch OK?
Pocket tester
YU-03112
NO
YES
EAS00738
Replace
switch.
the
main
EAS00795
4. Wiring
Check the entire signal systems wiring.
Refer to CIRCUIT DIAGRAM.
Is the signaling systems wiring properly
connected and without defects?
NO
Replace the fuse(s).
YES
Check the condition
of each of the signaling systems circuits.
Refer to CHECKING THE SIGNALING SYSTEM.
7 - 46
NO
Properly connect or
repair the signaling
systems wiring.
SIGNALING SYSTEM
ELEC
EAS00796
3. Horn 1
1. Horn switch
Check the horn switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the horn switch OK?
NO
YES
B/W
2. Voltage
Connect the pocket tester (DC 20 V) to the
horn 1 connector at the horn 1 terminal as
shown.
Positive tester probe black/white 1
Negative tester probe ground
B/W
NO
Replace the horn 1.
NO
The wiring circuit
from the main switch
to the horn connector
is faulty and must be
repaired.
7 - 47
YES
The horn 1 is OK.
SIGNALING SYSTEM
ELEC
EAS00796
3. Horn 2
1. Horn switch
Check the horn switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the horn switch OK?
NO
YES
NO
Replace the horn 2.
YES
The horn 2 is OK.
EAS00797
NO
7 - 48
NO
Replace the tail/
brake light assembly.
SIGNALING SYSTEM
ELEC
EAS00799
NO
YES
YES
L
Y
B
NO
YES
NO
YES
NO
Replace the left handlebar switch.
NO
The wiring circuit
from the main switch
to the tail/brake light
assembly coupler is
faulty and must be
repaired.
7 - 49
SIGNALING SYSTEM
ELEC
5. Voltage
4. Voltage
NO
7 - 50
NO
The turn signal relay
is faulty and must be
replaced.
SIGNALING SYSTEM
6. Voltage
Connect the pocket tester (DC 20 V) to the
turn signal light connectors or speedometer assembly coupler (wire harness side)
as shown.
Turn signal light
Turn signal indicator light
ELEC
NO
YES
This circuit is OK.
EAS00800
Br
Lg
Ch Dg
Br
Lg
YES
NO
Replace the speedometer assembly.
Dg Ch
1
2. Neutral switch
NO
Replace the neutral
switch.
7 - 51
ELEC
SIGNALING SYSTEM
EAS00803
3. Voltage
Connect the pocket tester (DC 20 V) to the
speedometer assembly coupler (wire harness side) as shown.
Br
Br
Lg
Lg
Ch Dg
Dg Ch
NO
YES
NO
The wiring circuit
from the main switch
to the speedometer
assembly coupler is
faulty and must be
repaired.
R/L
YES
Replace
pump.
7 - 52
the
fuel
ELEC
SIGNALING SYSTEM
2. Voltage
3. Voltage
Br
Br
Lg
Lg
Ch Dg
Dg Ch
Br
Br
Lg
Lg
Gy G/R G/R Gy
Dg Ch
Ch Dg
YES
Replace the speedometer assembly.
YES
EAS00800
NO
Replace the speedometer assembly.
7 - 53
NO
The wiring circuit
from the main switch
to the speedometer
assembly coupler is
faulty and must be
repaired.
ON
OFF
L/Y
Br/L R
Br/L L/B L/B
L/Y
7 - 54
Br/L
Br/L
Br/L
R/B
(GRAY)
R Br/L
L/Y L/B
W
W
W
WWW
W
W
W
R/Y
R/W
Br
R/B
Br/B
Ch
Dg
B L Y
(BLACK)
(BLACK)
Br
(BLACK)
R/B
Br
(BLACK)
R R
(BLACK)
(BLACK)
R/W
R/W L
B A B
R/W B/R Y
Br B/G L/W1
(BLACK)
G G/Y
W
G/Y G
L Y
Br
R/G
R/B
Dg
Ch
Y L B
L
B
L A
Y
L
R/W B/R
Gy/R
B/G
L/W1
L Y/G B/L
(BLACK)
(BLACK)
L
B/L
P
L
B/L
P/Y
L
B/L
P/W
B
Y
L
L/Y
Br/B
R/L
B/L
Gy
B/Y L/Y
(BLACK)
R/Y
R/Y
G/L
R/L
Br
P
(BLACK)
L
W/B
B/L
B/Y
B/L
Y/G
Sb
Lg
B Gy
B/Y
W L
B
(BLACK)
P B/L L
(GRAY)
P/Y B/L L
(BLACK)
P/W B/L L
(BLACK)
L Y B
Gy B/L
L/W1
L B/R
L W/B
B/L
Y G
G/L
Y/B
G
B
(L)
N
(R)
B/W
Br
Br/W
B/L
L
W/Y
(BLUE)
B L/G
B B
(BLUE)
Ch
Ch
Ch
Ch
Dg
Br/W
Br/W
Br
Y/R
Y/R
R/Y R/Y
Y/B
L/G
L/R
B B
(BLACK)
W L
B
Br
(BLACK)
W B
(BLACK)
Br B
(BLACK)
L W/Y
B/L
Sb
B/L Br/W
B/L
L/R
Br/B L
(BLUE)
Y G L/Y
Dg Ch B/Y
Br
Y/R B
Dg
Dg
Dg
Br/W P B
R/Y
Y/R
Br/W
B/Y
R/L
L/R
B/G
Y/G
R/B
Br/W
Br
W
P/W
P/Y
P
L/W
Gy
R/W
L/B
B/L
Y
L
W/B
W/Y
Dg
(BLUE)
B P Br/W
Y/R
G/L
B3 R/W
B3
L/Y G Y
B/Y Ch Dg
B/R
L Ch
Gy
G
Y/B
Lg
G/R
Y/L
Y/R
R/G
P/L
W/G
Br/L
B/O
B/W
(BLACK)
R/G
P/L
W/G
Br/L
Dg
Ch
Br
R/B
R/B
Y Ch
Lg Dg
(GREEN)
Ch Y Br
Dg Lg B
(GREEN)
Br
B
\
]
B G
Gy B Gy
Lg
B/L
G/R
Gy/R
W/G R/G
L
Y W/Y P P/W P/Y Br/W B/R W/B
R/W L/B G Gy Lg B3 B/W B/O
B/L Y/B L/R W Gy Y/R R/L Y/R L/W B3 B/Y B/G
R/W Y/L R/B Br
Br/L P/L G/R Y/G
Gy
G G
B B
(BLACK)
B/R
W Gy
W G
L/R Gy
B/L G/R
(BLUE)
R P
O Br/Y
(RED)
(GRAY)
G/R
L/R
B/L
P
R
O
Br/Y
Lg
Gy
(DARK GRAY)
(BLACK)
Gy/R Lg
G/R B/L
B/W
B/R
B/O
L/R Gy
B/L G/R
(BLUE)
R P
O Br/Y
(RED)
G/R
L/R
B/L
P
R
O
Br/Y
Y/L
R/G
Br
L
Gy
R/G G
(BLUE)
Gy L/R
G/R B/L
(RED)
P R
Br/Y O
G R/G
Br L
B Y/L
L Br
Y/L B
ELEC
7 - 55
ELEC
ELEC
EAS00738
TROUBLESHOOTING
YES
2. Battery
Check the condition of the battery.
