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YZFR6V(C) Service Manual

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1. 4 Install Left upper side cowling e Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS28030 CHECKING AND CHARGING THE BATTERY EWA13290 Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi sonous and highly caustic sulfuric acid Therefore always follow these preventive measures Wear protective eye gear when handling or working near batteries Charge batteries a well ventilated area Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion EC2C01024 CAUTION This is a sealed battery Never remove the sealing caps because the balance between cells will not be maintained and battery per formance will deteriorate Charging time charging amperage and charging voltage for an MF battery are
2. Compression damping ECA13590 CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust Compression damping fast compression damping Turn the adjusting bolt 1 in direction or Direction Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer 3 29 Compression damping adjusting positions fast compression damp ing Minimum Distance 8 mm 0 31 in Standard Distance 10 mm 0 39 in Maximum Distance c 12 mm 0 47 in DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Adjust Compression damping slow compression damping Turn the adjusting bolt 1 in direction or Direction a turn in Compression damping is increased suspension is harder Direction b turn out Compression damping is decreased suspension is softer 3 30 CHASSIS Compression damping adjusting positions slow compression damping Minimum 16 click s out Standard 10 click s out Maximum 1 click s out With the adjusting bolt fully turned in DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ADJUSTING THE REAR SHOCK ABSORBER ASSEM
3. Connect the throttle position sensor coupler to the throttle position sensor b Connect the digital circuit tester to the throttle position sensor Positive tester probe white terminal 1 or white red terminal 2 Negative tester probe black blue terminal 3 Digital circuit tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 c Measure the throttle position sensor voltage d Adjust the throttle position sensor angle so that the voltage is within the specified range li Output voltage 0 630 0 730 V e After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 4 ET2C01009 INSTALLING THE THROTTLE BODY JOINTS 1 Install Throttle body joints 1 Syr Throttle body joint bolt 10 Nm 1 0 m kg 7 2 ft Ib NOTE Be sure to install the throttle body joints with the L mark onto the throttle body openings for inders 1 and 2 and the joints with the mark onto the openings for cylinders 3 and 4 7 14 THROTTLE BODIES AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM ______ N ERES gt NS q t N x3 Ces MON 7 15 Lower air filter case Air ind
4. 3 15 CHECKING THE FUE EINE tbv 3 15 CHECKING THE CRANKCASE BREATHER 3 15 CHECKING THE EXHAUST SYSTEM 3 16 CHECKING THE CANISTER for California only 3 16 ADJUSTING THE EXUP CABLES etsi amici epi 3 16 CHECKING THE COOLANT 3 18 CHECKING THE COOLING 5 5 3 18 CHANGING EIE COOLANT 3 19 CHASSIS 3 21 ADJUSTING THE FRONT DISC 3 21 ADJUSTING THE REAR DISC 3 21 CHECKING THE BRAKE FLUID LEVEL Re etre pes 3 22 CHECKING THE FRONT BRAKE 5 3 22 CHECKING THE REAR BRAKE 3 22 CHECKING THE FRONT BRAKE 3 23 CHECKING THE REAR BRAKE 3 23 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 23 BLEEDING THE HYDRAULIC BRAKE 5 3 24 ADJUSTING THE SRIF T PEDAL iraire e e 3 25 ADJUSTING THE DRIVE CHAIN 3 25 LUBRICATING THE DRIVE CHAIN 3 26 CHEC
5. 528230 CHECKING THE FUEL SENDER 1 Disconnect Fuel pump coupler Fuel sender coupler from the wire harness 2 Remove Fuel tank 3 Remove Fuel pump from the fuel tank 4 Check Fuel sender resistance Fuel sender resistance 900 1050 Q at 25 C 77 F a Connect the pocket tester Q x 1 to the fuel sender terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe green white 1 Negative tester probe black 2 b Measure the fuel sender resistance DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE SPEED SENSOR 1 Check e Speed sensor output voltage Out of specification Replace Output voltage reading cycle 0 6 V to 4 8 V to 0 6 V to 4 8 V a Connect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown 8 96 ELECTRICAL COMPONENTS Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt white yellow 1 Negative tester probe gt black blue 2 b Turn the main switch to ON c Elevate the rear wheel and slowly rotate it d Measure the voltage of white yellow and black blue With each full rotation of the rear wheel the voltage reading should cycl
6. 8 9 TROUBLESHOOTING 8 11 CHARGING 5 8 13 CIRCUIT DIAGRAM trente 8 13 TROUBLESHOOTING essent tnnt 8 15 LIGHTING SYSTEM 8 17 e zie unma cr LE 8 17 TROUBLESHOOTING sese 8 19 SIGNALING SYSTEM 8 21 CIRCUIT DIAGRAM ibas street rien 8 21 TROUBLESHOOTING 8 23 COOLING 8 29 CIRCUIT DIAGRAM tette 8 29 TROUBLESHOOTING 8 31 FUEL INJECTION SYSTEM 8 33 CIRCUIT icri MMC 8 33 ECU SELF DIAGNOSTIC 8 35 SELF DIAGNOSTIC FUNCTION TABLE 8 36 TROUBLESHOOTING 22 8 39 DIAGNOSTIC MODE PNO 8 40 TROUBLESHOOTING 8 48 FUEL PUMP SYSTEM 8 73 CIRCO DIAGRAM Nm 8 73 TROUBLESHOOTING 8 75 ELECTRICAL 8 77 CHECKING THE SVU GIES ty uti 8 81 CHECKING THE BULBS AND BULB 8 84 CHECKING THE FUSES laevo atus 8 85 CHECKING AND CHARGING THE 8 86 CHECKING THE RELAYS dra Dept M RES 8 89 CHECKING THE TURN SIGNAL RELAY 8 90 CHECKING THE RELAY
7. _ Oil pipe 36 eonan NEN 12 Dowel pin Relief valve assembly ERE dure 5 51 OIL PUMP Disassembling the oil pump 2 10 Nm 1 0 kg 7 2 ft Ib eo a 2 S Oil pump housing pos Oil pump driven sprocket mm assembly reverse the disassembly pro cedure 5 52 24930 REMOVING THE OIL 1 Remove Oil level switch lead holder Bottom cowling brackets Oil pan Oil pan gasket NOTE Loosen each bolt 1 4 of a turn at a time in stag es and in a crisscross pattern After all of the bolts are fully loosened remove them EAS24960 CHECKING THE OIL PUMP 1 Check Oil pump driven sprocket Oil pump housing Oil pump housing cover Cracks damage wear Replace the defec tive part s 2 Measure nner rotor to outer rotor tip clearance Outer rotor to oil pump housing clearance Oil pump housing to inner rotor and outer rotor clearance Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing OIL PUMP Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 090 0 150 mm 0 0035 0 0059 in Limit 0 220 mm 0 0087 in Oil
8. 7 Install Spark plugs Ignition coils Spark plug 13 Nm 1 3 m kg 9 4 ft lb NOTE Before installing the spark plug clean the spark plug and gasket surface 8 Install Air induction system solenoid Refer to AIR INDUCTION SYSTEM on 7 15 Canister for California only Refer to THROTTLE BODIES on page 7 8 Air filter case Refer to AIR FILTER CASE page 7 5 Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl inders NOTE Insufficient compression pressure will result ina loss of performance 1 Measure e Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 4 2 Start the engine warm it up for several min utes and then turn it off 3 Remove e Side cowlings Bottom cowlings Refer to GENERAL CHASSIS on page 4 1 3 9 e Radiator Refer to RADIATOR on page 6 1 4 Remove Ignition coils Spark plugs ECA13340 CAUTION Before removing the spark plugs use com pressed air to blow away any dirt accumulat ed in the spark plug wells to prevent it from falling into the cylinders 5 Install Compression gauge 1 e Extension 2 Compression gauge 90890 03081 Engine compression tester YU 33223 Extension
9. THERMOSTAT 2 Check Thermostat cover Cracks damage Replace EAS26480 INSTALLING THE THERMOSTAT 1 Install Thermostat NOTE Install the thermostat with its breather hole a facing up 2 Fill e Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 3 Check Cooling system Leaks Repair or replace any faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 WATER PUMP EAS26500 WATER PUMP Removing the water pump 12 Nm 1 2 m kg 8 7 ft Ib 12 Nm 1 2 m kg 8 7 ft Ib It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil Right bottom cowling GENERAL CHASSIS on Air filter case ZEN Refer to AIR FILTER CASE on page 7 5 Canister for California only LJ Refer to THROTTLE BODIES on page 7 8 Drain Coolant 1 Refer to CHANGING THE COOLANT on Clutch cable page 3 19 Water pump inlet hose LL 2 For installation reverse the removal proce dure 6 9 26540 CHECKING THE WATER PUMP 1 Check Water pump assembly Cracks damage Replace 2 Check e Water pump inlet hose Water pump outlet hose e Water pump bre
10. Vy c E EVE fo 7 TT T 230 Ve 99 1 NO 1 52 9 0 5 0 i A e a a a A d ee A lat 169 ay T 1 162 6 gt 553 E SS3NuvH3uIN 15 8 8 SS3NHVH 9 8 ens HOLIMS TWHINN SINUVH 8 29 Main switch Ignition fuse Main fuse 7 Battery 11 Engine ground 22 ECU engine control unit 42 Coolant temperature sensor 87 Radiator fan motor relay 88 Right radiator fan motor fuse 89 Left radiator fan motor fuse 90 Right radiator fan motor 91 Left radiator fan motor 5550 8 30 COOLING SYSTEM COOLING SYSTEM EAS27320 TROUBLESHOOTING NOTE Before troubleshooting remove the following part s 1 Rider seat 2 Fuel tank 3 Side cowlings Check the fuses NG gt Main ignition and radiator fan mo tor Replace the fuse s Refer to CHECKING THE FUS ES on page 8 85 OK 2 Check the battery Refer to CHECKING AND e Clean the battery terminals CHARGING THE BATTERY on Recharge or replace the battery page 8 86 Check the main switch gt Refer to CHECKING THE SWITCHES o
11. Je 3 Install e Exhaust pipe assembly 9 Refer to ENGINE REMOVAL page 5 1 Bottom cowlings LOU EE Side cowlings 5 Drain Refer to GENERAL CHASSIS on page 4 1 e Coolant 2 from the engine and radiator CHANGING THE COOLANT 6 Remove 1 Remove Coolant reservoir 1 Right side panel Coolant reservoir cap 2 e Right upper side cowling 3 Right lower side cowling 2 2 Right bottom cowling Refer to GENERAL CHASSIS on page 4 1 2 Remove u 1 E 7 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may 7 Drain Coolant from the coolant reservoir 3 19 8 Install Coolant reservoir 9 Connect Water pump inlet hose 10 Install Coolant drain bolt water pump along with the copper washer 11 Coolant bolt water pump 10 Nm 1 0 m kg 7 2 ft lb 11 Fill Cooling system with the specified amount of the recom mended coolant Recommended antifreeze High quality ethylene glycol anti freeze containing corrosion in hibitors for aluminum engines Mixing ratio 1 1 antifreeze water Radiator capacity including all routes 2 30 L 2 43 US qt 2 02 Imp qt Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp
12. 2 57 P 12 13 14 15 16 m Canister purge hose throttle body 4 to 3 way joint for California only Canister purge hose 3 way joint to canister for California only Fuel tank breather hose fuel tank to rollover valve for California only Fuel tank breather hose fuel tank to hose joint except for California Fuel hose fuel tank to primary injector fuel rail Crankcase breather hose Fuel tank overflow hose Fuel tank breather hose except for California Fuel tank overflow hose fuel tank to hose joint Fuel hose primary injector fuel rail to secondary injector fuel rail Intake air pressure sensor lead Sub wire harness 3 Canister purge hose throttle body 2 to 3 way joint for California only Atmospheric pressure sensor lead Sub wire harness 2 Intake air pressure sensor hose Face the ends of the clamp rearward Route the sub wire harness 3 to the left side of the intake air pressure sensor Fasten the atmospheric pressure sensor lead with the holder on the air filter case Route the atmospheric pressure sensor lead in the groove in the air filter case Fasten the sub wire harness 3 with the holder on the air filter case 2 58 CABLE ROUTING CABLE ROUTING Otay p ER TT Yo TD m 47 77 r E j 1 7 S KAN 7 2 yj ty 4
13. es irae eet er 6 9 CHECKING THE WATER PUMP 6 10 INSTALLING THE WATER PUMP tt 6 10 RADIATOR EAS26380 RADIATOR Removing the radiator 5 Nm 0 5 kg 3 6 ft Ib 13 Nm 1 3 kg 9 4 ft Ib 10 Nm 1 0 kg 7 2 ft Ib Lower side cowlings Bottom cowlings m oe to GENERAL CHASSIS on page Drain Coolant Refer to CHANGING THE COOLANT on page 3 19 Coolant reservoir breather hose RUNE 2 3 7 4 2 mdawup Radar Radiator inlet hose N No Radiator inlet pipe 10 Radiator outlet hose holder 12 Radiator outlet pipe ERN 6 1 RADIATOR Removing the radiator 13 Nm 1 3 m kg 9 4 ft Ib 5 Nm 0 5 kg 3 6 ft Ib N gt 10 Nm 1 0 kg 7 2 ft Ib Radiator bracket 2 For installation reverse the removal dure 6 2 26390 CHECKING THE RADIATOR 1 Check e Radiator fins Obstruction Clean Apply compressed air to the rear of the radia tor Damage Repair or replace NOTE Straighten any flattened fins with a thin flat head screwdriver 2 Check e Radiator hoses e Radiator pipes Cracks damage Replace 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator c
14. Negative tester probe gt white 2 Positive tester probe gt white 1 Negative tester probe gt white 3 Positive tester probe gt white 2 Negative tester probe gt white 3 ELECTRICAL COMPONENTS 2 3 b Measure A coil resistance CHECKING THE RECTIFIER REGULATOR 1 Check Charging voltage Out of specification Replace the rectifi Charging voltage 14 V at 5000 r min Set the engine tachometer to the cylinder 1 ignition coil b Connect the pocket tester DC 20 V to the rectifier regulator coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt red 1 Negative tester probe gt black 2 c Start the engine and let it run at approximate ly 5000 r min d Measure the charging voltage AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 8 94 28180 CHECKING THE HORN 1 Check Horn resistance Out of specification Replace liil Coil resistance 1 15 1 25 at 20 68 F Disconnect the horn leads from the horn ter minals b Connect the pocket tester Q x 1 to the horn terminals Pocket tester 90890 03112 Analog pocket
15. SAG e ley EX D Throttle position sensor for throttle cable pulley Throttle servo motor Throttle position sensor for throttle valves ECU engine control unit ETV main CPU 32 bit ETV sub CPU 16 bit FI CPU 32 bit Throttle servo motor driver Throttle servo motor driver operation sensing shut off circuit 10 Throttle servo motor driver operation sensing feedback emergency stop 11 Emergency stop 12 Engine revolution pulse signal 13 Sensor input 14 Neutral switch 15 Crankshaft position sensor 16 Speed sensor 17 Coolant temperature sensor 1 5 FEATURES 18 Atmospheric pressure sensor FEATURES YCC T control outline 1 10 Sas gt 2225522 55555 LSS LIK LLP 55 Sos LEE 65455522595 9555 gt 2 222252222 252 LC LX SZ XI LE CIL LZ Z L L C L LL A lt gt lt 2 2 LISE SI ZZ ZO SN IX R Z 552222222226 222222224 26229 Q 12 13 2 7 14 19 Throttle position sensor for throttle cable 18 speed control pulley 19 Calculated throttle valve opening angle Throttle position sensor for throttle valves Crankshaft position sensor Speed sensor Coolant temperature sensor Neutral switch Atmospheric pressure sensor Throttle position for throttle cable pulley two signals Throttle position for throttle valv
16. dure 4 17 FRONT BRAKE Removing the front brake master cylinder 13 Nm 1 3 kg 9 4 ft Ib 30 Nm 3 0 kg 22 ft Ib Order Job Parts to remove Drain Brake fluid Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 Brake fluid reservoir cap holder 1 2 Brake fluid reservoir cap 4 p 7 W eopper washer 12 Front brake hose Front brake master cylinder holder Front brake master cylinder dure 4 18 Front brake light switch connector FRONT BRAKE Disassembling the front brake master cylinder 6 Nm 0 6 kg 4 3 ft Ib Re Brake master cylinder body For assembly reverse the disassembly pro cedure 4 19 FRONT BRAKE Removing the front brake calipers 7 Nm 0 7 m 5 1 ft Ib 30 Nm 3 0 m kg 22 ft 1 35 Nm 3 5 kg 25 ft Ib The following procedure applies to both of the front brake calipers Drain Brake fluid Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 4 Copper washer 5 Front brake hose 6 Front brake caliper dure n 4 20 FRONT BRAKE Disassembling the front brake calipers 5 Nm 0 5 m kg 3 6 ft Ib The following procedure applies to both of the front brake calipers 3 For a
17. 0 04 0 12 in of clear ance a between the throttle grip and the right grip end 6 Install Clutch lever assembly 1 NOTE Clutch lever bolt 11 Nm 1 1 m kg 8 0 ft lb Align the mating surfaces of the clutch lever as sembly with the punch mark a on the left han dlebar 7 Install e eft handlebar switch 1 NOTE Align the projection a on the left handlebar switch with the hole b in the left handlebar 8 Install e Handlebar grip 1 Left grip end 2 4 43 HANDLEBARS a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Slide the handlebar grip over the end of the left handlebar c Wipe off any excess rubber adhesive with a clean rag Do not touch the handlebar grip until the rub ber adhesive has fully dried NOTE There should be 1 3 mm 0 04 0 12 in of clear ance a between the handlebar grip and the grip end 9 Check Cable routing NOTE Make sure the main switch lead brake hoses throttle cables clutch cable and handlebar switch leads are routed properly Refer to CA BLE ROUTING on page 2 47 10 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 13 Clutch lever free play 10 0 15 0 mm 0 39 0 59
18. 23 Lower bearing inner race LJC pem Upper bearing oueres 4 56 STEERING HEAD Removing the lower bracket 115 Nm 11 5 kg 85 ft Ib 1181 52 Nm 5 2 kg 37 ft Ib 2nd 14 Nm 1 4 kg 10 ft Ib For installation reverse the removal dure 4 57 23110 REMOVING THE LOWER BRACKET 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Hemove Upper ring nut 1 e Rubber washer Lower ring nut 2 Lower bracket EWA13730 Securely support the lower bracket so that there is no danger of it falling NOTE Hold the lower ring nut with the ring nut wrench 3 and then remove the upper ring nut with the steering nut wrench 4 Ring nut wrench 90890 01268 Spanner wrench YU 01268 Steering nut wrench 90890 01403 Spanner wrench YU 33975 4 3 1 FESS Jig ges CHECKING THE STEERING HEAD 1 Wash Bearings Bearing races Recommended cleaning solvent Kerosene 2 Check Bearings Bearing races Damage pitting Replace STEERING HEAD 3 Replace Bearings Bearing races a Remove the bearing race from the steering head pipe 1 with a long rod 2 and hammer Remove the beari
19. Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 8 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION COILS on page 8 92 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 92 OK 6 Check the crankshaft position sen sor Refer to CHECKING THE CRANK SHAFT POSITION SENSOR on page 8 93 OK Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 OK gt NG gt gt OK gt gt gt gt 8 4 Replace the fuse s Clean the battery terminals Recharge or replace the battery Re gap or replace the spark plug s Ignition system is OK Replace the ignition coil s Replace the crankshaft position sensor Replace the main switch 8 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 81 OK Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 81 10 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 81 11 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE page 8 91 OK 12 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 93 OK 13 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1
20. ENGINE REMOVAL 3 Install e Shift arm 1 Shift arm bolt 10 Nm 1 0 m kg 7 2 ft lb NOTE Install the shift arm 1 with its punch mark aligned with the notch b in end of the shift shaft CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 8 Nm 0 8 kg 5 8 ft Ib 12 Nm 1 2 m kg 8 7 ft Ib 13 Nm 1 3 m kg 9 4 ft Ib Throttle body Refer to THROTTLE BODIES on page 7 8 Air cut off valve Reed valve assembly Refer to AIR INDUCTION SYSTEM on NEN i mM page 7 15 Timing chain guide upper side For installation reverse the removal proce dure 5 7 CAMSHAFTS Removing the camshafts 10 Nm 1 0 m kg 7 2 ft 16 Pickup rotor cover Refer to PICKUP ROTOR on page 5 30 L 3 msc 3 _ 3 Timing chain tensioner gasket NL NN 1 2 1 3 1 4 Intake camshaft cap 5 Exhaust camshaft cap 6 Camshaft sprocket 8 Timing chain guide intake side dure 5 8 23810 REMOVING THE CAMSHAFTS 1 Remove Pickup rotor cover Refer to PICKUP ROTOR on page 5 30 2 Align mark on the pickup rotor with the crankcase mating surface a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion st
21. Improperly installed sensor Latch up detected The vehicle has overturned No normal signal is re Defective lean angle sensor ceived from the lean angle Malfunction in ECU sensor Improperly installed lean angle sensor Open circuit detected in the Open circuit in wire harness primary lead of the cylin Malfunction in ignition coil der 1 ignition coil e Malfunction in ECU Open circuit detected in the Open circuit in wire harness primary lead of the cylin Malfunction in ignition coil der 2 ignition coil Malfunction in ECU Open circuit detected in the Open circuit in wire harness primary lead of the cylin Malfunction in ignition coil 3 ignition coil Malfunction ECU Open circuit detected in the Open circuit in wire harness primary lead of the cylin Malfunction in ignition coil der 4 ignition coil e Malfunction in ECU Open or short circuit in wire harness Open circuit detected ina Defective primary injector primary injector Malfunction in ECU Improperly installed primary injector Open or short circuit in wire harness Open circuit detected ina Defective secondary injector secondary injector Malfunction in ECU Improperly installed secondary injector Lean angle sensor Open or short circuit in wire harness open or short circuit detect Defective lean angle sensor ed Malfunction in ECU
22. YAMAHA YZFR6V C SERVICE MANUAL 2C0 28197 10 20050 YZFR6V C SERVICE MANUAL 2005 by Yamaha Motor Corporation U S A First edition December 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 P N LIT 11616 19 78 20070 NOTICE This manual was produced by the Yamaha Motor Company Lid primarily for use by Yamaha dealers and their qualified mechanics It is not possible to include all the knowledge of a mechanic in one man ual 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 vehi cle 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 vehi cle 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 objecti
23. on page 5 21 e Cylinder head water jacket Mineral deposits rust Eliminate 5 16 CYLINDER HEAD 3 Measure Cylinder head warpage Out of specification gt Resurface the cylinder head Warpage limit 0 05 mm 0 0020 in Place straightedge 1 and a thickness gauge 2 across the cylinder head LA Wyo C Measure the warpage If the limit is exceeded resurface the cylinder head as follows Place 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE To ensure an even surface rotate the cylinder head several times INSTALLING THE CYLINDER HEAD 1 Install Cylinder head NOTE Pass the timing chain through the timing chain cavity 2 Tighten Cylinder head nuts 1 7 10 CYLINDER HEAD Cylinder head nut 1st 25 Nm 2 5 m kg 18 ft lb Cylinder head nut final 42 Nm 4 2 m kg 30 ft lb Cylinder head cap nut 1st 30 Nm 3 0 m kg 22 ft lb Cylinder head cap nut final 60 Nm 6 0 m kg 43 ft lb Cylinder head bolts 11 12 Syr Cylinder head bolt 12 Nm 1 2 m kg 8 7 ft lb NOTE Tighten the cylinder head nuts cap nuts and bolts in the proper tightening sequence
24. c Tighten the connecting rod nuts further to reach the specified angle 175 185 Connecting rod nut final Specified angle 175 185 175 185 EWA13400 If the connecting rod nut is tightened more than the specified angle do not loosen the nut and then retighten it Instead replace the connecting rod bolt and nut with a new one and perform the procedure again ECA13950 CAUTION Do not use a torque wrench to tighten the connecting rod nut to the specified angle 5 66 On a hexagonal nut note that the angle from one corner to another is 60 CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Separate Refer to CRANKCASE page 5 55 Refer to CONNECTING RODS AND PIS TONS page 5 59 For installation reverse the removal proce dure 5 67 26040 REMOVING THE CRANKSHAFT JOURNAL BEARINGS 1 Remove Crankshaft journal lower bearings from the lower crankcase Crankshaft journal upper bearings from the upper crankcase NOTE Identify the position of each crankshaft journal bearing so that it can be reinstalled in its original place ET2C01018 CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles 1 Check Oil nozzle Damage wear Replace the oil nozzle O ring Damage wear
25. o p 3 4 r Weinen wespepsnsd For assembly reverse the disassembly cedure 4 33 22560 INTRODUCTION EWA14100 Disc brake components rarely require disas sembly Therefore always follow these pre ventive measures Never disassemble brake components less absolutely necessary If any connection on the hydraulic brake system is disconnected the entire brake system must be disassembled drained cleaned properly filled and bled after reas sembly Never use solvents on internal brake com ponents Use only clean or new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get im mediate medical attention EAS22570 CHECKING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 11 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 22 Brak
26. 1 58 mm 0 062 in The valve pad number 1 158 e Round off the valve pad number according to the following table and then select the suit able valve pad Last digit Rounded value 0 1 2 3 4 5 6 Refer to the following table for the available valve pads Valve pad range Nos 150 240 1 50 2 40 mm Valve pad thickness 0 0591 0 0945 in 25 thicknesses in 0 05 mm 0 002 in increments Available valve pads Example Valve pad number 158 Rounded value 160 New valve pad number 160 f Install the new valve pad 1 and the valve lift er 2 ENGINE NOTE Lubricate the valve lifter with engine oil The valve lifter must turn smoothly when rotat ed by hand Install the valve lifter and the valve pad in the correct place g Install the exhaust and intake camshafts tim ing chain and camshaft caps Camshaft cap bolt 10 Nm 1 0 m kg 7 2 ft lb NOTE Refer to CAMSHAFTS page 5 7 Lubricate the camshaft bearings camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshaft marks with the camshaft cap marks Turn the crankshaft clockwise several full turns to seat the parts h Measure the valve clearance again i If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained DAAAAAAAAAAAAAAAAAAAAAAAAAA
27. Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 22 e LOWER za 22 ZB 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 G EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE Before removing the front brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Front brake hose union bolt 1 e Copper washers 2 e Front brake hoses 3 FRONT BRAKE NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 22510 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Front brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake fluid reservoir Cracks damage Replace Brake fluid reservoir diaphragm Damage wear Replace 4 Check e Brake hose Brake fluid reservoir hose Cracks damage wear Replace EAS22520 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid e Never use s
28. Apel EXUP system operation a Activate the diagnostic mode and select the diagnostic code number 53 Refer to FUEL INJECTION SYSTEM on page 8 33 b Set the engine stop switch to O c Check that the EXUP valve operates proper ly NOTE Check that the projection a on the EXUP valve pulley contacts the stopper b fully open posi tion If the projection does not contact the stop per adjust the EXUP cable free play 3 Check e EXUP cable free play at the EXUP valve pul ley a Out of specification Adjust EXUP cable free play at the EXUP valve pulley 1 5 mm 0 06 in or less 3 17 ENGINE 4 Adjust e EXUP cable free play Loosen the locknuts 1 and 2 b Turn the adjusting bolt 3 in direction a or b until the specification Direction a Free play is increased Direction b Free play is decreased EXUP cable free play at the EXUP valve pulley c 1 5 mm 0 06 in or less Locknut EXUP cable adjusting bolt 7 Nm 0 7 m kg 5 1 16 d Turn the adjusting bolt 4 in direction a or b until the specification Direction a Free play is increased Direction b Free play is decreased
29. Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 Clutch plate thickness 1 90 2 10 mm 0 075 0 083 in Warpage limit 0 10 mm 0 0039 in 5 41 The clutch plate thickness specification listed above is for the plates with the standard thick ness only If a clutch plate with one of the other two plate thicknesses is installed use 1 50 1 70 mm 0 059 0 067 or 2 20 2 40 mm 0 086 0 094 in for the specification according to the plate 3 Measure Total width of the friction plates and clutch plates Out of specification Adjust Total width of the friction plates and clutch plates 42 4 43 0 mm 1 67 1 69 in a Adjust the total width by replacing the clutch plate 1 and if necessary clutch plate 2 b Select the clutch plate from the following ta ble Clutch plate 1 mee Emm 00 168 16325 00 392 16324 00 168 16324 00 CLUTCH Clutch plate 2 Thickness 3J2 16324 00 2 0 mm 0 079 in STD 168 16324 00 2 3 mm 0 091 NOTE When adjusting the clutch assembly width by replacing the clutch plate s be sure to replace the clutch plate 1 first After replacing the clutch plate 1 if specifications cannot be
30. DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE ATMOSPHERIC PRESSURE SENSOR 1 Check e Atmospheric pressure sensor output voltage Out of specification Replace Atmospheric pressure sensor output voltage 3 15 4 15 V a Connect the pocket tester DC 20 V to the at mospheric pressure sensor coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt pink 1 Negative tester probe gt black blue 2 b Turn the main switch to ON c Measure the atmospheric pressure sensor output voltage DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 28390 CHECKING THE CYLINDER IDENTIFICATION SENSOR 1 Remove Timing plate cover 2 Check Cylinder identification sensor output voltage Out of specification Replace Cylinder identification sensor output voltage ON Less than 0 8 V Cylinder identification sensor output voltage OFF More than 4 8 V a Connect the pocket tester DC 20 V to the cylinder identification sensor coupler wire harness side as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt white black 1 Negative tester probe gt black blue 2 b Turn the main switch to Rotate the crankshaft Measure
31. Gong Owe 6 ain ag E _ a olan 610v18 SS3NHVH 3HIM SS3NHVH 3UIM 905 LH NAYIH 815 HOLIMS Tox EX 8 21 switch Ignition fuse Main fuse 7 Battery 11 Engine ground 13 Relay unit 16 Neutral switch 19 Fuel sender 22 ECU engine control unit 40 Crankshaft position sensor 42 Coolant temperature sensor 45 Cylinder identification sensor 46 Speed sensor 49 Fuel level warning light 50 Oil level warning light 51 Neutral indicator light 52 Tachometer 53 Shift timing indicator light 54 Multi function meter 56 Coolant temperature warning light 58 Left turn signal indicator light 59 Right turn signal indicator light 61 Oil level switch 63 Front brake light switch 66 Turn signal relay 69 Horn switch 71 Turn signal switch 72 Horn 73 Rear right turn signal light 74 Rear left turn signal light 75 Front right turn signal position light 76 Front left turn signal position light 81 Rear brake light switch 82 Tail brake light 85 Signaling system fuse 5550 8 22 SIGNALING SYSTEM SIGNALING SYSTEM EAS27290 TROUBLESHOOTING e Any of the following fail to light turn signal light brake light or indicator light e The horn fails to sound NOTE Before troubleshooting remove the following part s Rider seat Fuel tank oide
32. ILI 077 7 KG 4 L 2 59 QI Oo Ure Imi 13 14 15 16 17 Negative battery lead Main fuse leads Lean angle sensor lead ECU engine control unit Tail brake light lead Turn signal light lead right and left side License plate light lead Seat lock cable Fuse box lead Sidestand switch lead Positive battery lead Starter relay lead Turn signal relay lead Starter motor lead Relay unit lead ECU lead Wire harness Connect the license plate light connectors and the turn signal light couplers Fasten the wire harness and the tail brake light lead with the holders on the frame Connect the tail brake light coupler making sure to position it under the wire harness and between the battery box and the frame Do not route the turn signal hazard relay lead or relay unit lead over the front of the battery box or the damper Pass the negative battery lead between the battery band and the battery Pass the plastic band through the hole in the rib on the rear lower cowling from the front and then fasten the turn signal light couplers and license plate light connectors with the band Place the end of the plastic band between the rear lower cowling and the frame Pass the turn signal light leads and license plate light leads through the hole in the rib on the rear lower cowling Face the end of the plastic band to the left Cut off the exces
33. Limit Valve guide inside diameter exhaust Limit Valve stem to valve guide clearance intake Limit Valve stem to valve guide clearance exhaust Limit Valve stem runout Cylinder head valve seat width intake Limit Cylinder head valve seat width exhaust Limit ENGINE SPECIFICATIONS 0 90 1 10 mm 0 0354 0 0433 in 0 8 mm 0 03 in 1 10 1 30 mm 0 0433 0 0512 in 1 0 mm 0 04 in 4 475 4 490 mm 0 1762 0 1768 4 460 mm 0 1756 in 4 460 4 475 mm 0 1756 0 1762 in 4 445 mm 0 1750 in 4 500 4 512 mm 0 1772 0 1776 in 4 542 mm 0 1788 in 4 500 4 512 mm 0 1772 0 1776 in 4 542 mm 0 1788 in 0 010 0 037 mm 0 0004 0 0015 in 0 080 mm 0 0032 in 0 025 0 052 mm 0 0010 0 0020 in 0 095 mm 0 0037 in 0 040 mm 0 0016 in 0 90 1 10 mm 0 0354 0 0433 in 1 6 mm 0 06 in 1 10 1 30 mm 0 0433 0 0512 in 1 8 mm 0 07 in Valve spring Free length intake Limit Free length exhaust Limit Installed length intake Installed length exhaust Spring rate K1 intake Spring rate K2 intake Spring rate K1 exhaust Spring rate K2 exhaust Installed compression spring force intake Installed compression spring force exhaust 2 5 37 47 mm 1 48 in 35 60 mm 1 40 in 37 67 mm 1 48 in 35 79 mm 1 42 in 32 80 mm 1 29 in 32 80 mm 1 29 in 38 11 N mm 217 61 Ib in 3 89 kgf mm 52 40 N mm 299 20 Ib in 5 34 kgf mm 36 36 N mm 207 62 Ib in 3 71 kgf mm 53 40 N
34. _____ 0 ____________ 11 Engine mounting collar inside Engine mounting bolt rear lower side For installation reverse the removal proce dure T e 23720 INSTALLING THE ENGINE 1 Install Engine 1 Engine mounting bolt rear lower side 2 Engine mounting bolt rear upper side 3 Engine mounting collars inside 4 Engine mounting collars outside 5 Engine mounting nut rear lower side 6 temporarily tighten e Engine mounting nut rear upper side 7 temporarily tighten Engine mounting bolts front left side 8 temporarily tighten Engine mounting collars inside 9 e Engine mounting collars outside 10 Engine mounting bolts front right side 11 temporarily tighten NOTE Be sure to pass the drive axle through the drive chain when installing the engine 1 Do not fully tighten the bolts and nuts 2 Tighten Engine mounting nut rear lower side 6 Engine mounting nut rear upper side 7 Engine mounting bolts front left side 8 Engine mounting bolts front right side 11 Engine mounting nut rear lower side 68 Nm 6 8 m kg 49 ft lb Engine mounting nut rear upper side 68 Nm 6 8 m kg 49 16 Engine mounting bolt front left side 45 Nm 4 5 m kg 32 ft lb Engine mounting bolt front right side 45 Nm 4 5 m kg 32 ft lb
35. kg 29 ft Ib 44 Nm 4 4 m kg 32 ft Ib 16 Nm 1 6 m kg 11 ft Ib 52 Nm 5 2 m kg 37 ft Ib 40 Nm 4 0 kg 29 ft Ib Oy Rome mE For installation reverse the removal proce dure 4 61 REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER EWA13740 This rear shock absorber contains highly compressed nitrogen gas Before handling the rear shock absorber read and make sure you understand the following information The manufacturer cannot be held responsi ble for property damage or personal injury that may result from improper handling of the rear shock absorber Do not tamper or attempt to open the rear shock absorber Do not subject the rear shock absorber to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber in any way Rear shock absorber damage will result in poor damping perfor mance EAS23190 DISPOSING OF A REAR SHOCK ABSORBER 1 Gas pressure must be released before dis posing of a rear shock absorber To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber at a point 50 mm 1 97 in from its end as shown EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMB
36. with the sheave holder 3 tighten the generator rotor bolt Sheave holder 90890 01701 Primary clutch holder YS 01880 A Wo 3 Apply e Sealant onto the stator coil assembly lead grommet 5 29 PICKUP ROTOR EAS24520 PICKUP ROTOR Removing the pickup rotor 12 Nm 1 2 m kg 8 7 ft Ib Right boroni cowo mE IAE GENERAL CHASSIS on page _ ___ STEP e S For installation reverse the removal proce dure 5 30 PICKUP ROTOR EAS24530 REMOVING THE PICKUP ROTOR 1 Remove NY 5 Pickup rotor bolt 1 L A a Washer SS Bac Pickup rotor x NOTE 2 Q O f amp e While holding the generator rotor 2 with the ro 1 tor sheave holder 3 loosen the pickup rotor bolt 2 Tighten Pickup rotor bolt 1 Sheave holder 90890 01701 Pickup coil rotor bolt Primary clutch holder YS 01880 A 35 Nm 3 5 m kg 25 ft lb NOTE While holding the generator rotor 2 with the sheave holder 3 tighten the pickup rotor bolt Sheave holder 90890 01701 Primary clutch holder YS 01880 A EAS24540 INSTALLING THE PICKUP ROTOR 1 Install Pickup rotor 1 Washer Pickup rotor bolt NOTE When installing the pickup rotor align the groove in the crankshaft with the projection 3 Apply b on the pickup rotor e Seal
37. 12 Fuel pump 7 1 FUEL TANK Removing the fuel tank and fuel pump 9 Nm 0 9 kg 6 5 ft Ib 4 Nm 0 4 kg 2 9 ft Ib c7 a Omer Job Parts to remove Q ty For installation reverse the removal dure 7 2 26630 REMOVING THE FUEL TANK 1 Extract the fuel in the fuel tank through the fuel tank cap with a pump 2 Remove Fuel hose fuel tank to primary injector rail EW2C01008 Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hoses NOTE To remove the fuel hose from the fuel pump slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown press the two buttons 2 on the sides of the connector and then remove the hose Remove the fuel hose manually without using any tools Before removing the hose place a few rags in the area under where it will be removed 3 Remove e Fuel tank NOTE Place the fuel tank on a level surface resting on its end and the bracket 1 as shown in the illus tration Make sure that the fuel pipe does not contact the ground otherwise the fuel pump could be damaged FUEL TANK 26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump ECA14720 CAUTION Do not drop the fuel pump or give it a strong shock Do
38. 2 with the recommended lubricant b Smaller pitch Recommended lubricant 4 Install Molybdenum disulfide oil e Valve cotters 1 NOTE Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment Valve spring compressor 90890 04019 YM 04019 Valve spring compressor 3 Install 90890 04109 Lower spring seat 1 Valve spring compressor attach Valve stem seal 2 ment e Valve 3 90890 04108 e Valve spring 4 Valve spring compressor adapt er 22 mm Upper spring seat 5 YM 04108 into the cylinder head sure each valve is installed its original place Install the valve springs with the larger pitch a facing up 5 24 5 secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer ECA13800 CAUTION Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve lifter with the recommended lubricant Recommended lubricant Engine oil 7 Install Valve pad e Valve lifter NOTE The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position VALVES AND VALVE SPRINGS 5 25 GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the generator
39. 2 onto the mating sur faces of the cylinder head cover gasket and cylinder head Tighten the cylinder head cover bolts stages and in a crisscross pattern OL OUC AUC ZU CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Y 154 25 Nm 2 5 kg 18 ft Ib Y 151 30 Nm 3 0 kg 22 ft Ib 42 Nm 4 2 kg 30 ft Ib 60 Nm 6 0 kg 43 ft Ib 12 Nm 1 2 kg 8 7 ft Ib 1 142 12572 1 a E NEM p For installation reverse the removal proce dure 5 15 24120 REMOVING THE CYLINDER HEAD 1 Remove Cylinder head bolts Cylinder head nuts NOTE Loosen the nuts cap nuts bolts in de creasing numerical order refer to the numbers in the illustration e Loosen each nut 1 2 of a turn at a time After all of the nuts are fully loosened remove them 8 6 2 4 10 dus 52222222 poor ANO OCHO e T i 212 V 5 lt Se 1 7 524160 CHECKING THE CYLINDER HEAD 1 Eliminate Combustion chamber carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid damag ing or scratching e Spark plug bore threads Valve seats 2 Check Cylinder head Damage scratches Replace NOTE Replace the titanium valves with the cylinder head Refer to CHECKING THE VALVE SEATS
40. 5 6 For installation reverse the removal dure 4 29 REAR BRAKE Removing the rear brake master cylinder 7 Nm 0 7 kg 5 1 ft Ib E 3 30 Nm 3 0 kg 22 ft Ib 13 Nm 1 3 m kg 9 4 ft Ib Omer Job Parts to remove Drain Brake fluid Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 Brake fluid reservoir bracket Brake tidreseroirbacket O 7 8 7 4 NEN gt I Rear brake hose For installation reverse the removal dure 4 30 REAR BRAKE Disassembling the rear brake master cylinder PU 00 Brake For assembly reverse the disassembly cedure 4 31 REAR BRAKE Removing the rear brake caliper 30 Nm 3 0 m kg 22 ft Ib 22 Nm 2 2 kg 16 ft Ib 27 Nm 2 7 kg 19 ft Ib Omer Job Parts to remove Drain Brake fluid Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 281 E MEE 2277 IM For installation reverse the removal dure 4 32 REAR BRAKE Disassembling the rear brake caliper 2 Nm 0 2 kg 1 4 ft Ib 17 Nm 1 7 m kg 12 ft Ib
41. Able un Symptom able to start No signals are received from the ECU within the specified duration 7902 Unable Data from the ECU cannot be re ceived correctly Unable Unable Non registered data has been re ceived from the meter Unable Unable 4 Turn the main switch to OFF and back to ON then check that no fault code number is displayed NOTE If fault codes are displayed repeat steps 1 to 4 until no fault code number is displayed 5 Erase the malfunction history in the diagnos tic mode Refer to Sensor operation table Diagnostic code No 62 NOTE Turning the main switch to OFF will not erase the malfunction history 2 Check and repair the probable cause of mal function Fault code No Check and repair Refer to TROUBLE SHOOTING DE TAILS on page 8 48 Monitor the opera tion of the sensors and actuators in the diagnostic mode Re fer to Sensor opera tion table and Actuator operation table No fault code No Check and repair The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of following sensors and actuators in the Diagnostic mode Refer to Sensor operation table and Actuator oper ation table 01 Throttle position sensor for throttle valves signal 1 throttle
42. Faulty turn signal relay Faulty main switch e Faulty turn signal switch Incorrect turn signal bulb Turn signal remains lit e Faulty turn signal relay Burnt out turn signal bulb Turn signal flashes quickly Incorrect turn signal bulb e Faulty turn signal relay Burnt out turn signal bulb Horn does not sound Improperly adjusted horn Damaged or faulty horn e Faulty main switch Faulty horn switch Faulty battery Blown damaged or incorrect fuse Faulty wire harness 28740 WIRING DIAGRAM bes 2006 AC magneto Rectifier regulator Main switch Ignition fuse Backup fuse odometer and clock Main fuse Battery Starter relay Fuel injection system fuse 10 Starter motor 11 Engine ground 12 ETV fuse 13 Relay unit 14 Starting circuit cut off relay 15 Fuel pump relay 16 Neutral switch 17 Sidestand switch 18 Fuel pump 19 Fuel sender 20 Throttle position sensor for throttle cable pulley 21 Throttle position sensor for throttle valves 22 ECU engine control unit 23 Spark plug 24 Cylinder 1 ignition coil 25 Cylinder 2 ignition coil 26 Cylinder 3 ignition coil 27 Cylinder 4 ignition coil 28 Primary injector 1 29 Primary injector 2 30 Primary injector 3 31 Primary injector 4 32 Secondary injector 1 33 Secondary injector 2 34 Secondary injector 3 35 Secondary injector 4 36 Throttle servo motor 37 Air
43. GENERAL CHASSIS on page 4 1 2 Check e Exhaust pipe assembly 1 Muffler 2 Cracks damage Replace Gaskets 3 Exhaust gas leaks Replace 3 Check Tightening torque Exhaust pipe assembly and cylinder head nuts 4 Exhaust pipe assembly and exhaust pipe as sembly bracket bolts 5 Exhaust pipe assembly and muffler bolt 6 Muffler and right rider footrest bracket bolt 7 Exhaust pipe assembly and cylin der head nut 20 Nm 2 0 m kg 14 ft lb Exhaust pipe assembly and ex haust pipe assembly bracket bolt 20 Nm 2 0 m kg 14 ft lb Exhaust pipe assembly and muf fler bolt 10 Nm 1 0 m kg 7 2 ft lb Muffler and right rider footrest bracket bolt 20 Nm 2 0 m kg 14 ft lb ENGINE 4 Install Bottom cowlings Side cowlings Refer to GENERAL CHASSIS on page 4 1 EAS21090 CHECKING THE CANISTER for California only 1 Remove Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE page 7 5 2 Check Canister e Canister purge hoses e 3 way joint Fuel tank breather hose rollover valve to canister Cracks damage Replace Refer to THROTTLE BODIES on page 7 8 3 Install Air filter case Refer to AIR FILTER CASE on page 7 5 Fuel tank Refer to FUEL TANK on page 7 1 EAS21100 ADJUSTING THE EXUP CABLES 1 Remove EXUP valve pulley cover 1 3 16 TR n D
44. NOTE When replacing the cylinder head replace the valves without lapping the valve seats and valve faces e When replacing the valves or valve guides use new valves to lap the valve seats and then re place them with new valves a Apply a coarse lapping compound to the valve face ECA13790 CAUTION Do not let the lapping compound enter the gap between the valve stem and the valve guide VALVES AND VALVE SPRINGS 5 22 Apply molybdenum disulfide oil onto the valve stem Install the valve into the cylinder head Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands Apply a fine lapping compound to the valve face and repeat the above steps After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat Apply Mechanic s blueing dye Dykem b onto the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear impres sion Measure the valve seat width again If the valve seat width is out of specification reface and lap the valve seat DAAAAAAAAAAAAAAAAAAAAAAAAA
45. SELECT button to reset the stop watch NOTE To change the display back to the prior mode push the SELECT button for a few seconds Coolant temperature display 1 Coolant temperature display The coolant temperature display indicates the temperature of the coolant Push the RESET button to switch the coolant temperature display to the air intake temperature display NOTE When the coolant temperature display is select ed C is displayed for one second and then the coolant temperature is displayed EC2C01021 CAUTION Do not operate the engine if it is overheated Air intake temperature display 1 Air intake temperature display The air intake temperature display indicates the temperature of the air drawn into the air filter case Push the button to switch the coolant temperature display to the air intake temperature display NOTE Even if the air intake temperature is set to be displayed the coolant temperature warning light comes on when the engine overheats When the key is turned to ON the coolant temperature is automatically displayed even if the air intake temperature was displayed prior to turning the key to OFF e When the air intake temperature display is se lected A is displayed before the temperature Self diagnosis device This model is equipped with a self diagnosis de vice for various electrical circuits If any of those circui
46. SWITCHES on page 8 81 OK Check the dimmer switch gt Refer to CHECKING THE SWITCHES on page 8 81 OK 6 Check the headlight relay on off Refer to CHECKING THE RE Replace the headlight relay on off LAYS on page 8 89 OK Check the headlight relay dimmer gt Refer to CHECKING THE RE Replace the left handlebar switch Replace the headlight relay dimmer LAYS on page 8 89 OK 8 19 LIGHTING SYSTEM 8 Check the entire lighting system s NG gt wiring Properly connect or repair the lighting sys Refer to CIRCUIT DIAGRAM on tem s wiring page 8 17 This circuit is OK 8 20 SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM EAS27270 EAS27280 1 ENSIS XXX t_ ova Box B AA V a L8 ee 41 ____ ____ b Hapa in 1 H 1 60 min gt oov Ig GD d d 28 9 1 Wd Va um N3399 99 m v 1 mot 9 gt OK A 2 3 ii 1 ERU FER 7 L A ew 4
47. Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Loosen Upper bracket pinch bolt 1 Handlebar pinch bolt 2 Handlebar bolt 3 Cap bolt 4 Lower bracket pinch bolts 5 EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg EAS22990 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs FRONT FORK 1 Position the collar 1 as shown in the illustra tion by turning the spring preload adjusting bolt 2 counterclockwise until it stops 2 Remove Cap bolt 1 from the damper adjusting rod Spacer 2 e Nut 3 Press down the spacer with the fork spring compressor 4 b Install the rod holder 5 between the nut 3 and the spacer 2 Fork spring compressor 90890 01441 YM 01441 Rod holder 90890 01434 Damper rod holder double ended YM 01434 NOTE Use the side of the rod holder that is marked B c Hold the spring preload adjusting bolt 6 and loosen the nut 3 EC2C01011 CAUTION When loosening the nut 3 be sure not to break the projections on the collar 7 of the cap bolt 1 L
48. ZN BLACK ZN BLACK b B L P W _ _ _ DARK BLUE B L P W B L W R e BLACK f MS BrW 8 BiW B L B Y LIB2 2 Gy BIL G W P W YIG 0 0 BLACK BLACK R L R L BLACK gj 631 QQ GylG 09 cL 1 1 Mj 0 0 0 0 0 e i o Lg R Lg R z BLACK Y R _Y R E Lg BIG BIR WIR o VIB2 Eb loc gt lt B3 BLACK HEADLIGHT SUB WIRE HARNESS SUB WIRE HARNESS2 WIRE HARNESS SUB WIRE HARNESS1 WIRE HARNESS WIRE HARNESS WIRE HARNESS HEADLIGHT SUB WIRE HARNESS NEUTRAL SWITCH SUB WIRE HARNESS SUB WIRE HARNESS3 WIRE HARNESS WIRE HARNESS YZFR6V C 2006 WIRING DIAGRAM L 00 IS Ert PM
49. in direction or b until the specified clutch lever free play is obtained Direction Clutch lever free play is increased Direction b Clutch lever free play is decreased NOTE If the specified clutch lever free play cannot be obtained on the handlebar side of the cable use the adjusting nut on the engine side Engine side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified clutch lever free play is ob tained Direction Clutch lever free play is increased Direction b Clutch lever free play is decreased c Tighten the locknut 1 3 14 ENGINE EAS20960 REPLACING THE AIR FILTER ELEMENT 1 Remove e Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Upper air filter case Refer to AIR FILTER CASE on page 7 5 2 Remove Air filter element 1 3 Check Air filter element Damage Replace NOTE Replace the air filter element every 40000 km 2400 mi of operation The air filter needs more frequent service if you are riding in unusually wet or dusty
50. on page 2 47 ECA14170 CAUTION When installing the brake hose onto the brake caliper 1 make sure the brake pipe touches the projection b on the brake caliper Rg 2 ANY M Spy 3 D gO 2 Remove Front brake caliper 3 Install Front brake pads Brake pad spring Brake pad pin Brake pad clips Front brake caliper Front brake caliper bolt 35 Nm 3 5 m kg 25 ft lb Refer to REPLACING THE FRONT BRAKE PADS on page 4 23 4 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid Recommended fluid DOT 4 EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance 4 25 Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM page 3 24 6 Check Brake fluid level Below the minimum level mark a
51. 37 ft lb with a torque wrench then loosen the lower ring nut completely 2 Retighten the lower ring nut to 14 Nm 1 4 m kg 10 ft lb with a torque wrench NOTE Lower bracket pinch bolt Tighten each bolt to 23 Nm 2 3 m kg 17 ft lb in the order pinch bolt 1 pinch bolt 2 pinch bolt 4 2 24 LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE ooo Piston pins Generator rotor bolt and washer Camshaft cam lobes and camshaft journals Valve stems intake and exhaust Valve stem ends intake and exhaust Valve lifter surface mas Oil pump rotors inner and outer and oil pump housing Oil strainer screen inside oil strainer Oil strainer gasket Primary driven gear inner surface Transmission gears wheel and pinion and collars Main axle and drive axle Shift forks and shift fork guide bars Shift shaft Yamaha bond No 1215 Cylinder head cover mating surface Three Bond No 12159 Cylinder head cover gasket Bond TB1215B Yamaha bond No 1215 Th Bond Crankcase mating surface Three Bon No 1215 Three Bond No 1280B 2 25 LUBRICATION POINTS AND LUBRICANT TYPES Yamaha bond No 1215 Crankshaft position sensor lead grommet Three Bond No 1215 Yamaha bond No 1215 Stator coil lead grommet Three Bond No 12159 2 26 LUBRICATION POINTS AND LUBRICANT TYPES EAS2038
52. 4 24 CHECKING THE FRONT BRAKE 4 24 ASSEMBLING THE FRONT BRAKE CALIPERS 4 25 INSTALLING THE FRONT BRAKE 4 25 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 26 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 26 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 26 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 27 REAR BRAKE 4 29 INTRODUC PI EE 4 34 CHECKING THE REAR BRAKE 4 34 REPLACING THE REAR BRAKE PADS 4 34 REMOVING THE REAR BRAKE 4 35 DISASSEMBLING THE REAR BRAKE 4 35 CHECKING THE REAR BRAKE 4 36 ASSEMBLING THE REAR BRAKE 4 36 INSTALLING THE REAR BRAKE 4 37 REMOVING THE REAR BRAKE MASTER CYLINDER 4 38 CHECKING THE REAR BRAKE MASTER CYLINDER 4 38 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 38 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 38 HANDL EBARS 4 40 REMOVING THE HANDLEBA
53. 6667 1234 5 6 121314 15 16 b Calculate the length of the 15 link section of the drive chain using the following formula Drive chain 15 link section length length a between pin inner sides length b between pin outer sides 2 NOTE When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time CHAIN DRIVE 123 4 5 6121314 15 16 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean e Drive chain Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it EC2C01014 CAUTION This vehicle has a drive chain with small rubber O rings 1 between the drive chain side plates Never use high pressure water or air steam gasoline certain solvents e g benzine or a coarse brush to clean the drive chain High pressure methods could force dirt or water into the drive chain s internals and solvents will deterio rate the O rings A coarse brush can also damage the O rings Therefore use only kerosene to clean the drive chain Do not soak the drive chain in kerosene for more than ten minut
54. 90890 03094 Carburetor synchronizer YU 44456 90890 03094 YU 44456 Compression gauge 90890 03081 Engine compression tester YU 33223 Extension 90890 04136 SPECIAL TOOLS Reference filter wrench 90890 01426 YU 3841 1 64 2 Oil pressure gauge set 90890 03120 3 3 gt 3 13 pressure adapter 13 90890 03139 M16xP1 5 20 50 Steering nut wrench 3 27 4 58 90890 01403 Spanner wrench YU 33975 7 Fork spring compressor p 4 47 4 52 90890 01441 Leo YM 01441 Rod holder 4 47 4 52 90890 01434 Damper rod holder double ended YM 01434 Damper rod holder 4 48 4 49 90890 01506 YM 01506 Fork seal driver 4 90890 01442 gt Adjustable fork seal driver 36 46 A YM 01442 du SPECIAL TOOLS Reference aoa E 90890 01437 LE 4 51 4 52 Universal damping rod bleeding tool set d YM A8703 Rod puller attachment M10 4 51 4 52 90890 01436 Universal damping rod bleeding tool set YM A8703 v 3 YM A8703 Ring nut wrench 90890 01268 Spanner wrench YU 01268 Ring nut wrench 4 67 4 69 90890 01507 YM 01507 Damper rod holder 24 mm 4 67 4 68 90890 01328 YM 01328 YM 01328 Valve spring compressor 5 19 5 24 90890 04019 YM 04019 SPECIAL TOOLS Reference Valve spring compressor attachment 5 19 5 24 90890 04108 Valve spring compressor adapter 22 mm YM 04108 Valve guide remover 94 5 90890 04116 Valve guide remover
55. 90890 04136 6 Measure Compression pressure Out of specification Refer to steps and Standard compression pressure at sea level 1550 kPa 400 r min 220 5 psi 400 r min 15 5 kgf cm 400 r min Minimum maximum 1300 1600 kPa 184 9 227 6 psi 13 0 16 0 kgf cm a Set the main switch to b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes To prevent sparking ground all spark plug leads before cranking the engine ENGINE NOTE The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 kg cm 14 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below min imum specification pour a teaspoonful of en gine oil into the spark plug bore and measure again Hefer to the following table Compression pressure with oil applied into the cylinder Higher than without Piston ring s wear or oil damage Repair Pistons valves cylin der head gasket or piston ring s possi bly defective Re pair Same as without oil DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 7 Install Spark plugs Ignition coils Syr Spark plug 13 Nm 1 3 m kg 9 4 ft Ib 8 Install e
56. Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery stabi lizes about 30 minutes after charging has been completed Therefore wait 30 min utes after charging is completed before measuring the open circuit voltage Open circuit voltage V Time minutes Charging Ambient temperature 20 68 F Check the open circuit voltage mooo r Charging method using a variable current voltage charger a Measure the open circuit voltage prior to charging NOTE Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging NOTE Set the charging voltage at 16 17 V If the set ting is lower charging will be insufficient If too high the battery will be over charged c Make sure that the
57. Direction b Throttle cable free play is decreased c Tighten the locknut 1 EWA12910 After adjusting the throttle cable free play start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Canister for California only Refer to THROTTLE BODIES on page 7 8 Air induction system solenoid Refer to AIR INDUCTION SYSTEM on page 7 15 2 Remove Ignition coils e Spark plugs ECA13320 CAUTION Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 3 Check e Spark plug type Incorrect Change Manufacturer model NGK CR10EK 4 Check e Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean Spark plug with a spark plug cleaner or wire brush 6 Measure Spark plug gap with a wire thickness gauge Out of specification Spark plug gap 0 6 0 7 mm 0 024 0 028
58. Latch up detected No normal signal is received from the lean angle sensor Diagnostic code No Lean angle sensor Item components and probable Check or maintenance job Reinstatement cause method The vehicle has overturned Raise the vehicle upright Turning the Installed state of the lean angle sen Check the installed direction and ON itch to SOr condition of the sensor however the engine can 2 3 Defective lean angle sensor e Execute the diagnostic mode not be restarted Code No 08 unless the main Replace if defective switch is first Refer to CHECKING THE turned to LEAN ANGLE SENSOR 8 93 8 57 FUEL INJECTION SYSTEM Fault code No Symptom Open circuit detected in the primary lead of the cylinder 1 ignition coil Diagnostic code No 30 1 ignition coil Connections Cylinder 1 ignition coil coupler Main wire harness ECU coupler e Sub wire harness 1 coupler Open or short circuit in wire harness and or sub wire harness 1 Defective cylinder 1 ignition coil Connections Cylinder 2 ignition coil coupler Main wire harness ECU coupler e Sub wire harness 1 coupler Open or short circuit in wire harness and or sub wire harness 1 Defective cylinder 2 ignition coil Reinstatement method Check the couplers for any pins Cranking the that may be pulled out engine Check the locking condition of Connect the the co
59. Loosen the bolts in decreasing numerical order refer to the numbers in the illustration The numbers embossed on the crankcase in dicate the crankcase tightening sequence M8 x 115 mm bolts 9 e M8 x 85 mm bolts 1 7 10 e M8 65 mm bolts 11 12 e M6 x 80 mm bolt 28 e M6 x 65 mm shoulder bolts 13 14 e M6 x 65 mm bolts 16 20 21 e M6 x 55 mm bolts 15 22 27 e M6 x 45 mm bolts 177 419 e M6 x 30 mm bolt 29 3 Remove e ower crankcase ECA13900 CAUTION Tap on one side of the crankcase with a soft face hammer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves sepa rate evenly EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air CRANKCASE EAS25600 CHECKING THE OIL PIPE 1 Check Oil pipe Damage Replace Obstruction Wash and blow out with com pressed air EAS25620 CHECKING THE TIMING CHAIN Refer to CAMSHAFTS on page 5 7 EAS25640 ASSEMBLING THE CRANKCASE 1 Lubricate Crankshaft journal bearings with the recommended
60. Measure cylinder bore by taking side to side and front to back measurements of the cylinder Then find the average of the measurements Bore 67 000 67 010 mm 2 6378 2 6382 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in maximum of D Dg T maximum of D4 02 maximum of Ds Or Dg maximum of D4 or Ds minimum of D Dy or Dg b If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set c Measure piston skirt diameter D a with the micrometer Piston Diameter D 66 975 66 990 mm 2 6368 2 6374 in b 10 mm 0 39 in from the bottom edge of the piston d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Piston to cylinder clearance Cylinder bore Piston skirt diameter D Piston to cylinder clearance 0 010 0 035 mm 0 0004 0 0014 in Limit 0 05 mm 0 0022 in f If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set EAS24430 CHECKING THE PISTON RINGS 1 Measure e Piston ring side clearance Out of specification Replace the piston and piston rings as a set NOTE Before measuring the piston ring side clearance el
61. OK Replace the ECU NG gt NG gt gt gt gt NG gt 8 5 IGNITION SYSTEM Replace the right handlebar switch Replace the neutral switch Replace the sidestand switch Replace the relay unit Replace the lean angle sensor Properly connect or repair the ignition sys tem s wiring IGNITION SYSTEM ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM LS 9 e a cea y B B N o 72 am EE o 02 gt am lt a 8 EZ 55 72 lt x a a 72 4 lt t ns p E eu Bees CN DARK GREEN Ch Dg 96 62 514 4 ISS A ipd v chi erl 8 7 Oo c Main switch Ignition fuse Main fuse Battery 8 Starter relay 10 Starter motor 11 Engine ground 13 Relay unit 14 Starting circuit cut off relay 16 Neutral switch 17 Sidestand switch 64 Engine stop switch 65 Start switch 70 Clutch switch ELECTRIC STARTING SYSTEM 8 8 ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT
62. Oo sensor lead EXUP servo motor lead Neutral switch lead Fuel pump coupler Fuel sender coupler Fuel tank breather hose except for California Fuel tank drain hose Negative battery lead Engine ground lead Sub wire harness 3 Oil level switch lead Sidestand switch lead Speed sensor lead Starter motor lead Left radiator fan motor lead Main switch lead Left handlebar switch lead Throttle cable accelerator cable Throttle cable decelerator cable Right handlebar switch lead To the headlight Fasten the headlight lead with the holder To the front right turn signal position light Insert the projection on the plastic band into the hole in the coupler holder and then fasten the wire harness right radiator fan motor lead throttle position sensor for throttle valves lead throttle servo motor lead and throttle position sensor for throttle cable pulley lead with the band making sure to route the right radiator fan motor lead to the inside of the wire harness and to face the end of the band upward To the engine To the throttle bodies To the coolant temperature sensor Route the coolant temperature sensor lead above the crankshaft position sensor lead neutral switch lead oil level switch lead and sidestand switch lead Position the sub wire harness 2 coupler on top of the wire harness Route the oil level switch lead speed sensor lead and crankshaft position sensor lead under the wire harness
63. Positive tester probe sky blue 4 22 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 4 22 Negative tester probe blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 4 22 Negative tester probe sky blue white 4 No continuity Positive tester probe sky blue white 4 Negative tester probe sky blue 1 Continuity Positive tester probe blue black 5 Negative tester probe blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe blue black 5 a Disconnect the relay unit coupler from the wire harness b Connect the pocket tester Q x 1 to the relay unit terminal as shown 8 91 Check the relay unit diode for continuity d Check the relay unit diode for no continuity DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE IGNITION COILS The following procedure applies to all of the igni tion coils 1 Check e Primary coil resistance Out of specification Replace lij Primary coil resistance 1 19 1 61 Q a Remove the
64. Replace Oil passage Obstruction Blow out with compressed air EAS26070 CHECKING THE CRANKSHAFT AND CONNECTING RODS 1 Measure Crankshaft runout Out of specification Replace the crank shaft Runout limit C 0 030 mm 0 0012 in 2 Check Crankshaft journal surfaces Crankshaft pin surfaces Bearing surfaces Scratches wear Replace the crankshaft CRANKSHAFT 3 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings Journal oil clearance using plas tigauge 0 020 0 044 mm 0 0008 0 0017 in ECA13920 CAUTION Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crank shaft journal bearings must be installed in their original positions Clean the crankshaft journal bearings crank shaft journals and bearing portions of the crankcase b Place the upper crankcase upside down bench c Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crank case NOTE Align the projections a on the crankshaft jour nal upper bearings with the notches b in the up per crankcase d Put a piece of Plastigauge on each crankshaft journal NOTE Do not
65. Tightening torque The following symbols are not relevant to every 6 Wear limit clearance vehicle 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 9 c JN 15 1 n New 11 Molybdenum disulfide oil 12 Wheel bearing grease 13 Lithium soap based grease 14 Molybdenum disulfide grease 15 Apply locking agent LOCTITE 16 Replace the part with a new one GENERAL INFORMATION 1 SPECIFICATIONS NO PERIODIC CHECKS AND ADJUSTMENTS IK CHASSIS COOLING SYSTEM o FUEL SYSTEM ELECTRICAL SYSTEM 8 m TROUBLESHOOTING 9 GENERAL INFORMATION IDENTIFICATION 1 1 VEHICLE IDENTIFICATION 1 1 MODELEABE Udemm ta diva i M _ 1 1 FEATURES ad dp ors 1 2 OUTLINE OF TAE Fl SY 1 2 E 1 3 YCC T Yamaha Chip Controlled 1 4 INSTRUMENT FUNCTIONS ERR Rx cR ades 1 7 IMPORTANT 1 11 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 11 REPLACEMENT PARTS eres eee ee 1 11 GASKETS OIL SEALS AND 1 11 LOCK WASHERS PLATES AND 5 1 11 BEARINGS AND OIE SE
66. b Install a good bulb into the bulb socket Connect the pocket tester probes to the re spective leads of the bulb socket Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE FUSES The following procedure applies to all of the fus es EC2C01003 CAUTION To avoid a short circuit always turn the main switch to OFF when checking or replacing a fuse 1 Remove Rider seat Left upper side cowling Refer to GENERAL CHASSIS on page 4 1 2 Check Fuse 8 85 b If the pocket tester indicates co replace the fuse DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Replace Blown fuse Set the main switch to OFF Install a new fuse of the correct amperage rating Set on the switches to verify if the electrical circuit is operational If the fuse immediately blows again check the electrical circuit AL Ignition 15A 1 Fudimecionsysem 18A 1 Right radiator fan motor Signaling syster Backup odometer and clock EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause a fire
67. e Tire surfaces Damage wear Replace the tire Wear limit front 1 0 mm 0 04 in Wear limit rear 1 0 mm 0 04 in 3 32 gt 1 Tire tread depth 2 Side wall 3 Wear indicator EWA14080 Do not use a tubeless tire on a wheel de signed only for tube tires to avoid tire fail ure and personal injury from sudden deflation When using a tube tire be sure to install the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality re placement A Tire B Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire EWA14090 After extensive tests the tires listed below have been approved by Yamaha Motor Co Lid for this model The front and rear tires should always be by the same manufacturer CHASSIS and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehicle Front tire Size 120 70 ZR17M C 58W Manufacturer model DUNLOP D209F PT Manufacturer model MICHELIN Pilot POWER P Rear tire Size 180 55 ZR17M C 73W Manufacturer model DUNLOP D209PT Manufacturer model MICHELIN Pilo
68. f gasoline touches the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before per forming the following test 1 Disconnect Fuel pump coupler Fuel sender coupler from the wire harness 2 Remove Fuel tank 3 Check Fuel pump operation Faulty rough movement Replace Fill the fuel tank b Put the end of the fuel hose 1 into an open container c Connect the battery DC 12 V to the fuel pump terminal as shown Positive battery lead gt red blue 2 Negative battery lead black 3 8 98 d Check the fuel pump operation DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1 Check e Air induction system solenoid resistance Out of specification Replace Solenoid resistance 18 22 at 20 C 68 F VV VV VV VV VV VV VV VV VV VV VV VV VV VV VV a Disconnect the air induction system solenoid coupler from the air induction system sole noid b Connect the pocket tester Q x 1 to the air in duction system solenoid terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt brown red 1 Negative tester probe gt red white 2 ELECTRICAL COMPONENTS 2 1 tel 0 Measure the air induction system solenoid re sistance
69. g Press down on the spacer with the fork spring compressor 8 h Pull up the rod puller and install the rod holder 9 between the nut 4 and the spacer 3 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 Rod puller attachment M10 90890 01436 Universal damping rod bleeding tool set YM A8703 Fork spring compressor 90890 01441 YM 01441 Rod holder 90890 01434 Damper rod holder double ended YM 01434 FRONT FORK NOTE Use the side of the rod holder that is marked B i Remove the rod puller and rod puller attach ment j Install the nut 4 all the way onto the damper rod assembly Install the damper adjusting rod l Install the washer and cap bolt and then fin ger tighten the cap bolt m Hold the nut and tighten the spring preload adjusting bolt 10 into the cap bolt to specifi cation A WARNING Always use a new cap bolt O ring EC2C01013 CAUTION When tightening the spring preload adjust ing bolt 10 into the cap bolt be sure not to break the projections on the collar 11 NOTE Hold the nut 4 using a proper tool that has a thickness of 3 mm 0 12 in or less Nut and cap bolt 25 Nm 2 5 m kg 18 ft lb A 10 ii 4 n Remove the rod holder and fork spring com pressor DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 16 Install Cap bolt to the outer tube NOTE Temporarily tighten the cap bolt EAS23
70. the valve guide VALVES AND VALVE SPRINGS If the valve is removed or replaced always re place the valve stem seal Valve stem runout 0 040 mm 0 0016 in EAS24300 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure e Valve seat width C Out of specification Replace the cylinder head Valve seat width C intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve seat width C exhaust 1 10 1 30 mm 0 0433 0 0512 in Limit 1 8 mm 0 07 in Apply Mechanic s blueing dye b onto the valve face 5 21 Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width NOTE Where the valve seat valve face contacted one another the blueing will have been re moved 4 Valve face e Valve seat 2 01028 CAUTION This model uses titanium intake and exhaust valves Titanium valves that have been used to lap the valve seats must not be used ways replace lapped valves with new valves
71. 0 mm 0 04 in 525V8 DAIDO 114 35 0 45 0 mm 1 38 1 77 239 3 mm 9 42 in 2 12 20310 ELECTRICAL SPECIFICATIONS Voltage System voltage Ignition system Ignition system Advancer type Ignition timing B T D C Engine control unit Model manufacturer Ignition coil Model manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance AC magneto Model manufacturer Standard output Stator coil resistance Rectifier regulator Regulator type Model manufacturer Regulated voltage DC Rectifier capacity Battery Model Voltage capacity Manufacturer Ten hour rate amperage Headlight Bulb type Bulb voltage wattage quantity Headlight Auxiliary light Tail brake light Front turn signal position light Rear turn signal light License plate light Meter lighting Indicator light Neutral indicator light Turn signal indicator light Oil level warning light ELECTRICAL SPECIFICATIONS 12V Transistorized coil ignition digital Throttle position sensor and electrical 10 0 1300 r min TBDF24 DENSO F6T558 MITSUBISHI 6 0 mm 0 24 in 1 19 1 61 Q 8 5 11 5 LMX62 DENSO 14 0 V 420 W 5000 r min 0 12 0 18 Q at 20 68 F Semi conductor short circuit SH678 1 1 SHINDENGEN 14 1 14 9 V 22 0A YTZ10S 12 V 8 6 Ah GS YUASA 0 86 Halogen bulb 12V 55 0W x2 12 V 5 0W x 1 LED 12 V 21 W 5 0W x2 12 V 241 0W x2 12 V 5 0W x 1 LED LED
72. 1 1 kg 8 0 ft Ib 32 Nm 3 2 m kg 23 ft Ib NEN Left side panel Left upper side cowling mM oe to GENERAL CHASSIS on page Fuel tank Refer to FUEL TANK page 7 1 Air filter case EE Refer to AIR FILTER CASE on page 7 5 NEN Canister for California only Refer to THROTTLE BODIES page 7 8 ros Refer to AIR INDUCTION SYSTEM on Air induction system cover EM page 7 15 6 5 0 4 40 HH HANDLEBARS Removing the handlebars hy 115 Nm 11 5 kg 85 ft Ib 13 Nm 1 3 kg 9 4 ft Ib 13 Nm 1 3 m kg 9 4 ft Ib 26 Nm 2 6 kg 19 ft Ib 11 Nm 1 1 kg 8 0 ft Ib 32 Nm 3 2 m kg 23 ft Ib Job Parts to remove Q ty 13 Front brake master cylinder holder 14 Front brake master cylinder assembly 16 Upper bracket pinch bolt m 1 EM Upper bracket 22 Handlebar pinch bolt 23 Left handlebar Right handlebar Loosen For installation reverse the removal proce dure 4 41 22870 REMOVING THE HANDLEBARS 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Remove Handlebar grip 1 NOTE Blow compr
73. 11 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 8 Throttle cable free play 3 0 5 0 mm 0 12 0 20 in FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 13 Nm 1 3 m kg 9 4 ft Ib 7 Nm 0 7 kg 5 1 ft Ib The following procedure applies to both of the front fork legs GENERAL CHASSIS D Front wheel Refer to FRONT WHEEL on page 4 4 29 bot 3 Handlebar pinch bolt 4 Handlebar bolt 1 1 1 For installation reverse the removal proce dure 4 44 FRONT FORK Disassembling the front fork legs 25 Nm 2 5 m kg 18 ft Ib 20 Nm 2 0 m kg 14 ft Ib 35 Nm 3 5 kg 25 ft Ib Job Parts to remove Q ty Cap bolt The following procedure applies to both of the front fork legs O ring Washer Damper adjusting rod E S ae NE EN NE NEN 1 EN NI Spacer Fork spring Waste w Dempermdsmemy 7 10 11 12 3 4 45 FRONT FORK Disassembling the front fork legs 25 Nm 2 5 m kg 18 ft Ib 20 Nm 2 0 m kg 14 ft Ib 13 Nen Emo For assembly reverse the disassembly pro cedure 22970 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Stand the vehicle on a level surface EWA13120
74. 2 Oil seal 3 e Washer 4 EC2C01012 FRONT FORK CAUTION cS Make sure the numbered side of the oil seal faces bottom side NOTE 2 Before installing the oil seal lubricate its lips with lithium soap based grease e Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of 7 Install the front fork leg with a plastic bag to protect Oil seal clip 1 the oil seal during installation NOTE 5 Install e Outer tube to the inner tube 6 Install Washer 2 Oil seal with the fork seal driver 2 Adjust the oil seal clip so that it fits into the outer tube s groove 8 Install Dust seal 1 with the fork seal driver weight 72 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 Fork seal driver 90890 01442 1 Adjustable fork seal driver 36 46 mm YM 01442 9 Install Rod puller 1 Rod puller attachment 2 onto the damper rod 3 4 50 Rod puller 90890 01437 Universal damping rod bleeding tool set 8703 Rod puller attachment M10 90890 01436 Universal damping rod bleeding tool set 8703 10 Fully compress the front fork leg 11 Fill Front fork leg with the specified amount of the recom mended fork oil Quantity 465 0 cm 15 72 US oz 16 37 Imp oz Recommended oil O
75. 2 10 ELECTRICAL 8 2 13 TIGHTENING TORQUE S 2 16 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT 5 2 25 zer p 2 25 2 27 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ENGINE OIL LUBRICATION CHART sees 2 29 LUBRIGATION DIAGRAM S E eU tp ims 2 31 COOLING SYSTEM 65 2 43 CABLE ROUTING tees 2 47 20280 GENERAL SPECIFICATIONS Model Model Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Weight With oil and fuel Maximum load 2 1 GENERAL SPECIFICATIONS 2C05 2C08 USA 2C06 California 2040 mm 80 3 in 700 mm 27 6 in 1100 mm 43 3 in 850 mm 33 5 in 1380 mm 54 3 in 130 mm 5 12 in 3600 mm 141 7 in 182 0 kg 401 Ib USA 183 0 kg 403 Ib California 193 kg 425 16 USA 192 kg 423 Ib California 20290 ENGINE SPECIFICATIONS Engine Engine type Displacement Cylinde
76. 2nd pinion gear Toothed lock washer 5 e seen gear ee Wee M NN eem 1 MEN 15 Main axle 1st pinion gear For assembly reverse the disassembly pro cedure 5 73 TRANSMISSION Disassembling the drive axle assembly Job Parts to remove Q ty 7 5 D RV 5 TRANSMISSION Disassembling the drive axle assembly 2nd wheel gear 19 Collar Drive axle For assembly reverse the disassembly pro cedure 5 75 ET2C01014 REMOVING THE TRANSMISSION 1 Remove Main axle assembly 1 a Remove the main axle assembly bearing housing bolts 2 b Insert two bolts 3 of the proper size as shown in the illustration into the main axle assembly bearing housing Aad c Tighten the bolts until they contact the crank case surface d Continue tightening the bolts until the main axle assembly comes free from the upper crankcase DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork TRANSMISSION 1 2 Shift fork guide bar Roll the shift fork guide bar on a flat surfa
77. 5 m kg 3 6 ft lb 2 SNm 5migSERE Exwsippessembyni MB 8 20 20 20 MEE __ Sc e i erem Muffler clamp bolt M6 _ 10 Nm 1 0 m kg 7 2 ft lb 20 Nm 2 0 m kg 14 ft lb 7 Nm 0 7 m kg 5 1 ft lb Muffler bolt M6 1 Muflebot 0 Locknut EXUP cable adjusting bolt 1 7 Nm 0 7 m kg 5 1 ft lb EXUP servo motor drive pulley M5 2 TNT MIG SAR _ ew EXUP valve pulley cover bolt 2 7 Nm 0 7 m kg 5 1 10 aA EXUP valve pulley cover bolt rear side EXUP valve nut 7 Nm 0 7 m kg 5 1 ft lb Crankcase bolt 2 see NOTE 85 mm Crankcase bolt 8 see NOTE 3 35 in m O 65 mm Crankcase bolt M8 2 24 Nm 2 4 m kg 17 ft lb 2 56 in i Crankcase bolt 10 Nm 1 0 m kg 7 2 ft lb 9 Clutch cover bolt 12 Nm 1 2 m kg 8 7 ft lb Clutch cover bolt 12 Nm 1 2 m kg 8 7 ft lb Pickup rotor cover bolt 12 Nm 1 2 m kg 8 7 ft lb Tuning mark accessing bolt 15 Nm 1 5 m kg 11 ft lb baffle plate 1 bolt 12 Nm 1 2 m kg 8 7 ft lb Oil baffle plate 2 bolt 12 Nm 1 2 m kg 8 7 ft lb Stator coil assembly bolt 10 Nm 1 0 m kg 7 2 ft lb a coil assembly lead holder 10 Nm 1 0 m kg 7 2 ft lb 2 18 TIGHTENING TORQUES Thread sbe Q ty Tightening torque M6 3 10 Nm 1 0 m kg 7 2 ft lb 8 Nm 0 8 mig 5 8 rib
78. 6 Lubricate e Crankshaft pins Big end bearings Connecting rod inner surface with the recommended lubricant Recommended lubricant Engine oil 7 Install Big end bearings Connecting rod and piston assembly Connecting rod NOTE Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place While compressing the piston rings one hand install the connecting rod assembly into the inder with the other hand e Make sure the Y marks a on the connecting rods face towards the left side of the crank shaft Make sure the characters b on both the con necting rod and connecting rod cap are aligned 8 Tighten Connecting rod nuts 1 ANS 5 Lubricate 9 1 Bolt threads Nut seats with the recommended lubricant i 2 24 O 9 ra 5 65 CONNECTING RODS AND PISTONS EW2C01007 WARNING Replace connecting rod bolts and nuts with new ones NOTE Tighten the connecting rod nuts using the follow ing procedure a Tighten the connecting rod nuts with a torque wrench Syr Connecting rod nut 1st 15 Nm 1 5 m kg 11 ft Ib b Puta mark 1 on the corner of the connecting rod nut 2 and the connecting rod 3