Refer to CHECKING AND CHARGING
THE BATTERY in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20 C (68 F)
Is the battery OK?
NO
YES
EAS00749
3. Main switch
Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the main switch OK?
NO
YES
Replace
switch.
Pocket tester
YU-03112
7 - 56
the
main
ELEC
EAS00750
YES
EAS00759
W Gy
NO
3
B/R L/W R/L
Br/B L
L/R
NO
Replace the relay
unit.
7 - 57
ELEC
EAS00817
W G
2
Measure the cylinder #2-injector resistance.
G
R/L
YES
NO
NO
Replace the fuel
pump.
7 - 58
ELEC
EAS00748
1
W
L
B
L W/B
B/L
NO
YES
Replace the crankshaft position sensor.
7 - 59
NO
Replace the cylinder
identification sensor.
ELEC
B B
L W/Y
B/L
WARNING
Measure the speed sensor output voltage.
T.
R.
YES
YES
7 - 60
NO
Replace the intake
air temperature sensor.
ELEC
P/W B/L L
P/Y B/L L
NO
YES
NO
Replace the intake
air pressure sensor
2.
7 - 61
ELEC
3
1
2 1
2
P B/L L
WARNING
Handle the engine temperature sensor
with special care.
Never subject the engine temperature
sensor to strong shocks. If the engine
temperature sensor is dropped, replace
it.
NO
T.
R.
YES
7 - 62
NO
Replace the engine
temperature sensor.
ELEC
EAS00818
18.Wiring
3
1
2
Measure the oil temperature sensor resistance.
Oil temperature sensor
resistance
308 ~ 339 at 150 C (302 F)
209 ~ 231 at 170 C (338 F)
WARNING
Handle the oil temperature sensor with
special care.
Never subject the oil temperature sensor
to strong shocks. If the oil temperature
sensor is dropped, replace it.
T.
R.
NO
Replace the oil temperature sensor.
7 - 63
NO
Properly connect or
repair the fuel injection systems wiring.
ELEC
EAS00819
WARNING
@
1. Check:
fuel pump operation
G
R/L
EAS00502
7 - 64
2 3 1
ELEC
1. Check:
throttle position sensor
(installed on the throttle body)
a. Disconnect the throttle position sensor coupler from the throttle position sensor.
b. Connect the pocket tester ( 1k) to the
throttle position sensor.
Positive tester probe blue 1
Negative tester probe black 2
c. Measure the maximum throttle position sensor resistance.
Out of specification Replace the throttle
position sensor.
Maximum throttle position sensor
resistance
4.0 ~ 6.0 k at 20 C (68 F)
(blue black)
d. Connect the pocket tester ( 1k) to the
throttle position sensor.
Positive tester probe yellow 3
Negative tester probe black 2
e. While slowly opening the throttle, check that
the throttle position sensor resistance is
within the specified range.
NOTE:
Check mainly that the resistance changes
gradually when turning the throttle, since the
readings (from closed to wide-open throttle)
may differ slightly from those specified.
Out of specification or the resistance
changes abruptly Go to step 2 below.
Throttle position sensor
resistance
(520 ~ 900 ) ~ (4.0 ~ 6.0 k) at
20 C (68 F)
(yellow black)
7 - 65
2 3 1
ELEC
2. Check:
throttle position sensor
(removed from the throttle body)
a. Disconnect the throttle position sensor coupler from the throttle position sensor.
b. Remove the throttle position sensor from
the throttle body.
c. Connect the pocket tester ( 1k) to the
throttle position sensor.
Positive tester probe blue 1
Negative tester probe black 2
d. Measure the maximum throttle position sensor resistance.
Out of specification Replace the throttle
position sensor.
Maximum throttle position sensor
resistance
4.0 ~ 6.0 k at 20 C (68 F)
(blue black)
e. Connect the pocket tester ( 1k) to the
throttle position sensor.
Positive tester probe yellow 3
Negative tester probe black 2
f. While slowly opening the throttle, check that
the throttle position sensor resistance is
within the specified range.
The resistance does not change or it
changes abruptly Replace the throttle
position sensor.
The slot is worn or broken Replace the
throttle position sensor.
NOTE:
Check mainly that the resistance changes
gradually when turning the throttle, since the
readings (from closed to wide-open throttle)
may differ slightly from those specified.
Throttle position sensor
resistance
0 ~ 5 1.0 k at 20 C (68 F)
(yellow black)
7 - 66
ELEC
3. Adjust:
throttle position sensor angle
2 3 1
a. Disconnect the throttle position sensor coupler from the throttle position sensor.
b. Connect the pocket tester ( 1k) to the
throttle position sensor.
B
Example:
If the maximum resistance = 5 k, then the
throttle position sensors maximum resistance
when the throttle is fully closed should be:
5 k (0.13 ~ 0.15) = 650 ~ 750
Lift the throttle body assembly slightly out of
the intake manifolds. Loosen the throttle position sensor screws 4.
Connect the pocket tester ( 100) to the
throttle position sensor.
Positive tester probe yellow 3
Negative tester probe black 2
e. Adjust the throttle position sensor angle so
the measured resistance is within the specified range.
Throttle position sensor
resistance
650 ~ 750
(yellow black)
After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws.
7 - 67
STARTING FAILURES
TRBL
SHTG
EAS00844
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
_
STARTING FAILURES
FUEL SYSTEM
Fuel tank
Empty fuel tank
Clogged fuel filter
Clogged fuel strainer
Clogged fuel tank drain hose
Clogged rollover valve
Clogged rollover valve hose
Deteriorated or contaminated fuel
Fuel pump
Faulty fuel pump
Faulty fuel pump relay
Throttle body(-ies)
Deteriorated or contaminated fuel
Sucked-in air
Improperly adjusted starter cable
ENGINE
Cylinder(s) and cylinder head(s)
Loose spark plug
Loose cylinder head or cylinder
Damaged cylinder head gasket
Damaged cylinder gasket
Worn or damaged cylinder
Incorrect valve clearance
Improperly sealed valve
Incorrect valve-to-valve-seat contact
Incorrect valve timing
Faulty valve spring
Seized valve
Piston(s) and piston ring(s)
Improperly installed piston ring
Damaged, worn or fatigued piston ring
Seized piston ring
Seized or damaged piston
Air filter
Improperly installed air filter
Clogged air filter element
Crankcase and crankshaft
Improperly assembled crankcase
Seized crankshaft
8-1
STARTING FAILURES/
INCORRECT ENGINE IDLING SPEED
ELECTRICAL SYSTEMS
Battery
Discharged battery
Faulty battery
Fuse(s)
Blown, damaged or incorrect fuse
Improperly installed fuse
Spark plug(s)
Incorrect spark plug gap
Incorrect spark plug heat range
Fouled spark plug
Worn or damaged electrode
Worn or damaged insulator
Faulty spark plug cap
Ignition coil(s)
Cracked or broken ignition coil body
Broken or shorted primary or secondary
coils
Faulty spark plug lead
TRBL
SHTG
Ignition system
Faulty ECU
Faulty crankshaft position sensor
Broken generator rotor woodruff key
Switches and wiring
Faulty main switch
Faulty engine stop switch
Broken or shorted wiring
Faulty neutral switch
Faulty start switch
Faulty sidestand switch
Faulty clutch switch
Improperly grounded circuit
Loose connections
Starting system
Faulty starter motor
Faulty starter relay
Faulty starting circuit cut-off relay
Faulty starter clutch
EAS00846
ENGINE
Cylinder(s) and cylinder head(s)
Incorrect valve clearance
Damaged valve train components
Air filter
Clogged air filter element
FUEL SYSTEM
Throttle body(-ies)
Damaged or loose throttle body joint
Improperly synchronized throttle bodies
Improperly adjusted engine idling speed
(throttle stop screw)
Improper throttle cable free play
Flooded throttle body
Faulty air induction system
8-2
1
2
3
4
5
6
7
8
TRBL
SHTG
EAS00848
FUEL SYSTEM
Fuel pump
Faulty fuel pump
EAS00850
SHIFTING IS DIFFICULT
Refer to CLUTCH DRAGS.