79. 66 FUEL INJECTION SYSTEM Fault code No Symptom error is detected while reading or writing on EEPROM CO adjustment value Diagnostic code No 60 EEPROM fault cylinder No Item components and probable Check or maintenance job Reinstatement cause method Malfunction in ECU Set the faulty cylinder s exhaust Turning gas volume main switch to 1 Execute the diagnostic mode ON Code No 60 to check the Readjust the faulty cylinder number If exhaust gas multiple cylinders are defec volume after it tive the numbers of the is reinstated faulty cylinders are displayed alternately at 2 second inter vals Execute the CO adjustment mode and set the exhaust gas volume of the faulty inder to O Replace ECU if it does not re cover from the malfunction Fault code No 46 Symptom Power supply is not normal Item components and probable Check or maintenance job Reinstatement cause method Malfunction in rectifier regulator Replace if defective Starting the en Refer to CHARGING SYS gine and oper on page 8 13 ating it at idle 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit in the charging system s wiring Refer to CHARGING SYS page 8 13 Fault code No Symptom Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Item
80. 8 20 cm 0 45 0 50 cu in 0 05 mm 0 0020 in Chain drive right 22 500 22 521 mm 0 8858 0 8867 in 22 459 22 472 mm 0 8842 0 8847 in 0 028 0 062 mm 0 001 1 0 0024 0 080 mm 0 0032 in 33 725 33 875 mm 1 3278 1 3337 in 33 675 mm 1 3258 in 25 225 25 325 mm 0 9931 0 9970 in 25 175 mm 0 9911 in 32 925 33 075 mm 1 2963 1 3022 in 32 875 mm 1 2943 in ENGINE SPECIFICATIONS Exhaust B 25 082 25 182 mm 0 9875 0 9914 Limit 25 032 mm 0 9855 in A B Camshaft runout limit 0 030 mm 0 0012 in Timing chain Model number of links 98XRH2015 118 Tensioning system Automatic Valve valve seat valve guide Valve clearance cold Intake 0 12 0 19 mm 0 0047 0 0075 in Exhaust 0 16 0 23 mm 0 0063 0 0091 in Valve dimensions Valve head diameter A intake 26 90 27 10 mm 1 0591 1 0669 Valve head diameter exhaust 22 90 23 10 mm 0 9016 0 9094 in Valve face width B intake 1 410 2 550 mm 0 0555 0 1004 in Valve face width B exhaust 1 400 2 670 mm 0 0551 0 1051 in N Valve seat width C intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve seat width C exhaust 1 10 1 30 mm 0 0433 0 0512 in Limit 1 8 mm 0 07 in C 2 4 Valve margin thickness intake Limit Valve margin thickness D exhaust Limit gu Valve stem diameter intake Limit Valve stem diameter exhaust Limit Valve guide inside diameter intake
81. 805 1 91 HOLIMS TWHLNAN 8 33 Main switch Ignition fuse Backup fuse odometer and clock Main fuse Battery 9 Fuel injection system fuse 11 Engine ground 12 ETV fuse 13 Relay unit 15 Fuel pump relay 16 Neutral switch 17 Sidestand switch 18 Fuel pump 20 Throttle position sensor for throttle cable pulley 21 Throttle position sensor for throttle valves 22 ECU engine control unit 23 Spark plug 24 Cylinder 1 ignition coil 25 Cylinder 2 ignition coil 26 Cylinder 3 ignition coil 27 Cylinder 4 ignition coil 28 Primary injector 1 29 Primary injector 2 30 Primary injector 3 31 Primary injector 4 32 Secondary injector 1 33 Secondary injector 2 34 Secondary injector 3 35 Secondary injector 4 36 Throttle servo motor 3 Air induction system solenoid 38 EXUP servo motor 39 02 sensor 40 Crankshaft position sensor 41 Air temperature sensor 42 Coolant temperature sensor 43 Intake air pressure sensor 44 Atmospheric pressure sensor 45 Cylinder identification sensor 46 Speed sensor 47 Lean angle sensor 54 Multi function meter 55 Engine trouble warning light 64 Engine stop switch NOOR 0 8 34 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EAS27350 ECU SELF DIAGNOSTIC FUNCTION The ECU is equipped with a self diagnostic function in order to ensure that the fuel injection system is operating normally If this function detects a malfunction in the system it immediately operat
82. Able Able open or short circuit No normal signal is received from Latch up detected No normal signal is received from Unable Unable the lean angle sensor ble Able A depending Intake air pressure sensor or atmospher ic pressure sensor Coolant temperature sensor open or short circuit Coolant temperature sensor open or short circuit detected Air temperature sen sor open or short circuit Air temperature sensor open or short circuit detected PAENG preg Atmospheric pressure sensor open or short circuit detected NO N Lean angle sensor depending Cylinder 1 ignition Primary lead of the cylinder 1 ig NO NO NO O NO O co open circuit Cylinder 2 ignition Coll open circuit Cylinder 3 ignition open circuit Cylinder 4 ignition coll open circuit nition coil open circuit detected Primary lead of the cylinder 2 ig nition coil open circuit detected Primary lead of the cylinder 3 ig nition coil open circuit detected Primary lead of the cylinder 4 ig nition coil open circuit detected 8 37 on the number of faulty cylin ders Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders on the number of faulty cyl
83. CRANKSHAFT JOURNAL BEARINGS 5 68 CHECKING e 5 68 CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 68 INSTALLING THE CRANKSHAF T ker cse YR 5 70 TRANSMISSION Sine eee 5 71 REMOVING THE TRANSMISSION 5 76 CHECKING THE SHIFT FORK S 5 76 CHECKING THE SHIFT DRUM 55 5 76 CHECKING THE 5 77 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 77 INSTALLING THE 5 5 78 ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe assembly 7 Nm 0 7 kg 5 1 ft Ib Lower side cowlings m oe to GENERAL CHASSIS on page Bottom cowlings fa to GENERAL CHASSIS on page Radiator bracket Refer to RADIATOR on page 6 1 Eurwwwym 3 4 Gasket Exhaust pipe assembly bracket left lower side 11 Exhaust pipe assembly bracket left upper side 5 1 ENGINE REMOVAL Removing the exhaust pipe assembly 7 Nm 0 7 kg 5 1 ft Ib Job Parts to remove Q ty ME Exhaust pipe assembly bracket right side 14 EXUP servo motor cover sone mtr espa Domest UP senomoor dure 5 2 ENGINE REMOVAL Disconnect
84. Check condition and Check operation Check operation fluid evel and for fluid leakage Front brake Replace brake pads if neces sary Check operation fluid level and for fluid leakage Rear brake Replace brake pads if neces sary PERIODIC MAINTENANCE INITIAL ODOMETER READINGS ITEM ROUTINE 5 Brakehoses Brakehoses m e Check for cracks or damage Replace ss TEFdAT runout and for dam Replace if necessary operation Replace if necessary Check bearing assemblies for Swingarm pivot bearings um soap based grease Check chain slack alignment Drive chain ee chain Every 500 mi 800 km and after washing the motorcycle or riding in the with a special O ring chain lu en bricant thoroughly Check bearing assemblies for Check all chassis fitting and Chassis fasteners fasteners Correct if necessary Apply lithium soap based Spee acne all purpose grease mu lithium soap based Brake and shift grease all purpose grease pedal pivot shafts lightly Check tread depth and for damage 7 Tires e Replace if necessary e Check air pressure e Correct if necessary looseness repack with lithi Every 12000 mi 19000 km Check operation Apply lithium soap based Sidestand pivot grease all purpose grease lightly Check bearings for smooth Whe
85. EXUP cable free play at the EXUP valve pulley d 1 5 mm 0 06 in or less e Tighten the locknut 2 to specification Locknut EXUP cable adjusting bolt 7 Nm 0 7 m kg 5 1 16 i a ie Lm f Repeat steps 2 and 3 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 5 Install EXUP valve pulley cover EXUP valve pulley cover bolt front side 8 Nm 0 8 m kg 5 8 ft lb EXUP valve pulley cover bolt rear side 7 Nm 0 7 m kg 5 1 16 EAS21110 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface NOTE e Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check Coolant level The coolant level should be between the maximum level mark a and minimum level mark b Below the minimum level mark Remove the coolant reservoir cap add the recom mended coolant to the proper level To access the coolant reservoir cap remove the right side panel Refer to GENERAL CHASSIS on page 4 1 ECA13470 CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used ENGINE AC 3 Start the engine warm it up for several min utes and then turn it o
86. Fasten the left handlebar switch lead on the front side of the front fork 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 2 10 mm 0 08 0 39 in Be sure to position the plastic locking tie above where the horn leads branch off from the other leads 40 50 mm 1 57 1 97 in Pass the throttle cables through the guide on the lower bracket making sure to route the decelerator cable above the accelerator cable as shown in the illustration Fasten the horn leads with the holder on the lower bracket cover Install the horn L shaped connectors so that the leads are routed rearward To the headlight relay on off Fasten the wire harness at the white tape with a plastic locking tie Fasten the headlight relay lead at the white tape with a plastic locking tie Install the headlight relay dimmer completely onto the tab on the headlight assembly 2 48 CABLE ROUTING CABLE ROUTING SKA 2 Hes AN ay ii pu M Woo k tate H 2 49 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 EXUP servo motor lead Crankshaft position sensor lead Ignition coil lead Wire harness Right radiator fan motor lead Front brake fluid reservoir hos
87. Gear ratio 1st 2nd 3rd 4th 5th 6th Main axle runout limit Drive axle runout limit Shifting mechanism Shift mechanism type Shift fork guide bar bending limit Shift fork thickness Shift fork thickness Air filter Air filter element Fuel pump Pump type Model manufacturer Maximum consumption amperage Output pressure Injector Model quantity Manufacturer Throttle body Type quantity Manufacturer ID mark Throttle valve size Throttle position sensor Resistance ENGINE SPECIFICATIONS 8 pcs 0 10 mm 0 0039 in 55 00 mm 2 17 in 54 00 mm 2 13 in 6 pcs Constant mesh 6 speed Spur gear 85 41 2 073 Chain drive 45 16 2 813 Left foot operation 31 12 2 583 32 16 2 000 30 18 1 667 26 18 1 444 27 21 1 286 23 20 1 150 0 02 mm 0 0008 in 0 02 mm 0 0008 in Shift drum 0 050 mm 0 0020 in 5 760 5 890 mm 0 2268 0 2319 in 5 795 5 868 mm 0 2281 0 2310 in Oil coated paper element Electrical 2CO DENSO 5 1A 319 0 329 0 kPa 46 3 47 7 psi 3 19 3 29 kgf cm 297500 0640 4 297500 0660 4 DENSO 41EIDW 1 MIKUNI 2C01 00 USA 2 06 10 California 50 2 0 3 0 Fuel injection sensor Crankshaft position sensor resistance Cylinder identification sensor output voltage ON Cylinder identification sensor output voltage OFF Intake air pressure sensor output voltage Atmospheric pressure sensor output voltage Idling condition Engine idling spe
88. No normal signals re Open circuit in wire harness ceived from the speed sen Malfunction in speed sensor sor e Malfunction in ECU Neutral switch Open circuit in wire harness open or short circuit detect Malfunction in neutral switch ed Malfunction in ECU 8 42 Symptom Power supply to the injec tors and the fuel pump is not normal An error is detected while reading or writing on EE PROM CO adjustment val ue Power supply is not normal Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Throttle position sensor for throttle cable pulley open or short circuit detect ed Throttle position sensor for throttle cable pulley cou pler connection is loose Throttle servo motor open or short circuit detect ed Defective throttle servo mo tor Malfunction in ECU servo motor driving system No signals are received from the ECU No signals are received from the ECU within the specified duration Data from the ECU cannot be received correctly Non registered data has been received from the meter FUEL INJECTION SYSTEM Diagnostic Probable cause of malfunction code No Open or short circuit in wire harness Malfunction ECU Malfunction in ECU The CO adjustment value is not properly written on or read from the internal memo ry Malfunction in the
89. OFF SYSTEM OPERATION If the engine stop switch is set to CQ and the main switch is set to ON both switches are closed the starter motor can only operate if at least one of the following conditions is met The transmission is in neutral the neutral switch is closed The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the start switch e 14 126 o 8 9 9 IM WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR Battery Main fuse Main switch Ignition fuse Engine stop switch Helay unit starting circuit cut off relay Relay unit diode Clutch switch Sidestand switch 10 Neutral switch 11 Start switch 12 Starter relay 13 Starter motor 14 Engine ground ELECTRIC STARTING SYSTEM 8 10 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn NOTE Before troubleshooting remove the following part s Rider s
90. OK The speedometer fails to operate 1 Check the speed sensor NG Refer to CHECKING THE SPEED Replace the speed sensor SENSOR page 8 96 2 Check the entire signaling system s gt wiring Properly connect or repair the signaling Refer to CIRCUIT DIAGRAM on system s wiring page 8 21 Replace the meter assembly The shift timing indicator light fails to come on 1 Check that the shift timing indicator gt light is set to come on and that the brightness level of the light is ad Replace the meter assembly justed properly Refer to FEATURES on page 1 2 OK 8 26 SIGNALING SYSTEM 2 Check the entire signaling system s gt wiring Properly connect or repair the signaling Refer to CIRCUIT DIAGRAM on system s wiring page 8 21 OK This circuit is OK 8 27 SIGNALING SYSTEM COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM EAS27300 EAS27310 SEN O 80 ar ovig 1 fir fr EH OBE DG e 69 io 00 18 lt HU 1 va am AM un ya va 1 1 3l 99 ama cr wap I QI rie 2 Nmous VV
91. Oil pan Bottom cowling brackets Oil level switch lead holder Oil pan bolt 12 Nm 1 2 m kg 8 7 ft lb NOTE Tighten the oil pan bolts in stages and in a criss cross pattern CRANKCASE EAS25540 CRANKCASE Separating the crankcase 8 Nm 0 8 kg 5 8 ft Ib 12 Nm 1 2 kg 8 7 ft Ib KE X Wi 4 2 12 Nm 1 2 kg 8 7 ft Ib Engine Refer to ENGINE REMOVAL page 5 1 Cylinder head Refer to CYLINDER HEAD on page 5 15 Starter clutch Refer to GENERATOR AND STARTER CLUTCH on page 5 26 Refer to SHIFT SHAFT on page 5 47 Rickuprotor ________ Refer to PICKUP ROTOR on page 5 30 T Refer to OIL PUMP on page 5 50 Ca pea p 5 Timing chain 5 55 CRANKCASE Separating the crankcase 8 Nm 0 8 kg 5 8 ft Ib 12 Nm 1 2 kg 8 7 ft Ib 3 M 2777 DA 7 0 LQ di oy 39 For installation reverse the removal dure 5 56 25550 DISASSEMBLING THE CRANKCASE 1 Place the engine upside down 2 Remove Crankcase bolts NOTE e Loosen each bolt 1 4 of a turn at a time After all of the bolts are fully loosened remove them
92. The control mode changes to the shift timing indicator light activation function To set the shift timing indicator light activation function NOTE The shift timing indicator light activation function can be set between 10000 r min and 18000 r min From 10000 r min to 13000 r min the indi cator light can be set in increments of 500 r min From 13000 r min to 18000 r min the indicator light can be set in increments of 200 r min 1 sired engine speed for activating the indicator light Push the SELECT button to confirm the se lected engine speed The control mode changes to the shift timing indicator light de activation function Push the RESET button to select the de FEATURES To set the shift timing indicator light deactivation function NOTE The shift timing indicator light deactivation function can be set between 10000 r min and 18000 r min From 10000 r min to 13000 r min the indicator light can be set in increments of 500 r min From 13000 r min to 18000 r min the indicator light can be set in increments of 200 r min Be sure to set the deactivation function to a higher engine speed than for the activation function otherwise the shift timing indicator light will remain deactivated 1 Push the RESET button to select the de sired engine speed for deactivating the indi cator light Push the SELECT button to confirm the se lected engine speed The control mode
93. With the adjusting screw fully turned in 521650 CHECKING THE TIRES The following procedure applies to both of the tires 1 Check e Tire pressure Out of specification Regulate A VA CNN CHASSIS EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and ac cessories and the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 Ib Front 250 kPa 36 psi 2 50 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Loading condition 90 193 kg 198 425 Ib USA 90 192 kg 198 423 Ib Califor nia Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 250 kPa 36 psi 2 50 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Maximum load 193 kg 425 Ib USA 192 kg 423 Ib California Total weight of rider passenger cargo and accessories EWA13190 It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit re place the tire immediately 2 Check
94. a Crankcase stud bolt See NOTE 1 B Pressure plate bolt 8 Nm 0 8 m kg 5 8 ft lb Clutch boss nut 1 115 Nm 11 5 m kg 85 ft lb Stake Clutch boss plate stud bolt M8 6 25 Nm 2 5 m kg 18 ft lb Stake Main axle screw 3 12 Nm 1 2 m kg 8 7 ft lb 5 2 10 Nm 1 0 m kg 7 2 ft lb 5 5 Shift drum retainer bolt M6 2 22 Nm 2 2 m kg 16 ft lb M6 Shift shaft spring stopper M8 1 1 10 Nm 1 0 m kg 7 2 ft lb 1 1 Shift arm bolt 35 Nm 3 5 m kg 25 ft lb 1 0 m kg 7 2 ft lb 2 0 m kg 14 ft lb 1 0 m kg 7 2 ft lb 1 0 m kg 7 2 ft lb 10 20 10 2 EN 2 Starter motor bolt 2 Neutral switch Oil level switch bolt 2 20 8 20 ______ Pickup rotor bolt 10 6 6 6 6 Cylinder identification sensor bolt 8 Nm 0 8 m kg 5 8 ft lb Negative battery terminal engine ground terminal bolt m NOTE Connecting rod nut Tighten the connecting rod nuts to 15 Nm 1 5 m kg 11 ft Ib and then tighten them further to reach the specified angle 175 185 NOTE Crankcase bolt 1 First tighten the bolts to approximately 20 Nm 2 0 m kg 14 ft lb with a torque wrench 2 Loosen all bolts one by one following the tightening order and then retighten the bolts 25 Nm 2 5 m kg 18 ft lb with a torque wr
95. a Symptom Lean angle sensor open or short circuit detected Check or maintenance job Reinstatement method Connections e Check the couplers for any pins Reinstated au Lean angle sensor coupler that may be pulled out tomatically if a Main wire harness ECU coupler Check the locking condition of normal signal is the couplers received f there is a malfunction repair it and connect the coupler se curely Open or short circuit in lead e Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler blue blue yellow green yellow green black blue black blue Defective lean angle sensor e Execute the diagnostic mode Code No 08 Replace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 93 8 63 FUEL INJECTION SYSTEM Fault code No Symptom A No normal signals are received from the speed sensor B Open circuit is detected in the neutral switch Diagnostic code No A Speed sensor 0 Item components and probable Check or maintenance job Reinstatement cause method Installed state of soeed sensor Check for looseness or pinching Starting the en Connections e Check the couplers for any pins 9116 and acti Speed sensor coupler that may be pulled out vating the Main wire harness ECU coupler Check the locking condition of speed the couplers by operating If there is a malfunction repair it tne Ve
96. and starter clutch 70 Nm 7 0 m 50 ft Ib Left bottom cowling to GENERAL CHASSIS page Drain Engine oil Refer to CHANGING THE ENGINE OIL on page 3 11 3 r 3 5 26 GENERATOR AND STARTER CLUTCH Removing the generator and starter clutch 70 Nm 7 0 kg 50 ft Ib Starter clutch gear For installation reverse the removal dure 5 27 GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1 Remove Generator rotor bolt 1 Washer NOTE While holding the generator rotor 2 with the sheave holder 3 loosen the generator rotor bolt Sheave holder 90890 01701 Primary clutch holder YS 01880 A 2 Remove Generator rotor 1 with the flywheel puller 2 ECA13880 CAUTION To protect the end of the crankshaft place an appropriate sized socket between the fly wheel puller set s center bolt and the crank shaft Flywheel puller 90890 01404 Flywheel puller YM 01404 EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers Damage wear Replace 2 Check e Starter clutch idle gear e Starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Check e Starter clutch gear s contacting
97. angle 13 Throttle position sensor for throttle valves signal 2 throttle angle 14 Throttle position sensor for throttle cable pulley signal 1 throttle angle 15 Throttle position sensor for throttle cable pulley signal 2 throttle angle 48 Air induction system solenoid 3 Perform Fuel injection system reinstatement action Refer to Reinstatement method of table in TROUBLESHOOTING DETAILS If a malfunction is detected in the sensors actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair inner parts of the engine 8 39 FUEL INJECTION SYSTEM EAS27420 DIAGNOSTIC MODE Setting the diagnostic mode 1 Turn the main switch to OFF 2 Disconnect the wire harness coupler from the fuel pump 3 Press and hold the SELECT and RESET buttons turn the main switch to and continue to press the buttons for 8 seconds or more NOTE gt All displays on the meter disappear except the odometer trip meter fuel reserve trip meter stopwatch display e appears on the odometer trip meter fuel reserve trip meter stopwatch LCD 4 Press the SELECT button to select the diagnostic mode 5 After selecting simultaneously press the SELECT and RESET buttons for 2 seconds or more to activate the diagnostic mode The diagnostic code number 401 appears on the clock LC
98. areas 4 Install e Air filter element EC2C01007 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 synchronization leading to poor en gine performance and possible overheating NOTE _ When installing the air filter element into the low er air filter case make sure that the sealing sur faces are aligned to prevent any air leaks 5 Install Upper air filter case Refer to AIR FILTER CASE on page 7 5 Fuel tank Refer to FUEL TANK on page 7 1 e Rider seat Refer to GENERAL CHASSIS on page 4 1 21010 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds 1 Remove e Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Canister for California only Refer to THROTTLE BODIES on page 7 8 Throttle body Refer to THROTTLE BODIES on page 7 8 2 Check Throttle body joints 1 Cracks damage Replace 3 Install Throttle body Refer to THROTTLE BODIES on page 7 8 Canister for California only Refer to THROTTLE BODIES on page 7 8 Air filter case
99. changes to the shift timing indicator light brightness function To adjust the shift timing indicator light bright ness 1 Push the RESET button to select the de sired indicator light brightness level Push the SELECT button to confirm the se lected indicator light brightness level The dis play will return to the odometer or tripmeter mode 2 20180 IMPORTANT INFORMATION EAS20190 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 Before removal and disassembly remove all dirt mud dust and foreign material 2 Use only the proper tools and cleaning equip ment Refer to SPECIAL TOOLS on page 1 14 3 When disassembling always keep mated parts together This includes gears cylinders pistons and other parts that have been mat ed through normal wear Mated parts must always be reused or replaced as an assem bly 4 During disassembly clean all of the parts and place them in trays in the order of disassem bly This will soeed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality IMPORTANT INFORMATION EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine
100. charging system Refer to CHARGING SYSTEM on page 8 13 e Malfunction ECU The program and data are not properly written on or read from the internal memo ry Open or short circuit in wire harness Defective throttle position sensor Improperly installed throttle position sensor Malfunction ECU Open or short circuit in wire harness Defective throttle servo motor potentiome ter circuit Stuck throttle servo motor mechanism Stuck throttle servo motor motor Malfunction in ECU Open or short circuit in wire harness e Malfunction in meter e Malfunction in ECU e Defective wire connection of the ECU cou pler Improper connection in wire harness Malfunction in meter Malfunction in ECU Improper connection in wire harness Malfunction in meter Malfunction ECU Improper connection in wire harness e Malfunction in meter Malfunction ECU 8 43 FUEL INJECTION SYSTEM Sensor operation table Diag nostic code Meter display Checking method No Throttle position sensor for throttle valves signal 1 Fully closed position Check with throttle valves fully closed Fully opened position Check with throttle valves fully opened Atmospheric pressure Displays the atmospheric Compare the actually mea pressure sured atmospheric pres sure with the meter display value Intake air pressure Disp
101. components and probable Check or maintenance job Reinstatement cause method Malfunction in ECU Replace the ECU Turning the switch to Be sure to turn the main switch to ON OFF before replacing the ECU 8 67 Fault code No FUEL INJECTION SYSTEM Symptom Throttle position sensor for throttle cable pulley open or short circuit detected Throttle position sensor for throttle cable pulley coupler connection is loose Diagnostic code No Throttle position sensor for throttle cable pulley signal 1 Throttle position sensor for throttle cable pulley signal 2 Item components and probable Check or maintenance job Reinstatement cause method sor for throttle cable pulley Installed state of throttle position sen 2 Connections Throttle position sensor for throttle cable pulley coupler Main wire harness ECU coupler Open or short circuit in wire harness 3 4 Defective throttle position sensor for throttle cable pulley Check for looseness or pinch ing Check that the sensor is in Stalled in the specified position Turning the main switch to ON Check the couplers for any pins that may be pulled out e Check the locking condition of the couplers f there is a malfunction repair it and connect the coupler se Repair or replace if there is open or short circuit Between throttle position sen sor
102. constant changes in the operating conditions of the en gine 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 accom modate this need this model has adopted an electronically controlled fuel injection Fl 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 Fl system has resulted in a highly precise fuel supply improved engine response better fuel economy and reduced exhaust emissions 345 6789 10 11 12 19 18 17 16 15 14 13 1 Air temperature sensor 15 Speed sensor 2 Engine trouble warning light 16 Coolant temperature sensor 3 Air induction system solenoid 17 Crankshaft position sensor 4 Throttle servo motor 18 Throttle position sensor for throttle cable 5 Atmospheric pressure sensor pulley 6 Secondary injectors 19 Throttle position sensor for throttle valves 7 Primary injectors 20 Spark plug 8 Intake air pressure sensor 21 Ignition coil 9 Fuel pump 22 Cylinder identification sensor 10 Relay unit fuel pump relay 11 Lean angle sensor 12 ECU engine control unit 13 EXUP servo motor 14 sensor 1 2 FEATU
103. dif ferent from those of conventional batteries The MF battery should be charged accord ing to the instructions for the charging method If the battery is overcharged the ELECTRICAL COMPONENTS electrolyte level will drop considerably Therefore take special care when charging the battery NOTE Since MF batteries are sealed it is not possible to check the charge state of the battery by mea suring 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 Rider seat Fuel tank bracket Refer to GENERAL CHASSIS on page 4 1 2 Disconnect Battery leads from the battery terminals ECA13640 CAUTION First disconnect the negative battery lead 1 and then positive battery lead 2 CN Oa amp 62 TENY 3 Remove e Battery band Battery 4 Check Battery charge a Connect a pocket tester to the battery termi nals Positive tester probe gt positive battery terminal Negative tester probe gt negative battery terminal 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 ter minal is disconnected No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V 8 86
104. for throttle cable pulley coupler and ECU coupler black blue black blue white white white red white red blue blue Execute the diagnostic mode Code Nos 14 15 Replace if defective Refer to CHECKING THE THROTTLE POSITION SEN SOR FOR THROTTLE BLE PULLEY on page 8 98 8 68 FUEL INJECTION SYSTEM Fault code No Symptom Throttle servo motor open or short circuit detected Defective throttle servo motor Malfunction in ECU servo motor driving system Diagnostic code No Throttle position sensor for throttle valves signal 1 Throttle position sensor for throttle valves signal 2 Item components and probable Check or maintenance job Reinstatement cause method Installed state of throttle position sen Check for looseness or pinch Turning the sor for throttle valves ing main switch to Check that the sensor is in ON stalled in the specified position Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between throttle servo motor coupler and ECU coupler yellow red yellow red light green red light green red Defective throttle servo motor Execute the diagnostic mode Code Nos 01 13 Connections e Check the couplers for any pins Throttle servo motor coupler that may be pulled out Main wire harness ECU coupler e Check the locking condition of the couplers f th
105. lead under the left radiator fan motor lead 2 52 CABLE ROUTING CABLE ROUTING gt SS SS hn 222 741 7 gt 2 LZ x J 5 gt 0 7 lt wy A 4 ne in 5 LITT Tree gt s gt C 28 zt RID MO S LU BRS S 2 lt 2 gt N XN gt NN a 22 di 2 K NS CS V SSS 3 ST VI ANN OS KN KS e A 4 qu mi 7 m 7X LR 2 4 f 2 53 Urge ces qw 10 12 13 14 15 16 17 18 19 20 21 22 23 24 2 26 27 28 29 30 Headlight sub wire harness 2 Wire harness gt Front right turn signal position light lead Right radiator fan motor lead Throttle position sensor for throttle valves lead Throttle servo motor lead Throttle position sensor for throttle cable pulley lead Ignition coil lead Crankshaft position sensor lead Sub wire harness 2 Coolant temperature sensor lead Rear brake light switch lead
106. lever For installation reverse the removal dure 5 48 25420 CHECKING THE SHIFT SHAFT 1 Check Shift shaft Bends damage wear Replace Shift shaft spring Damage wear Replace EAS25430 CHECKING THE STOPPER LEVER 1 Check Stopper lever Bends damage Replace Roller turns roughly Replace the stopper lever Stopper lever spring Damage wear Replace EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Shift shaft spring stopper 1 Shift shaft assembly Shift shaft spring 2 Shift shaft spring stopper 22 Nm 2 2 m kg 16 ft lb LOCTITE NOTE e Lubricate the oil seal lips with lithium soap based grease Hook the end of the shift shaft spring onto the shift shaft spring stopper Hook the ends of the stopper lever spring 3 onto the stopper lever 4 and the crankcase boss 5 Mesh the stopper lever with the shift drum seg ment assembly 5 49 SHIFT SHAFT OIL PUMP EAS24920 OIL PUMP St Job Parts to remove Drain Engine oil Refer to CHANGING THE ENGINE OIL on page 3 11 Drain Coolant Refer to CHANGING THE COOLANT on page 3 19 8 Botomcowingbaciet 5 50 OIL PUMP cae 1 N lt 1
107. may be pulled out tomatically Main wire harness ECU coupler Check the locking condition of normal signal is the couplers received f there is a malfunction repair it and connect the coupler se Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between EXUP servo motor coupler and ECU coupler blue blue white red white red black blue black blue Defective EXUP servo motor potenti Execute the diagnostic mode ometer circuit Code No 53 Replace if defective Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 55 EXUP servo motor Item components and probable Check or maintenance job Reinstatement cause method 1 Connections Check the couplers for any pins Turning the EXUP servo motor coupler that may be pulled out main switch to e Main wire harness ECU coupler Check the locking condition of ON the couplers It takes 3 sec f there is a malfunction repair it onds at the and connect the coupler se maximum be curely fore the origi Open or short circuit in wire harness Repair or replace if there is an is open or short circuit pe purius Between EXUP servo motor coupler and ECU coupler black green black green black red black red 2 3 Defective EXUP servo motor Execute the diagnostic mode Code No 53 Replace if defective 4 Defective E
108. mm 304 91 Ib in 5 45 kgf mm 166 00 190 00 37 32 42 71 Ib 16 93 19 37 kof 165 00 189 00 37 09 42 49 Ib 16 83 19 27 kof Spring tilt intake Spring tilt exhaust 7 Winding direction intake Winding direction exhaust Cylinder Bore Taper limit Out of round limit Piston Piston to cylinder clearance Limit Diameter D Height H an Offset Offset direction Piston pin bore inside diameter Limit Piston pin outside diameter Limit Piston pin to piston pin bore clearance Piston ring Top ring Ring type Dimensions B x T B p End gap installed Limit Ring side clearance ENGINE SPECIFICATIONS 2 5 1 6 mm 2 5 1 6 mm Clockwise Clockwise 67 000 67 010 mm 2 6378 2 6382 in 0 050 mm 0 0020 in 0 050 mm 0 0020 in 0 010 0 035 mm 0 0004 0 0014 in 0 05 mm 0 0022 in 66 975 66 990 mm 2 6368 2 6374 in 10 0 mm 0 39 in 0 50 mm 0 0197 in Intake side 15 002 15 013 mm 0 5906 0 5911 15 043 0 5922 14 991 15 000 mm 0 5902 0 5906 in 14 971 0 5894 0 002 0 022 0 00007 0 00068 Barrel 0 80 x 2 40 mm 0 03 x 0 09 in 0 25 0 35 0 0098 0 0138 0 55 mm 0 0217 0 030 0 065 0 0012 0 0026 2nd ring Ring type Dimensions B x T ETE End gap installed Limit Ring side clearance Oil ring Dimensions B x T 3 ac M A End gap installed Conn
109. not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump as sembly 2 Check Diaphragms and gaskets Tears fatigue cracks Replace fuel pump assembly EAS26690 CHECKING THE FUEL PUMP OPERATION 1 Check Fuel pump operation Refer to CHECKING THE FUEL PUMP on page 8 98 EAS26710 INSTALLING THE FUEL PUMP 1 Tighten Fuel pump Fuel pump bolt 4 Nm 0 4 m kg 2 9 ft lb NOTE Do not damage the installation surfaces the fuel tank when installing the fuel pump e Always use a new fuel pump gasket Install the fuel pump as shown in the illustra tion Align the projection on the fuel pump with the slot in the fuel pump bracket Tighten the fuel pump bolts in the proper tight ening sequence as shown INSTALLING THE FUEL TANK 1 Connect Fuel tank breather hose fuel tank to hose joint 1 except for California Fuel tank overflow hose fuel tank to hose joint 2 Fuel tank breather hose 3 except for Cali fornia Fuel tank overflow hose 4 A Except for California B For California 2 Connect Fuel hose fuel tank to primary injector rail EC2C01017 CAUTION When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in th
110. on page 8 81 OK 2 Check the rear brake light switch gt Refer to CHECKING THE Replace the rear brake light switch SWITCHES on page 8 81 OK Replace the front brake light switch Check the entire signaling system s gt wiring Refer to CIRCUIT DIAGRAM on page 8 21 OK This circuit is OK The turn signal light turn signal indicator light or both fail to blink Properly connect or repair the signaling system s wiring 1 Check the turn signal light bulbs gt and sockets Refer to CHECKING THE BULBS turn signal light bulb s sock AND BULB SOCKETS on page 8 84 Check the turn signal switch gt Refer to CHECKING THE Replace the left handlebar switch SWITCHES on page 8 81 OK Check the turn signal relay gt Refer to CHECKING THE TURN Replace the turn signal relay SIGNAL RELAY on page 8 90 8 24 SIGNALING SYSTEM 4 Check the entire signaling system s gt wiring Properly connect or repair the signaling Refer to CIRCUIT DIAGRAM on system s wiring page 8 21 OK This circuit is OK The neutral indicator light fails to come on 1 Check the neutral switch NG gt Refer to CHECKING THE Replace the neutral switch SWITCHES on page 8 81 OK 2 Check the relay unit diode NG Refer to CHECKING THE RELAY Replace the relay unit UNIT DIOD
111. one with the lowest vacuum pressure as the standard e After each step rev the engine two or three times each time for less than a second and check the synchronization again f an air screw was removed turn the screw 3 4 turn in and be sure to synchronize the throttle body NOTE The difference in vacuum pressure between two throttle bodies should not exceed 1 33 kPa 10 mmHg f you are unable to adjust the throttle body synchronization using this procedure use the following procedure instead Intake vacuum 20 0 kPa 5 9 inHg 150 mmHg MAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Alternate procedure NOTE Use this alternate procedure if you are unable to adjust the throttle body synchronization using the basic procedure a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed tat Engine idling speed 1250 1350 r min b Turn all the bypass air screws in fully c Using the throttle body with the lowest vacu um pressure as the standard turn out the by pass air screws of the other throttle bodies to adjust them NOTE Do not turn out the bypass air screw of the throttle body with the lowest vacuum pressure e After each step rev the engine two or three times each time for less than a second and check the synchronization again f an air screw was removed turn
112. or gas Tire s Uneven tire pressures front and rear Incorrect tire pressure Uneven tire wear Wheel s Incorrect wheel balance e 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 EAS28710 FAULTY LIGHTING OR SIGNALING SYSTEM Headlight does not come on Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts main switch Burnt out headlight bulb Headlight bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier regulator Improperly grounded circuit e Faulty main switch Headlight bulb life expired Tail brake light does not come on Wrong tail brake light LED Too many electrical accessories Incorrect connection Burnt out tail orake light LED Tail brake light bulb burnt out Wrong tail brake light LED Faulty battery Incorrectly adjusted rear brake light switch Tail orake light LED life expired TROUBLESHOOTING Turn signal does not come on e Faulty turn signal switch e Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal flashes slowly
113. outlet hose 4 Om Water pump outlet pipe 6 4 COOLER Removing the oil cooler Order Job Parts to remove Q ty For installation reverse the removal dure 26420 CHECKING THE OIL COOLER 1 Check Oil cooler Cracks damage Replace 2 Check Oil cooler inlet hose Oil cooler outlet hose e Water jacket joint hose Cracks damage wear Replace 3 Check Water jacket joint pipe Damage Replace Obstruction Wash and blow out with com pressed air EAS26430 INSTALLING THE OIL COOLER 1 Clean e Mating surfaces of the oil cooler and the crankcase with a cloth dampened with lacquer thinner 2 Install O ring Oil cooler 1 Gasket 2 e Oil cooler union bolt 3 Before installing the oil cooler lubricate the its union bolt with a thin coat of engine oil Make sure the O ring is positioned properly Make sure the projection on the oil cooler touches the projection b on the crankcase BAS Ve ICS TN OLN d L 1 AWS Ws 3 Oil cooler union bolt 63 Nm 6 3 m kg 43 ft lb NS 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT page 3 19 6 6 OIL COOLER e Crankcase with the specified amo