SHIFT PEDAL DOES NOT MOVE
Shift shaft
Improperly adjusted shift rod
Bent shift shaft.
Shift drum and shift forks
Foreign object in a shift drum groove
Seized shift fork
Bent shift fork guide bar
Transmission
Seized transmission gear
Foreign object between transmission gears
Improperly assembled transmission
EAS00851
FAULTY CLUTCH
CLUTCH DRAGS
Clutch
Unevenly tensioned clutch springs
Warped pressure plate
Bent clutch plate
Swollen friction plate
Bent clutch push rod
Broken clutch boss
Burnt primary driven gear bushing
Match marks not aligned
Engine oil
Incorrect oil level
Incorrect oil viscosity (high)
Deteriorated oil
CLUTCH SLIPS
Clutch
Improperly assembled clutch
Improperly adjusted clutch cable
Loose or fatigued clutch spring
Worn friction plate
Worn clutch plate
Engine oil
Incorrect oil level
Incorrect oil viscosity (low)
Deteriorated oil
8-3
TRBL
SHTG
EAS00854
OVERHEATING
CHASSIS
Brake(s)
Dragging brake
ELECTRICAL SYSTEMS
Spark plug(s)
Incorrect spark plug gap
Incorrect spark plug heat range
Ignition system
Faulty ECU
ENGINE
Cylinder head(s) and piston(s)
Heavy carbon buildup
Engine oil
Incorrect oil level
Incorrect oil viscosity
Inferior oil quality
FUEL SYSTEM
Throttle body(-ies)
Faulty throttle body(-ies)
Damaged or loose throttle body joint
Air filter
Clogged air filter element
EAS00857
EAS00861
LEAKING OIL
Bent, damaged or rusty inner tube
Cracked or damaged outer tube
Improperly installed oil seal
Damaged oil seal lip
Incorrect oil level (high)
Loose damper rod assembly bolt
Damaged damper rod assembly bolt copper
washer
Cracked or damaged cap bolt O-ring
8-4
UNSTABLE HANDLING
TRBL
SHTG
EAS00862
UNSTABLE HANDLING
Rear shock absorber assembly(-ies)
Faulty rear shock absorber spring
Leaking oil or gas
Tire(s)
Uneven tire pressures (front and rear)
Incorrect tire pressure
Uneven tire wear
Wheel(s)
Incorrect wheel balance
Deformed cast wheel
Damaged wheel bearing
Bent or loose wheel axle
Excessive wheel runout
Frame
Bent frame
Damaged steering head pipe
Improperly installed bearing race
Handlebar
Bent or improperly installed handlebar
Steering head components
Improperly installed upper bracket
Improperly installed lower bracket
(improperly tightened ring nut)
Bent steering stem
Damaged ball bearing or bearing race
Front fork leg(s)
Uneven oil levels (both front fork legs)
Unevenly tensioned fork spring (both front
fork legs)
Broken fork spring
Bent or damaged inner tube
Bent or damaged outer tube
Swingarm
Worn bearing or bushing
Bent or damaged swingarm
8-5
TRBL
SHTG
EAS00866
8-6
Generator
Rectifier/regulator
Main switch
Battery
Backup fuse (odometer and clock)
Main fuse
Starter relay
Starter motor
Relay unit
Starting circuit cut-off relay
Fuel injection system relay
Fuel pump
Neutral switch
Sidestand switch
Crankshaft position sensor
Throttle position sensor
Intake air pressure sensor 1
Intake air pressure sensor 2
Atmospheric pressure sensor
Cylinder identification sensor
Lean angle cut-off switch
Speed sensor
Intake air temperature sensor
Engine temperature sensor
Oil temperature sensor
ECU
Linear control valve
Ignition coil
Spark plug
Decompression solenoid
Cylinder #1 - injector
Cylinder #2 - injector
Tachometer assembly
Tachometer
Tachometer light
Speedometer assembly
Engine trouble warning light
Neutral indicator light
Speedometer
Fuel level warning light
Left turn signal indicator light
Right turn signal indicator light
High beam indicator light
Speedometer light
Turn signal relay
Horn 1
Horn 2
Headlight relay
Left handlebar switch
Clutch switch
Dimmer switch
Horn switch
Turn signal switch
Front turn signal/position light (left)
Front turn signal/position light (right)
Rear turn signal light (right)
Rear turn signal light (left)
Headlight
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
Tail/brake light
License plate light
Rear brake light switch
Headlight fuse
Ignition fuse
|
}
~
XV1700P/XV1700PC
WIRING DIAGRAM (For USA)
9
0
WIRE HARNESS
(BLACK)
(BLACK)
WIRE HARNESS
INJECTION
SUB-WIRE HARNESS
(BLUE)
C
1
(BLUE)
(BLACK)
(GRAY)
(BLACK)
S
6
(BLACK)
ON
OFF
Q
P
S
G
(BLACK)
M
(GRAY)
H
(BLACK)
(BLACK)
(BLACK)
I
J
(BLACK)
(BLACK)
(BLACK)
(BLACK)
(BLACK)
(BLACK)
(DARK GRAY)
}
(GRAY)
|
W
{
(BLACK)
X
]
(BLACK)
(BLACK)
t
(BLACK)
^
(L)
N
(R)
(BLUE)
(BLUE)
(BLACK)
b
c
(BLACK)
A
A
(RED)
(GREEN)
(BLUE)
(RED)
(RED)
(BLUE)
(BLUE)
w
r
q
p
COLOR CODE
(GREEN)
Black
Dark green
Orange
White
Black/Orange
Blue/Black
Blue/Yellow
Brown/Yellow
Gray/Red
Red/Black
Red/Yellow
Yellow/Black
Blue
Green
Pink
Yellow
Black/Red
Blue/Green
Brown/Black
Green/Blue
Pink/Blue
Red/Green
White/Black
Yellow/Green
Brown
Gray
Red
Black/Green
Black/White
Blue/Red
Brown/Blue
Green/Red
Pink/White
Red/Blue
White/Green
Yellow/Blue
Chocolate
Light green
Sky blue
Black/Blue
Black/Yellow
Blue/White
Brown/White
Green/Yellow
Pink/Yellow
Red/White
White/Yellow
Yellow/Red
PRINTED IN U.S.A.