114. primary injector Execute the diagnostic mode Code Nos 36 37 38 39 Replace if defective Refer to CHECKING THE PRI MARY INJECTORS on page 7 12 8 61 FUEL INJECTION SYSTEM Fault code No Symptom circuit detected in a secondary injector Diagnostic code No Secondary injector 1 Secondary injector 2 Secondary injector 3 Secondary injector 4 Item components and probable Check or maintenance job cause Connections Secondary injector coupler Main wire harness ECU coupler e Sub wire harness 2 coupler Open or short circuit in wire harness and or sub wire harness 2 Defective secondary injector Reinstatement method Check the couplers for any pins Execute the di that may be pulled out agnostic mode Check the locking condition of Code No 63 the couplers Set the engine f there is a malfunction repair it stop switch to and connect the coupler se 3 2 curely Repair or replace if there is an open or short circuit Between secondary injector coupler and ECU coupler red blue red blue 1 white blue white blue 2 sky blue white sky blue white 3 brown yellow brown yel low 4 brown black brown black Execute the diagnostic mode Code Nos 40 41 42 43 Replace if defective Refer to CHECKING THE SECONDARY INJECTORS on 7 7 8 62 FUEL INJECTION SYSTEM Fault code No
115. qt Handling notes for coolant Coolant is potentially harmful and should be handled with special care EWA13040 If coolant splashes in your eyes thorough ly wash them with water and consult a doc tor If coolant splashes on your clothes quickly wash it away with water and then with soap and water f coolant is swallowed induce vomiting and get immediate medical attention ECA13480 CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used ENGINE If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 12 Install Radiator cap 13 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark NS 14 Install Coolant reservoir cap 15 Start the engine warm it up for several min utes and then stop it 16 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 18 NOTE Before checking the coolant level wait a few minutes until the coolant has settled 17 Install Right bottom cowling e Right lower side cowling e Right upper side cowling e Right side panel Refer to GENERAL CHASSIS on p
116. replacing the brake pads it is not neces sary to disconnect the brake hose or disassem ble the brake caliper 1 Measure Brake pad wear limit Out of specification Replace the brake pads as a set Brake pad lining thickness in ner 4 5 mm 0 18 in Limit 0 5 mm 0 02 in Brake pad lining thickness out er 4 5 mm 0 18 in Limit 0 5 mm 0 02 in 2 Install Brake pads Brake pad spring FRONT BRAKE NOTE Always install new brake pads and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Syr Bleed screw 5 Nm 0 5 m kg 3 6 ft lb d Install new brake pads and a new brake pad spring NOTE The arrow mark a on the brake pad spring must point in the direction of disc rotation DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Install Brake pad pin Brake pad clips Front brake caliper Brake caliper bolt 35 Nm 3 5 m kg 25 ft lb 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level 4 23 Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 22 X m N gt eLOWER
117. shaft web J numbers are 6 and 2 respective ly then the bearing size for J is 2 J crankcase J crankshaft web 1 6 2 123 brown Bearing color code 1 Blue 2 Black 3 Brown 4 Green 5 Yellow 26200 INSTALLING THE CRANKSHAFT 1 Install Crankshaft journal upper bearings into the upper crankcase e Crankshaft journal lower bearings into the lower crankcase NOTE Align the projections on the crankshaft jour nal bearings 1 with the notches b in the crankcases Be sure to install each crankshaft journal bear ing in its original place 5 70 CRANKSHAFT TRANSMISSION TRANSMISSION Removing the transmission shift drum assembly and shift forks 12 Nm 1 2 m kg 8 7 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Job Parts to remove Separate Refer to CRANKCASE page 5 55 Circlip Oil seal Bearing 7 LI NN Shift fork R 0 Shift drum assembly 11 Shift fork C Main axle assembly Wm GW N D 5 71 TRANSMISSION Removing the transmission shift drum assembly and shift forks 12 Nm 1 2 m kg 8 7 ft Ib 10 Nm 1 0 kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib For installation reverse the removal dure 5 72 TRANSMISSION Disassembling the main axle assembly Job Parts to remove
118. the direc tion of the arrow shown in the illustration The rollover valve must be in an upright posi tion when checking the airflow EAS27010 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the rider seat Refer to GENERAL CHASSIS on page 4 1 THROTTLE BODIES b Disconnect the fuel hose fuel tank to primary injector fuel rail 1 from the primary injector fuel rail EW2C01008 WARNING Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hoses B N IPS Jh N 2 LAE SN MENS Connect the pressure gauge 2 and adapter 3 to the fuel hose fuel tank to primary injec tor fuel rail alm 1 A Pressure gauge 90890 03153 Pressure gauge YU 03153 Fuel pressure adapter 90890 03176 7 12 03176 d Start the engine e Measure the fuel pressure Fuel pressure 324 kPa 46 1 psi 3 24 kg cm Faulty Replace the fuel pump DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ET2C01007 ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 1 Check Throttle position sensor for throttle valves Refer to CHECKING THE THROTTLE PO SITION SENSOR FOR THROTTLE VALVES on page 8 97 2 Adjust Throttle position s
119. the starter motor a Measure the armature assembly resistances with the pocket tester ELECTRIC STARTER Pocket tester 90890 03112 Analog pocket tester YU 03112 C Armature coil Commutator resistance 1 0 0012 0 0022 at 20 68 F Insulation resistance 2 Above 1 MQ at 20 C 68 F b If any resistance is out of specification re place the starter motor DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 5 Measure Brush length a Out of specification Replace the brushes as a Set Limit 3 50 mm 0 14 in 6 Measure e Brush spring force Out of specification Replace the brush springs as a set Brush spring force 7 16 9 52 25 77 34 27 oz 730 971 91 5 35 ELECTRIC STARTER 7 Check Gear teeth Damage wear Replace the gear 8 Check Bearing Oil seal Damage wear Replace the defective part s ASSEMBLING THE STARTER MOTOR 1 Install Starter motor yoke 1 NOTE Align the tab a on the brush holder with the slot b in the starter motor yoke 2 Install e Starter motor yoke 1 e Starter motor front cover 2 e Starter motor rear cover 3 NOTE Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers 5 36 CLUTCH EAS25060 CLUTCH Removing the clutch cover 12 Nm 1
120. the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM page 3 24 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 on page 3 22 VO xU 700 Ne E Y HE 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM page 3 24 4 37 22700 REMOVING THE REAR BRAKE MASTER CYLINDER NOTE Before removing the rear brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Rear brake hose union bolt 1 Copper washers 2 Rear brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22720 CHECKING THE REAR BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid de
121. the voltage of white black and black blue Turn the crankshaft twice and check that the output voltage rises to approx imately 4 8 V once DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace ELECTRICAL COMPONENTS Intake air pressure sensor output voltage 3 15 4 15 V a Connect the pocket tester DC 20 V to the in take air pressure sensor coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt pink white 1 Negative tester probe gt black blue 2 b Turn the main switch to ON c Measure the intake air pressure sensor out put voltage DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE AIR TEMPERATURE SENSOR 1 Remove Air temperature sensor EW2C01002 Handle the air temperature sensor with special care Never subject the air temperature sensor to strong shocks If the air temperature sen sor is dropped replace it 2 Check e Air temperature sensor resistance Out of specification Replace Air temperature sensor resis tance 290 390 at 80 C 176 F 8 100 ELECTRICAL COMPONENTS a Connect the pocket tester Q x 100 to the air temperature sensor te
122. 0 CHASSIS Tube guide throttle grip inner surface and throttle cables _ _ iik x Swingarm pivot shaft nut seals rear shock absorber relay arm and connecting Seat lock lever pivoting point Sidestand pivoting point and metal to metal moving parts striker and sidestand switch a Sidesendhookandserng and sdestandbok lt _ _ Brake o _ earwheslavehubotsel _ ear wheel sive hub mating Rear wheel axle gt n n lt n n n n 34 n n n n an n 34 n n LUBRICATION POINTS AND LUBRICANT TYPES 2 28 LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS ENGINE OIL LUBRICATION CHART 2 29 OF a o ect Oil strainer Oil pump Relief valve Oil filter Oil cooler Main gallery Oil nozzle Timing chain tensioner Intake camshaft Exhaust camshaft Oil pipe Main axle Shift fork Drive axle LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION DIAGRAMS SRR 0 UU 4 RON LUBRICATION SYSTEM CHART AND DIAGRAMS V
123. 0 3 818 HOLIMS WHLNAN Juss 8 17 switch Main fuse 7 Battery 11 Engine ground 22 ECU engine control unit 57 High beam indicator light 60 Meter light 68 Dimmer switch 75 Front right turn signal position light 76 Front left turn signal position light 77 Headlight low beam 78 Headlight high beam 79 Auxiliary light 80 License plate light 82 Tail brake light 83 Headlight relay on off 84 Headlight relay dimmer 86 Headlight fuse 3 6 8 18 LIGHTING SYSTEM LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light headlight high beam headlight low beam high beam indicator light taillight license plate light auxiliary light or meter light NOTE Before troubleshooting remove the following part s Rider seat Fuel tank oide cowlings Rear cowling Front cowling 1 Check the condition of each bulb and bulb socket Refer to CHECKING THE BULBS Replace the bulb s and bulb socket s AND BULB SOCKETS on page 8 84 OK Check the fuses Main and headlight Refer to CHECKING THE FUS ES on page 8 85 Check the battery gt Refer to CHECKING AND CHARGING THE BATTERY on page 8 86 Replace the fuse s Clean the battery terminals Recharge or replace the battery 4 Check the main switch NG Refer to CHECKING THE Replace the main switch
124. 050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts EWA13680 WARNING Make sure the brake hoses are routed prop erly NOTE Make sure the outer tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 and 2 Lower bracket pinch bolt 23 Nm 2 3 m kg 17 ft lb NOTE Tighten each bolt to 23 Nm 2 3 m kg 17 ft lb in the order pinch bolt 1 pinch bolt 2 pinch bolt 1 4 53 FRONT FORK PA 2 N SY 022 PS 3 3 Tighten Cap bolt 1 bolt 20 Nm 2 0 m kg 14 Handlebar bolt 2 Handlebar pinch bolt 3 Upper bracket pinch bolt 4 Upper bracket pinch bolt 26 Nm 2 6 m kg 19 ft lb Handlebar bolt 13 Nm 1 3 m kg 9 4 ft lb Handlebar pinch bolt 32 Nm 3 2 m kg 23 ft lb e Cable routing NOTE Make sure the brake hose throttle cables clutch cable and handlebar switch leads are routed properly Refer to CABLE ROUTING on page 2 47 5 Install Plastic locking tie 1 e Plastic locking tie 2 NOTE _ e Fasten the left handlebar switch lead to the left front fork leg with the plastic locking tie e Fasten the front brake hose to the right front fork leg w
125. 1 16 Front brake hose joint 3 Front brake hose joint bolt 10 Nm 1 0 m kg 7 2 ft lb 4 59 STEERING HEAD NOTE Make sure that the tab a on the front brake hose joint bracket contacts the side b of the front brake hose joint HES 7 Check Cable routing NOTE Make sure the main switch lead brake hoses throttle cables clutch cable and handlebar switch leads are routed properly Refer to CA BLE ROUTING on page 2 47 REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 40 Nm 4 0 kg 29 ft Ib 40 Nm 4 0 m kg 29 ft Ib 44 Nm 4 4 m kg 32 ft Ib 16 Nm 1 6 m kg 11 ft Ib 52 Nm 5 2 m kg 37 ft Ib 40 Nm 4 0 kg 29 ft Ib Job Parts to remove Q ty eee Exhaust pipe assembly brackets Refer to ENGINE REMOVAL on page 5 1 1 Connecting arm nutWasheriBor 228 8 _____ 2 Rear shock absorber assembly lower nut Wash 1 1 1 er Bolt 3 4 Rear shock absorber Rear shock absorber assembly bracket nut bracket nut a tab eer a Rearshockabeorerassemtybacret Rearshockateorerassemby 7 9 RewyammuBipaer 4 60 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 40 Nm 4 0 kg 29 ft Ib 40 Nm 4 0
126. 1 m kg 8 0 ft lb ed cable locknut engine 7 Nm 0 7 mg 5 1 ftb Upper bracket pinch bolt 26 Nm 2 6 m kg 19 ft lb 21 Lower ring nut initial tightening See torque 52 Nm 5 2 m kg 37 ft lb NOTE Lower ring nut final tightening M30 torque gt See 1 1 14 Nm 1 4 m kg 10 ft lb 2 21 TIGHTENING TORQUES Thread a Lower bracket pinch bolt 23 Nm 2 3 m kg 17 ft lb NE and front brake hose joint 10 Nm 1 0 m kg 7 2 ft lb mE TOT mag Cap bolt 20 Nm 2 0 m kg 14 ft lb Cap bolt damper rod assembly and nut M10 25 Nm 2 5 m kg 18 ft lb Damper rod assembly 35 Nm 3 5 m kg 25 ft lb Front fender bolt 7 Nm 0 7 m kg 5 1 ft lb 11 Relay arm and frame nut 1 40 Nm 4 0 m kg 29 ft lb 2 40 Nm 4 0 m kg 29 ft lb Rear shock absorber assembly M12 upper nut Rear shock absorber assembly M12 lower nut Rear shock absorber assembly M spacer bolt M M M 1 44 Nm 4 4 m kg 32 ft lb 1 40 Nm 4 0 m kg 29 ft lb 1 16 Nm 1 6 m kg 11 ft lb 1 52 Nm 5 2 m kg 37 ft lb 1 22 Rear shock absorber assembly 14 bracket nut Swingarm pivot shaft 16 Nm 1 6 m kg 11 ft lb Swingarm pivot shaft ring nut 95 Nm 9 5 m kg 68 ft lb 6 8 Swingarm pivot shaft nut 1 70 Nm 7 0 m kg 50 ft lb Drive chain guide swingarm 6 side bolt Drive chain guard bolt Drive chain adjusting locknut Drive chain adjustin
127. 2 Check Bulb for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 Analog pocket tester YU 03112 C NOTE Before checking for continuity set the pocket tester to O and to the Q x 1 range 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 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 8 84 Checking the condition of the bulb sockets The following procedure applies to all of the bulb sockets 1 Check Bulb socket for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 Analog pocket tester YU 03112 C ELECTRICAL COMPONENTS a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Q x 1 Pocket tester 90890 03112 Analog pocket tester YU 03112 C NOTE Check each bulb socket for continuity in the same manner as described in the bulb section however note the following
128. 2 m kg 8 7 ft Ib mE to GENERAL CHASSIS page Drain Engine oil 1 Drain Refer to CHANGING THE COOLANT on page 3 19 Disconnect Disconnect Refer to CHANGING THE ENGINE OIL on OX Water pump breather hose Pull lever spring Clutch cover 2 3 4 6 1 For installation reverse the removal proce dure 5 37 CLUTCH Removing the pull lever shaft sonraretoremove 3 2 Pull lever shaft 4 Beating mE For installation reverse the removal proce dure 5 38 CLUTCH the clutch 1115 Nm 11 5 kg 85 ft Ib 8 Nm 0 8 kg 5 8 ft Ib Job Parts to remove Q ty E onpage 550 1 T BONN ach Boss ise Ls qme E e fse 5 39 CLUTCH Removing the clutch 1115 Nm 11 5 kg 85 ft Ib 8 Nm 0 8 m kg 5 8 ft Ib Emm 3 3 21 Thrust washer 3 Oil pump drive chain guide L3 For installation reverse the removal dur
129. 3 loosen the clutch boss nut Universal clutch holder 90890 04086 YM 91042 Clutch housing 2 Oil pump drive chain NOTE Remove the spacer and bearing from the main axle then remove the oil pump drive chain from the oil pump driven sprocket and then remove the clutch housing and oil pump drive chain from the main axle EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places Friction plate thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 80 mm 0 1102 in EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to ail of the clutch plates 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 Clutch plate thickness 1 90 2 10 mm 0 075 0 083 in Warpage limit 0 10 mm 0 0039 in 20100 SYMBOLS with engine mounted Filling fluid The following symbols are used in this manual 3 Lubricant for easier understanding 4 Special tool NOTE 5
130. 3 five times Check the operating sound of the secondary injector 4 five times Air induction system sole noid Fuel injection system relay Radiator fan motor relay Headlight relay EXUP servo motor EAS27460 TROUBLESHOOTING DETAILS FUEL INJECTION SYSTEM Actuates the air induction system solenoid five times at one second intervals Illuminates the engine trou ble warning light Actuates the fuel injection system relay five times at one second intervals Illuminates the engine trou ble warning light The engine trouble warning light is OFF when the relay is ON and the engine trouble warning light is ON when the relay is OFF Actuates the radiator fan mo tor relay five times at one second intervals ON 2 sec onds OFF 3 seconds Illuminates the engine trou ble warning light Actuates the headlight relay five times at one second in tervals ON 2 seconds OFF 3 seconds Illuminates the engine trou ble warning light Actuates the servo motor turns to open side and to closed side Illuminates the engine trou ble warning light Checking method Check the operating sound of the air induction system solenoid five times Check the operating sound of the fuel injection system relay five times Check the operating sound of the radiator fan motor re lay five times Check the operating sound of the headlight relay five times Check the operating sound This secti
131. 4 5 mm YM 04116 Valve guide installer 04 5 5 90890 04117 Valve guide installer 4 5 YM 04117 21 21 Valve guide reamer 4 5 21 90890 04118 Valve guide reamer 4 5 YM 04118 24 Valve spring compressor 5 90890 04109 01 Sheave holder 90890 01701 Primary clutch holder YS 01880 A Flywheel puller 5 28 90890 01404 Flywheel puller YM 01404 Yamaha bond No 1215 90890 85505 Three Bond No 121 5 SPECIAL TOOLS Reference 1 2 holder T2 5 41 5 45 YM 91042 91042 5 41 Thickness gauge 90890 03180 0 204 7 0 03 Feeler gauge set YU 26900 9 Piston pin puller set 90890 01304 Piston pin puller YU 01304 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 90890 0 SPECIAL TOOLS Reference Tool name Tool No pages Pressure gauge 90890 03153 Pressure gauge YU 03153 Fuel pressure adapter 90890 03176 YM 03176 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE 85 2 2 CHASSIS SPECIFICATIONS
132. 43 ft lb Spark plug 13 Nm 1 3 m kg 9 4 ft lb M 12 Nm 1 2 m kg 8 7 ft lb M 20 Nm 2 0 m kg 14 ft lb m O es lt 10 Nm 1 0 m kg 7 21 1 24 Nm 2 4 m kg 17 ft lb 18 Nm 1 8 m kg 13 ft lb 10 Nm 1 0 m kg 7 2 16 see Connecting rod nut 1st 15 Nm 1 5 m kg 11 ft lb NOTE 4 v oee Connecting rod nut final 7 Specified angle 175 185 NOTE 70 Nm 7 0 m kg 50 ft lb 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 16 10 Nm 1 0 m kg 7 2 16 12 Nm 1 2 m kg 8 7 16 10 Nm 1 0 m kg 7 2 ft Ib 12 Nm 1 2 m kg 8 7 16 12 Nm 1 2 m kg 8 7 16 43 Nm 4 3 m kg 31 ft lb 70 Nm 7 0 m kg 50 ft lb 17 Nm 1 7 m kg 12 ft lb 12 Nm 1 2 m kg 8 7 16 12 Nm 1 2 m kg 8 7 16 63 Nm 6 3 m kg 45 ft lb lt No gt z lt lt lt lt NO Upper air filter case to secondary injector holder bolt Oil filter cartridge bolt 5 Nm 0 5 m kg 3 6 ft lb lt 2 17 TIGHTENING TORQUES Thread a i 5 Upper air filter case to lower air filter case bolt 2 Nm 0 2 m kg 1 4 ft lb Upper air filter case joint bolt M5 16 4 Nm 0 4 m kg 2 9 ft lb 6 2 5 Nm 0
133. 5 mm 1st 20 Nm 2 0 m kg 14 116 2nd 25 Nm 2 5 m kg 18 ft Ib 3rd 27 Nm 2 7 m kg 20 16 CRANKCASE all bolts following the tightening or der and then tighten to specification torque NOTE Tighten the bolts in the tightening sequence cast on the crankcase 8 Tighten e Crankcase bolts 11 29 Crankcase bolt M8 x 65 mm 24 Nm 2 4 m kg 17 ft lb Crankcase bolt M6 10 Nm 1 0 m kg 7 2 ft lb NOTE Tighten the bolts in the tightening sequence cast on the crankcase CONNECTING RODS AND PISTONS EAS24370 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 15 Nm 1 5 m kg 11 ft Ib Specified angle 175 185 A lt gt MS AA A NANA A SARA A N 7 427 YQ Separate Connecting rod cap mmm pen REN 1 2 0 11 eg dure m 5 59 CONNECTING RODS AND PISTONS EAS26030 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the con necting rods and pistons 1 Remove Connecting rod cap 1 NOTE Identify the position of each connecting rod so that it can be reinstalled in its original place J e d IH O A 9 2 Remove Big end bearings fro
134. 7 Of 89 ex SBN 2X NR SEZ E 0 22 9 A 5 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers NOTE Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Front brake hose union bolt 1 Copper washers 2 Front brake hose 3 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22360 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Remove Brake caliper pistons 1 Brake caliper piston seals 2 FRONT BRAKE EW2C01005 Do not loosen the bolts 3 a Blow compressed air into the brake hose joint 6667 opening to force out the left side pistons from the brake caliper EWA13580 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake master cylin der Never try to pry out the brake caliper pis ton b Remove the brake caliper piston seals DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS22390 CHECKING THE FRONT BRAKE CALIPERS Recommended brake compo
135. 7 CHECKING THE SWINGARM 4 67 INSTALLING OE pO DOR 4 68 e 4 70 REMOVING THE DRIVE CHAINS 4 71 CHECKING THE DRIVE CHAIN 4 71 CHECKING THE DRIVE ea 4 72 CHECKING THE REAR WHEEL 4 72 CHECKING THE REAR WHEEL DRIVE 4 72 INSTALLING THE DRIVE CHAIN epe par 4 72 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 kg 5 1 ft Ib D EE E HK NN For installation reverse the removal dure 4 1 GENERAL CHASSIS Removing the tail brake light assembly 7 Nm 0 7 m kg 5 1 ft Ib 28 Nm 2 8 kg 20 ft Ib Omer Job Parts to remove Rider seat Passenger seat 11 9 Rearriohttum signal 1 Disconnect OOO 4 Reartettium signal ight coupler 1 5 Gicense connector 2 Dema 6 7 9 10 Right passenger footrest For installation
136. 7 INSTALLING THE FUEL HOSE PRIMARY INJECTOR FUEL RAIL TO SECONDARY INJECTOR FUEL 7 7 THROTTLE BODIES eset epu Rd epu Iu ian eS 7 8 CHECKING THE PRIMARY 2 2 0 0 7 12 CHECKING THE THROTTLE BODIE 7 12 CHECKING THE ROLLOVER VALVE for California only 7 12 CHECKING THE FUEL PRESSURE VERSER XH EAE 7 12 ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 7 13 ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY n Pene 7 13 INSTALLING THE THROTTLE BODY 5 7 14 AIR INDUCTION 7 15 CHECKING THE AIR INDUCTION SYSTEM 7 19 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank and fuel pump 9 Nm 0 9 kg 6 5 ft Ib 9 Nm 0 9 kg 6 5 ft Ib 4 Nm 0 4 m kg 2 9 ft Ib c7 a MEM Rider seat Fuel tank bracket mM oe to GENERAL CHASSIS on page Fuel hose fuel tank to primary injector fuel rail Disconnect Fuel sender coupler Disconnect Fuel pump coupler Disconnect Fuel tank breather hose Se alifornia 2 0000 0 Fuel tank overflow hose fuel tank to hose joint Except for California Fuel tank breather hose fuel tank to hose joint Fuel tank breather hose fuel tank to rollover valve
137. 89 Left radiator fan motor fuse 90 Right radiator fan motor 91 Left radiator fan motor EAS28750 COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray L Blue Lg Light green O Orange P Pink H Hed Sb Sky blue W White Y Yellow B G Black Green B L Black Blue B R Black Red BAN Black White B Y Black Yellow Br B Br G Br L Br R BrAN Br Y G B G R G W G Y Gy G Gy R L B L R L Y Lg R O B O G P B P W R B R G R L R W R Y Sb W W B W L W R Y B Y G Y L Y R Brown Black Brown Green Brown Blue Brown Red Brown White Brown Yellow Green Black Green Red Green White Green Yellow Gray Green Gray Red Blue Black Blue Red Blue White Blue Yellow Light green Red Orange Black Orange Green Pink Black Pink White Red Black Red Green Red Blue Red White Red Yellow Sky blue White White Black White Blue White Red White Yellow Yellow Black Yellow Green Yellow Blue Yellow Red YAMAHA YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN YZFR6V C 2006 WIRING DIAGRAM een L O B B L L B UB B L O B L Bep 22218 BLACK BLACK L B ter aay BLUE BLUE DARK GREEN 4 4 5 LN 1 1 YIL A Man v o by bog v piv er B W amp 8BNI 4
138. AAAAA 7 Install All removed parts NOTE For installation reverse the removal procedure EAS20570 SYNCHRONIZING THE THROTTLE BODIES NOTE Prior to synchronizing the throttle bodies the valve clearance and the engine idling speed should be properly adjusted 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand 2 Remove e Rider seat Refer to GENERAL CHASSIS on page 4 1 e Fuel tank Refer to FUEL TANK on page 7 1 3 Remove Caps 1 4 Install Vacuum gauge 1 Digital tachometer Cz Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 5 Install Fuel tank Refer to FUEL TANK on page 7 1 6 Adjust Throttle body synchronization VYYVYYYYYYYYYYYYYYYYYYYYYYYYYYYYY Basic procedure a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed Py Engine idling speed 1250 1350 r min 3 7 ENGINE b Turn the bypass air screw 1 with a white paint mark out a little and then turn it in fully NR DX WERE EOE WT 1 1 C E N Using the throttle body that has the bypass air screw with a white paint mark as the stan dard turn the bypass air screws without white paint marks in or out to the adjust the other throttle bodies NOTE If more than one throttle body has a bypass air screw with a white paint mark use the
139. AAAAAA CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free length a Out of specification Replace the valve spring Free length intake 37 47 mm 1 48 in Limit 35 60 mm 1 40 in Free length exhaust 37 67 mm 1 48 in Limit 35 79 mm 1 42 in 2 Measure Compressed valve spring force Out of specification Replace the valve spring 5 23 VALVES AND VALVE SPRINGS Installed compression spring force intake 166 00 190 00 37 32 42 71 Ib 16 93 19 37 kgf Installed compression spring force exhaust 165 00 189 00 37 09 42 49 Ib 16 83 19 27 kgf Installed length intake 32 80 mm 1 29 in Installed length exhaust 32 80 mm 1 29 in b Installed length 3 Measure Valve spring tilt a Out of specification Replace the valve spring Spring tilt intake 2 5 1 6 mm Spring tilt exhaust 2 5 1 6 mm En ANA 524320 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters 1 Check Valve lifter Damage scratches Replace the valve lift ers and cylinder head VALVES AND VALVE SPRINGS EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate e Valve stem 1 e Valve stem seal
140. ALS eite E PESO oput bote 1 12 Se c 1 12 CHECKING THE 6 1 13 SPECIAL TOOLS Gea 1 14 IDENTIFICATION IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right side of the steering head pipe MODEL LABEL The model label 1 is affixed to the frame under the passenger seat This information will be needed to order spare parts 1 1 FEATURES EAS20170 FEATURES ET2C01025 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the 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 used in the respective carburetor Despite the same volume of intake air the fuel volume requirement varies by the engine operating con ditions 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
141. AS22110 CHECKING THE REAR WHEEL DRIVE HUB 1 Check Rear wheel drive hub Cracks damage Replace Rear wheel drive hub dampers Damage wear Replace EAS22120 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check Rear wheel sprocket More than 1 4 tooth a wear rear wheel sprocket Bent teeth Replace the rear wheel sprock et Replace the b Correct 1 Drive chain roller 2 Rear wheel sprocket 2 Replace Rear wheel sprocket a Remove the self locking nuts and the rear wheel sprocket b Clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the sprocket c Install the new rear wheel sprocket Rear wheel sprocket self locking nut 100 Nm 10 0 m kg 72 ft lb NOTE Tighten the self locking nuts in stages and ina crisscross pattern 522140 ASSEMBLING THE REAR WHEEL 1 Install e Wheel bearings Oil seals Refer to ASSEMBLING THE FRONT WHEEL on page 4 8 REAR WHEEL EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE After replacing the tire wheel both the rear wheel static balance should be adjusted e Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel s
142. B Right side e Spacers e Oil seals 3 Install Damage wear Replace Swingarm pivot shaft 1 Bearings INSTALLING THE SWINGARM NOTE 1 Lubricate Tighten the swingarm pivot shaft with the damp Bearings er rod holder 24 mm 2 e Spacers i S 52222 Damper rod holder 24 2 90890 01328 Recommended lubricant YM 01328 Lithium soap based grease 2 Install E Bearing 1 Bearing 2 Bearings 3 j cA Oil seals 4 YN Installed depth of bearing ow TE 0 1 0 mm 00 04 in RTF OSS Installed depth of bearing b 4 0 mm 0 16 in 4 Install u Installed depth of oil seal Swingarm pivot shaft ring nut 1 1 0 mm 0 04 in 4 68 Swingarm pivot shaft ring nut 95 Nm 9 5 m kg 68 16 NOTE Lubricate the swingarm pivot ring nut threads and mating surfaces with lithium soap based grease Tighten the swingarm pivot shaft ring nut with the ring nut wrench 2 Ring nut wrench 90890 01507 YM 01507 Xd J Sas ci AS rn 2 M 5 2 5 Install Swingarm pivot shaft nut NOTE Lubricate the swingarm pivot shaft nut threads and mating surfaces with lithium soap based grease 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 25 Drive chain slack 35 0 45 0 mm 1 38 1 77 in 4 69
143. BLY EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload ECA13590 CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust Spring preload Adjust the spring preload with the special wrench and wrench handle included in the owner s tool kit b Turn the adjusting ring 1 in direction a or Align the desired position the adjusting ring with the position indicator 2 Direction Spring preload is increased suspen sion is harder Direction b Spring preload is decreased suspen sion is softer Spring preload adjusting positions Minimum 1 Standard 4 Maximum Rebound damping ECA13590 CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a the adjusting screw 1 in direction or D Direction turn in Rebound damping is increased sus pension is harder Direction b turn out Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Minimum 20 click s out Standard 10 click s out Maximum 3 click s out With the a
144. CHECKING THE STARTER eene 5 28 INSTALLING THE STARTER 5 28 INSTALLING THE GENERA TOR 5 29 PICKUP ROTOR REMIS 5 30 REMOVING THE PICKUP ROTOR 2 5 31 INSTALLING THE PICKUP ROTOR 5 31 ELECTRIC STARTER 5 33 CHECKING TAR TER IMO TODPU i iiio etit t 5 35 ASSEMBLING THE STARTER 5 36 5 3 REMOVING THE GEU TEE nine 5 41 CHECKING THE FRICTION PLATES eese 5 41 CHECKING THE CEUT CH PLATES 5 41 CHECKING THE CLUTCH 5 6 5 5 42 CHECKING THE CLUTCH HOUSING eee 5 43 CHECKING THE CLUTCH iam thc Bbliuts isa 5 43 CHECKING THE PRESSURE PLATE 5 43 CHECKING THE PRIMARY DRIVE 5 43 CHECKING THE PRIMARY DRIVEN 5 43 CHECKING THE PULL LEVER SHAFT AND PULL ROD 5 43 CHECKING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVE CHAIN 5 44 INSTALLING THE GUT aur va puo oS Erde e eis 5 44 5 47 CHECKING THE SHIFT SHAR T 5 49 CHECKING THE STOPPER GEV ER sr
145. D 6 Select the diagnostic code number corresponding to the fault code number by pressing the SE LECT and RESET buttons NOTE h 5 5 2 00 40 b W J Go To decrease the selected diagnostic code number press the RESET button Press the RESET button for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELECT button Press the SELECT button for 1 second or longer to automatically increase the diagnostic code numbers 7 Merify the operation of the sensor or actuator e Sensor operation The data representing the operating conditions of the sensor appears on the odometer trip meter fu el reserve trip meter stopwatch LCD Actuator operation Set the engine stop switch to CQ to operate the actuator NOTE If the engine stop switch is set to O set it to g and then set it to O again 8 Turn the main switch to OFF to cancel the diagnostic mode 8 40 Fault code table Fault code Symptom No normal signals are re ceived from the cylinder identification sensor when the engine is started or while the vehicle is being driven No normal signals are re ceived from the crankshaft position sensor Intake air pressure sensor open or short circuit detect ed Intake air pressure sensor hose system malfunction clogged or detached hose Throttle position sensor for th
146. DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear the engine will stop if the sidestand is moved down This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to OFF thereby preventing the spark plugs from producing a spark However the engine continues to run under the following conditions e The transmission is in gear the neutral switch circuit is open and the sidestand is up the sidestand switch circuit is closed The transmission is in neutral the neutral switch circuit is closed and the sidestand is down the sid estand switch circuit is open Battery Main fuse Main switch Ignition fuse Engine stop switch Ignition coil Spark plug ECU engine control unit 9 Sidestand switch 10 Relay unit diode 11 Neutral switch 12 Engine ground ee ex 8 3 27150 TROUBLESHOOTING IGNITION SYSTEM The ignition system fails to operate no spark or intermittent spark NOTE Before troubleshooting remove the following part s Rider seat Fuel tank Air filter case Canister for California only oide cowlings Bottom cowlings 1 Check the fuses Main and ignition Refer to CHECKING THE FUS ES on page 8 85 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 86 OK
147. Drive axle 2 42 COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2 43 RON Radiator inlet hose Radiator inlet pipe Thermostat outlet hose Radiator COOLING SYSTEM DIAGRAMS 2 44 COOLING SYSTEM DIAGRAMS a 2 7 aye 2 45 On OF OM co A Water pump breather hose Coolant reservoir hose Coolant reservoir Radiator Radiator outlet hose Oil cooler outlet hose Radiator outlet pipe Water jacket joint inlet hose Water pump outlet pipe Water pump inlet hose Water pump outlet hose Water pump Water jacket joint Oil cooler Oil cooler inlet hose COOLING SYSTEM DIAGRAMS 2 46 CABLE ROUTING EAS20430 CABLE ROUTING MRS O P wrx D y 1 JH T V T ai 2 Fi f LO man lt PA INE HT 06 2 47 QNO Ur Im 13 14 15 16 17 18 Front brake light switch lead Front brake fluid reservoir hose Right handlebar switch lead Clutch cable Main switch lead Left handlebar switch lead Clutch switch lead Horn lead Front brake hose Throttle cable decelerator cable Throttle cable accelerator cable Air temperature sensor lead Auxiliary light lead Headlight lead low beam Headlight relay lead on off Headlight sub wire harness Headlight relay lead dimmer Headlight lead high beam
148. E page 8 91 OK Check the entire signaling system s gt wiring Refer to CIRCUIT DIAGRAM on page 8 21 This circuit is The oil level warning light fails to come on 1 Check the oil level switch gt Refer to CHECKING THE OIL Replace the oil level switch LEVEL SWITCH on page 8 95 OK Properly connect or repair the signaling system s wiring 2 Check the entire signaling system s gt wiring Refer to CIRCUIT DIAGRAM on page 8 21 This circuit is OK The fuel level warning light fails to come on 1 Check the fuel sender gt Refer to CHECKING THE FUEL Replace the fuel pump assembly SENDER on page 8 95 Properly connect repair the signaling system s wiring 8 25 SIGNALING SYSTEM 2 Check the entire signaling system s gt wiring Properly connect or repair the signaling Refer to CIRCUIT DIAGRAM on system s wiring page 8 21 OK This circuit is OK The coolant temperature warning light fails to come on 1 Check the coolant temperature sen NG sor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 97 Replace the coolant temperature sensor 2 Check the entire signaling system s gt wiring Properly connect or repair the signaling Refer to CIRCUIT DIAGRAM on system s wiring page 8 21 OK This circuit is
149. ECKING THE SWITCHES on page 8 81 11 Check the sidestand switch Refer to CHECKING THE SWITCHES page 8 81 OK 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 81 OK 13 Check the start switch Refer to CHECKING THE SWITCHES page 8 81 OK 14 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 7 The starting system circuit is OK ELECTRIC STARTING SYSTEM gt gt gt gt gt NG gt gt 8 12 Replace the main switch Replace the right handlebar switch Replace the neutral switch Replace the sidestand switch Replace the clutch switch Replace the right handlebar switch Properly connect or repair the starting sys tem s wiring CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ee etse ZN R R eS Sa See Ss Ss Ss Ss SS es SS OS Ss SS Ss SS AS Q Br a bs RIY Br RIY 8 8 13 CHARGING SYSTEM AC magneto Rectifier regulator Main fuse Battery 1 Engine ground doma 8 14 CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged NOTE Before troubleshooting remove the following
150. Front wheel turns roughly or is loose Re place the wheel bearings e Oil seals Damage wear Replace 21960 ASSEMBLING THE FRONT WHEEL 1 Install e Wheel bearings Oil seals VV VVVVVV VV VV VV VV VV VV VV VV VV VV VV a Install the new wheel bearings and oil seals in the reverse order of disassembly EC2C01010 CAUTION Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 NOTE Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal 521970 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE e After replacing the tire wheel or both the front wheel static balance should be adjusted e Adjust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot FRONT WHEEL NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X4 mark at the bottom of the wheel c Turn the front wheel 90 so that the X4 mark is positioned as shown d Release the front wheel e When the wheel stops put an X5 mark at the bottom of the wheel f Repeat steps d thr
151. ING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Remove Left lower side cowling Left bottom cowling Refer to GENERAL CHASSIS on page 4 1 3 Place a container under the engine oil drain bolt 4 Remove e Engine oil filler cap 1 SM Do 5 Remove Engine oil drain bolt 1 along with the gasket RON 6 Drain Engine completely from the crankcase 7 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the shift arm 1 b Pull the fuel tank breather hose 2 except for California and fuel tank over flow hose 3 upward to remove them from the guide 4 Remove the oil filter cartridge 5 with an oil filter wrench 6 Z Oil filter wrench 90890 01426 YU 38411 ENGINE DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 8 Check Engine oil drain bolt gasket Damage Replace 9 Install Engine oil drain bolt along with the gasket i Engine drain bolt d Lubricate the O ring 1 of the new oil filter 43 Nm 4 3 m kg 31 16 cartridge with a thin coat of engine oil EC2C01006 10 Fill CAUTION Crankcase Make sure the O ring 1 is positioned cor with the specified amount of the recom rectly in the groove of the
152. ISASSEMBLING THE 4 7 CHECKING THE FRONT WHEEL esa sut 4 7 ASSEMBLING TFE FRONT itin 4 8 ADJUSTING THE FRONT WHEEL STATIC BALANCE 4 8 CHECKING THE FRONT BRAKE DISCS 4 9 INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS 4 9 REAR WHE E eee er eee ere 4 11 REMOVING TRE REAR WHEEL 4 14 DISASSEMBLING THE REAR WHEEL 4 14 CHECKING THE REAR WHEEL 4 14 CHECKING THE REAR BRAKE CALIPER BRACKET 4 14 CHECKING THE REAR WHEEL DRIVE 4 14 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 4 14 ASSEMBLING THE REAR 4 15 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 15 CHECKING THE REAR BRAKE 4 15 INSTALLING THE REAR WHEEL REAR BRAKE 5 4 15 FRONT BRAKE 4 17 INTRODUCTION sche Bust 4 22 CHECKING THE FRONT BRAKE DISCS 4 22 REPLACING THE FRONT BRAKE 5 4 23 REMOVING THE FRONT BRAKE 4 24 DISASSEMBLING THE FRONT BRAKE CALIPERS
153. Insert the projection on the plastic locking tie that is fastened around the wire harness into the hole in the frame Pass the neutral switch lead between the frame and the engine 2 54 CABLE ROUTING To the ECU Install both the engine ground lead terminal and the negative battery lead terminal to the crankcase with the bolt Make sure that the oil level switch lead and speed sensor lead are routed under the engine ground lead and negative battery lead the leads are positioned on top of their terminals and the terminals contact the stopper on the crankcase Position the sub wire harness 3 coupler under the wire harness To the secondary injectors Insert the projection on the plastic band into the hole in the coupler holder and then fasten the wire harness and left radiator fan motor lead with the band making sure to face the end of the band upward Pass a plastic locking tie through the hole in the coupler holder and then fasten the wire harness with the tie Face the end of the plastic locking tie inward To the radiator Either lead the left handlebar switch lead or the main switch lead may be routed on top Route the throttle cables to the right of the projection on the center air baffle plate on top of the radiator making sure not to twist them Route the clutch cable above the right air baffle plate on top of the radiator and then route it downward between the plate and the coupler
154. KING AND ADJUSTING THE STEERING HEAD 3 26 CHECKING THE FERONT 6 sat e no enean estos 3 28 ADJUSTING THE FRONT FORK LEGS eee 3 28 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 30 CHECKING THE TIRE S qvin guru ra 3 32 CHECKING THE WHEEL S 3 33 CHECKING AND LUBRICATING THE CABLES 3 34 LUBRICATING THE LEVERS MIU 3 34 LUBRICATING THE PEDALS 3 34 LUBRICATING THE SIDESTAND 3 34 LUBRICATING THE REAR SUSPENSION 3 34 ELECTRICAL SYSTEM 3 35 CHECKING AND CHARGING THE 3 35 CHECKING THE FUSES erint 3 35 REPLACING THE HEADLIGHT 3 35 ADJUSTING THE HEADLIGHT 3 35 PERIODIC MAINTENANCE EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments If followed these preventive maintenance procedures will ensure more reliable vehicle operation a long er service life and reduce the need for costly overhaul work This information applies to vehicles already in service as w
155. LED LED High beam indicator light Fuel level warning light Coolant temperature warning light Engine trouble warning light Shift timing indicator light Electric starting system System type Starter motor Model manufacturer Power output Armature coil resistance Brush overall length Limit Brush spring force Commutator diameter Limit Mica undercut depth Starter relay Model manufacturer Amperage Horn Horn type Quantity Model manufacturer Maximum amperage Coil resistance Performance Turn signal relay Relay type Model manufacturer Built in self canceling device Turn signal blinking frequency Wattage Oil level switch Model manufacturer Fuel gauge Model manufacturer Sender unit resistance full Starting circuit cut off relay Model manufacturer Headlight relay Model manufacturer ELECTRICAL SPECIFICATIONS LED LED LED LED LED Constant mesh SM14 MITSUBA 0 60 kW 0 0012 0 0022 Q at 20 C 68 F 10 0 mm 0 39 in 3 50 mm 0 14 in 7 16 9 52 25 77 34 27 0z 730 971 gf 28 0 mm 1 10 in 27 0 mm 1 06 in 0 70 mm 0 03 in 2768109 A JIDECO 180 0 Plane 1 pc YF 12 NIKKO 3 0A 1 15 1 25 Q at 20 C 68 F 105 113 dB 2m Full transistor FE246BH DENSO No 75 0 95 0 cycles min 21 23 27 W x 2 0 W 5VX SOMIC ISHIKAWA 2C0 DENSO 750 0 1100 0 Q G8R 30Y V4 OMRON ACM33211M04 MATSUSHITA 2 14 ELECTRICAL SPECIFICATIONS Fuel pump relay Model
156. LY 1 Stand the vehicle on a level surface WARNING Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove Connecting arm bolts 1 Connecting arms 2 Rear shock absorber assembly lower bolt 3 NOTE While removing the connecting arm bolts hold the swingarm so that it does not drop down Is 3 Remove Rear shock absorber assembly bracket nut 4 Rear shock absorber assembly upper bolt 2 Rear shock absorber assembly bracket 3 Rear shock absorber assembly NOTE Lower the swingarm and then remove the rear shock absorber assembly from between the swingarm and frame EAS23240 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber assembly Rear shock absorber Gas leaks oil leaks Replace the rear shock absorber assembly REAR SHOCK ABSORBER ASSEMBLY e Spring Damage wear Replace the rear shock ab sorber assembly Bushing Damage wear Replace Spacer Damage scratches Replace Bolts Bends damage wear Replace EAS23260 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Connecting arms Relay arm Damage wear Replace 2 Check Bearings Oil seals Damage pitting Replace 3 Check 4 Rear shock abso
157. NG THE AIR TEMPERATURE 8 100 IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM EAS27090 EAS27110 18 18 ENG Lg 8 v 1 gt lt 1315 6 Vg hee a Sse 1 1 1 1 ip eS 16 16 ERE jl d jl t 99 NEUEN one ota S 5 PE ees ES ae ah ds 00 m 610v18 16 z i 1 5 9 9 el TF 90 9 0 4 ol LIT T 320 IOJOJOIO NO SS3NHVH 3HIM SS3NHVH 3UIM ANS 10 3 815 HOLIMS 8 1 switch Ignition fuse Main fuse 7 Battery 11 Engine ground 13 Relay unit 16 Neutral switch 17 Sidestand switch 22 ECU engine control unit 23 Spark plug 24 Cylinder 1 ignition coil 25 Cylinder 2 ignition coil 26 Cylinder 3 ignition coil 27 Cylinder 4 ignition coil 40 Crankshaft position sensor 47 Lean angle sensor 64 Engine stop switch 8 2 IGNITION SYSTEM IGNITION SYSTEM ET2C01023 ENGINE STOPPING
158. ODIES Removing the rollover valve and canister for California only 7 0 7 kg 5 1 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Job Parts to remove Canister purge hose throttle body 4 to 3 way joint Refer to FUEL TANK on page 7 1 Refer to AIR FILTER CASE on page 7 5 Air filter case Canister purge hose throttle body 2 to 3 way 3 way joint Canister purge hose 3 way joint to canister Rollover valve Fuel tank breather hose rollover valve to canis ter NE E Canister bracket For installation reverse the removal proce dure 7 8 THROTTLE BODIES Removing the throttle body assembly Order Job Parts to remove IEEE Fuel tank Refer to FUEL TANK on page 7 1 D Air filter case i Refer to AIR FILTER CASE on page 7 5 71 Canister for California only Refer to THROTTLE BODIES on page 7 8 Refer to AIR INDUCTION SYSTEM on Air induction system cover 7 15 Throttle position sensor for throttle cable pulley coupler 1 Disconnect ______ Fuel hose primary injector fuel rail to second 1 ary injector fuel rail 7 Fuel hose fuel tank to primary injector fuel rail Throttle cable decelerator cable red Throttle cable accelerator cable 4 Throttle body assembly 11 Throttle body joint clamp 7 9 THROTTLE BODIES Removing the
159. OTE Refer to CAMSHAFTS page 5 7 When removing the timing chain and cam shafts fasten the timing chain with a wire to re trieve it if it falls into the crankcase 6 Adjust e Valve clearance Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 2 Valve lapper 2 90890 04101 Valve lapping tool YM A8998 NOTE Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be in stalled in the correct place Calculate the difference between the speci fied valve clearance and the measured valve clearance Example Specified valve clearance 0 11 0 20 mm 0 004 0 008 in Measured valve clearance 0 23 mm 0 009 in 0 23 mm 0 009 in 0 20 mm 0 008 in 0 03 mm 0 001 in Check the thickness of the current valve pad NOTE The thickness of each valve pad is marked in hundredths of millimeters on the side that touch es the valve lifter Example If the valve pad is marked 155 the pad thickness is 1 55 mm 0 061 in d Calculate the sum of the values obtained in steps b and c to determine the required valve pad thickness and the valve pad num ber Example 1 55 mm 0 061 in 0 03 0 001 in
160. OTE e Stack the springs on top of each other making sure that the tab a on each spring is in a dif ferent position e Fit the tabs a on the springs into the grooves b in the clutch boss plate 4 Tighten e Clutch boss nut 1 Clutch boss nut 115 Nm 11 5 m kg 85 ft lb NOTE While holding the clutch boss 2 with the uni versal clutch holder 3 tighten the clutch boss nut e Stake the clutch boss nut at a cutout in the main axle Universal clutch holder 90890 04086 YM 91042 90 2 5 Lubricate Friction plates e Clutch plates with the recommended lubricant Recommended lubricant Engine oil 6 Install Friction plates Clutch plates NOTE First install a friction plate and then alternate between a clutch plate and a friction plate Install the last friction plate 1 offset from the other friction plates 2 making sure to align projection on the friction plate with the punch mark on the clutch housing bt 50 A 594 lt omy AS p ea 2 pu 7 Install Pressure plate 1 NOTE a f Align the punch marks the pressure with one of the three punch marks b in the clutch boss 5 45 CLUTCH 8 Install Seat plate Clutch springs Clutch spring bolts NOTE Tighten the clutch spring bolts in stages and
161. P SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate NOTE Before troubleshooting remove the following part s 1 Rider seat 2 Fuel tank 3 Side cowlings 1 Check the fuses NG Main ignition and fuel injection system Replace the fuse s Refer to CHECKING THE FUS ES on page 8 85 OK Check the battery gt Refer to CHECKING AND CHARGING THE BATTERY on page 8 86 OK Clean the battery terminals Recharge or replace the battery Check the main switch gt Refer to CHECKING THE SWITCHES on page 8 81 Replace the main switch 4 Check the engine stop switch NG gt Refer to CHECKING THE Replace the right handlebar switch SWITCHES page 8 81 OK Check the relay unit fuel pump re NG lay Refer to CHECKING THE RE LAYS on page 8 89 Replace the relay unit 6 Check the fuel pump gt Refer to CHECKING THE FUEL Replace the fuel pump PUMP page 8 98 OK Check the entire fuel pump sys NG tem s wiring Properly connect or repair the fuel pump Refer to CIRCUIT DIAGRAM on page 8 73 OK Replace the ECU system s wiring 8 75 FUEL PUMP SYSTEM 8 76 ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8 77 Main switch Front brake light switch Clutch switch Battery Fuse box backup ETV Main fuse Fue
162. R 1 Check Primary driven gear 1 Damage wear Replace the clutch housing and crankshaft as a set Excessive noise during operation gt Replace the clutch housing and crankshaft as a set 1 525220 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check Pull lever shaft pinion gear teeth 1 Pull rod teeth 2 Damage wear Replace pull rod and pull lever shaft pinion gear as a set 2 Check Bearing Damage wear Replace ET2C01011 CHECKING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVE CHAIN 1 Check Oil pump drive sprocket Cracks damage wear Replace the clutch housing oil pump drive chain and oil pump driven sprocket as a set 2 Check Oil pump drive chain Damage stiffness Replace the clutch housing oil pump drive chain and oil pump driven sprocket as a set INSTALLING THE CLUTCH 1 Install Oil pump drive chain 1 Clutch housing 2 NOTE Install the oil pump drive chain onto the clutch housing and then install the chain onto the oil pump driven sprocket while installing the clutch housing onto the main axle Make sure that the oil pump drive chain passes through the oil pump drive chain guide 2 Install Clutch boss plate 1 Clutch boss 2 CLUTCH NOTE Fit the projections a on the clutch boss into the grooves b in the clutch boss plate 3 Install Springs 1 N
163. R S 4 42 CHECKING THE 6 4 42 INSTALLING THE 4 42 FRONT FORK qmm 4 44 REMOVING THE FRONT FORK LEGS eee 4 47 DISASSEMBLING THE FRONT 4 47 CHECKING THE FRONT FORK LEGS iO 4 48 ASSEMBLING THE FRONT FORK eene 4 49 INSTALLING THE FRONT FORK 5 02 04 4 53 STEERING HEAD ia 4 55 REMOVING THE LOWER 4 58 CHECKING THE STEERING EAD 4 58 INSTALLING THE STEERING HEAD 4 58 REAR SHOCK ABSORBER ASSEMBLY 4 60 HANDLING THE REAR SHOCK 4 62 DISPOSING OF A REAR SHOCK ABSORBER 4 62 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 62 CHECKING THE CONNECTING ARM AND RELAY ARM 4 63 INSTALLING EHE RELA VARM 4 63 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 SWINGARM m 4 65 REMOVING THE SWINGARM 4 6
164. RES ET2C01019 SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa 3 24 kg cm 46 1 psi Accordingly when the energizing signal from the ECU energizes the fuel injector the fuel passage opens causing the fuel to be injected into the intake manifold only during the time the passage remains open There fore the longer the length of time the fuel injector is energized injection duration the greater the vol ume of fuel that is supplied Conversely the shorter the length of time the fuel 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 for throttle cable pulley throttle position sensor for throttle valves coolant temperature sensor atmospheric pressure sensor cylinder identification sensor lean angle sensor crankshaft position sensor intake air pressure sensor air temperature sensor speed sensor and O sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position 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 1 Secondary injector 12 Catalytic convert
165. Radiator Refer to RADIATOR on page 6 1 Bottom cowlings e Side cowlings Refer to GENERAL CHASSIS on page 4 1 EAS20730 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface NOTE e Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Remove Dipstick 1 4 Check Engine oil level The engine oil level should be between the minimum level mark and maximum level mark Below the minimum level mark Add the recommended engine oil to the proper level NOTE Before checking the engine oil level wait a few minutes until the oil has settled Do not screw the dipstick in when inspecting the oil level yp YAMALUBE 4 SAE10W30 SAE20W40 Recommended engine oil grade API service SF SG type or higher ACEA standard G4 or G5 0 30 a s aC ter YAMALUBE 4 10W30 or SAE 10W30 1 pe 1 1 YAMALUBE 4 20W40 or SAE 20W40 20 10 0 10 20 30 40 50 C 5 Start the engine warm it up for several min utes and then turn it off 6 Check the engine oil level again NOTE Before checking the engine oil level wait a few minutes until the oil has settled 7 Install Dipstick ENGINE EAS20780 CHANG
166. Refer to AIR FILTER CASE on page 7 5 Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21030 CHECKING THE FUEL LINE The following procedure applies to all of the fuel vacuum and breather hoses 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 e Fuel tank Refer to FUEL TANK on page 7 1 2 Check Fuel hoses 1 e Vacuum hoses e Overflow hose 2 ENGINE e Breather hose 3 except for California Cracks damage Replace Loose connection gt Connect properly ECA14940 CAUTION Make sure the fuel tank breather hose is rout ed correctly 3 Install e Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21070 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove e Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 2 Check e Crankcase breather hose 1 Cracks damage Replace Loose connection gt Connect properly ECA13450 CAUTION Make sure the crankcase breather hose is routed correctly 3 Install e Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipe assembly and gaskets 1 Remove Side cowlings Bottom cowlings Refer to
167. Repair or replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler yellow blue yellow blue Malfunction in meter assembly Replace the meter assembly Malfunction in ECU Replace the ECU Fault code No Eras Symptom Data from the ECU cannot be received correctly Reinstatement method Connections Check the couplers for any pins Turning the Main wire harness ECU coupler that may be pulled out main switch to e Main wire harness meter assembly Check the locking condition of ON coupler the couplers f there is a malfunction repair it and connect the coupler se Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler yellow blue yellow blue Malfunction in meter assembly Replace the meter assembly Malfunction in ECU Replace the ECU 8 70 FUEL INJECTION SYSTEM Fault code No Er 4 Symptom Non registered data has been received from the meter Reinstatement method Connections e Check the couplers for any pins Turning the e Main wire harness ECU coupler that may be pulled out main switch to Main wire harness meter assembly Check the locking condition of ON coupler the couplers f there is a malfunction repair it and connect the coupler se Open or short circuit in wire harness Repair or replace if ther
168. SWINGARM CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain 85 Nm 8 5 kg 61 ft Ib 10 Nm 1 0 kg 7 2 ft Ib Job Parts to remove Q ty Left lower side cowling to GENERAL CHASSIS page Left bottom cowling ET to GENERAL CHASSIS on page sites RES on page E ie ean aie S Fea COCO For installation reverse the removal dure Gd N 145 4 70 23410 REMOVING THE DRIVE CHAIN 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove e Drive chain with the drive chain cutter NOTE Only cut the drive chain if it or the swingarm is to be replaced EAS23440 CHECKING THE DRIVE CHAIN 1 Measure e 15 link section of the drive chain Out of specification Replace the drive chain 15 link length limit 239 3 mm 9 42 in a Measure the length between the inner sides of the pins and the length b between the outer sides of the pins on a 15 link section of the drive chain as shown in the illustration
169. Steering head tension 200 500 g e Repeat the above procedure on the opposite handlebar f Ifthe steering head tension is out of specifica tion both handlebars should be within speci fication remove the upper bracket and loosen or tighten the lower ring nut g Reinstall the upper bracket and measure the steering head tension again as described above h Repeat the above procedure until the steer ing head tension is within specification i Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 21530 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube 1 Damage scratches Replace Oil seal 2 Oil leakage Replace CHASSIS 7 3 Hold the vehicle 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 on page 4 44 EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs EW2C01006 Always adjust both front fork legs evenly Uneven adjustment can result in poor han d
170. TION 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 trouble shooting Refer to the relative procedure in this manual for checks adjustments and replace ment of parts EAS28470 STARTING FAILURES Engine 1 Cylinder s and cylinder head Loose spark plug Loose cylinder head Damaged cylinder head gasket Worn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve to valve seat contact Incorrect valve timing e Faulty valve spring e Seized valve 2 Piston s and piston ring s Improperly installed piston ring Damaged worn or fatigued piston ring e Seized piston ring Seized or damaged piston 3 Air filter Improperly installed air filter Clogged air filter element 4 Crankcase and crankshaft Improperly assembled crankcase e Seized crankshaft Fuel system 1 Fuel tank e Empty fuel tank Clogged fuel tank drain hose Clogged rollover valve for California only Clogged rollover valve hoses for California only Deteriorated or contaminated fuel 2 Fuel pump Faulty fuel pump e Faulty fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air 9 1 TROUBLESHOOTING Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly instal
171. UNIT DIODE sees 8 91 CHECKING THE JONLIHON COILS 8 92 CHECKING THE CRANKSHAFT POSITION SENSOR 8 93 CHECKING THE LEAN ANGLE 8 93 CHECKING THE STARTER MOTOR 8 93 CHECKING THE STATOR CO 8 94 CHECKING THE RECTIFIER REGULATOR esee 8 94 CHEOKING THE HORN eirinen a 8 95 CHECKING THE OIL LEVEL SWITCH 8 95 CHECKING THE FUEL SENDER EEA 8 95 CHECKING THE SPEED SENSO PR sinu ten REFER EN SRERK Sape EDU QI ep 8 96 CHECKING THE RADIATOR FAN 8 96 CHECKING THE COOLANT TEMPERATURE SENSOR 8 97 CHECKING THE THROTTLE POSITION SENSOR FOR THROTICE VALVES 8 97 CHECKING THE THROTTLE POSITION SENSOR FOR THRO TIRE GABLE PULLE Y dotes 8 98 CHECKING THE FUEL PUMP Ret 8 98 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 8 99 CHECKING THE ATMOSPHERIC PRESSURE 8 99 CHECKING THE CYLINDER IDENTIFICATION SENSOR 8 100 CHECKING THE INTAKE AIR PRESSURE SENSOR 8 100 CHECKI
172. XUP valve pulley and ca Replace if defective bles 8 53 FUEL INJECTION SYSTEM Fault code No Symptom Open circuit is detected in the input lead from the side stand switch to the ECU Diagnostic code No 0 Sidestand switch Reinstatement method Connections e Execute the diagnostic mode If the transmis Main wire harness ECU coupler Code No 20 sion is in gear Check the coupler for any pins retracting the that may be pulled out sidestand Check the locking condition of If the transmis the coupler sion is in neu f there is a malfunction repair it tral and connect the coupler se reconnecting the wiring Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between ECU coupler and main switch coupler blue black blue black Between main switch coupler and relay unit coupler blue yellow blue yellow Between relay unit coupler and sidestand switch coupler blue black blue black Between sidestand switch cou pler and engine ground black black Defective sidestand switch Replace if defective Refer to CHECKING THE SWITCHES on page 8 81 Fault code No Symptom When the main switch is turned to ON the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ greatly Diagnostic code No Intake air pressure sensor Atmospheric pressure sensor Item components and proba
173. a piece of Plastigauge shaft pin on crank DA d Assemble the connecting rod halves NOTE Do not move the connecting rod or crankshaft until the clearance measurement has been completed e Lubricate the bolt threads and nut seats with molybdenum disulfide grease Make sure the Y mark c on the connecting rod faces towards the left side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned e Tighten the connecting rod nuts Refer to INSTALLING THE CONNECTING RODS AND PISTONS on page 5 64 f Remove the connecting rod and big end bearings Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 60 g Measure the compressed Plastigauge width e on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select re placement big end bearings CONNECTING RODS AND PISTONS 2 Select Big end bearings 4 NOTE The numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes P P refer to the bearings shown in the crank shaft illustration For example if the connecting rod P4 and the crankshaft web numbers are 5 1 re spectively then th
174. adjustments made by the rider In par ticular optimized control of the throttle valve opening provides the optimum volume of intake air for easy to use torque even in a high revving engine Aims and advantages of using YCC T Increased engine power By shortening the air intake path higher engine speed is possible Increased engine power Improved driveability Air intake volume is controlled according to the operating conditions Improved throttle response to meet engine requirement Driving force is controlled at the optimal level according to the transmission gear position and engine speed Improved throttle control Engine braking control Due to the throttle control optimal engine braking is made possible e Simplified idle speed control ISC mechanism The bypass mechanism and ISC actuator are eliminated A simple mechanism is used to maintain a steady idle speed Reduced weight Compared to using a sub throttle mechanism weight is reduced A 1 2 7 24 9755 mLAN ae fi Ore 3 E Throttle position sensor for throttle cable pulley Throttle servo motor Throttle position sensor for throttle valves Throttle valves Throttle cable pulley with linkage guard To throttle grip gt WP 1 4 system outline Oe I a Vg 2 3 1 E A
175. age 4 1 21140 CHASSIS EAS21150 ADJUSTING THE FRONT DISC BRAKE 1 Adjust Brake lever position distance from the throttle grip to the brake lever Push the brake lever forward Turn the adjusting knob 1 in direction a b a Or b until the brake lever is in the desired posi tion Direction Brake lever distance is increased Direction b Brake lever distance is decreased the mark d on the brake lever EWA13050 A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance Align the mark c on the adjusting knob with 3 21 CHASSIS ECA13490 CAUTION After adjusting the brake lever position make sure there is no brake drag DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ADJUSTING THE REAR DISC BRAKE 1 Adjust Brake pedal position Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained Direction Brake pedal is raised Direction b Brake pedal is lowered EWA13070 After adjusting the brake pedal
176. air or replace the bulb bulb socket or both Types of bulbs The bulbs used on this vehicle are shown in the following illustration Bulbs and b are used for the headlights and usually use a bulb holder that must be de tached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them coun terclockwise Bulbs c are 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 indi cator lights and can be removed from their re spective socket by carefully pulling them out Checking the condition of the bulbs The following procedure applies to all of the bulbs A 2 ELECTRICAL COMPONENTS 1 Remove e Bulb EW2C01001 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down EC2C01002 CAUTION Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a 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 adverse ly affected If a headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner
177. als to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Recommended fluid DOT 4 ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM page 3 24 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 on page 3 22 FRONT BRAKE eLOWER 17 23 24 SEO O BY 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM page 3 24 4 28 REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 5 Nm 0 5 m kg 3 6 ft Ib 27 Nm 2 7 m kg 19 ft Ib 1 22 Nm 2 2 kg 16 ft Ib 17 Nm 1 7 kg 12 ft Ib 2 Nm 0 2 m kg 1 4 ft Ib Ou _ 3 Oe 2
178. amage these O rings Therefore use only kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings Recommended lubricant Engine oil or chain lubricant suitable for O ring chains EAS21500 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check e Steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove Upper bracket Refer to STEERING HEAD on page 4 55 3 26 4 Adjust e Steering head Remove the lock washer 1 upper ring nut 2 and rubber washer 3 b Loosen the lower ring nut 4 and then tighten it to specification with a steering nut wrench D Steering nut wrench 90890 01403 Spanner wrench YU 33975 Lower ring nut initial tightening torque 52 Nm 5 2 m kg 37 ft lb NOTE Set the torque wrench at a right angle to the steering nut wrench c Loosen the lower ring nut completely then tig
179. ant lt lt 6 lt lt lt onto the crankshaft position sensor lead grommet Yamaha bond No 1215 90890 85505 Three Bond 12159 5 31 PICKUP ROTOR 5 32 ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor jArfilercase Refer to AIR FILTER CASE page 7 5 Canister for California Refer to THROTTLE BODIES on page 7 8 1 Siartermotortead 8 Siartermotorassemby Y dure 5 33 ELECTRIC STARTER Disassembling the starter motor Job Parts to remove Lock washer Oil seal Washer set Starter motor yoke 1 Brush holder along with the brushes For assembly reverse the disassembly pro cedure lt 5 34 24790 CHECKING THE STARTER MOTOR 1 Check Commutator Dirt Clean with 600 grit sandpaper 2 Measure Commutator diameter 1 Out of specification Replace the starter motor Limit 27 0 mm 1 06 in 3 Measure Mica undercut Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator Mica undercut depth 0 70 mm 0 03 in The mica of the commutator must be undercut to ensure proper operation of the commutator 4 Measure e Armature assembly resistances commutator and insulation Out of specification Replace
180. ap Radiator cap opening pressure 107 9 137 3 kPa 15 6 19 9 psi 1 08 1 37 kgf cm a Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 6 3 RADIATOR b Apply the specified pressure for ten seconds and make sure there is no drop in pressure DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 Check e Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 29 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure e Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 COOLER EAS26410 COOLER Removing the oil cooler 10 Order Job Parts to remove Drain Engine oil Refer to CHANGING THE ENGINE OIL on page 3 11 Drain Coolant Refer to CHANGING THE COOLANT on page 3 19 Exhaust pipe assembly Refer to ENGINE REMOVAL page 5 1 1 Oil cooler
181. are aligned with the cylinder head edge 0 Be sure to install the timing chain so that the exhaust side of the chain is taut and the intake side is slack OX E Re a 3 Install Intake camshaft caps Exhaust camshaft caps NOTE e Make sure each camshaft cap is installed in its original place Refer to the identification marks as follows 42 Intake E1 E2 Exhaust Make sure the arrow mark on each cam shaft points towards the right side of the en gine E2 E1 1 1 1 CAMSHAFTS a a UE S Ten ES e 4 Install Camshaft cap bolts Camshaft cap bolt 10 Nm 1 0 m kg 7 2 ft lb ECA13730 CAUTION The camshaft cap bolts must be tightened evenly or damage to the cylinder head cam shaft caps and camshafts will result ge a NOTE Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out 5 Install Timing chain tensioner gasket 1 e Timing chain tensioner 2 Timing chain tensioner bolt 12 Nm 1 2 m kg 8 7 ft lb NOTE Be sure to install the timing chain tensioner gasket so that its section with the L mark a is protruding from the lower left side of the tim ing chain tensi
182. as shown and torque them in two stages b E E id hy eu 5 17 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Refer to CYLINDER HEAD on page 5 15 M ____ ME 2 0 2 For installation reverse the removal proce dure x gt D E n e lt a lt o 5 5 18 24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components NOTE Before removing the internal parts of the cylinder head e g valves valve springs valve seats make sure the valves properly seal 1 Remove Valve lifter 1 Valve pad 2 NOTE Make note the position of each valve lifter and valve pad so that they can be reinstalled in their original place w A N 2 2 Check Valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS on page 5 21 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 6 777 3 Remove e Valve cot
183. at there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Remove Left brake caliper Right brake caliper NOTE Do not apply the brake lever when removing the brake calipers EAS21910 DISASSEMBLING THE FRONT WHEEL 1 Remove Oil seals Wheel bearings Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface 5 Remove the wheel bearings 3 with a gener al bearing puller FRONT WHEEL EAS21920 CHECKING THE FRONT WHEEL 1 Check e Wheel axle Roll the wheel axle on a flat surface Bends Replace EWA13460 Do not attempt to straighten a bent wheel ax le U 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 33 3 Measure e 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 ge TU d Ip 4 Check e Wheel bearings
184. ather hose Cracks damage wear Replace EAS26590 INSTALLING THE WATER PUMP 1 Install Water pump assembly 1 e O ring 2 NOTE Align the slit on the impeller shaft with the projection b on the oil pump shaft Lubricate the O ring with a thin coat of lithium soap based grease amm 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 3 Check Cooling system Leaks Repair or replace the faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 6 10 WATER PUMP 6 11 WATER PUMP FUEL SYSTEM FUECTANK ee M 7 1 REMOVING THE FUEL DANI 7 3 REMOVING THE FEE PUMP tet beds iu eR 7 3 CHECKING THE F EE PUMIP BODY ies 7 3 CHECKING THE FUEL PUMP 7 3 INSTALEING THE FUEL 55 7 3 INSTALLING TAE 7 4 FILTER Mc 7 5 REMOVING THE FUEL HOSE PRIMARY INJECTOR FUEL RAIL TO SECONDARY INJECTOR FUEL 7 7 CHECKING THE SECONDARY INJECTORS eese 7
185. b Check the charge of the battery as shown in the charts and the following example Example Open circuit voltage 12 0 V Charging time 6 5 hours Charge of the battery 20 30 Open circuit voltage V Charging time hours Relationship between the open circuit voltage and the charging time at 20 C 68 F These values vary with the temperature the condition of the battery plates and the electrolyte level OU A Open circuit voltage V B Charging condition of the battery C Ambient temperature 20 C 68 F DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 5 Charge Battery refer to the appropriate charging method il lustration EWA13300 Do not quick charge a battery ECA13670 CAUTION Never remove the MF battery sealing caps 8 87 ELECTRICAL COMPONENTS Do not use a high rate battery charger since it forces a high amperage current into the battery quickly and can cause bat tery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overcharge the battery When charging a battery be sure to remove it from the vehicle If charging has to be done with the battery mounted on the vehi cle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery
186. beless 180 55 ZR17M C 73W DUNLOP D209PT 1 0 mm 0 04 in 0 90 kg 0 198 Ib 250 kPa 36 psi 2 50 kgf cm 250 kPa 36 psi 2 50 kgf cm 90 193 kg 198 425 Ib USA 90 192 kg 198 423 Ib California 250 kPa 36 psi 2 50 kgf cm 290 kPa 42 psi 2 90 kgf cm 250 kPa 36 psi 2 50 kgf cm 250 kPa 36 psi 2 50 kgf cm Dual disc brake Right hand operation 310 0 x 4 5 mm 12 20 x 0 18 in Brake disc thickness limit Brake disc deflection limit Brake pad lining thickness inner Limit Brake pad lining thickness outer Limit Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Rear brake Type Operation Rear disc brake Disc outside diameter x thickness Brake disc thickness limit Brake disc deflection limit Brake pad lining thickness inner Limit Brake pad lining thickness outer Limit Master cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Steering Steering head tension Steering bearing type Lock to lock angle left Lock to lock angle right Front suspension Type Spring shock absorber type Front fork travel Fork spring free length Limit Collar length Installed length Spring rate K1 Spring stroke K1 Inner tube outer diameter Inner tube bending limit Optional spring available Recommended oil Quantity Level Rear suspension Type Spring shock absorber type Rear shock absorber assem
187. ble Check or maintenance job Reinstatement cause method 1 Defective intake air pressure sensor Execute the diagnostic mode Turning the or atmospheric pressure sensor Code Nos 03 02 main switch to Replace if defective ON Refer to CHECKING THE IN TAKE AIR PRESSURE SEN on page 8 100 or CHECKING THE ATMO SPHERIC PRESSURE SEN page 8 99 8 54 FUEL INJECTION SYSTEM Fault code No il Symptom Coolant temperature sensor open or short circuit detect ed Diagnostic code No 06 Coolant temperature sensor Item components and probable Check or maintenance job Reinstatement cause method Connections Check the couplers for any pins Reinstated au Coolant temperature sensor coupler that may be pulled out tomatically if a e Main wire harness ECU coupler Check the locking condition of normal signal is the couplers received f there is a malfunction repair it and connect the coupler se curely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between coolant temperature sensor coupler and ECU cou pler green white green white black blue black blue Defective coolant temperature sensor Execute the diagnostic mode Code No 06 Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 97 Fault code No 22 Symptom Air temperature sensor open o
188. bly travel CHASSIS SPECIFICATIONS 4 0 mm 0 16 in 0 10 mm 0 0039 4 5 mm 0 18 in 0 5 mm 0 02 in 4 5 mm 0 18 in 0 5 mm 0 02 in 16 00 mm 0 63 in 30 23 mm x 1 1 19 in x 1 27 00 mm x 1 1 06 in x 1 DOT 4 oingle disc brake Right foot operation 220 0 x 5 0 mm 8 66 x 0 20 in 4 5 mm 0 18 in 0 15 mm 0 0059 in 6 0 mm 0 24 in 1 0 mm 0 04 in 6 0 mm 0 24 in 1 0 mm 0 04 in 12 7 mm 0 50 in 38 18 mm 1 50 in DOT 4 200 500 g Angular bearing 25 0 25 0 Telescopic fork Coil spring oil damper 120 0 mm 4 72 in 247 0 mm 9 72 in 242 1 mm 9 53 in 80 0 mm 3 15 in 240 0 mm 9 45 in 8 80 N mm 50 25 Ib in 0 90 kgf mm 0 0 120 0 mm 0 00 4 72 in 41 0 mm 1 61 in 0 2 mm 0 01 in No Ohlins amp 43 ACC RT43F 00 00 465 0 cm 15 72 US oz 16 37 Imp oz 108 0 mm 4 25 in Swingarm link Suspension Coil spring gas oil damper 60 0 mm 2 36 in Spring free length Installed length Spring rate K1 Spring stroke K1 Optional spring available Enclosed gas air pressure STD Swingarm Swingarm end free play limit radial Swingarm end free play limit axial Drive chain Type manufacturer Link quantity Drive chain slack 15 link length limit CHASSIS SPECIFICATIONS 163 5 mm 6 44 in 152 5 mm 6 00 in 98 00 N mm 559 58 Ib in 9 99 kgf mm 0 0 60 0 mm 0 00 2 36 1200 kPa 170 7 psi 12 0 kgf cm 1 0 mm 0 04 in 1
189. brake hose joint opening to force out the piston from the brake caliper EWA13550 Cover the brake caliper piston with rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton CN E 2 b ON ES 2 VJ A 7 BS 2 2042 j N b Remove the brake caliper piston seals DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS22640 CHECKING THE REAR BRAKE CALIPER Recommended brake component replace ment schedule Brake pads If necessary Every two years and whenever the brake is disassembled Brake fluid 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly REAR BRAKE Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air EWA13610 WARNING Whenever brake caliper is disassembled replace the brake caliper piston seals LO 2 Check Brake caliper bracket 1 Cracks damage Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on in
190. ce Bends Replace WARNING Do not attempt to straighten bent shift fork guide bar 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 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Damage wear Replace the shift drum as sembly 5 76 Shift drum bearing 2 Damage pitting Replace the shift drum as sembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle Main axle runout limit 0 02 mm 0 0008 in 2 Measure e Drive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle Drive axle runout limit 0 02 mm 0 0008 in 3 Check e Transmission gears Blue discoloration pitting wear Replace the defective gear s TRANSMISSION e Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect gt Reassemble the transmission axle assemblies 5 Check e Transmission gear movement Rough movement Replace the defective part s 6 Check Circlips Bends damag
191. continuity with the pocket tester If the continuity reading is incorrect check the wiring connections and if necessary replace the switch ECA14370 CAUTION Never insert the tester probes into the coupler terminal slots a Always insert the probes from the opposite end of the coupler taking care not to loosen or damage the leads Pocket tester 90890 03112 Analog pocket tester YU 03112 C NOTE Before checking for continuity set the pocket tester to 0 and to the Q x 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch position is indication by O _ There is continuity between red and brown blue blue yellow and blue black when the switch is set to ON 8 83 27990 CHECKING THE BULBS AND BULB SOCKETS NOTE Do not check any of the lights that use LEDs Check each bulb and bulb socket for damage or wear proper connections and also for continuity between the terminals Damage wear Repair or replace the bulb bulb socket or both Improperly connected Properly connect No continuity Rep
192. cowlings Bottom cowlings Rear cowling 1 Check the fuses gt Main ignition and signaling sys tem Replace the fuse s Refer to CHECKING THE FUS ES on page 8 85 OK Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 86 Clean the battery terminals Recharge or replace the battery Check the main switch 9 Refer to CHECKING THE SWITCHES on page 8 81 Replace the main switch 4 Check the entire signaling system s gt wiring Properly connect or repair the signaling Refer to CIRCUIT DIAGRAM on system s wiring page 8 21 Check the condition of each of the sig naling system s circuits Refer to Checking the signaling system Checking the signaling system The horn fails to sound 1 Check the horn switch NG Refer to CHECKING THE SWITCHES page 8 81 OK 2 Check the horn gt Refer to CHECKING THE HORN Replace the left handlebar switch Replace the horn on page 8 95 8 23 SIGNALING SYSTEM 3 Check the entire signaling system s gt wiring Properly connect or repair the signaling Refer to CIRCUIT DIAGRAM on system s wiring page 8 21 OK This circuit is OK The brake light fails to come on 1 Check the front brake light switch gt Refer to CHECKING THE SWITCHES