XV17PCV(C)
XV17PCMV(C)
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-19-46
5PX-28197-12
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
XV17PCV(C)/XV17PCMV(C). For complete service information procedures it is necessary to use
this Supplementary Service Manual together with the following manual.
XV1700P/XV1700PC SERVICE MANUAL: LIT-11616-15-37 (5PX-28197-10)
XV1700PCR/XV1700PCRC SUPPLEMENTARY SERVICE MANUAL:
LIT-11616-16-36 (5PX-28197-11)
XV17PCV(C)/XV17PCMV(C)
SUPPLEMENTARY
SERVICE MANUAL
2005 by Yamaha Motor Corporation, U.S.A.
First edition, June 2005
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.
LIT-11616-19-46
EAS00003
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. 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.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
_
EAS00004
CAUTION:
NOTE:
EAS00007
EAS00009
GEN
INFO
SYMBOLS
The following symbols are not relevant to
every vehicle. Symbols 1 to 8 indicate the
subject of each chapter.
SPEC
CHK
ADJ
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Chassis
5 Engine
6 Fuel injection system
7 Electrical system
8 Troubleshooting
CHAS
FI
ENG
7
ELEC
TRBL
SHTG
T.
R.
E
J
K
B
L
M
LS
LT
G Engine oil
H Gear oil
I Molybdenum-disulfide oil
J Wheel-bearing grease
K Lithium-soap-based grease
L Molybdenum-disulfide grease
New
CONTENTS
SPECIFICATIONS .............................................................................................. 1
GENERAL SPECIFICATIONS ..................................................................... 1
ENGINE SPECIFICATIONS ........................................................................ 1
CHASSIS SPECIFICATIONS....................................................................... 4
ELECTRICAL SPECIFICATIONS ................................................................ 4
TIGHTENING TORQUES............................................................................. 5
ENGINE TIGHTENING TORQUES ....................................................... 5
CHASSIS TIGHTENING TORQUES ..................................................... 6
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 6
ENGINE ................................................................................................ 6
CABLE ROUTING ........................................................................................ 7
PERIODIC CHECKS AND ADJUSTMENTS.................................................... 18
INTRODUCTION ........................................................................................ 18
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM .................................................................................................... 18
GENERAL MAINTENANCE AND LUBRICATION CHART ........................ 19
SEAT AND SIDE COVERS ........................................................................ 21
FUEL TANK................................................................................................ 22
INSTALLING THE FUEL HOSE JOINT 2 ............................................ 23
CHASSIS .......................................................................................................... 24
FRONT WHEEL AND BRAKE DISCS........................................................ 24
FRONT AND REAR BRAKES .................................................................... 26
FRONT BRAKE PADS......................................................................... 26
FRONT BRAKE CALIPERS................................................................. 27
ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPERS .......................................................................................... 29
FRONT FORK ............................................................................................ 32
DRIVE BELT AND DRIVE PULLEY ........................................................... 33
INSTALLING THE DRIVE BELT AND DRIVE PULLEY....................... 35
ENGINE ............................................................................................................ 36
ENGINE...................................................................................................... 36
TRANSFER GEAR CASE .......................................................................... 41
INSTALLING THE TRANSFER GEAR CASE...................................... 43
CRANKCASE ............................................................................................. 45
INSTALLING THE BEARING RETAINER............................................ 46
TRANSMISSION ........................................................................................ 47
XV17PCV(C)/XV17PCMV(C) 2006 WIRING DIAGRAM
GENERAL SPECIFICATIONS/
ENGINE SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Standard
Model code
Limit
-------------
ENGINE SPECIFICATIONS
Item
Engine oil
Lubrication system
Recommended oil
Recommended engine oil grade
Quantity
Total amount
Engine
Oil tank
Without oil filter cartridge replacement
With oil filter cartridge replacement
Oil pressure (hot)
Relief valve opening pressure
Oil temperature
Valve lifters
Valve lifter outside diameter
Valve lifter case inside diameter
Valve lifter-to-valve lifter case clearance
Pistons
Piston-to-cylinder clearance
Diameter D
Standard
Limit
Dry sump
Yamalube 4 (20W40) or SAE 20W40 type
API service SE, SF, SG type or higher
----------
-------------
-------------
22.9620 ~ 22.9744 mm
(0.9040 ~ 0.9045 in)
23.000 ~ 23.021 mm (0.9055 ~ 0.9063 in)
0.0256 ~ 0.0590 mm (0.0010 ~ 0.0023 in)
----------
0.15 mm
(0.006 in)
96.960 ~ 96.975 mm (3.8173 ~ 3.8179 in)
----
H
D
Height H
10 mm (0.39 in)
----
ENGINE SPECIFICATIONS
Item
Standard
SPEC
Limit
Offset
Piston pins
Outside diameter
Ring type
Dimensions (B T)
End gap (installed)
Barrel
1.2 3.8 mm (0.047 0.150 in)
0.30 ~ 0.45 mm (0.012 ~ 0.018 in)
Plating/coating
2nd ring
Chrome plated/parkerizing
------0.65 mm
(0.026 in)
0.12 mm
(0.0047 in)
----
B
T
Ring type
Dimensions (B T)
End gap (installed)
Taper
1.2 3.8 mm (0.047 0.150 in)
0.30 ~ 0.45 mm (0.012 ~ 0.018 in)
Plating/coating
Oil ring
Parkerizing
------0.8 mm
(0.031 in)
0.12 mm
(0.0047 in)
----
B
T
Dimensions (B T)
End gap (installed)
Plating/coating
----------
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Limit
Crankshaft
C
E
D
A
Width A
Max. runout C
Crankshaft-journal-to-crankshaftjournal-bearing clearance
Clutch
Clutch type
Clutch release method
Clutch release method operation
Operation
Clutch cable free play (at the end of
the clutch lever)
Friction plates
Thickness
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
Min. length
Clutch housing thrust clearance
Clutch housing radial clearance
Primary reduction gear backlash tolerance
Primary drive gear backlash number
Primary driven gear backlash number
---0.04 mm
(0.0016 in)
---0.09 mm
(0.0035 in)
0.1 mm
(0.0039 in)
----------------
2.8 mm
(0.110 in)
----
------0.2 mm
(0.008 in)
7 mm (0.276 in)
1
----
------6.5 mm
(0.256 in)
----------
-------
CHASSIS SPECIFICATIONS/
ELECTRICAL SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item
Standard
Rear brake
Brake type
Single-disc brake
Operation
Right-foot operation
Brake pedal free play
0 mm (0 in)
Brake pedal position
86 mm (3.4 in)
(from the top of the rider footrest to
the top of the brake pedal)
Recommended fluid
DOT 4
Brake discs
Diameter thickness
282 6 mm (11.10 0.24 in)
Min. thickness
---Max. deflection
----
Limit
-------------
------5.5 mm
(0.22 in)
0.15 mm
(0.006 in)
0.8 mm
(0.03 in)
-------
ELECTRICAL SPECIFICATIONS
Item
Bulbs (voltage/wattage quantity)
Headlight
Licence plate light
Tail/brake light
Front turn signal/position light
Rear turn signal light
Speedometer light
Tachometer light
Starting circuit cut-off relay
Model/manufacturer
Coil resistance
Fuel injection system relay
Model/manufacturer
Coil resistance
Throttle position sensor
Resistance
Output voltage (at idle)
Standard
Limit
12 V 60 W/55 W 1
12 V 3.8 W 2
LED
12 V 23 W/8 W 2
12 V 21 W 2
LED 1
LED 1
----------------------
G8R-30Y-U3/OMRON
162 ~ 198
-------
G8R-30Y-U3/OMRON
162 ~ 198
-------
4 ~ 6 k/L-B
0.63 ~ 0.73 V
-------
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item
Front cylinder camshaft end cover
Oil filter bracket
A.I.S. bracket
Crankshaft position sensor
Stator coil assembly
Generator rotor
Fastener
Thread
Qty
size
Tightening torque
Nm
mkg
ftlb
Bolt
Bolt
Bolt
Bolt
Screw
Bolt
M5
M6
M5
M6
M6
M12
2
4
4
2
1
1
7
10
6
7
10
80
0.7
1.0
0.6
0.7
1.0
8.0
5.1
7.2
4.3
5.1
7.2
58
Clutch boss
Nut
M20
105
10.5
75
Nut
M22
100
10.0
72
Drive pulley
Nut
M22
120
12.0
85
Screw
Screw
M6
M5
1
1
12
4
1.2
0.4
8.7
2.9
Remarks
LT
LT
LT
LT
LT
Use a lock
washer.