193. current is higher than the standard charging current written on the bat tery NOTE If the current is lower than the standard charging current written on the battery set the charging voltage adjust dial at 20 24 V and monitor the amperage for 3 5 minutes to check the battery e Standard charging current is reached Battery is good e Standard charging current is not reached Replace the battery d Adjust the voltage so that the current is at the standard charging level e Set the time according to the charging time suitable for the open circuit voltage f If charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current g Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery Charging method using constant volt age charger a Measure the open circuit voltage prior to charging 8 88 ELECTRICAL COMPONENTS NOTE Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and
194. d start counting the distance traveled from that point In that case push the SELECT button to switch the display between the various tripme ter odometer and stopwatch modes in the fol lowing order F TRIP Stopwatch TRIP A gt TRIP B gt ODO F TRIP Toreseta tripmeter select it by pushing the SE LECT button and then push the but ton 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 Stopwatch mode To change the display to the stopwatch mode select it by pushing the SELECT button The stopwatch digits will start flashing Release the FEATURES SELECT button and then push it again for a few seconds until the stopwatch digits stop flashing Standard measurement 1 Push the RESET button to start the stop watch 2 Push the SELECT button to stop the stop watch 3 Push the SELECT button again to reset the stopwatch Split time measurement 1 Push the RESET button to start the stop watch 2 Push the RESET button or start switch to measure split times The colon 77 will start flashing 3 Push the RESET button or start switch to display the final split time or push the SE LECT button to stop the stopwatch and dis play total elapsed time 4 Push the
195. djusting screw fully turned in 3 31 CHASSIS gt p x 569598 gt Nee 6 Ne Trea 2 MAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Compression damping ECA13590 CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust Compression damping fast compression damping a the adjusting screw 1 in direction a or Direction turn in Compression damping is increased suspension is harder Direction b turn out Compression damping is decreased suspension is softer Compression damping adjusting positions fast compression damp ing Minimum 16 click s out Standard 7 click s out Maximum 1 click s out With the adjusting screw fully turned in 2 Adjust Compression damping slow compression damping a the adjusting screw 1 in direction Or Direction a turn Compression damping is increased suspension is harder Direction b turn out Compression damping is decreased suspension is softer Compression damping adjusting positions slow compression damping Minimum 24 click s out Standard 15 click s out Maximum 1 click s out
196. e 5 40 25070 REMOVING THE CLUTCH 1 Remove Friction plates e Clutch plates NOTE Be sure to mark the friction plates and clutch plates or note the position of each part so that they are installed in their original positions 2 Loosen Clutch boss nut 1 NOTE While holding the clutch boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut Universal clutch holder 90890 04086 YM 91042 3 Remove Spacer 1 Bearing Clutch housing 2 Oil pump drive chain NOTE Remove the spacer and bearing from the main axle then remove the oil pump drive chain from the oil pump driven sprocket and then remove the clutch housing and oil pump drive chain from the main axle CLUTCH EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places Friction plate thickness 2 92 3 08 mm 0 115 0 121 Wear limit 2 80 mm 0 1102 in EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check e Clutch plate Damage Replace the clutch plates as a set 2 Measure
197. e Right handlebar switch lead Throttle cable accelerator cable Throttle cable decelerator cable Front brake hose Headlight sub wire harness Coolant reservoir hose Front right turn signal position light lead Coolant reservoir breather hose Clutch cable Radiator outlet hose Water pump outlet hose Water pump breather hose EXUP cables O sensor lead Rear brake light switch lead Rear brake fluid reservoir hose Rear brake hose Headlight sub wire harness 2 Headlight sub wire harness 1 Right radiator fan motor sub wire harness Right handlebar switch lead Fasten the EXUP cables EXUP servo motor lead and rear brake light switch lead with a plastic locking tie making sure to fasten the tie on the metal tubes around the cables 0 20 mm 0 0 79 in from the ends of the tubes Face the end of the plastic locking tie rearward and then cut off the excess end of the tie to 2 4 mm 0 08 0 16 in Route the wire harness on top of the heat protector making sure to push the harness inward so that it does not protrude past the frame To the front right turn signal position light Route the coolant reservoir breather hose between the radiator and the coolant reservoir then to the outside of the damper on the radiator Fasten the clutch cable with the holder making sure that the metal band around the cable is above the holder Cross the coolant reservoir breather hose and clutch cable and then fasten them w
198. e bearing size for P is P4 connecting rod crankshaft 5 64 Bearing color code 1 Blue 2 Black 3 Brown 4 Green EAS26170 INSTALLING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the pis tons and connecting rods 1 Install Top ring 1 2nd ring 2 Upper oil ring rail 3 Oil ring expander 4 Lower oil ring rail 5 NOTE Be sure to install the piston rings so that the manufacturer s marks or numbers face up 2 Install Piston 1 onto the respective connecting rod 2 Piston pin 3 Piston pin clips 4 NOTE e Apply engine oil onto the piston pin Make sure that the Y mark on the connect ing rod left when the punch mark b on the pis ton is pointing up Refer to the illustration Install the piston pin clips so that the clip ends are 3 mm 0 12 in c or more from the cutout in the piston Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Offset e Piston ring end gaps 90 ring Upper oil ring rail Oil ring expander 2nd ring Lower oil ring rail Exhaust side gt 4 Lubricate e Piston e Piston rings Cylinder with the recommended lubricant Recommended lubricant 6 Engine oil CONNECTING RODS AND PISTONS Recommended lubricant Molybdenum disulfide oil
199. e correct position otherwise the fuel hose will not be properly installed 7 4 FUEL TANK NOTE Install the fuel hose securely onto the fuel pump until a distinct click is heard To install the fuel hose onto the fuel pump slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown gt AIR FILTER CASE ET2C01003 AIR FILTER CASE Removing the air filter case and secondary injectors 2 11 5 Nm 0 15 kg 1 08 ft Ib 5 Nm 0 5 m kg 3 6 ft Ib 2 Nm 0 2 m kg 1 4 ft Ib 4 Nm 0 4 kg 2 9 ft Ib 9 4 Sub wire harness 3 coupler 1 Disconnect Disconnect Disconnect Disconnect Disconnect Fuel hose primary injector fuel rail to second ary injector fuel rail o Upper air filter case Secondary injector holder 14 Cylinder 1 secondary injector coupler Cylinder 2 secondary injector coupler 10 Cylinder 3 secondary injector coupler 7 5 AIR FILTER CASE Removing the air filter case and secondary injectors Disconnect For installation reverse the removal proce dure Air induction system hose air filter case to air cut off valve Air filter case joint lower 7 6 ET2C01005 REMOVING THE FUEL HOSE PRIMARY INJECTOR FUEL RAIL TO SECONDARY INJECTOR FUEL RAIL 1 Remove Fuel hose primary injector fuel rail to second ary injector fuel rail EW2C01008 Cover fuel hose connections w
200. e diameter a EAS24440 CHECKING THE PISTON PINS following procedure applies to all of the pis Piston pin to piston pin bore ton pins clearance 1 Check 0 002 0 022 mm 0 00007 Piston pin 0 00068 in Blue discoloration grooves Replace the piston pin and then check the lubrication sys tem 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 5 62 CONNECTING RODS AND PISTONS 2 01013 CHECKING THE CONNECTING RODS 1 Measure Crankshaft pin to big end bearing clearance Out of specification Replace the big end bearings Oil clearance using plasti gauge 0 037 0 061 mm 0 0015 0 0024 The following procedure applies to all the connecting rods ECA13930 CAUTION Do not interchange the big end bearings and connecting rods To obtain the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their origi nal positions a Clean the big end bearings crankshaft pins and the inside of the connecting rods halves b Install the big end upper bearing into the con necting rod and the big end lower bearing into the connecting rod cap NOTE Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap E Put
201. e disc deflection limit 0 15 mm 0 0059 in 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 22 REAR BRAKE Brake disc thickness limit 4 5 mm 0 18 in 5 Adjust Brake disc deflection Refer to CHECKING THE FRONT BRAKE DISCS on page 4 22 Rear brake disc bolt 30 Nm 3 0 m kg 22 ft lb LOCTITE 6 Install Rear wheel Refer to REAR WHEEL on page 4 11 EAS22580 REPLACING THE REAR BRAKE PADS NOTE When replacing the brake pads it is not neces sary to disconnect the brake hose or disassem ble the brake caliper 1 Measure Brake pad wear limit Out of specification Replace the brake pads as a set Brake pad lining thickness in ner 6 0 mm 0 24 in Limit 1 0 mm 0 04 in Brake pad lining thickness out er 6 0 mm 0 24 in Limit 1 0 mm 0 04 in 2 Install Brake pad insulators onto the brake pads Brake pad shims onto the brake pads Brake pads Brake pad spring NOTE Always install new brake pads brake pad insu lators brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the ble
202. e engine trou ble warning light Actuates the primary injector 2 five times at one second intervals Illuminates the engine trou ble warning light Actuates the primary injector 3 five times at one second intervals Illuminates the engine trou ble warning light Actuates the primary injector 4 five times at one second intervals Illuminates the engine trou ble warning light Actuates the secondary in jector 1 five times at one second intervals Illuminates the engine trou ble warning light Actuates the secondary in jector 42 five times at one second intervals Illuminates the engine trou ble warning light Actuates the secondary in jector 43 five times at one second intervals Illuminates the engine trou ble warning light Actuates the secondary in jector 44 five times at one second intervals Illuminates the engine trou ble warning light 8 47 Checking method Check the spark five times Connect an ignition checker Check the operating sound of the primary injector 1 five times Check the operating sound of the primary injector 2 five times Check the operating sound of the primary injector 3 five times Check the operating sound of the primary injector 4 five times Check the operating sound of the secondary injector 1 five times Check the operating sound of the secondary injector 2 five times Check the operating sound of the secondary injector
203. e from 0 6 V to 4 8 V to 0 6 V to 4 8 V DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE RADIATOR FAN MOTORS 1 Check Radiator fan motor Faulty rough movement Replace Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown Positive tester probe gt blue 1 Negative tester probe gt black 2 c Measure the radiator fan motor movement 28260 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to THERMOSTAT on page 6 7 EWA14130 Handle the coolant temperature sensor with special care Never subject the coolant temperature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace Resistance at 80 290 354 a Connect the pocket tester Q x 100 to the coolant temperature sensor as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C o6 55046524 b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 8 97 ELECTRICAL COMPONENTS NOTE Make sure the coolant temperature sensor ter minals do not
204. e is an open or short circuit Between meter assembly cou pler and ECU coupler yellow blue yellow blue Malfunction in meter assembly Replace the meter assembly Malfunction in ECU Replace the ECU 8 71 FUEL INJECTION SYSTEM 8 72 FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM EAS27550 EAS27560 penne 9 cde 18 iowa J 1 DD 1 ea 1365 b ee r 8 FIE ore hs gt 78 14 9 e x v D d d d IERI 1 1 Wd Wd Wd TE 1 F F 99 T a GEL did ees e 1 bor 58 Aa 230 IOJOIOIO NO 90 99 1 SS3NuvH 3UIM SS3NUVH 3HIM 2915 1 915 HOLIMS uo Twa 8 73 9 pue REM Main switch Ignition fuse Main fuse Battery Fuel injection system fuse 11 Engine ground 13 Relay unit 15 Fuel pump relay 18 Fuel pump 22 ECU engine control unit 64 Engine stop switch 8 74 FUEL PUMP SYSTEM FUEL PUM
205. e looseness Replace ET2C01015 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1 Install Toothed washer 1 Circlip 2 NOTE Be sure the sharp edged corner is positioned opposite side to the toothed washer and gear Install the circlip so that both ends b rest on the sides of a spline with both axles aligned 5 77 2 Install Toothed lock washer retainer 1 Toothed lock washer 2 NOTE e With the toothed lock washer retainer 1 in the groove a in the axle align the projection on the retainer with an axle spline b and then install the toothed lock washer 2 Be sure to align the projection on the toothed lock washer that is between the alignment marks e with the alignment mark d on the retainer ET2C01016 INSTALLING THE TRANSMISSION 1 Install Bearing 1 NOTE Face the seal side of the bearing to the outside and install it close to the right side end of the crankcase TRANSMISSION 2 Install Main axle assembly 1 NOTE Stake the main axle assembly bearing housing bolts 2 at a cutout a in the main axle assem bly bearing housing 3 IN NA et 3 Install Shift fork C 1 Shift drum assembly 2 Shift fork guide bar 3 NOTE The embossed marks the shift forks should face towards the right side of the engine a
206. e received from the cylinder identification sensor when the engine is started Unable Able or while the vehicle is being driv en normal signals received 12 oa poston from the crankshaft position sen Unable Unable sor Intake air pressure sensor open short circuit detected BOIS mole open or short circuit Intake air pressure Intake air pressure sensor 14 sensor hose line hose system malfunction clogged Able Able piping system or detached hose 15 17 Throttle position sensor for throt Throttle position sen tle valves sor for throttle valves open or short circuit detected Able Un Able Un open or short cir Throttle position sensor for throt able able cuit loose connection tle valves coupler connection is loose EXUP servo motor circuit Able ABE open or short circuit or short circuit detected 8 36 FUEL INJECTION SYSTEM Able un able to Fault Able un code No om Symptom able to start drive EXUP servo motor 18 stuck EXUP servo motor is stuck Sidestand switch open circuit in the wire to the ECU Open circuit is detected in the in put line from the sidestand switch Unable Unable to the ECU When the main switch is turned to the atmospheric pressure sensor voltage and intake air pres DI Oe sure sensor voltage differ greatly Able Able sure sensor
207. e than 1 4 tooth wear Replace the camshaft sprocket and the timing chain as a set 1 4 tooth Correct Timing chain roller Camshaft sprocket 3 Check e Timing chain guide exhaust side Timing chain guide intake side e Timing chain guide upper side Damage wear Replace the defective part s CHECKING THE TIMING CHAIN TENSIONER 1 Remove Timing chain tensioner rod 1 Timing chain tensioner spring seat 2 Timing chain tensioner inner spring 3 Timing chain tensioner outer spring 5 Timing chain tensioner housing 6 NOTE Squeeze the timing chain tensioner clip 4 and then remove the timing chain tensioner springs and timing chain tensioner rod Coe 2 Check Timing chain tensioner housing Timing chain tensioner e Timing chain tensioner spring seat Timing chain tensioner springs Damage wear Replace the as a set 3 Assemble Timing chain tensioner springs Timing chain tensioner spring seat e Timing chain tensioner rod Prior to installing the timing chain tensioner rod drain the engine oil from the timing chain ten sioner housing a Install the timing chain tensioner springs tim ing chain tensioner spring seat and timing chain tensioner rod 1 b Squeeze the timing chain tensione
208. eat Fuel tank Air filter case Canister for California only oide cowlings Thermostat 1 2 3 4 5 6 1 Check the fuses gt and ignition Refer to CHECKING THE FUS ES on page 8 85 Check the battery NG gt Refer to CHECKING AND CHARGING THE BATTERY on page 8 86 OK Replace the fuse s Clean the battery terminals Recharge or replace the battery Check the starter motor operation OK gt Refer to CHECKING THE START ER MOTOR OPERATION on page 8 93 NG 4 Check the starter motor NG Refer to CHECKING THE START Repair or replace the starter motor ER MOTOR on page 5 35 OK Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 8 89 OK 6 Check the relay unit diode NG Refer to CHECKING THE RELAY Replace the relay unit UNIT DIODE on page 8 91 OK Replace the relay unit Check the starter relay Refer to CHECKING THE RE Replace the starter relay LAYS on page 8 89 OK 8 11 8 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 OK Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 81 10 Check the neutral switch Refer to CH
209. ecting rod Oil clearance using plastigauge9 Bearing color code Crankshaft Width A Width B Runout limit C Big end side clearance D XM D A Small end free play F Journal oil clearance using plastigauge Bearing color code Clutch Clutch type Clutch release method Clutch lever free play Friction plate thickness Wear limit Plate quantity Clutch plate thickness ENGINE SPECIFICATIONS Taper 0 80 x 2 50 mm 0 03 x 0 10 in 0 70 0 80 mm 0 0276 0 0315 in 1 00 mm 0 0394 in 0 020 0 055 mm 0 0008 0 0022 in 1 50 x 2 00 mm 0 06 x 0 08 in 0 10 0 35 mm 0 0039 0 0138 0 037 0 061 mm 0 0015 0 0024 in 1 2 Black 3 Brown 4 Green Cylinders 1 2 48 20 48 25 mm 1 898 1 900 in Cylinders 3 4 47 90 47 95 mm 1 886 1 888 in 268 80 270 00 10 58 10 63 0 030 mm 0 0012 in 0 160 0 262 mm 0 0063 0 0103 0 32 0 50 mm 0 01 0 02 in 0 020 0 044 0 0008 0 0017 1 Blue 2 Black 3 Brown 4 Green 5 Yellow Wet multiple disc Outer pull rack and pinion pull 10 0 15 0 mm 0 39 0 59 2 92 3 08 mm 0 115 0 121 in 2 80 mm 0 1102 in 9 pcs 1 90 2 10 mm 0 075 0 083 Plate quantity Warpage limit Clutch spring free length Minimum length Spring quantity Transmission Transmission type Primary reduction system Primary reduction ratio secondary reduction system Secondary reduction ratio Operation
210. ed Intake vacuum Water temperature Oil temperature Throttle cable free play Air induction system Reed valve bending limit Solenoid resistance 2 9 ENGINE SPECIFICATIONS 248 372 Q at 20 C 68 F Less than 0 8 V More than 4 8 V 3 15 4 15 V 3 15 4 15 V 1250 1350 r min 20 0 kPa 5 9 inHg 150 mmHg 95 0 105 0 203 00 221 00 F 82 92 C 180 198 F 3 0 5 0 mm 0 12 0 20 in 0 4 mm 0 016 in 18 22 at 20 68 F 20300 CHASSIS SPECIFICATIONS Chassis Frame type Caster angle Trail Front wheel Wheel type Rim size Rim material Wheel travel Radial wheel runout limit Lateral wheel runout limit Rear wheel Wheel type Rim size Rim material Wheel travel Radial wheel runout limit Lateral wheel runout limit Front tire Type Size Manufacturer model Wear limit front Rear tire Type Size Manufacturer model Wear limit rear Tire air pressure measured on cold tires Loading condition Front Rear Loading condition Front Rear High speed riding Front Rear Front brake Type Operation Front disc brake Disc outside diameter x thickness CHASSIS SPECIFICATIONS Diamond 24 00 97 0 mm 3 82 in Cast wheel 17M C x MT3 50 Aluminum 120 0 mm 4 72 in 1 0 mm 0 04 in 0 5 mm 0 02 in Cast wheel 17M C x MT5 50 Aluminum 120 0 mm 4 72 in 1 0 mm 0 04 in 0 5 mm 0 02 in Tubeless 120 70 ZR17M C 58W DUNLOP D209F PT 1 0 mm 0 04 in Tu
211. ed primary or secondary coils Cracked or broken ignition coil 4 Ignition system Faulty ECU Faulty crankshaft position sensor e Faulty cylinder identification sensor EAS28510 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING FAILURES on page 9 1 Engine 1 Air filter Clogged air filter element Fuel system 1 Fuel pump Faulty fuel pump EAS28530 FAULTY GEAR SHIFTING Shifting is difficult Refer to Clutch drags EAS28540 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 TROUBLESHOOTING EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks e Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission e Worn gear dog EAS28560 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil Clutch drags 1 Clutch Unevenly tensioned clutch springs Warped pr
212. ed screw and push the brake caliper piston into the brake caliper with your finger c Tighten the bleed screw d Install a new brake pad insulator and new brake pad shim 3 onto each new brake pad 4 Bleed screw 5 Nm 0 5 m kg 3 6 ft lb DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Install Rear brake caliper Brake pad pin Screw plug Rear brake caliper bolt M12 27 Nm 2 7 m kg 19 ft lb Rear brake caliper bolt M8 22 Nm 2 2 m kg 16 ft lb LOCTITE REAR BRAKE 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 on page 3 22 IE t 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake hose union bolt 1 Copper washers 2 e Rear brake hose 3 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22600 DISASSEMBLING THE REAR BRAKE CALIPER 1 Remove Brake caliper piston 1 Brake caliper piston seals 2 a Blow compressed air into the
213. ed shift rod length 267 2 269 2 mm 10 52 10 60 in 3 Adjust Installed shift rod length Loosen both locknuts 1 b Turn the shift rod 2 in direction a or b until the specified installed shift rod length is ob tained CHASSIS Direction Installed shift rod length increases Direction b Installed shift rod length decreases Locknut shift rod upper side 7 Nm 0 7 m kg 5 1 16 Locknut shift rod lower side 10 Nm 1 0 m kg 7 2 ft lb d Make sure the installed shift rod length is within specification DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 Install Left lower side cowling Refer to GENERAL CHASSIS on page 4 1 EAS21390 ADJUSTING THE DRIVE CHAIN SLACK ECA13550 CAUTION A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Check Drive chain slack a Out of specification Adjust 3 25 Drive chain slack 35 0 45 0 mm 1 38 1 77 in NOTE Measure the drive chain slack halfwa
214. el bearings Moderately repack with lithi grease Check S D and replace Check operation and for oil leakage Replace if necessary Shock absorber Check operation and for oil assembl leakage y Replace if necessary Rear suspension Check operation link pivots Correct if necessary warm engine before mme ET Engine oil filter _ Check hoses for cracks damage y y Replace if necessary 9 Change with ethylene glycol anti freeze coolant every 24 Change months x Front and rear Apply Yamaha chain and ca Control cables ble lube or engine oil SAE y y 10W 30 thoroughly Check operation and free Throttle grip housing and ca play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable ble PERIODIC MAINTENANCE INITIAL ODOMETER READINGS 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE 1000 7000 13000 19000 25000 31000 or or 29 and switches Adustheadight Adjust beam Since these items require special tools data 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 EAU17650 NOTE Air filter This model s air filter is equ
215. ell as to new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter EAU17600 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM INITIAL ODOMETER READINGS ITEM ROUTINE or Check fuel hoses for cracks or t damage y Check condition Adjust gap and clean Spark plugs Replace every 8000 mi Replace Replace 13000 km 12 months Check and 4 valve clear Valve clearance clearance AGE 4 Every 26600 mi 42000 km Check breather hose for x breather system cracks or damage Replace if necessary 5 Fuel injection Adjust synchronization Check for leakage Tighten if necessary Exhaustsystem Replace gasket s if neces sary Evaporative emis sion control sys tem For California only Check control system for damage Replace if necessary Check the air cut off valve Air induction sys reed valve and hose for dam tem age Replace any damaged parts Since these items require special tools data and technical skills have a Yamaha dealer perform the service EAU32183 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS 4000 mi 13000 19000 25000 31000 5 ITEM ROUTINE 1000 km 7000 km m S em Om d or or or or 1 month 6 months 12 months 18 months 24 months 30 months
216. ench 3 Loosen all bolts one by one following the tightening order and then tighten them to 27 Nm 2 7 m kg 20 ft lb again NOTE Crankcase stud bolt Install the crankcase stud bolts M10 so that their installed length is 68 2 mm 2 69 in 2 19 TIGHTENING TORQUES Cylinder head tightening sequence Crankcase tightening sequence 2 20 TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread a Engine mounting bolt front right side M10 2 45 Nm 4 5 m kg 32 ft lb Engine mounting bolt front left Engine mounting nut rear upper side M12 1 68 Nm 6 8 m kg 49 ft lb Engine mounting nut rear lower Engi T TP Front wheel axle 91 Nm 9 1 m kg 66 ft lb Front wheel axle pinch bolt 21 Nm 2 1 m kg 15 ft lb IE a a 8 30 Nm 3 0 m kg 22 ft lb Brake caliper bleed screw front and rear 5 Nm 0 5 m kg 3 6 ft lb Front brake hose holder bolt Rear brake hose union bolt lt lt 7 Nm 0 7 m kg 5 1 ft lb Rear brake caliper bolt 27 Nm 2 7 m kg 19 ft lb 4 Rearbrakepadpin 1 57 12 tb Rewbmkescewpug 1 2 Handeberpmdhtot ____ M8 2 2 mu Handlebar bolt 13 Nm 1 3 m kg 9 4 ft lb Front brake master cylinder bolt 13 Nm 1 3 m kg 9 4 ft Ib master cylinder bleed 6 Nm 0 6 m kg 4 3 ft Ib Tm OT mG Clutch lever assembly bolt 11 Nm 1
217. ensor angle a Connect the two size batteries to the throt tle servo motor terminal as shown Positive battery lead light green red terminal 1 Negative battery lead yellow red terminal 2 EC2C01027 CAUTION Do not use a 12 V battery to operate the throt tle valves SSS b Check that the throttle valves are fully closed c Connect the throttle position sensor coupler to the throttle position sensor d Connect the digital circuit tester to the throttle position sensor Positive tester probe blue terminal 1 or green terminal 2 Negative tester probe black blue terminal 3 Digital circuit tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 e Measure the throttle position sensor voltage f Adjust the throttle position sensor angle so that the voltage is within the specified range Output voltage 0 590 0 690 V 7 13 THROTTLE BODIES g After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 4 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY 1 Check Throttle position sensor for throttle cable pul ley Refer to CHECKING THE THROTTLE PO SITION SENSOR FOR THROTTLE CABLE PULLEY on page 8 98 2 Adjust Throttle position sensor angle
218. entilation chamber cover Relief valve Ventilation chamber oil drain pipe Oil cooler 2 32 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 It LUBRICATION SYSTEM CHART AND DIAGRAMS Timing chain tensioner Intake camshaft Exhaust camshaft Oil check bolt Oil strainer Ventilation chamber oil drain pipe Oil pipe Oil pump 2 34 LUBRICATION SYSTEM CHART AND DIAGRAMS pu esses ues NN NUS ips PM ii 53 1 7 TM gy Food 3 PV N A 1 lt MN LA fe me MSS Oil cooler Oil filter Oil pipe Oil pump strainer LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 LUBRICATION SYSTEM CHART AND DIAGRAMS Main axle Oil pump Oil pipe Ventilation chamber oil drain pipe Relief valve LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 LUBRICATION SYSTEM CHART AND DIAGRAMS PS A Mioi um 110 up pp ES TH 2 2 39 Cylinder head Intake camshaft Exhaust camshaft Crankshaft Oil nozzle LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 LUBRICATION SYSTEM CHART AND DIAGRAMS ae D 6 SP pho A I OS PTT F MEN SSS 2 41 LUBRICATION SYSTEM CHART AND DIAGRAMS 1 Oil pipe 2 Main axle 3
219. er 2 Fuel pump 13 Coolant temperature sensor 3 Primary injector 14 Crankshaft position sensor 4 Cylinder identification sensor 15 Intake air pressure sensor 5 ECU engine control unit 16 Throttle servo motor 6 Throttle position sensor for throttle cable 17 Throttle body pulley 18 Atmospheric pressure sensor 7 Throttle position sensor for throttle valves 19 Air filter case 8 Speed sensor A Fuel system B Air system C Control system 9 Air temperature sensor 10 Lean angle sensor 11 sensor FEATURES ET2C01026 YCC T Yamaha Chip Controlled Throttle Mechanism characteristics Yamaha developed the YCC T system employing the most advanced electronic control technologies Electronic control throttle systems have been used on automobiles but Yamaha has developed fast er more compact system specifically for the needs of a sports motorcycle The Yamaha developed system has a high speed calculating capacity that produces computations of running conditions every 1 1000th of a second The YCC T system is designed to respond to the throttle action of the rider by having the ECU instan taneously calculate the ideal throttle valve opening and generate signals to operate the motor driven throttle valves and thus actively control the intake air volume The ECU contains three CPUs with a capacity about five times that of conventional units making it pos sible for the system to respond extremely quickly to the slightest
220. ere is a malfunction repair it and connect the coupler se Replace the throttle body as sembly if defective Malfunction in ECU Replace the ECU Fault code No Ert Symptom No signals are received from the ECU Diagnostic code No Item components and probable Check or maintenance job Reinstatement cause method 1 Connections Check the couplers for any pins Turning the Main wire harness ECU coupler that may be pulled out main switch to Main wire harness meter assembly Check the locking condition of ON coupler the couplers f there is a malfunction repair it and connect the coupler se 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly cou 2 3 4 5 and ECU coupler yellow blue yellow blue 3 Malfunction in meter assembly Replace the meter assembly Malfunction in ECU Replace the ECU 8 69 FUEL INJECTION SYSTEM Fault code No Symptom No signals are received from the ECU within the specified duration Reinstatement method Connections Check the couplers for any pins Turning the Main wire harness ECU coupler that may be pulled out main switch to Main wire harness meter assembly Check the locking condition of ON coupler the couplers f there is a malfunction repair it and connect the coupler se curely Open or short circuit in wire harness
221. ers 1 Check Brake hoses 1 Cracks damage wear Replace 2 Check Brake hose holders 2 Loose Tighten the holder bolt 3 Hold the vehicle upright and apply the brake several times 4 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to FRONT BRAKE on page 4 17 EAS21290 CHECKING THE REAR BRAKE HOSES 1 Check Brake hoses 1 Cracks damage wear Replace 3 23 CHASSIS 2 Check e Brake hose holders 2 Loose connection Connect be JA SS 3 Hold the vehicle upright and apply the brake several times 4 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 29 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction a Brake light comes on sooner Directio
222. es two signals 10 Engine revolution 11 Vehicle speed 12 Coolant temperature 13 Neutral In gear 14 Atmospheric pressure 15 Throttle servo motor 16 ECU engine control unit 17 Base map ET2C01020 INSTRUMENT FUNCTIONS Multi function meter unit EW2C01003 Be sure to stop the vehicle before making any setting changes to the multi function meter unit Clock Speedometer SELECT button RESET button Tachometer Coolant temperature display air intake temperature display 7 Odometer tripmeters fuel reserve tripmeter stopwatch 8 Shift timing indicator light WD The multi function meter unit is equipped with the following a speedometer which shows the riding speed a tachometer which shows engine speed an odometer which shows the total distance traveled two tripmeters which show the distance trav eled since they were last set to zero a fuel reserve tripmeter which shows the dis tance traveled since the fuel level warning light came on stopwatch clock coolant temperature display an air intake temperature display a self diagnosis device a display brightness and shift timing indicator light control mode NOTE Be sure to turn the key to ON before using the SELECT and RESET buttons FEATURES To switch the speedometer and odometer trip meter displays between kilome
223. es otherwise the O rings can be damaged CHAIN DRIVE EAS23460 CHECKING THE DRIVE SPROCKET 1 Check Drive sprocket More than 1 4 tooth a wear Replace the drive chain sprockets as a set Bent teeth Replace the drive chain sprock ets as a set b Correct 1 Drive chain roller 2 Drive chain sprocket 4 Check D O rings 1 CHECKING THE REAR WHEEL SPROCKET Damage Replace the drive chain Refer to CHECKING AND REPLACING THE Drive chain rollers 2 REAR WHEEL SPROCKET on page 4 14 Damage wear Replace the drive chain Drive chain side plates 3 2 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 14 Damage wear Replace the drive chain Cracks Replace the drive chain and make sure the battery breather hose is properly routed away from the drive chain and below swingarm INSTALLING THE DRIVE CHAIN 1 Lubricate e Drive chain Recommended lubricant Engine oil or chain lubricant suitable for O ring chains 2 Install Drive sprocket 1 Washer 2 5 Lubricate Drive sprocket nut 3 Drive chain NOTE Recommended lubricant While applying the rear brake tighten the drive Engine oil or chain lubricant sprocket nut suitable for O ring chains e Stake the drive sprocket n
224. es the en gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system Once a malfunction has been detected a fault code is stored in the memory of the ECU To inform the rider that the fuel injection system is not functioning the engine trouble warning light flashes when the start switch is being pushed to start the engine malfunction is detected in the system by the self diagnostic function the ECU provides an appro priate substitute characteristic operation and alerts the rider of the detected malfunction by illuminat ing the engine trouble warning light e After the engine has been stopped the lowest fault code number appears on the odometer tripme ter fuel reserve tripmeter LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation Warning ECU operation nue opera Vehicle operation Warning provided Flashing when unable to start Operation stopped Cannot be operated engine Operated with substi tute characteristics Can or cannot be oper Remains on Malfunction detected accordance with the ated depending on the description of the mal fault code function The warning light flashes when any one of the conditions listed below is present and the start switch is pu
225. essed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar EAS22890 CHECKING THE HANDLEBARS 1 Check Left handlebar e Right handlebar Bends cracks damage Replace EWA13690 Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS22900 INSTALLING THE HANDLEBARS 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Front brake master cylinder 1 Front brake master cylinder holder 2 Front brake master cylinder hold er bolt 13 Nm 1 3 m kg 9 4 ft lb NOTE Install the brake master cylinder holder with the UP mark a facing up HANDLEBARS Align the mating surfaces of the brake master cylinder holder with the punch mark b on the handlebar First tighten the upper bolt then the lower bolt 3 Install e Right handlebar switch 1 Right handlebar switch bracket 2 NOTE Align the projection a on the right handlebar switch with the hole b on the right handlebar a 4 Install e Throttle grip Throttle cables Throttle cable housings 1 NOTE Align the projection a on the throttle cable housing with the hole b in the right handlebar 5 Install Right grip end 1 4 42 There should be 1 3
226. essure plate Bent clutch plate Swollen friction plate Bent clutch pull rod Broken clutch boss Burnt primary driven gear bushing Match marks not aligned 2 Engine oil Incorrect oil level Incorrect oil viscosity high Deteriorated oil EAS28600 OVERHEATING Engine 1 Clogged coolant passages Cylinder head and piston s Heavy carbon buildup 2 Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality Cooling system 1 Coolant Low coolant level 2 Radiator Damaged or leaking radiator e Faulty radiator cap Bent or damaged radiator fin 3 Water pump Damaged or faulty water pump Thermostat Thermostat stays closed Oil cooler Clogged or damaged oil cooler Hose s and pipe s Damaged hose Improperly connected hose Damaged pipe Improperly connected pipe Fuel system 1 Throttle body ies Damaged or loose throttle body joint 2 Air filter Clogged air filter element Chassis 1 Brake s Dragging brake Electrical system 1 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range 2 Ignition system Faulty ECU 3 Cooling system e Faulty radiator fan motor relay e Faulty coolant temperature sensor Faulty ECU EAS28610 OVERCOOLING Cooling system 1 Thermostat Thermostat stays open EAS28620 POOR BRAKING PERFORMANCE Worn brake pad TROUBLESHOOTING Worn brake d
227. ff 4 Check Coolant level NOTE Before checking the coolant level wait a few minutes until it settles CHECKING THE COOLING SYSTEM 1 Remove Side cowlings Bottom cowlings Refer to GENERAL CHASSIS on page 4 1 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 2 Check e Radiator 1 e Radiator inlet hose 2 Radiator inlet pipe 3 e Thermostat outlet hose 4 e Radiator outlet hose 5 Radiator outlet pipe 6 e Oil cooler 7 Oil cooler outlet hose 8 Oil cooler inlet hose 9 e Water pump outlet hose 10 Water pump inlet hose e Water pump outlet pipe 11 Water jacket joint inlet hose 12 Water jacket joint 13 Cracks damage Replace Refer to RADIATOR on page 6 1 and OIL COOLER on page 6 4 ENGINE be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 3 Remove SN Coolant drain bolt water pump 1 13 gt 8 along with the copper washer 4 Disconnect em Water Mi inlet hose 2 2 lt gt 2 192 E 1 me 11 De Ex 1 ees
228. fication The wiring circuit from the main switch to the turn signal relay cou pler is faulty and must be repaired Turn signal relay input voltage DC 12 V a Connect the pocket tester DC 20 V to the turn signal relay terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt brown 1 Negative tester probe gt ground b Turn the main switch to ON c Measure the turn signal relay input voltage DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Check Turn signal relay output voltage Out of specification Replace 1 Turn signal relay output voltage DC 12 V a Connect the pocket tester DC 20 V to the turn signal relay terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt brown white 1 Negative tester probe gt ground b Turn the main switch to ON c Measure the turn signal relay output voltage DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE RELAY UNIT DIODE 1 Check Relay unit diode Out of specification Replace Pocket tester 90890 03112 Analog pocket tester YU 03112 C NOTE The pocket tester or the analog pocket tester readings are shown in the following table ELECTRICAL COMPONENTS Continuity
229. flush with the front fork However if the surface of the front wheel axle end is not parallel to the surface of the front fork align a point on the outer edge of the axle with the fork making sure that the axle does not protrude past the fork d In the order pinch bolt 4 pinch bolt 73 gt pinch bolt 4 tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 6 Install Front brake calipers Front brake caliper bolt 35 Nm 3 5 m kg 25 ft lb 4 10 REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel 2 Nm 0 2 m kg 1 4 ft Ib 16 Nm 1 6 m kg 11 ft Ib Place the vehicle on a suitable stand so that the rear wheel is elevated Rear brake caliper Drive chain adjusting locknut Loosen Drive chain adjusting bolt Rear wheel axle nut Loosen Washer Rear wheel axle 7 Brake pad spring For installation reverse the removal proce dure 4 11 REAR WHEEL Removing the rear brake disc and rear wheel sprocket 30 Nm 3 0 kg 22 ft Ib wwe ow Rema 2 4 mmm jmd _ Emm 7 3 7 LL MRNA RN dure 4 12 REAR WHEEL Disassembling the rear wheel Job Parts to remove 8 Beati