Stake
E
Stake
E
LT
LT
TIGHTENING TORQUES/
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
Thread size
M6
M8
M6
M6
M10
M10
Tightening torque
Nm
mkg
ftlb
7
23
7
7
63
35
0.7
2.3
0.7
0.7
6.3
3.5
5.1
17
5.1
5.1
45
25
Remarks
LT
LT
EAS00031
Lubricant
E
M
E
E
CABLE ROUTING
CABLE ROUTING
1 Clutch cable
2 Left handlebar switch lead
3 Right handlebar switch lead
4 Throttle cable 1
5 Throttle cable 2
6 Brake hose
SPEC
SPEC
CABLE ROUTING
A-A
SPEC
CABLE ROUTING
Place the couplers (crankshaft position sensor
coupler, sidestand switch coupler, decompression solenoid couplers, tail/brake light coupler,
cylinder identification sensor coupler and speed
sensor coupler) in the tray.
To the tail/brake light.
When installing the ECU, be sure not to pinch
the tail/brake light lead and the fuel pump lead in
the shaded areas shown in the illustration.
Route the fuel pump lead under the seat lock
cable.
A-A
SPEC
CABLE ROUTING
Position the gray mark on the starter motor lead
at the center of the bolt. Fit the starter motor lead
and sidestand switch lead into the groove in the
frame, and then fasten them with a plastic locking tie. Face the end of the plastic locking tie outward, and then cut off the excess end of the tie.
10 ~ 30 mm (0.4 ~ 1.2 in)
A-A
10
CABLE ROUTING
1 Oil temperature sensor
2 Fuel hose
3 Spark plug cap (ignition coil
1-R spark plug lead)
4 Injector lead
5 Throttle position sensor lead
6 Intake air pressure sensor 1
7 Intake air temperature sensor
coupler
8 Intake air pressure sensor 2
lead
9
6 7
8
SPEC
H
G
J
AA
A-A
B-B
C-C
D-D
K
L
M
N
O
11
AC
AB
CABLE ROUTING
To the battery box.
Fasten the oil temperature sensor lead with the
lead holder.
Fasten the main wire harness and fuel hose with
a plastic locking tie to the frame. Position the
buckle of the plastic locking tie under the fuel
hose, with the end facing outward, and then cut
off the excess end of the tie.
9
6 7
8
SPEC
H
G
J
AA
A-A
B-B
C-C
D-D
K
L
M
N
O
12
AC
AB
CABLE ROUTING
Fasten the main wire harness and ignition coil 1R spark plug lead to the frame between the air
filter case joint and the fuel hose with a plastic
locking tie, making sure to install the tie around
the protective sleeve of the spark plug lead, not
the lead itself. Position the buckle of the plastic
locking tie under the spark plug lead, with the
end facing outward, and then cut off the excess
end of the tie so that it does not contact the air
filter case joint.
9
6 7
8
SPEC
H
G
J
AA
A-A
B-B
C-C
D-D
K
L
M
N
O
13
AC
AB
CABLE ROUTING
Fasten the main wire harness and ignition coil 1R spark plug lead to the frame between the
intake air pressure sensor 1 and the fuel hose
with a plastic locking tie, making sure to install
the tie around the protective sleeve of the spark
plug lead, not the lead itself. Position the buckle
of the plastic locking tie under the spark plug
lead, with the end facing outward, and then cut
off the excess end of the tie so that it does not
contact the air filter case joint.
Fasten the main wire harness, intake air pressure sensor 2 lead, ignition coil 1-R spark plug
lead, and intake air temperature sensor coupler
with a plastic locking tie. Position the buckle of
the plastic locking tie under the main wire harness, with the end facing outward, and then cut
off the excess end of the tie.
Pass the intake air pressure sensor 2 lead
through the lead guide.
Route the throttle cables behind the brake hose.
9
6 7
8
SPEC
H
G
J
AA
A-A
B-B
C-C
D-D
K
L
M
N
O
14
AC
AB
CABLE ROUTING
Fasten the rear brake light switch lead and ignition coil 2-R spark plug lead to the pipe section
of the linear control valve bracket with a plastic
band, making sure that there is no slack in the
rear brake light switch lead. Be sure to fasten
the rear brake light switch lead between the
main wire harness and the rear brake light
switch coupler, and to face the end of the plastic
band downward.
Fasten the main wire harness and intake vacuum hose with a plastic locking tie.
To the engine temperature sensor.
To the injector sub lead.
Pass the cylinder identification sensor lead
between the decompression solenoid and the
decompression solenoid cover.
To the stator coil.
10 ~ 30 mm (0.4 ~ 1.2 in)
9
6 7
8
SPEC
H
G
J
AA
A-A
B-B
C-C
D-D
K
L
M
N
O
15
AC
AB
CABLE ROUTING
Position the gray mark on the stator coil lead at
the center of the bolt, and then fasten it with a
plastic locking tie. Face the end of the plastic
locking tie outward, and then cut off the excess
end of the tie.
To the decompression solenoid.
Fasten the corrugated tube and oil delivery hose
with the holder.
To the speed sensor.
To the neutral switch.
9
6 7
8
SPEC
H
G
J
AA
A-A
B-B
C-C
D-D
K
L
M
N
O
16
AC
AB
CABLE ROUTING
Fasten the crankshaft position sensor lead,
sidestand switch lead, lean angle sensor lead,
starter motor lead, and horn 2 lead with a plastic locking tie. Face the end of the plastic locking tie outward, and then cut off the excess
end of the tie.
A B Install the plastic locking ties 0 ~ 20 mm (0 ~
0.79 in) below the bends in the frame.
AA
9
6 7
8
AC
SPEC
H
G
J
AA
A-A
B-B
C-C
D-D
K
L
M
N
O
17
AC
AB
CHK
ADJ
EAS00036
ITEM
ODOMETER READINGS
600 mi
4000 mi
8000 mi
12000 mi 16000 mi 20000 mi
(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or
or
or
or
or
or
1 month 6 months 12 months 18 months 24 months 30 months
ROUTINE
1 * Fuel line
2 * Spark plugs
Check condition.
Adjust gap and clean.
Replace every 8000 mi (13000 km) or 12
months.
Replace.
Replace.
3 * Valve clearance
4 *
Crankcase
breather system
5 * Fuel injection
6 * Exhaust system
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
18
CHK
ADJ
ITEM
ROUTINE
2 * Clutch
Check operation.
Adjust or replace cable.
3 * Front brake
4 * Rear brake
5 * Brake hoses
ODOMETER READINGS
600 mi
8000 mi
4000 mi
12000 mi 16000 mi 20000 mi
(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or
or
or
or
or
or
1 month 6 months 12 months 18 months 24 months 30 months
Every 4 years
Replace.
6 * Wheels
7 * Tires
8 * Wheel bearings
9 *
Swingarm pivot
bearings
10 * Drive belt
11 * Steering bearings
12 * Chassis fasteners
Repack.
Repack.
13
14
15
Sidestand pivot
Check operation.
Apply lithium-soap-based grease (all-purpose
grease) lightly.
16 * Sidestand switch
17 * Front fork
18 *
Shock absorber
assembly
19 *
Rear suspension
link pivots
20
Engine oil
Replace.
19
Change.
23 *
ITEM
24 * Control cables
ODOMETER READINGS
600 mi
4000 mi
8000 mi
12000 mi 16000 mi 20000 mi
(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or
or
or
or
or
or
1 month 6 months 12 months 18 months 24 months 30 months
ROUTINE
Check operation.
CHK
ADJ
* 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.
NOTE:
Air filters
This models air filters are equipped with disposable oil-coated paper elements, which must not
be cleaned with compressed air to avoid damaging them.
The air filter elements need to be replaced more frequently when riding in unusually wet or dusty
areas.
Hydraulic brake service
After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
_
20
CHK
ADJ
EAS00038
R.
T.
R.
T.
R.
R.
T.
R.
5
T.
R.
LT
T.
R.
LT
T.
R.
Order
1
2
3
4
5
6
7
Job/Part
Removing the seat and side covers
Rider seat
Passenger seat
Cover
Tool kit
Left side cover 1
Left side cover 2
Right side cover
Qty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
21
FUEL TANK
CHK
ADJ
FUEL TANK
T.
R.
6
4
T.
R.
(4)
Order
1
2
3
4
5
6
7
Job/Part
Removing the fuel tank
Seat
Air induction system cover
Air duct
Fuel hose joint 1
Hose joint cover
Fuel hose joint 2
Fuel tank breather hose
Fuel tank
Qty
1
1
1
1
1
2
1
Remarks
Remove the parts in the order listed.
Refer to SEAT AND SIDE COVERS.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
22
FUEL TANK
1
CHK
ADJ
23
CHAS
CHASSIS
FRONT WHEEL AND BRAKE DISCS
1
T.
R.
3
2
1
3
T.
R.
T.
R.
T.
R.
5
6
4
T.
R.
(5)
LT
T.
R.
T.
R.
8
LT
(5)
10
8
T.
R.
Order
9
10
Job/Part
Removing the front wheel and brake
discs
Qty
Remarks
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
_
1
2
3
4
5
6
7
2
2
2
2
2
1
1
24
CHAS
T.
R.
3
2
1
3
T.
R.
T.
R.
T.
R.
5
6
4
T.
R.
(5)
LT
T.
R.
T.
R.
8
LT
(5)
10
8
T.
R.
Order
8
9
10
Job/Part
Collar (left and right)
Front wheel
Brake disc (left and right)
9
10
Qty
Remarks
2
Refer to INSTALLING THE FRONT
1
WHEEL in chapter 4.
(Manual No.: 5PX-28197-10)
2
For installation, reverse the removal
procedure.
25
CHAS
EAS00577
1
35 Nm (3.5 m kg, 25 ft Ib)
T.
R.
4
T.
R.
5
6
Order
Job/Part
Removing the front brake pads
Qty
1
2
3
4
2
2
1
1
5
6
Brake pad
Brake pad shim
2
2
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
26
CHAS
EAS00613
T.
R.
4
3
4
5
1
2 New
T.
R.
Order
Job/Part
Removing the front brake calipers
Qty
1
2
3
4
5
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper bolt
Brake caliper
1
2
1
2
1
27
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Refer to FRONT WHEEL AND BRAKE
DISCS.
Drain.
Refer to DISASSEMBLING THE FRONT
Disconnect. BRAKE CALIPERS in
chapter 4 (Manual No.:
5PX-28197-10) and
ASSEMBLING AND
INSTALLING THE FRONT
BRAKE CALIPERS.
For installation, reverse the removal
procedure.
CHAS
EAS00615
T.
R.
9
2
7 New
8 New
6
5
8 New
4
5
7 New
Order
Job/Part
Disassembling the front brake
calipers
Qty
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
1
2
3
4
5
6
7
8
9
2
1
1
2
2
4
4
4
1
28
CHAS
EAS00638
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake
components as they will cause the piston
seals to swell and distort.
Whenever a brake caliper is disassembled, replace the brake caliper piston
seals and dust seals.
Recommended brake fluid
DOT 4
b
4
T.
R.
2 New
1
1. Install:
brake caliper 1
(temporarily)
copper washers 2 New
brake hose 3
union bolt 4
32 Nm (3.2 m kg, 23 ft lb)
WARNING
_
29
Install:
brake pads
brake pad spring
brake caliper bolts
35 Nm (3.5 m kg, 25 ft lb)
T.
R.
CHAS
R.
NOTE:
The arrow a on the brake pad spring must
point in the direction of rotation.
4. Fill:
brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
_
30
CHAS
6. Check:
brake fluid level
Below the minimum level mark a Add
the recommended brake fluid to the proper
level.
Refer to CHECKING THE BRAKE FLUID
LEVEL in chapter 3.
(Manual No.: 5PX-28197-10)
7. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
(Manual No.: 5PX-28197-10)
31
FRONT FORK
CHAS
EAS00647
FRONT FORK
T.
R.
T.
R.
3
2
T.
R.
4
5
T.
R.
1
T.
R.
Order
Job/Part
Removing the front fork legs
Qty
Front wheel
1
2
3
4
5
6
Front fender
Upper bracket pinch bolt
Cap bolt
Turn signal light bracket pinch bolt
Lower bracket pinch bolt
Front fork leg
1
2
1
1
2
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front fork legs.