230. from the throttle body 2 Check Throttle position sensor for throttle cable pul ley maximum resistance Out of specification Replace the throttle position sensor for throttle cable pulley Resistance 2 0 3 0 a Connect the pocket tester Q x 1k to the throttle position sensor for throttle cable pul ley terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt blue 1 Negative tester probe gt black blue 2 VA b Measure the throttle position sensor for throttle cable pulley maximum resistance DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Install Throttle position sensor for throttle cable pul ley ELECTRICAL COMPONENTS NOTE When installing the throttle position sensor for throttle cable pulley adjust its angle properly Refer to ADJUSTING THE THROTTLE POSI TION SENSOR FOR THROTTLE CABLE PUL LEY on page 7 13 EAS28350 CHECKING THE FUEL PUMP EWA13850 Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire Be extremely careful and note the following points Stop the engine before refueling Do not smoke and keep away from open flames sparks or any other source of fire If you do accidentally spill gasoline wipe it up immediately with dry rags
231. g bolt Rear fender bolt Fuel pump bolt M 5 6 1 7 Nm 0 7 m kg 5 1 16 Fuel tank upper cover and frame bolt Fuel tank bolt 9 Nm 0 9 m kg 6 5 ft lb Fuel tank bracket and frame bolt 7 Nm 0 7 m kg 5 1 ft lb lt 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 16 Nm 1 6 m kg 11 ft lb 2 Nm 0 2 m kg 1 4 ft lb 7 Nm 0 7 m kg 5 1 ft lb 4 Nm 0 4 m kg 2 9 ft lb 2 22 TIGHTENING TORQUES Thread Q ty Tightening torque Fuel tank bracket and fuel tank M6 1 7 Nm 0 7 m kg 5 1 ft Ib bolt Canister and canister bracket 7 Nm 0 7 m kg 5 1 ft lb 6 10 Nm 1 0 m kg 7 2 ft lb 6 Canister bracket and ventilation 2 chamber cover 2 2 10 Nm 1 0 m kg 7 2 ft lb 2 1 1 Radiator bolt M6 2 Radiator and coupler holder bolt M6 2 5 Nm 0 5 m kg 3 6 ft lb M 10 Nm 1 0 m kg 7 2 ft lb 6 Radiator bracket and radiator bolt 10 M6 10 Nm 1 0 m kg 7 2 ft lb Seatlockpatebot me 2 7NmOT MEG Rersema lame _____ 2 7 07 538b Bateryborandtame 2 7 07 STR Rear upper cowling damper plate License plate light assembly bolt 7 Nm 0 7 m kg 5 1 ft lb Rider footrest left and right as Passenger footrest left and right 28 Nm 2 8 m kg 20 ft Ib bolt Rear brake fluid reservoir bracket 7 Nm 0 7 m kg 5 1 ft lb bolt diui Rear brake master cylinder bol
232. get wet c Place a thermometer 3 in the coolant d Slowly heat the coolant then let it cool down to the specified temperature e Measure the coolant temperature sensor re sistance DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES 1 Remove Throttle position sensor for throttle valves from the throttle body 2 Check Throttle position sensor for throttle valves maximum resistance Out of specification Replace the throttle position sensor for throttle valves Resistance 2 0 3 0 a Connect the pocket tester Q x 1k to the throttle position sensor for throttle valves terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt blue 1 Negative tester probe gt black blue 2 b Measure the throttle position sensor for throttle valves maximum resistance DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Install Throttle position sensor for throttle valves When installing the throttle position sensor for throttle valves adjust its angle properly Refer to ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE VALVES on page 7 13 ET2C01001 CHECKING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY 1 Remove Throttle position sensor for throttle cable pul ley
233. he illustration Front Bend back the right radiator fan motor sub wire harness as shown in the illustration and then insert the projection on the coupler into the hole in the right coupler holder making sure to route the lead to the inside of the coupler Route the right radiator fan motor sub wire harness to the inside of the clutch cable CABLE ROUTING 2 1 7 7 i zz EP SN S S 222 Ci AS Y 9 vo a AX ds EY SS LY D EE 72 1 2 51 QNM OU m 13 14 Main switch lead Left handlebar switch lead Left radiator fan motor lead Wire harness Radiator inlet pipe Fuel tank breather hose except for California Sidestand switch lead AC magneto lead Front left turn signal position light lead Main switch lead Left handlebar switch lead Left radiator fan motor lead Fuel tank drain hose Oil level switch lead Bend the wire harness so that it is routed along the rectifier regulator holder and is aligned with the plastic locking tie installation locations 45 55 mm 1 77 2 17 in Pass a plastic locking tie through the holes in the coupler holder and then fasten the wire harness with the tie Pass the left radiator fan motor lead through the opening in the frame and then route the lead under the wire har
234. hicle and connect the coupler se Open or short circuit in lead e Repair or replace if there is an open or short circuit Between speed sensor coupler and ECU coupler blue blue white yellow white yellow black blue black blue Defective speed sensor Execute the diagnostic mode Code No 07 Replace if defective Refer to CHECKING THE SPEED SENSOR on page 8 96 8 64 FUEL INJECTION SYSTEM Fault code No Symptom A No normal signals are received from the speed sensor B Open circuit is detected in the neutral switch Diagnostic code No A Speed sensor 0 Item components and probable Check or maintenance job Reinstatement cause method Installed state of neutral switch Check for looseness or pinching Starting the en Connections e Check the couplers for any pins 9116 and acti Neutral switch coupler that may be pulled out vating the Main wire harness ECU coupler Check the locking condition of speed the couplers by operating If there is a malfunction repair it te Vehicle and connect the coupler se Open circuit in neutral switch lead Repair or replace if there is an B 4 5 open circuit Between neutral switch coupler and relay unit coupler sky blue sky blue Between ECU coupler and main switch coupler blue black blue black Between relay unit coupler and main switch coupler blue yellow blue ye
235. hlins amp T43 ACC RT43F 00 00 ECA14230 CAUTION e Be sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 12 After filling the front fork leg slowly stroke the damper rod 1 up and down at least ten times to distribute the fork oil NOTE Be sure to stroke the damper rod slowly be cause the fork oil may spurt out FRONT FORK 13 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed NOTE Be sure to bleed the front fork leg of any residual air 14 Measure Front fork leg oil level from the top of the outer tube with the outer tube fully compressed and without the fork spring Out of specification Correct Level 108 0 mm 4 25 in 15 Install e Spring seat 1 Fork spring 2 Spacer 3 e Nut 4 Damper adjusting rod 5 e Washer 6 Cap bolt 7 with O ring Remove the rod puller attachment b Install the spring seat c Install the fork spring NOTE Install the spring with the smaller pitch a facing up A d Install the spacer e Install the nut f Reinstall the rod puller attachment
236. holder Pass a plastic locking tie through the hole in the stay on the frame from above and then fasten the wire harness and sub wire harness 3 with the tie making sure to fasten the lead within the 135 angle shown in the illustration Face the end of the plastic locking tie inward Pass a plastic locking tie through the hole in the stay on the frame from above and then fasten the leads shown in the illustration with the tie making sure to fasten the sub wire harness 2 above the stay and the other leads below Face the end of the plastic locking tie inward CABLE ROUTING Se V X lt 7 Z A V LN 2 55 gt Throttle cable decelerator cable Throttle cable accelerator cable Front brake hose Pass the throttle cables between the front fork and the front brake hose When installing the guide on the lower bracket be sure to pass the front brake hose through it Fasten the front brake hose with the holder making sure that the paint mark on the hose is visible through the hole in the holder 2 56 CABLE ROUTING CABLE ROUTING NY S Rk Ro lt gt c u E aS i TAP a F HOSA lt 2 a si T gf N A 55 sun V
237. hten Connecting arm nuts Syr Connecting arm nuts 40 Nm 4 0 m kg 29 ft lb 4 64 SWINGARM EAS23330 SWINGARM Removing the swingarm Nm 0 7 kg 5 1 ft Ib 95 Nm 9 5 kg 68 ft Ib 70 Nm 7 0 kg 50 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib Omer Job Parts to remove Rear wheel 7 Refer to REAR WHEEL page 4 11 S nA Drive chain guard Drive chain guide swingarm side 4 65 SWINGARM Removing the swingarm 7 Nm 0 7 m kg 5 1 ft Ib 95 Nm 9 5 kg 68 ft Ib 70 Nm 7 0 m kg 50 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 14 Dust cover m dure 4 66 SWINGARM s 4 Remove REMOVING THE SWINGARM Cui 1 Stand the vehicle a level surface EWA13120 NOTE Loosen the swingarm pivot shaft ring nut with Securely support the vehicle so that there is the ring nut wrench 2 no danger of it falling over Ring nut wrench NOTE M 2 90890 01507 Place the vehicle on a suitable stand so that the YM 01507 rear wheel is elevated 2 Measure e Swingarm side play e Swingarm vertical movement Measure the tightening torque of the pivot shaft nut pivot shaft ring nut and pivot shaft Swingarm pivot shaft
238. hten it to specification EWA13140 Do not overtighten the lower ring nut Lower ring nut final tightening torque 14 Nm 1 4 m kg 10 16 CHASSIS d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 55 e Install the rubber washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOTE Make sure the lock washer tabs a sit correctly in the ring nut slots b DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 5 Install Upper bracket Refer to STEERING HEAD on page 4 55 6 Measure Steering head tension NOTE Make sure all of the cables wires erly routed a Point the front wheel straight ahead b Install a plastic locking tie 1 loosely around the end of the handlebar as shown c Hook a spring gauge 2 onto the plastic lock ing tie d Hold the spring gauge at a 90 angle from the handlebar pull the spring gauge and then record the measurement when the handlebar Starts to run
239. ignition coil from the spark plug b Connect the pocket tester Q x 1 to the igni tion coil as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe red black 1 Negative tester probe orange or gray red or orange green or gray green 2 c Measure the primary coil resistance DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Check Secondary coil resistance Out of specification Replace Secondary coil resistance 8 5 11 5 Connect the pocket tester Q x 1k to the ig nition coil as shown ELECTRICAL COMPONENTS Pocket tester 90890 03112 Analog pocket tester YU 03112 C Negative tester probe gt red black 1 Positive tester probe gt spark plug terminal 2 b Measure the secondary coil resistance DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Check Ignition spark gap Out of specification Replace Connect the ignition checker 1 as shown Minimum ignition spark gap 6 0 mm 0 24 in Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 2 Ignition coil b Turn the main switch to ON and engine stop switch to O c Measure the ignition spark gap a 8 92 d Crank the engine by pushing the start switch and gradually increase the spar
240. iminate any carbon deposits from the piston ring grooves and piston rings Piston ring Top ring Ring side clearance 0 030 0 065 mm 0 0012 0 0026 2nd ring Ring side clearance 0 020 0 055 mm 0 0008 0 0022 2 Install e Piston ring into the cylinder CONNECTING RODS AND PISTONS NOTE i ae Piston pin outside diameter Level the piston ring into the cylinder with the 14 991 15 000 mm 0 5902 piston crown 0 5906 in Limit 14 971 mm 0 5894 in a 5mm 0 20 in 3 Measure Piston ring end 3 Measure Out of specification Replace the piston Piston pin bore diameter b ring Out of specification Replace the piston TEMA Piston pin bore inside diameter The oil ring expander spacer s end gap cannot 15 002 15 013 mm 0 5906 be measured If the oil ring rail s gap is exces 0 5911 in sive replace all three piston rings Limit 15 043 mm 0 5922 in Piston ring Top ring End gap installed 0 25 0 35 mm 0 0098 0 0138 Limit 0 55 mm 0 0217 in 2nd ring End gap installed 0 70 0 80 mm 0 0276 0 0315 Limit 4 Calculate 1 00 mm 0 0394 in Piston pin to piston pin bore clearance Oil ring Out of specification gt Replace the piston pin End gap installed 0 10 0 35 mm 0 0039 0 0138 and piston as set Piston pin to piston pin bore clearance Piston pin bore diameter b Piston pin outsid
241. in ders Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders FUEL INJECTION SYSTEM Fault code No Symptom Able un Able depending on the number of Primary injector open circuit Primary injector open circuit detected co faulty cylin ders Able depending on the number of faulty cylin ders Secondary injector open circuit Secondary injector open circuit detected iN O able to start Able un able to drive Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders Lean angle sensor Lean angle sensor open or short circuit open or short circuit detected Neutral switch open or short circuit detected No normal signals are received Speed sensor Neutral switch Fuel system voltage Power supply to the injectors and B monitoring voltage the fuel pump is not normal Able Able Error in writing the amount of CO adjust ment on EEPROM Vehicle system power supply monitoring voltage iN A O NO iN O ECU internal malfunc tion O Throttle position sen sor for throttle cable pulley open or short cir cuit loose connection co Throttle servo motor An error is detected while reading or writing on EEPROM CO justmen
242. in a crisscross pattern Clutch spring bolt 8 Nm 0 8 m kg 5 8 ft lb 9 Install Dowel pins Clutch cover gasket e Clutch cover 1 Clutch cover bolt 12 Nm 1 2 m kg 8 7 ft lb NOTE Position the pull rod so that the teeth a face towards the rear of the vehicle Then install the clutch cover Apply locking agent LOCTITE to the threads of only the clutch cover bolts a shown in the illustration Tighten the clutch cover bolts in stages and in a crisscross pattern 10 Install Pull lever spring 1 Pull lever 72 e Washer Circlip NOTE Make sure that the mark on the lever is facing up When installing the pull lever push it and check that its punch mark b aligns with the mark c on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged 11 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 13 5 46 CLUTCH SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Job Parts to remove Q ty rt ENGINE REMOVAL on page 5 Wee 0 S _ 8 s 5 47 SHIFT SHAFT Removing the shift shaft and stopper
243. induction system solenoid 38 EXUP servo motor 39 sensor 40 Crankshaft position sensor 41 Air temperature sensor 42 Coolant temperature sensor 43 Intake air pressure sensor 44 Atmospheric pressure sensor 45 Cylinder identification sensor 46 Speed sensor 47 Lean angle sensor 48 Meter assembly 49 Fuel level warning light 50 Oil level warning light 51 Neutral indicator light 52 Tachometer 53 Shift timing indicator light 54 Multi function meter VI ds pode co 55 Engine trouble warning light 56 Coolant temperature warning light 57 beam indicator light 58 Left turn signal indicator light 59 Right turn signal indicator light 60 Meter light 61 Oil level switch 62 Right handlebar switch 63 Front brake light switch 64 Engine stop switch 65 Start switch 66 Turn signal relay 67 Left handlebar switch 68 Dimmer switch 69 Horn switch 70 Clutch switch 71 Turn signal switch 72 Horn 73 Rear right turn signal light 74 Rear left turn signal light 75 Front right turn signal position light 76 Front left turn signal position light 77 Headlight low beam 78 Headlight high beam 79 Auxiliary light 80 License plate light 81 Rear brake light switch 82 Tail brake light 83 Headlight relay on off 84 Headlight relay dimmer 85 Signaling system fuse 86 Headlight fuse 87 Radiator fan motor relay 88 Right radiator fan motor fuse
244. ing the leads and hoses 3 amp 10 Nm 1 0 m kg 7 2 ft Ib 2 17 Nm 1 7 kg 12 ft Ib Job Parts to remove Q ty jArfilercase Refer to AIR FILTER CASE on page 7 5 Canister for California Refer to THROTTLE BODIES page 7 8 Throttle body Refer to THROTTLE BODIES on page 7 8 Refer to AIR INDUCTION SYSTEM on Air cut off valve mM page 7 15 Drive sprocket Refer to CHAIN DRIVE on page 4 70 ites S 1 w 3 Oillfilter cartridge I MM 4 Oi fiter cartridge bolt 5 Crankcase breather hose 5 3 ENGINE REMOVAL Disconnecting the leads and hoses 3 amp 10 Nm 1 0 m kg 7 2 ft Ib 2 17 Nm 1 7 kg 12 ft Ib Job Parts to remove Q ty E 28 NEN 7 6 Nemwebweywmmi 3 OHeeswehcage S Disconnect 1 7 9 Gemeapeonseworpier 11 Speed sensor 1 1 12 Stator coil assembly coupler Disconnect Cylinder identification sensor coupler Disconnect For installation reverse the removal proce dure 5 4 ENGINE REMOVAL Removing the engine 3 45 Nm 4 5 m kg 32 ft Ib 68 Nm 6 8 m kg 49 ft Ib NOTE _ Place a suitable stand under the engine __ Engine mounting bolt front right side NO Engine mounting collar inside MEME ___
245. ion coil Reinstatement method Connections e Check the couplers for any pins Cranking the Cylinder 3 ignition coil coupler that may be pulled out engine e Main wire harness ECU coupler Check the locking condition of Connect the Sub wire harness 1 coupler the couplers cylinder 3 ig f there is a malfunction repair it nition coil cou and connect the coupler se pler curely Open or short circuit in wire harness Repair or replace if there is and or sub wire harness 1 open or short circuit Between cylinder 3 ignition coil coupler and ECU coupler red black red blue orange green orange green Defective cylinder 3 ignition coil Execute the diagnostic mode Code No 32 Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IG NITION COILS on page 8 92 8 59 FUEL INJECTION SYSTEM Fault code No Symptom Open circuit detected in the primary lead of the cylinder 4 ignition coil Diagnostic code No Cylinder 4 ignition coil Reinstatement method Connections e Check the couplers for any pins Cranking the Cylinder 4 ignition coil coupler that may be pulled out engine e Main wire harness ECU coupler Check the locking condition of Connect the e Sub wire harness 1 coupler the couplers cylinder 4 ig f there is a malfunction repair it nition coil cou and connect the coupler se pler curely Open o
246. ipped with a disposable oil coated paper element which must not be cleaned with compressed air to avoid damaging it The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake service e 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 20470 ENGINE EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves NOTE Valve clearance adjustment should be made on a cold engine at room temperature When the valve clearance is to be measured adjusted the piston must be attop dead center TDC on the compression stroke 1 Remove e Hider seat e Side cowlings Bottom cowlings Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 5 Canister for California only Refer to THROTTLE BODIES on page 7 8 Throttle body Refer to THROTTLE BODIES on page 7 8 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 Radiator Refer to RADIATOR on page 6 1 2 Remove Igni
247. isc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit e Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod assembly Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring e Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28680 UNSTABLE HANDLING Handlebars Bent or improperly installed right handlebar Bent or improperly installed left handlebar 1 Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race 2 Front fork leg s Uneven oil levels both front fork legs e Unevenly tensioned fork spring both front fork legs Broken fork spring Bent or damaged inner tube Bent or damaged outer tube 3 Swingarm Worn bearing or bushing Bent or damaged swingarm Rear shock absorber assembly e Faulty rear shock absorber spring Leaking oil
248. ith a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hoses NOTE To remove the fuel hose from the secondary injector fuel rail slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown press the two buttons 2 on the sides of the connector and then remove the hose Remove the fuel hose manually without using any tools Before removing the hose place a few rags in the area under where it will be removed t 1 ET2C01017 CHECKING THE SECONDARY INJECTORS 1 Check Injectors Damage Replace ET2C01006 INSTALLING THE FUEL HOSE PRIMARY INJECTOR FUEL RAIL TO SECONDARY INJECTOR FUEL RAIL 1 Connect Fuel hose primary injector fuel rail to second ary injector fuel rail 7 7 AIR FILTER CASE EC2C01017 CAUTION When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed NOTE Install the fuel hose securely onto the second ary injector fuel rail until a distinct click is heard To install the fuel hose onto the secondary in jector fuel rail slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown THROTTLE BODIES EAS26970 THROTTLE B
249. ith the holder making sure to align the top of the holder with the bottom edge of the white paint mark on the cable Fasten the clutch cable to the radiator outlet hose with the plastic band making sure to position the band between the screw clamp and the hose protector Install the plastic band with its buckle positioned toward the rear of the vehicle and its end facing inward Fasten the coolant reservoir breather hose with the holder making sure that the white paint mark on the hose is positioned to the rear of the holder Pass the clutch cable through the guide on the engine Make sure that the sensor lead and EXUP cables are not twisted or crossed between the plastic locking ties 2 50 CABLE ROUTING Fasten the EXUP cables and sensor lead with a plastic locking tie Face the end of the plastic locking tie rearward and then cut off the excess end of the tie to 2 4 mm 0 08 0 16 in Be sure to position the plastic locking tie 0 20 mm 0 0 78 in below the plastic locking tie fastened around the sensor lead Pass a plastic locking tie through the bottom hole in the bracket and then fasten the wire harness at the positioning tape with the tie Face the end of the plastic locking tie downward and then cut off the excess end of the tie to 2 10 mm 0 08 0 39 in Fasten the clutch cable with the plastic band making sure that the cable is positioned within the 60 angle shown in t
250. ith the plastic locking tie 2 MIS N SAANS v Sene 27 6 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 28 4 54 FRONT FORK STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 1115 Nm 11 5 kg 85 ft Ib Bn 52 Nm 5 2 m kg 37 ft Ib 2nd 14 Nm 1 4 kg 10 ft Ib NEM E Refer to GENERAL CHASSIS on pago _ Front fork legs Referto FRONT FORK on page 4 44 HEN Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE page 7 5 2 Canister for California only Refer to THROTTLE BODIES on page 7 8 Refer to AIR INDUCTION SYSTEM on Air induction system cover page 7 15 Rectifier regulator holder ME E EN Left coupler holder Horn connector NE EN 9 Disconnect Disconnect Disconnect Front brake hose joint 4 55 STEERING HEAD Removing the lower bracket 115 Nm 11 5 kg 85 ft Ib 151 52 Nm 5 2 kg 37 ft Ib 14 Nm 1 4 kg 10 ft Ib e _ hese Cae fwe Upper nga 15 Upper ring nut 38 UpperBearing cover
251. k gap un til a misfire occurs DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor Crankshaft position sensor resis tance 248 372 at 20 68 F a Connect the pocket tester Q x 100 to the crankshaft position sensor coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gray 4 Negative tester probe gt black 2 Bley 2 1 b Measure the crankshaft position sensor sistance DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE LEAN ANGLE SENSOR 1 Remove e Lean angle sensor from the bracket 2 Check ean angle sensor output voltage Out of specification Replace ELECTRICAL COMPONENTS Lean angle sensor output voltage Less than 65 0 4 1 4 V More than 65 3 7 4 4 V a Connect the lean angle sensor coupler to the lean angle sensor b Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt yellow green 1 Negative teste
252. kage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately NOTE In order to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicators a almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 17 OS a w 5 EN 0 p v o CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads j 3 22 1 Operate the brake 2 Check Rear brake pad Wear limit reached Replace the brake pads as set Refer to REAR BRAKE on page 4 29 Limit 1 0 mm 0 04 in EAS21280 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose hold
253. l injection system fuse Starter relay 9 Neutral switch 10 EXUP servo motor 11 Rear brake light switch 12 sensor 13 Sidestand switch 14 Speed sensor 15 Oil level switch 16 Ignition coil 17 Radiator fan motor 18 Rectifier regulator 19 Horn 20 Fuse box radiator fan motor signaling system ignition headlight OF Y 8 78 ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 8 79 Air temperature sensor Atmospheric pressure sensor Coolant temperature sensor Fuel pump ECU engine control unit Lean angle sensor Relay unit Turn signal relay 9 Crankshaft position sensor 10 Intake air pressure sensor 11 Throttle servo motor 12 Throttle position sensor for throttle cable pulley 13 Throttle position sensor for throttle valves 14 Cylinder identification sensor 15 Radiator fan motor relay 16 Headlight relay dimmer 17 Headlight relay on off 5 WD 8 80 ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS CHECKING THE SWITCHES EAS27980 ARO je 10 IB e 190 8 81 9 Or OY e Ic Clutch switch Main switch Dimmer switch Horn switch Turn signal switch Sidestand switch Front brake light switch Engine stop switch Start switch 10 Neutral switch 11 Rear brake light switch 6 82 ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS Check each switch for
254. larly sensitive to foreign material When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 4 Check Cap bolt O ring 1 Damage wear Replace Cap bolt collar projections 2 Cracks damage Replace EAS23040 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs EWA13660 e Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability NOTE When assembling the front fork leg be sure to replace the following parts Oil seal Dust seal O ring Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 Inner tube 2 FRONT FORK ECA14210 CAUTION Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate Inner tube s outer surface Recommended oll Ohlins R amp T43 ACC RT43F 00 00 3 Tighten Damper rod assembly Syr Damper rod assembly 35 Nm 3 5 m kg 25 ft Ib NOTE Tighten the damper rod assembly with the damper rod holder 1 Damper rod holder 90890 01506 YM 01506 4 49 qx 1 4 Install Dust seal 1 Oil seal clip
255. lays intake air pressure Compare the actually mea sured atmospheric pres sure with the meter display value without cranking the engine Intake air temperature Displays the intake air tem Compare the actually mea perature sured air temperature with the meter display value Coolant temperature Displays the coolant temper Compare the actually mea ature sured coolant temperature with the meter display val ue Vehicle speed pulse Check that the number in creases when the rear wheel is rotated The num ber is cumulative and does not reset each time the wheel is stopped Lean angle sensor Remove the lean angle sensor and incline it more DRE than 65 degrees e Overturned Fuel system voltage bat Approximately 12 0 Set the engine stop switch tery voltage to Q and then compare with the actually measured battery voltage If the bat tery voltage is lower re charge the battery Throttle position sensor for throttle valves signal 2 Fully closed position Check with throttle valve fully closed Fully opened position Check with throttle valve fully opened 8 44 FUEL INJECTION SYSTEM Meter display Checking method Throttle position sensor for throttle cable pulley signal 1 Fully closed position Check with throttle grip fully closed Fully opened position Check with throttle grip fully opened Throttle position sensor for throttle cable pulley signal 2 Ful
256. led fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug e Worn or damaged electrode Worn or damaged insulator 4 Ignition coil s e Cracked or broken ignition coil body Broken or shorted primary or secondary coils 5 Ignition system Faulty ECU e Faulty crankshaft position sensor Faulty cylinder identification sensor 6 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 7 Starting system e Faulty starter motor e Faulty starter relay Faulty starting circuit cut off relay e Faulty starter clutch EAS28490 INCORRECT ENGINE IDLING SPEED Engine 1 Cylinder s and cylinder head Incorrect valve clearance Damaged valve train components 2 Air filter Clogged air filter element Fuel system 1 Throttle body ies Damaged or loose throttle body joint Improperly synchronized throttle bodies Improper throttle cable free play Flooded throttle body Faulty air induction system Electrical system 1 Battery Discharged battery Faulty battery 2 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 3 Ignition coil s Broken or short
257. limit 0 030 mm 0 0012 in 5 10 CAMSHAFTS 4 Measure Camshaft journal to camshaft cap clearance Out of specification Measure the camshaft journal diameter Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in a Install the camshaft into the cylinder head without the camshaft caps b Position a strip of Plastigauge camshaft journal as shown ali onto the c Install the camshaft Caps NOTE Tighten the camshaft cap bolts stages and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge Camshaft cap bolt 10 Nm 1 0 m kg 7 2 ft lb d Remove the camshaft caps and then mea sure the width of the Plastigauge CAMSHAFTS DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 5 Measure Camshaft journal diameter Out of specification Replace the camshaft Within specification Replace the cylinder head and the camshaft caps as a set Camshaft journal diameter 22 459 22 472 mm 0 8842 0 8847 523870 CHECKING THE TIMING CHAIN CAMSHAFT SPROCKETS AND TIMING CHAIN GUIDES 1 Check Timing chain 1 Damage stiffness Replace the timing chain and camshaft and camshaft sprocket as a Set 2 Check Camshaft sprocket Mor
258. ling and loss of stability Securely support the vehicle so that there is no danger of it falling over Spring preload ECA13570 CAUTION Grooves are provided to indicate the ad justment position Never go beyond the maximum or mini mum adjustment positions 1 Adjust Spring preload Turn the adjusting bolt 1 in direction or Direction Spring preload is increased suspen sion is harder Direction b Spring preload is decreased suspen sion is softer Spring preload adjusting positions Minimum 0 Standard 1 Maximum 2 Current setting 3 Cap bolt collar Rebound damping ECA13590 CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a the adjusting screw 1 in direction a or CHASSIS Direction a turn in Rebound damping is increased sus pension is harder Direction b turn out Rebound damping is decreased sus pension is softer Rebound damping adjusting posi tions Minimum 17 click s out Standard 15 click s out Maximum 1 click s With the adjusting screw fully turned in
259. livery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake fluid reservoir Cracks damage Replace Brake fluid reservoir diaphragm Cracks damage Replace 4 Check Rear brake hose Brake fluid reservoir hose Cracks damage wear Replace 4 38 REAR BRAKE EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid e Never use solvents on internal brake com ponents Recommended fluid DOT 4 EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Rear brake hose 1 Copper washers 2 e Rear brake hose union bolt 3 Rear brake hose union bolt 30 Nm 3 0 m kg 22 ft lb EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 47 ECA14160 CAUTION When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown 2 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid Recommended fluid DOT 4 EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poo
260. ll of the positions rebalance it 2947 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA eT SN 2 01002 CHECKING THE FRONT BRAKE DISCS 5 Install Refer to CHECKING THE FRONT BRAKE Front wheel axle DISCS on page 4 22 Front wheel axle bolt Front wheel axle pinch bolts EAS22000 INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS The following procedure applies to both of the brake discs 4 9 FRONT WHEEL EWA13500 Front wheel axle WARNING 91 Nm 9 1 m kg 66 ft lb Make sure the brake hose is routed properly Front wheel axle pinch bolt 21 Nm 2 1 m kg 15 ft lb EC2C01015 CAUTION Before tightening the wheel axle push down hard on the handlebar several times and check if the front fork rebounds smoothly NOTE Lubricate the front wheel axle bolt mating surfac es with lithium soap based grease a Insert the front wheel axle from the right side and tighten it with the front wheel axle bolt from the left side to 91 Nm 9 1 m kg 66 ft lb without performing temporary tightening b In the order pinch bolt 2 pinch bolt 1 gt pinch bolt 2 tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening c Check that the right end of the front wheel axle is flush with the front fork If necessary manually push the front wheel axle or lightly tap it with a soft hammer until its end is
261. llow Defective neutral switch Execute the diagnostic mode Code No 21 Replace if defective Refer to CHECKING THE SWITCHES on page 8 81 Faulty shift drum neutral detection ar Replace if defective Refer to TRANSMISSION on page 5 71 8 65 FUEL INJECTION SYSTEM Fault code No Symptom supply to the injectors and fuel pump is not mal Diagnostic code No o Fuel system voltage battery voltage Item components and probable Check or maintenance job Reinstatement cause method Connections Check the couplers for any pins Turning the e Relay unit coupler fuel pump relay that may be pulled out main switch to Main wire harness ECU coupler Check the locking condition of ON when the the couplers engine stop f there is a malfunction repair it switch is set to and connect the coupler se ieu curely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between relay unit coupler and ECU coupler blue yellow blue yellow red blue red blue Between relay unit coupler and starter relay coupler red red Between relay unit coupler and right handlebar switch coupler red black red black Malfunction or open circuit in fuel Execute the diagnostic mode pump relay Code No 09 Replace if defective f there is no malfunction with the fuel pump relay replace the ECU 8
262. lubricant Recommended lubricant Engine oil 2 Apply Sealant onto the crankcase mating surfaces 5 Yamaha bond No 1215 90890 85505 Three Bond 12159 NOTE Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear ings Do not apply sealant to within 2 3 mm 0 08 0 12 in of the crankshaft journal bearings 1 Three Bond No 12159 3 Install Dowel pins 4 Setthe shift drum assembly and transmission gears in the neutral position 5 Install e Lower crankcase 1 onto the upper crankcase 2 5 57 ECA13980 CAUTION Before tightening the crankcase bolts make sure the transmission gears shift correctly when the shift drum assembly is turned by hand 6 Install Crankcase bolts NOTE Lubricate the bolts 1 10 thread part and washers with engine oil Lubricate the bolts 11 29 thread part and mating surfaces with engine oil Finger tighten the crankcase bolts M8 x 115 mm bolts 9 e M8 85 mm bolts 1 7 10 e M8 x 65 mm bolts 11 12 e M6 x 80 mm bolt 28 e M6 x 65 mm shoulder bolts 13 14 e M6 x 65 mm bolts 16 20 21 e M6 x 55 mm bolts 15 22 27 e M6 45 mm bolts 177 419 e M6 x 30 mm bolt 29 7 Tighten e Crankcase bolts 1 10 Crankcase bolt M8 x 115 mm M8 x 8
263. ly closed position Check with throttle grip fully closed Fully opened position Check with throttle grip fully opened Sidestand switch Set ON OFF the sidestand e Stand retracted switch with the transmis sion in gear e Stand extended Neutral switch Shift the transmission e Neutral n gear EEPROM fault cylinder No No history History exists 01 04 fault cylinder No If more than one cylinder is defective the display changes every two seconds to show all the detected inder numbers When all cylinder numbers are shown the display re peats Malfunction history code No history 00 History exists Fault codes 11 60 If more than one code number is detected the dis play changes every two seconds to show all the de tected code numbers When all code numbers are shown the display re peats 8 45 Malfunction history code erasure No history History exists Malfunction code reinstate for fault code No 24 and 40 only No malfunction code e Malfunction code exists FUEL INJECTION SYSTEM Meter display Checking method 00 Displays the total number of malfunctions including the current malfunction that have occurred since the history was last erased For example if there have been three malfunctions 03 is displayed To erase the history set the engine stop switch from to koe 00 Fault codes 24 40 To reinsta
264. m the connecting rods and connecting rod Caps NOTE Identify the position of each big end bearing so that it can be reinstalled in its original place 3 Remove Piston pin clips 1 e Piston pin 2 e Piston 3 Connecting rod 4 ECA13810 CAUTION Do not use a hammer to drive the piston pin out NOTE For reference during installation put an identi fication mark on each piston crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 5 Piston pin puller set 90890 01304 Piston pin puller YU 01304 4 Remove Top ring 2nd ring Oil ring When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24410 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl inders and pistons 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance Measure cylinder bore with the cylinder bore gauge CONNECTING RODS AND PISTONS NOTE
265. manufacturer G8R 30Y V4 OMRON Fan motor relay Model manufacturer ACM33211M05 MATSUSHITA Fuses Main fuse 50 0A Headlight fuse 15 0A Signaling system fuse 10 0A Ignition fuse 15 0A Radiator fan fuse 15 0 2 Fuel injection system fuse 15 0A Backup fuse 7 5A Electric throttle valve fuse Reserve fuse 15 0 Reserve fuse 10 0A Reserve fuse 7 5 Reserve fuse 15 0A 2 15 TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan dard fasteners with a standard ISO thread pitch Tightening torque specifications for special com ponents or assemblies are provided for each chapter of this manual To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter General tightening A nut bolt torques eo 96 2 16 TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Size Tightening torque Camshaft cap bolt intake and exhaust M6 20 10 Nm 1 0 m kg 7 2 ft lb Cylinder head stud bolt exhaust MB 8 11 fb pipe assembly M10 30 Nm 3 0 m kg 22 ft lb 60 Nm 6 0 m kg
266. met replace the clutch plate 2 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specification Replace the clutch springs as a set Clutch spring free length 55 00 mm 2 17 in Minimum length 5 42 54 00 mm 2 13 in mr CLUTCH EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause er ratic clutch operation 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch boss splines will cause er ratic clutch operation EAS25170 CHECKING THE PRESSURE PLATE 1 Check Pressure plate 1 Cracks damage Replace Bearing 2 Damage wear Replace 5 43 EAS25200 CHECKING THE PRIMARY DRIVE GEAR 1 Check Primary drive gear Damage wear Replace the clutch housing and crankshaft as a set Excessive noise during operation Replace the clutch housing and crankshaft as a set EAS25210 CHECKING THE PRIMARY DRIVEN GEA