Refer to FRONT WHEEL AND BRAKE
DISCS.
Loosen.
Loosen.
Loosen.
Loosen.
32
CHAS
Order
Job/Part
Removing the drive belt and drive
pulley
Rear wheel
Qty
Remarks
Remove the parts in the order listed.
1
2
2
1
1
1
1
33
Order
8
Job/Part
Drive pulley
Qty
1
CHAS
Remarks
For installation, reverse the removal
procedure.
34
CHAS
2. Install:
drive belt
CAUTION:
_
4. Tighten:
drive pulley nut 1
T.
R.
NOTE:
When tightening the drive pulley nut, press
down on the brake pedal so the drive pulley
does not move.
Stake the drive pulley nut 1 at a cutout a in
the middle driven shaft.
_
35
ENGINE
ENG
ENGINE
ENGINE
T.
R.
LT
T.
R.
2
1
T.
R.
T.
R.
Order
Job/Part
Removing the oil filter bracket and
horn
Seat/side covers
Fuel tank
Air filter case
Qty
36
Remarks
Remove the parts in the order listed.
Refer to SEAT AND SIDE COVERS.
Refer to FUEL TANK.
Refer to AIR FILTER CASE in
chapter 3. (Manual No.: 5PX-28197-10)
Refer to SILENCER AIR FILTER CASE
in chapter 3.
(Manual No.: 5PX-28197-10)
Refer to FUEL INJECTION SYSTEM in
chapter 6. (Manual No.: 5PX-28197-10)
Refer to AIR INDUCTION SYSTEM in
chapter 6. (Manual No.: 5PX-28197-10)
Refer to STARTER MOTOR in
chapter 7. (Manual No.: 5PX-28197-10)
ENGINE
ENG
T.
R.
LT
T.
R.
2
1
T.
R.
T.
R.
Order
Job/Part
Engine oil/oil filter cartridge
Qty
37
Remarks
Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3. (Manual No.: 5PX-28197-10)
Refer to SUB FUEL TANK in chapter 5.
(Manual No.: 5PX-28197-10)
Drain.
Refer to CHANGING THE TRANSFER
GEAR OIL in chapter 3.
(Manual No.: 5PX-28197-10)
Refer to TRANSFER GEAR CASE.
Refer to ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS.
(Manual No.: 5PX-28197-11)
Refer to GENERATOR AND STARTER
CLUTCH in chapter 5.
(Manual No.: 5PX-28197-10)
ENGINE
ENG
T.
R.
LT
T.
R.
2
1
T.
R.
T.
R.
Order
1
2
3
4
5
6
7
Job/Part
Oil filter bracket
Rectifier/regulator coupler
Stator coil assembly coupler
Rectifier/regulator
Rectifier/regulator bracket
Horn 2
Lean angle sensor
Qty
Remarks
1
1
Disconnect.
1
Disconnect.
1
1
1
1
For installation, reverse the removal
procedure.
38
ENGINE
ENG
1
12
14
T.
R.
10
3
.
R.
R.
12
T.
13
15
R.
17
10
11
9
10
7
6
T.
R.
T.
R.
T.
R.
19
5
7
T.
R.
8
Order
18
16
Job/Part
Removing the engine
Qty
Remarks
Remove the parts in the order listed.
NOTE:
Place a suitable stand under the frame
and engine.
_
1
2
3
4
5
6
7
8
9
10
2
2
1
1
1
4
4
2
4
3
39
ENGINE
ENG
1
12
14
T.
R.
10
3
.
R.
R.
12
T.
13
15
R.
17
10
11
9
10
7
6
T.
R.
T.
R.
T.
R.
19
5
R.
Job/Part
Upper rear mounting bolt
Rear engine bracket nut
Rear engine bracket bolt
Rear engine bracket (left)
Rear engine bracket (right)
Spacer bolt
Lower rear mounting bolt
Lower front mounting bolt
Engine
T.
8
Order
11
12
13
14
15
16
17
18
19
18
16
Qty
Remarks
1
2
2
1
Refer to INSTALLING THE
1
ENGINE in chapter 5.
1
Loosen. (Manual No.: 5PX-28197-10)
1
1
1
For installation, reverse the removal
procedure.
40
ENG
R.
R.
R.
T.
T.
T.
T.
6 New
14
12
8 New
4
13
LT
LT
11
(4)
New 10
New
LS
LS
(5)
4
1
T.
R.
LS
T.
R.
T.
R.
R.
Order
Job/Part
Removing the transfer gear case
cover
Muffler/exhaust pipes
Qty
Drive pulley
Oil pipe #1
Oil pipe #2
Cover
Remarks
Remove the parts in the order listed.
Refer to ENGINE in chapter 5.
(Manual No.: 5PX-28197-10)
Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3. (Manual No.: 5PX-28197-10)
Drain.
Refer to CHANGING THE TRANSFER
GEAR OIL in chapter 3.
(Manual No.: 5PX-28197-10)
Refer to DRIVE BELT AND DRIVE PULLEY.
Engine oil
1
2
3
LS
1
1
1
41
R.
R.
R.
T.
T.
T.
T.
6 New
ENG
14
12
8 New
4
13
LT
LT
11
(4)
New 10
New
LS
LS
(5)
4
1
T.
R.
LS
T.
R.
T.
R.
R.
Order
4
5
6
7
8
9
10
11
12
13
14
Job/Part
Dowel pin
Transfer gear oil pump
Transfer gear oil pump gasket
Transfer gear case cover
Transfer gear case cover gasket
Oil strainer
Middle drive gear nut
Conical spring washer
Primary chain
Middle drive gear
Middle driven shaft
Qty
4
1
1
1
1/1
1
1
1
1
1
1
LS
Remarks
42
ENG
2.
Install:
oil strainer 1
dowel pins 2
transfer gear case cover gasket 3
New
3. Install:
transfer gear case cover 1
T.
R.
T.
R.
nut 2
4. Install:
conical spring washer 1
middle drive gear nut 2 New
NOTE:
Lubricate the middle driven gear nut threads
and conical spring washer mating surfaces
with engine oil.
Install the washer 1 with the OUT mark a
facing out.
43
ENG
5. Tighten:
middle driven gear nut 1
New
T.
R.
NOTE:
Stake the middle driven gear nut 1 at a cutout
a in the drive axle.
6. Remove:
drive pulley nut
7. Install:
transfer gear oil pump gasket
transfer gear oil pump 1
New
T.
R.
NOTE:
Apply locking agent (LOCTITE) only to the
threads of the transfer gear oil pump bolts (M6
25 mm) bolts 2.
_
44
CRANKCASE
ENG
CRANKCASE
Order
1
2
3
4
5
Job/Part
Removing the baffle plate and
bearings
Crankshaft
Transmission
Baffle plate
Bearing retainer
Bearing retainer
Oil seal
Bearing
Qty
Remarks
Remove the parts in the order listed.
Refer to CRANKSHAFT AND CONNECTING RODS in chapter 5.
(Manual No.: 5PX-28197-10)
Refer to TRANSMISSION.
1
1
1
1
4
For installation, reverse the removal
procedure.
45
CRANKCASE
a
1
T
OU
ENG
NOTE:
Install the bearing retainer 1 with its OUT
mark a facing outward.
Apply locking agent (LOCTITE) to the
threads of the bearing retainer bolt.
46
TRANSMISSION
ENG
EAS00419
TRANSMISSION
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the transmission, shift
drum assembly, and shift forks
Crankcase
Qty
2
1
1
1
1
1
1
1/1
Remarks
Remove the parts in the order listed.
Separate.
Refer to CRANKCASE in chapter 5.
(Manual No.: 5PX-28197-10)
47
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
0
A
Job/Part
Disassembling the main axle
assembly
Circlip
Washer
5th pinion gear
Spacer
Washer
2nd/3rd pinion gear
Circlip
Washer
4th pinion gear
Spacer
Main axle/1st pinion gear
Qty
ENG
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
48
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
0
A
B
Job/Part
Disassembling the drive axle
assembly
5th wheel gear
Circlip
Washer
2nd wheel gear
Spacer
Circlip
Washer
1st wheel gear
Spacer
Washer
4th wheel gear
Circlip
Qty
1
1
1
1
1
1
1
1
1
1
1
1
49
ENG
Remarks
Remove the parts in the order listed.
TRANSMISSION
Order
C
D
E
F
Job/Part
Washer
3rd wheel gear
Spacer
Drive axle
Qty
1
1
1
1
ENG
Remarks
50
Lg
L B/R
Br/B
0
W
(BLACK)
Lg BR L
RL LR
LG LY Sb BY LW/1 Br/B
G G/Y
G/Y G
Ch
Dg
B L Y
Dg
Ch
Y L B
(BLACK)
B/Y
L/W1
Sb
L/R
Sb
R/L
L/G
B
B
B B
(BLUE)
W
W
W
W
W
W
R/L
B L/G
(BLUE)
R/G
B L/B G Gy Lg B3 /W B/O
W/G R/G
L
R/W
Y W/Y P P/W P/Y Br/W B/R W/B
B/L Y/B L/R W Gy Y/R R/L Y/R L/W B3 B/Y B/G
R/W Y/L R/B Br
Br/L P/L G/R Y/G
Gy
(BLACK)
(GRAY)
5
B
WWW
R
R R
R/W L
Gy B/L
L W/Y
B/L
B Gy
W L
B
Gy
R/W
L/B
B/L
Y
L
W/B
W/Y
R/B
R/W
B/L
L Y B
R
R Br/L
L/Y L/B
ON
OFF
L/Y
L/B
Br/L R
L/B L/Y
R/W
R/B
P/W B/L L
B
B
B
L
B/L
P/W
(BLACK)
(GRAY)
Br/W
B/L Br/W
(BLACK)
Br/B
L W/B
B/L
W L
B
(BLACK)
(BLACK)
R/B
R/B
R/B
Y/R
Y/G
Br
R/L
L/R
B/G
(BLACK)
B/W
Y/L
L
W/B
B/L
G/R
G/R
Gy/R
G G
Lg
Lg
B/L
B B
(BLACK)
Gy
G
Y/B
B/Y
G/R B/L
Gy/R Lg
(BLACK)
U
Gy B Gy
W B
Gy
L
L Y/G B/L
W Gy
(BLACK)
Y/G
B/R
R/B
Br B
~
R/B
R/G
P/L
W/G
Br/L
Br/W
Br
W
B B
(BLACK)
(BLACK)
L
B/L
P
P B/L L
B/L
L
B/L
P/Y
P/Y B/L L
R/G
P/L
W/G
Br/L
P/W
P/Y
P
B/O
B/O
B/W
L/W
B
B
Br/L
(BLACK)
B
Y
L
B/R
(BLACK)
B/L
L
W/Y
B/R
B/L
B3 R/W
B3
V
G
B G
(DARK GRAY)
W
W
W G
Gy/R
(GRAY)
|
W
Br
Br/L
Br
{
Br/L
Br
Br
P
(BLACK)
R/W
Br/L
B/W
R/Y
Y/R
Br/W
B
R/W B/R
Br
R/W B/R Y
Br B/G L/W1
(RED)
(RED)
L/W1
R/Y
(BLACK)
Br
Br/W
B/Y L/Y
(BLACK)
Y/R
(L)
N
(R)
(BROWN)
L/Y G Y
B/Y Ch Dg
Y G L/Y
Dg Ch B/Y
Ch
(BROWN)
Br/W P B
R/Y
Y/R
Ch
Dg
B/G
R P
O Br/Y
(RED)
A
Y
L A
L Y
Y
B
L
B
Ch
Dg
Ch
Dg
Br
B
Dg
Dg
L Ch
Y G
G
n
B
B
B A B
B
B
A
B
Ch Y Br
Dg Lg B
(GREEN)
Y Ch
Lg Dg
L/R Gy
B/L G/R
(BLUE)
(GREEN)
Ch
G/R
L/R
B/L
P
R
O
Br/Y
G/R
L/R
B/L
P
R
O
Br/Y
R P
O Br/Y
(RED)
(BLACK)
Y/L
R/G
Br
L
G R/G
Br L
B Y/L
Dg
B P Br/W
Y/R
G/L
Y
Br
Lg
G/L
Gy
Y/B
B/Y
Gy
L Br
Y/L B
Y/B
Br
Y/R B
L/Y
Br
R/Y
G/L
Br/W
W
R/Y R/Y
R/G G
L/R Gy
B/L G/R
(BLUE)
P R
Br/Y O
(RED)
Gy L/R
G/R B/L
(BLUE)
COLOR CODE
B............ Black
B3.......... Black 3
Br .......... Brown
Ch ......... Chocolate
Dg ......... Dark green
G ........... Green
Gy ......... Gray
L ............ Blue
Lg .......... Light green
O ........... Orange
P............ Pink
R ........... Red
Sb.......... Sky blue
W........... White
Y............ Yellow
B/G ........ Black/Green
B/L......... Black/Blue
B/O ........ Black/Orange
B/R ........ Black/Red
B/W ....... Black/White
B/Y ........ Black/Yellow
Br/B ....... Brown/Black
Br/L ....... Brown/Blue
Br/W ...... Brown/White
Br/Y ....... Brown/Yellow
G/L ........ Green/Blue
G/R........ Green/Red
G/W ....... Green/White
G/Y ........ Green/Yellow
Gy/R ...... Gray/Red
L/B......... Blue/Black
L/G ........ Blue/Green
L/R ........ Blue/Red
L/W........ Blue/White
L/W1...... Blue/White 1
L/Y......... Blue/Yellow
P/L......... Pink/Blue
P/Y ........ Pink/Yellow
P/W ....... Pink/White
R/B ........ Red/Black
R/G........ Red/Green
R/L ........ Red/Blue
R/W ....... Red/White
R/Y ........ Red/Yellow
W/B ....... White/Black
W/G ....... White/Green
W/Y ....... White/Yellow
Y/B ........ Yellow/Black
Y/G ........ Yellow/Green
Y/L......... Yellow/Blue
Y/R ........ Yellow/Red
PRINTED IN U.S.A.