267. n b Brake light comes on later A ON DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA13100 Bleed the hydraulic brake system whenever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty NOTE Be careful not to spill any brake fluid or allow the brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this pre caution could allow air to enter the hydraulic brake system considerably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Hydraulic brake system a Fill the brake fluid reservoir to the proper level with the recommended brake fluid b Install the brake fluid reservoir diaphragm Connect a clear plastic hose 1 tightly to the bleed screw 2 3 24 CHASSIS A Front brake master cylinder B Front brake caliper C Rear brake caliper NOTE The bleeding order of the front hydraulic brake system is the following 1 Front brake master cylinder 2 Front brake calipers 3 Fr
268. n page 8 81 Replace the main switch Check the radiator fan motors gt Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 96 Replace the radiator fan motor s OK 5 Check the radiator fan motor relay gt Refer to CHECKING THE RE Replace the radiator fan motor relay LAYS on page 8 89 OK Check the coolant temperature NG Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 97 Replace the coolant temperature sensor 7 Check the entire cooling system s gt wiring Properly connect or repair the cooling sys Refer to CIRCUIT DIAGRAM on tem s wiring page 8 29 OK This circuit is OK 8 31 COOLING SYSTEM FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM r 1 I I vig Govag C 1444 wie aora 1 ve amp 1 09 d Va 169 1 Wd Wd Mid Va a TE 1 1 1 99 uva 7 TTE Vv mt D Va Vy wa O mph En did 97197 1 Wd 610v 18 330 NO 553 SS3NuVH 3uIM
269. nd be in the following sequence L Carefully position the shift forks so that they are installed correctly into the transmission gears Install shift fork C into the groove a in the 3rd and 4th pinion gear on the main axle 4 Install e Shift fork R 1 e Shift fork L 2 5 78 TRANSMISSION Shift fork guide bar e Springs Shift drum retainers 3 Bearing Oil seal e Circlip 4 Drive axle assembly 5 Shift drum retainer bolt 10 Nm 1 0 m kg 7 2 ft Ib LOCTITE NOTE Install shift fork R into the groove in the 5th wheel gear and shift fork L into the groove b in the 6th wheel gear on the drive axle Install the shift drum retainer with its OUT mark c facing outward Make sure that the drive axle bearing circlip 4 is inserted into the grooves d in the upper crankcase NES pi tj e 176 3 p lt 5 79 COOLING SYSTEM RADIATOR HMM IM EE 6 1 CHECKING THE RADIATOR 6 3 INSTALLING THE RADIATOR A 6 3 6 4 OL COOLER 6 6 INSTALLING 6 6 THERMOSTAT eine 6 7 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT 6 8
270. ndicator light brightness This function allows you to adjust the bright ness of the indicator light to suit your prefer ence NOTE In this mode the odometer trip meter fuel re serve trip meter stopwatch display shows the current setting for each function except the shift timing indicator light activity function adjust the brightness of the multi function meter displays and tachometer 1 Turn the key to OFF 2 Push and hold the SELECT button 3 Turn the key to ON and then release the SELECT button after five seconds Push the button to select the de sired brightness level Push the SELECT button to confirm the se lected brightness level The control mode changes to the shift timing indicator light ac tivity function 4 5 set the shift timing indicator light activity func tion 1 Push the RESET button to select one of the following indicator light activity settings The indicator light will stay on when activated This setting is selected when the indicator light stays on The indicator light will flash when activated This setting is selected when the indicator light flashes four times per second e The indicator light is deactivated in other words it will not come on or flash This set ting is selected when the indicator light flash es once every two seconds Push the SELECT button to confirm the se lected indicator light activity
271. nent replace ment schedule Brake pads If necessary Every two years and Brake fluid whenever the brake is disassembled 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 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air EWA13600 Whenever a brake caliper is disassembled replace the piston seals EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals EAS22450 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Front brake caliper 1 temporarily Copper washers Front brake hose 2 Front brake hose union bolt 3 Recommended fluid DOT 4 FRONT BRAKE Syr Front brake hose union bolt 30 Nm 3 0 m kg 22 ft Ib EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING
272. ness Pass the starter motor lead speed sensor lead sidestand switch lead and oil level switch lead between the holder on the engine and the crankcase boss making sure to route the starter motor lead to the outside of the other leads Fasten the fuel tank drain hose and fuel tank breather hose except for California with the holder making sure to fasten the hoses below the holder on the engine 30 50 mm 1 18 1 97 Pass the fuel tank hose fuel tank breather hose except for California and sidestand switch lead through the guides on the sidestand shield making sure to route the lead to the inside of the hoses Pass the AC magneto lead between the frame and the throttle body and then route it under the radiator inlet pipe After connecting the AC magneto coupler slide the cover over the coupler To the front left turn signal position light Pass a plastic locking tie through the holes in the coupler holder and then fasten the wire harness with the tie making sure to install the tie with its buckle positioned toward the rear of the vehicle and its end facing inward Cut off the excess end of the plastic locking tie to 2 10 mm 0 08 0 39 Bend back the left radiator fan motor lead as shown in the illustration and then insert the projection on the coupler into the hole in the left coupler holder The lead may be routed to the inside or the outside of the coupler Route the AC magneto
273. ng For assembly reverse the disassembly pro cedure 4 13 22040 REMOVING THE REAR WHEEL 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove Rear brake caliper 1 NOTE Do not depress the brake pedal when removing the brake caliper 3 Remove Rear wheel axle nut 1 e Rear wheel axle 2 Rear wheel NOTE Push the rear wheel forward and remove the drive chain from the rear wheel sprocket EAS22080 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4 7 REAR WHEEL EAS22090 CHECKING THE REAR WHEEL 1 Check Rear wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 7 2 Check e Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 33 3 Measure Radial wheel runout e Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 7 Radial wheel runout limit 1 0 mm 0 04 in Lateral wheel runout limit 0 5 mm 0 02 in 4 14 ET2C01024 CHECKING THE REAR BRAKE CALIPER BRACKET 1 Check Rear brake caliper bracket Cracks damage Replace E
274. ng race from the lower bracket 3 with a floor chisel 4 and ham mer c Install new bearing races CAUTION If the bearing race is not installed properly the steering head pipe could be damaged b NOTE Always replace the bearings and bearing races as a set S AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 Check Upper bracket Lower bracket along with the steering stem Bends cracks damage Replace EAS23140 INSTALLING THE STEERING HEAD 1 Lubricate Upper bearing Lower bearing Bearing races Recommended lubricant Lithium soap based grease 4 58 2 Install Lower ring nut 1 e Rubber washer 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 26 _ EI 3 M 3 Install Upper bracket e Steering stem nut e Right handlebar assembly Left handlebar assembly NOTE Temporarily tighten the steering stem nut and handlebar bolts 4 Install Front fork legs Refer to FRONT FORK on page 4 44 NOTE Temporarily tighten the lower bracket pinch bolts 5 Tighten e Steering stem nut Steering stem nut 115 Nm 11 5 m kg 85 6 Install Front brake hose joint bracket 1 Front brake hose joint bracket bolt 10 Nm 1 0 m kg 7 2 ft lb e Lower bracket cover 2 Lower bracket cover bolt 7 Nm 0 7 m kg 5
275. ng the engine 82 92 C 180 198 F oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine Out of specification Adjust 3 Remove Left lower side cowling Faulty oil pump Left bottom cowling s Clogged oil filter Refer to GENERAL CHASSIS on page 4 1 Below specification Leaking oil passage 4 Remove Broken or dam Main gallery bolt 1 aged oil seal EWA12980 The engine muffler and engine oil are ex Leaking oil passage Faulty oil filter Oil viscosity too tremely hot high Above specification 7 Install Main gallery bolt M Main gallery bolt 8 Nm 0 8 m kg 5 8 ft lb 8 Install Left bottom cowling Left lower side cowling Refer to GENERAL CHASSIS on page 4 1 5 Install Oil pressure gauge set 1 ADJUSTING THE CLUTCH LEVER FREE Oil pressure adapter H 2 PLAY 1 Check vz eet Clutch lever free play 4 Oil pressure adapter H Out of specification Adjust Clutch lever free play y 10 0 15 0 mm 0 39 0 59 in AS 2 p QUO Y VAS co S 9 9 6 Engine oil pressure 2 Adjust at the following conditions Clutch lever free play 3 13 Handlebar side Turn the adjusting bolt 1
276. ng the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance 2 Replace e Valve guide NOTE NOTE To ease valve guide removal and installation After replacing the valve guide reface the valve and to maintain the correct fit heat the cylinder seat head to 100 C 212 F in an oven Remove the valve guide with the valve guide remover 1 5 20 Valve guide remover 04 5 90890 04116 Valve guide remover 4 5 mm YM 04116 Valve guide installer 04 5 90890 04117 Valve guide installer 4 5 mm YM 04117 Valve guide reamer 04 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 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 Measure Valve margin thickness D Out of specification Replace the valve Valve margin thickness D intake 0 90 1 10 mm 0 0354 0 0433 Limit 0 8 mm 0 03 in Valve margin thickness D ex haust 1 10 1 30 mm 0 0433 0 0512 in Limit 1 0 mm 0 04 in 6 Measure Valve stem runout Out of specification Replace the valve NOTE e When installing a new valve always replace
277. nut 70 Nm 7 0 m kg 50 ft lb Swingarm pivot shaft ring nut 95 Nm 9 5 m kg 68 ft lb 5 Remove Swingarm pivot shaft Swingarm pivot shaft 1 16 Nm 1 6 m kg 11 ft lb NOTE Loosen the swingarm pivot shaft with the damp er rod holder 24 mm 2 b Measure the swingarm side play A by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers Damper rod holder 24 mm and dust covers 90890 01328 01328 Swingarm side play at the end of the swingarm 1 0 mm 0 04 in d Check the swingarm vertical movement B by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers bear ings washers and dust covers EAS23360 CHECKING THE SWINGARM 1 Check e Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace 3 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 71 4 67 SWINGARM WARNING Do not attempt to straighten bent pivot shaft 3 Wash Pivot shaft oH Dust covers m oN 4 Spacers Washers 3 Bearings b b Recommended cleaning solvent 5 Swingarm Kerosene 6 Swingarm pivot shaft 7 Bolt 4 Check A Left side Dust covers
278. ocket tester 1 Disconnect YU 03112 C e Lead Coupler _ __ e Connector f there is no continuity clean the terminals 2 Check When checking the wire harness perform e ead steps 1 to 3 Coupler As a quick remedy use a contact revitalizer e Connector available at most part stores Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Check e All connections Loose connection gt Connect properly NOTE gt If the 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 SPECIAL TOOLS 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 NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Reference Pocket tester 90890 03112 Analog pocket tester YU 03112 C Valve lapper 90890 04101 Valve lapping tool YM A8998 Vacuum gauge
279. oil filter cartridge mended engine oil Engine oil quantity Total amount 3 40 L 3 59 US qt 2 99 Imp qt Without oil filter cartridge re placement 2 40 L 2 54 US qt 2 11 Imp qt With oil filter cartridge replace ment 2 60 L 2 75 US qt 2 29 Imp qt e Tighten the new oil filter cartridge to specifi 11 lnstal cation with an oil filter wrench Engine oil filler cap 12 Start the engine warm it up for several Syr Cil filter cartridge utes and then turn it off 17 Nm 1 7 m kg 12 16 13 Check Engine f Insert the fuel tank breather hose except for for engine oil leaks California and fuel tank overflow hose into 14 Check the guide and place them in their original po Engine oil level sition Refer to CHECKING THE ENGINE OIL g Install the shift arm 1 by aligning the match LEVEL on page 3 10 mark a on the shift arm with the match mark b on the shift shaft 2 EAS20820 MEASURING THE ENGINE OIL PRESSURE Syr Shift arm bolt 1 Check 10 Nm 1 0 m kg 7 2 ft Ib Engine oil level Below the minimum level mark Add the recommended engine oil to the proper level 3 12 ENGINE 2 Start the engine warm it up for several min utes and then turn it off Oil pressure hot _ ECA13410 80 0 kPa 1300 r min 1 1 6 CAUTION psi 1300 r min 0 80 When the engine is cold the engine oil will kgf cm 1300 r min Oil temperature have a higher viscosity causi
280. olvents on internal brake com ponents Recommended fluid DOT 4 22540 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Front brake master cylinder 1 Front brake master cylinder holder 2 Front brake master cylinder hold er bolt 13 Nm 1 3 m kg 9 4 ft lb NOTE Install the brake master cylinder holder with the UP mark a facing up Align the mating surfaces of the brake master cylinder holder with the punch mark b on the handlebar First tighten the upper bolt then the lower bolt 2 Install e Front brake hose 1 Copper washers 2 e Front brake hose union bolt 3 Syr Front brake hose union bolt 30 Nm 3 0 m kg 22 1 EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 47 NOTE _ _____ __ m Install the brake hose at a 15 8 angle to the front brake master cylinder as shown in the il lustration While holding the brake hose tighten the union bolt Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 4 27 FRONT BRAKE 3 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber se
281. om the wire harness 2 Connect the pocket tester Q x 1 and battery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 ELECTRICAL COMPONENTS Relay unit starting circuit cut off relay 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe E od Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 8 89 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 lt G INO 4182 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 8 90 ELECTRICAL COMPONENTS ET2C01021 CHECKING THE TURN SIGNAL RELAY 1 Check Turn signal relay input voltage Out of speci
282. on describes the measures per fault code number displayed on the meter Check and service the items or components that are the probable cause of the malfunction following the order given After the check and service of the malfunctioning part has been completed reset the meter display ac cording to the reinstatement method Fault code No Code number displayed on the meter when the engine failed to work normally Refer to Self Diagnostic Function table Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to DIAGNOSTIC on page 8 40 8 48 FUEL INJECTION SYSTEM Fault code No Symptom normal signals are received from the cylinder identifi cation sensor when the engine is started or while the ve hicle is being driven Installed condition of cylinder identifi cation sensor Connections Cylinder identification sensor cou pler Main wire harness ECU coupler Open or short circuit in wire harness Defective cylinder identification sen sor Reinstatement method Cranking the engine Check for looseness or pinching Check the couplers for any pins that may be pulled out e Check the locking condition of the couplers f there is a malfunction repair it and connect the coupler se Repair or replace if there is open or short circuit Between the cylinder identifica tion sensor coupler and ECU couple
283. oner The arrow mark b on the timing chain ten sioner should face up 6 Rotate the crankshaft a few times to release the timing chain tensioner rod NOTE If the engine is not disassembled set the engine stop switch to g and then crank the engine a few times by pressing the start switch for approx imately 0 5 1 0 second each time 7 Check that the timing chain is taut If the chain is slack reinstall the timing chain ten sioner NOTE If the engine is not disassembled start the en gine and check for any abnormal noise If any abnormal noise is heard reinstall the timing chain tensioner 8 Check mark Make sure the TDC mark on the pickup rotor is aligned with the crankcase mating surface Af Aso 42 gt 4 EE Ln Camshaft sprocket match mark Make sure the marks on the camshaft sprockets are aligned with the edge of the cyl inder head d Out of alignment Adjust Hefer to the installation steps above CAMSHAFTS 9 Measure e Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 4 10 Install Cylinder head cover gasket e Cylinder head cover Syr Cylinder head cover bolt 12 Nm 1 2 m kg 8 7 ft lb NOTE Apply bond TB1541B 1 onto the mating sur faces of the cylinder head cover and cylinder head cover gasket Apply bond TB1215B
284. ont brake master cylinder d Place the other end of the hose into a con tainer Slowly apply the brake several times Fully pull the brake lever or fully press down the brake pedal and hold it in position g Loosen the bleed screw NOTE Loosening the bleed screw will release the pres sure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend f h Tighten the bleed screw and then release the brake lever or brake pedal Repeat steps to h until all of the air bub bles have disappeared from the brake fluid in the plastic hose Tighten the bleed screw to specification Bleed screw front brake master cylinder 6 Nm 0 6 m kg 4 3 ft lb Bleed screw front brake caliper 5 Nm 0 5 m kg 3 6 ft lb Bleed screw rear brake caliper 5 Nm 0 5 m kg 3 6 ft lb k Fill the brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 22 After bleeding the hydraulic brake system check the brake operation 521380 ADJUSTING THE SHIFT PEDAL NOTE The shift pedal position is determined by the in stalled shift rod length a 1 Remove Left lower side cowling Refer to GENERAL CHASSIS on page 4 1 2 Measure Installed shift rod length Incorrect Adjust Install
285. oosen the nut using a proper tool that has a thickness of 3 mm 0 12 in or less 6 3 d Remove the cap bolt e Remove the rod holder and fork spring com pressor f Remove the nut and spacer 3 Drain Fork oil Stroke the damper rod 1 several times while draining the fork oil 1 4 Remove Damper rod assembly NOTE Remove the damper rod assembly with the damper rod holder 1 Damper rod holder 90890 01506 YM 01506 FRONT FORK E 1 5 Remove Oil seal clip 1 with a flat head screwdriver 1 2 523010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube Outer tube Bends damage scratches Replace EWA13650 WARNING Do not attempt to straighten bent inner tube as this may dangerously weaken it 2 Measure Spring free length Out of specification Replace Fork spring free length 247 0 mm 9 72 in Limit 242 1 mm 9 53 in 3 Check Damper rod Damage wear Replace Obstruction Blow out all of the oil passag es with compressed air Damper adjusting rod Bends damage Replace ECA14200 CAUTION The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particu
286. ough f several times un til all the marks come to rest at the same spot g The spot where all the marks come to rest is the front wheel s heavy spot X DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Adjust Front wheel static balance a Install a balancing weight 1 onto the rim actly opposite the heavy spot X NOTE Start with the lightest weight FRONT WHEEL 1 Install Front brake disc Front brake disc bolt 18 Nm 1 8 m kg 13 ft Ib LOCTITE NOTE Tighten the brake disc bolts in stages and in a crisscross pattern b Turn the front wheel 90 so that the heavy spot is positioned as shown we c If the heavy spot does not stay in that posi Front brake discs tion install a heavier weight Refer to CHECKING THE FRONT BRAKE d Repeat steps b and c until the front wheel DISCS on page 4 22 is balanced 3 Lubricate DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA seal lips 4 Check Recommended lubricant Front wheel static balance Lithium soap based grease a Turn front wheel and make sure it stays at 4 Install each position shown siEront wheel NOTE Install the tire and wheel with the mark 1 point ing in the direction of wheel rotation ex po omo b If the front wheel does not remain stationary n at a
287. p 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 6 Attach e Headlight bulb holder 7 Connect e Headlight coupler 8 Install e Headlight bulb cover EAS21810 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights 1 Adjust Headlight beam vertically a the adjusting screw 1 in direction a or Direction a Headlight beam is raised Direction b Headlight beam is lowered ELECTRICAL SYSTEM A Left headlight B Right headlight DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Adjust Headlight beam horizontally a Turn the adjusting screw 1 in direction or b Direction a Headlight beam moves to the left Direction b Headlight beam moves to the right A Left headlight B Right headlight 3 36 ELECTRICAL SYSTEM 3 37 CHASSIS GENERAL CHASSIS 4 1 FRONT WHEEL 4 4 REMOVING THE FRONT WHEEL 4 7 D
288. part s 1 Rider seat 2 Fuel tank 3 Bottom cowlings 1 Check the fuse gt Main Refer to CHECKING THE FUS ES on page 8 85 Check the battery gt Refer to CHECKING AND CHARGING THE BATTERY on page 8 86 Check the stator coil NG gt Refer to CHECKING THE STATOR COIL on page 8 94 OK Replace the fuse Clean the battery terminals Recharge or replace the battery Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI Replace the rectifier regulator FIER REGULATOR on page 8 94 Check the entire charging system s gt wiring Properly connect or repair the charging Refer to CIRCUIT DIAGRAM on page 8 13 OK The charging system circuit is OK system s wiring 8 15 CHARGING SYSTEM LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM EAS27240 EAS27250 AvH9 1 1 99 TA ew 4 Gong Owe 6 ag 29 9 m 610v18 95 pun farijwe few va ana gt lt 2330 E BIO SS3NHVH 3HIM SS3NHVH 3UIM ANS 1
289. position check that the end of the adjusting bolt is visible through the hole c Tighten the locknut 1 to specification BN Locknut 25 16 Nm 1 6 m kg 11 ft Ib EW2C01004 A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance and could result in loss of control and possibly an accident Therefore check and if neces sary bleed the brake system EC2C01009 CAUTION After adjusting the installed rear master inder length make sure there is no brake drag AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Adjust Rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 23 EAS21240 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface NOTE e Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check e Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Front brake Recommended fluid DOT 4 Rear brake Recommended fluid DOT 4 N ey e M A Front brake B Rear brake CHASSIS EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing lea
290. pump housing to inner and outer rotor clearance 0 06 0 11 mm 0 0024 0 0043 in Limit 0 18 mm 0 0071 in 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 e Spring 3 O ring 4 Damage wear Replace the defective part s s o2 2 3 24980 CHECKING THE OIL PIPES The following procedure applies to all of the oil delivery pipes 1 Check Ventilation chamber oil drain pipe Oil pipe Damage Replace Obstruction Wash and blow out with com pressed air EAS24990 CHECKING THE OIL STRAINER 1 Check e Oil strainer Damage Replace Contaminants Clean with solvent EAS25010 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant Recommended lubricant Engine oil 2 Install Oil pump driven sprocket Oil pump housing 1 Washer 2 e Pin 3 Oil pump inner rotor 4 Oil pump outer rotor NOTE When installing the inner rotor align the pin 3 in the oil pump shaft with the groove in the in ner rotor 4 Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 53 OIL PUMP EAS25050 INSTALLING THE OIL PAN 1 Install Oil pan gasket
291. put the Plastigauge over the oil hole in the crankshaft journal 5 68 e NK e Install the crankshaft journal lower bearings 1 into the lower crankcase and assemble the crankcase halves NOTE Align the projections a of the crankshaft jour nal lower bearings with the notches b in the lower crankcase Do not move the crankshaft until the clearance measurement has been completed Tighten the bolts to specification in the tight ening sequence cast on the crankcase Refer to CRANKCASE on page 5 55 Remove the lower crankcase and the crank shaft journal lower bearings Measure the compressed Plastigauge width on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft journal bear 4 Select Crankshaft journal bearings 3 5 5 69 CRANKSHAFT NOTE The numbers A stamped into the crankshaft web and the numbers B stamped into the lower crankcase are used to determine the re placement crankshaft journal bearing sizes J4 J5 refer to the bearings shown the crank shaft illustration f J4 J5 are the same use the same size for all of the bearings a VE dr Leg Ey AN Ji J2 Js Ja Js For example if the crankcase J and crank
292. r blue blue white black white black black blue black blue Replace if defective Refer to CHECKING THE CYLINDER IDENTIFICATION SENSOR page 8 100 8 49 FUEL INJECTION SYSTEM Fault code No Symptom No normal signals are received from the crankshaft posi tion sensor Item components and probable Check or maintenance job Reinstatement method Installed condition of crankshaft posi Check for looseness or pinching Cranking the Connections Check the couplers for any pins Crankshaft position sensor coupler that may be pulled out Main wire harness ECU coupler e Check the locking condition of the couplers f there is a malfunction repair it and connect the coupler se Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou pler gray gray black blue black blue Defective crankshaft position sensor Replace if defective Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 93 8 50 FUEL INJECTION SYSTEM Fault code No 13 Symptom Intake air pressure sensor open or short circuit detected Diagnostic code No Intake air pressure sensor Check or maintenance job Reinstatement method Connections Check the couplers for any pins Reinstated au e Intake air pressure sensor coupler that may be pulled out tomaticall
293. r brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 4 Check Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 22 1 D miy CN LJ R 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM page 3 24 6 Adjust Brake pedal position Refer to ADJUSTING THE REAR DISC BRAKE on page 3 21 7 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 23 4 39 REAR BRAKE HANDLEBARS EAS22850 HANDLEBARS Removing the handlebars 34 115 Nm 11 5 kg 85 ft Ib 13 Nm 1 3 m kg 9 4 ft Ib 13 Nm 1 3 m kg 9 4 ft Ib 26 Nm 2 6 kg 19 ft Ib 11 Nm
294. r arrangement Bore x stroke Compression ratio Standard compression pressure at sea level Minimum maximum Starting system Fuel Hecommended fuel Fuel tank capacity Fuel reserve amount Engine oil Lubrication system Type Recommended engine oil grade Engine oil quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil cooler capacity including all routes Oil pressure hot Cil filter Oil filter type Oil pump Oil pump type Inner rotor to outer rotor tip clearance Limit Outer rotor to oil pump housing clearance Limit Oil pump housing to inner and outer rotor clearance Limit Bypass valve opening pressure Relief valve operating pressure Pressure check location Cooling system Radiator capacity including all routes ENGINE SPECIFICATIONS Liquid cooled 4 stroke DOHC 599 cm 36 55 cu in Forward inclined parallel 4 cylinder 67 0 x 42 5 mm 2 64 x 1 67 in 12 8 1 1550 400 r min 220 5 psi 400 r min 15 5 kgf cm 400 r min 1300 1600 kPa 184 9 227 6 psi 13 0 16 0 kgf cm Electric starter Premium unleaded gasoline only 17 5 L 4 62 US gal 3 85 Imp gal 3 5 L 0 92 US gal 0 77 Imp gal Wet sump YAMALUBE 4 SAE10W30 SAE20W40 API service SF SG type or higher 3 40 L 3 59 US qt 2 99 Imp qt 2 40 L 2 54 US qt 2 11 Imp qt 2 60 L 2 75 US qt 2 29 Imp qt 0 23 L 2 43 US qt 2 02 Imp qt 80 0 kPa 1300 r min 11 6 psi 1300
295. r clip 2 and then push the timing chain tensioner rod 3 into the timing chain tensioner housing NOTE Do not release the timing chain tensioner clip while pushing the rod into the housing other wise the rod may be ejected c Hook the clip 4 to the timing chain tensioner rod 3 NOTE Hook the timing chain tensioner rod pin 5 to the center of the clip 4 After the installation check that the clip 4 can come off by its own weight by pushing the timing chain tensioner rod 3 at the position of installation 5 12 CAMSHAFTS 0 524010 INSTALLING THE CAMSHAFTS 1 Align TDC mark on the pickup rotor with the crankcase mating surface a Turn the crankshaft clockwise Pr 1 44 2 k e 2 b When piston 1 is at TDC on the compres sion stroke align the TDC mark on the pickup rotor with the crankcase mating sur face b gt pe 2 Install Timing chain 1 e Exhaust camshaft 2 Intake camshaft 3 with the camshaft sprockets temporarily tightened NOTE e Make sure the match marks on the cam shaft sprockets
296. r cut off valve The air cut off valve is controlled by the signals from the ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe assembly until the temperature be comes higher than the specified value A From the air filter case B To the cylinder head 1 Check Hoses Loose connections Connect properly Cracks damage Replace AIR INDUCTION SYSTEM 2 Check Reed valve Reed valve stopper Reed valve seat Cracks damage Replace the reed valve assembly 3 Measure Reed valve bending limit Out of specification Replace the reed valve assembly ee 4 Check e Air cut off valve Cracks damage Replace 5 Check e Air induction system solenoid Refer to CHECKING THE AIR INDUCTION SYSTEM SOLENOID on page 8 99 Reed valve bending limit 0 4 mm 0 016 in ELECTRICAL SYSTEM IGNITION SYSTEM 8 1 8 1 ENGINE STOPPING DUE TO SIDESTAND 8 3 TROUBLESHOOTING sssssscssseesssssecssssecssssecesssccesssecesssecsssseessssecesssessnae 8 4 ELECTRIC STARTING SYSTEM 8 7 CIRCUIT DIA GIA Me ER 8 7 STARTING CIRCUIT CUT OFF SYSTEM
297. r min 0 80 kgf cm 1300 r min Cartridge paper Trochoid Less than 0 12 mm 0 0047 in 0 20 mm 0 0079 in 0 090 0 150 mm 0 0035 0 0059 0 220 0 0087 0 06 0 11 0 0024 0 0043 0 18 mm 0 0071 in 78 4 117 6 kPa 11 4 17 1 psi 0 78 1 18 kgf cm 660 0 740 0 kPa 95 7 107 3 psi 6 60 7 40 kgf cm MAIN GALLERY 2 30 L 2 43 US qt 2 02 Imp qt Coolant reservoir capacity up to the maximum level mark Radiator cap opening pressure Thermostat Valve opening temperature Valve full open temperature Valve lift full open Thermo sensor Model manufacturer Resistance at 80 C Radiator core Width Height Depth Water pump Water pump type Reduction ratio Impeller shaft tilt limit Spark plug s Manufacturer model Spark plug gap Cylinder head Volume Warpage limit Camshaft Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft journal to camshaft cap clearance Limit Camshaft lobe dimensions Intake A Limit Intake B Limit Exhaust A Limit ENGINE SPECIFICATIONS 0 25 L 0 26 US qt 0 22 Imp qt 107 9 137 3 kPa 15 6 19 9 psi 1 08 1 37 kgf cm 71 159 8 F 85 185 F More than 8 mm 0 31 in KOO3T20191 MITSUBISHI 290 354 Q 3 4 0 mm 14 72 in 257 8 mm 10 15 in 24 0 mm 0 94 in Single suction centrifugal pump 85 41 x 29 31 1 939 0 15 mm 0 006 in NGK CR10EK 0 6 0 7 mm 0 024 0 028 in 7 40
298. r probe gt black blue 2 c Turn the main switch to ON d Turn the lean angle sensor to 65 e Measure the lean angle sensor output volt age DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE STARTER MOTOR OPERATION 1 Check e Starter motor operation Does not operate Perform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 11 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 EWA13810 wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn 8 93 check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS28150 CHECKING THE STATOR COIL 1 Disconnect e Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator coil Stator coil resistance 0 12 0 18 at 20 C 68 F a Connect the pocket tester Q x 1 to the stator coil coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt white 1
299. r short circuit detected Diagnostic code No 05 temperature sensor Item components and probable Check or maintenance job Reinstatement cause method Connections Check the couplers for any pins Reinstated au e Air temperature sensor coupler that may be pulled out tomatically if a e Main wire harness ECU coupler Check the locking condition of normal signal is the couplers received f there is a malfunction repair it and connect the coupler se Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between air temperature sen sor coupler and ECU coupler brown white brown white black blue black blue Defective air temperature sensor Execute the diagnostic mode Code No 05 Replace if defective Refer to CHECKING THE AIR TEMPERATURE SENSOR on page 8 100 8 55 FUEL INJECTION SYSTEM Fault code No ul Symptom Atmospheric pressure sensor open or short circuit de tected Diagnostic code No 02 Atmospheric pressure sensor Item components and probable Check or maintenance job Reinstatement cause method Connections Check the couplers for any pins Reinstated au e Atmospheric pressure sensor cou that may be pulled out tomatically if a pler Check the locking condition of normal signal is Main wire harness ECU coupler the couplers received f there is a malfunction repair it and connect the coupler se cu
300. r short circuit in wire harness Repair or replace if there is an and or sub wire harness 1 open or short circuit Between cylinder 4 ignition coil coupler and ECU cou pler main wire harness red black red blue gray green gray green Defective cylinder 4 ignition coil e Execute the diagnostic mode Code No 33 Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IG NITION COILS on page 8 92 8 60 FUEL INJECTION SYSTEM Fault code No E Symptom Open circuit detected in a primary injector Diagnostic code No Primary injector 1 Primary injector 2 Primary injector 3 Primary injector 4 Item components and probable Check or maintenance job Reinstatement cause method Connections e Check the couplers for any pins Cranking the Primary injector coupler that may be pulled out engine Main wire harness ECU coupler Check the locking condition of Connect the Sub wire harness 2 coupler the couplers fuel injector f there is a malfunction repair it couplers and connect the coupler se Open or short circuit in wire harness Repair or replace if there is and or sub wire harness 2 open or short circuit Between primary injector cou pler and ECU coupler red blue red blue 1 red black red black 2 green black green black 3 blue black blue black 4 orange black or ange black Defective
301. rber Spacers 5 Relay arm Damage scratches Replace 6 Connecting arms A Left side INSTALLING THE RELAY ARM Right side 1 Lubricate Spacers INSTALLING THE REAR SHOCK Bearings ABSORBER ASSEMBLY Recommended lubricant scia Lithium soap based grease peser 2 install Recommended lubricant Bearings 1 2 Lithium soap based grease to the relay arm 2 Tighten Oil seals Relay arm nut Installed depth of bearing a 4 5 0 18 40 Nm 4 0 m kg 29 ft lb Installed depth of bearing b 2 3 Install Spacer bolt Rear shock absorber assembly Rear shock absorber assembly bracket 1 NOTE Be sure to fit the projection on either side of the rear shock absorber assembly bracket into the indentation in the frame 3 5 mm 0 14 in Installed depth of oil seal c 1 0 mm 0 04 in 4 63 REAR SHOCK ABSORBER ASSEMBLY 4 Tighten Spacer bolt Syr Spacer bolt 16 Nm 1 6 m kg 11 ft Ib Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 40 Nm 4 0 m kg 29 Rear shock absorber assembly upper nut 44 Nm 4 4 m kg 32 ft lb Rear shock absorber assembly bracket nut Rear shock absorber assembly bracket nut 52 Nm 5 2 m kg 37 ft lb 5 Install Connecting arms When installing the connecting arms lift up the swingarm 6 Tig
302. rely Open or short circuit in wire harness Repair or replace if there is an and or sub wire harness 2 open or short circuit Between atmospheric pressure sensor coupler and ECU cou pler black blue black blue pink pink blue blue Defective atmospheric pressure sen Execute the diagnostic mode sor Code No 02 Replace if defective Refer to CHECKING THE AT MOSPHERIC PRESSURE SENSOR page 8 99 8 56 FUEL INJECTION SYSTEM Fault code No 24 Symptom No normal signal is received from the sensor Item components and probable Check or maintenance job Reinstatement cause method n 1 Installed state of O sensor heck for looseness or pinching Execute the di agnostic mode the couplers f there is a malfunction repair it and connect the coupler se 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between O sensor coupler and ECU coupler gray green gray green 2 Connections Check the couplers for any pins Code No 63 sensor coupler that may be pulled out Set the engine Main wire harness ECU coupler e Check the locking condition of stop switch to black blue black blue pink black pink black red blue red blue 4 Check fuel pressure Refer to THROTTLE BODIES on page 7 8 Defective sensor Replace if defective Fault code No Symptom
303. replace all gaskets seals and O rings All gasket surfac es oil seal lips and O rings must be cleaned 2 During reassembly properly oil all mating parts and bearings and lubricate the oil seal lips with grease Oil Lip Spring Grease oe 520220 LOCK WASHERS PLATES AND COTTER PINS After removal replace all lock washers plates 1 and cotter pins After the bolt or nut has been tightened to specification bend the lock tabs along a flat of the bolt or nut 20230 BEARINGS AND OIL SEALS Install bearings 1 and oil seals 2 so that the manufacturer s marks or numbers are visible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appropriate ECA13300 CAUTION Do not spin the bearing with compressed air because this will damage the bearing surfac es XX QQ zu 520240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust S that the circlip receives IMPORTANT INFORMATION CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester Check the leads couplers and connectors for 90890 03112 stains rust moisture etc Analog p
304. reverse the removal dure 2 Refer to GENERAL CHASSIS page 4 1 424244 2 44 4 2 GENERAL CHASSIS Removing the side cowlings and front cowling assembly Job Parts to remove Upper side cowling NO Bottom cowling inner panel 7 Air intake duct Rearview mirror For installation reverse the removal proce dure 4 3 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 7 Nm 0 7 kg 5 1 ft Ib 35 Nm 3 5 m kg 25 ft Ib 91 Nm 9 1 m kg 66 ft Ib 21 Nm 2 1 kg 15 ft Ib 18 Nm 1 8 kg 13 ft Ib Job Parts to remove Q ty NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 774 brake hose Peer Left front brake caliper Right front brake caliper 2 3 4 5 Frntwhestaxe bor 4 4 FRONT WHEEL Removing the front wheel and brake discs 7 Nm 0 7 kg 5 1 ft Ib 35 Nm 3 5 m kg 25 ft Ib mE For installation reverse the removal proce dure 4 5 FRONT WHEEL Disassembling the front wheel Oil seal 2 NN For assembly reverse the disassembly pro cedure 21900 REMOVING THE FRONT WHEEL 1 Stand the vehicle on a level surface WARNING Securely support the vehicle so th
305. rminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C b b Immerse the air temperature sensor 1 container filled with water 2 Make sure that the air temperature sensor termi nals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the air temperature sensor resis tance 8 101 TROUBLESHOOTING MROUB LE SHOOTIN 9 1 GENERAL INFORMATION 9 1 STARTING PAIL UIA 9 1 INCORRECT ENGINE IDLING 9 1 POOR MEDIUM AND HIGH SPEED 9 2 EAULTY GEAR Olt WINGY etim tnis eph ui 9 2 SHIFT FEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR A 9 2 S 9 2 Ta tl IN Castes het ade 9 2 OVE COO G Cm 9 3 POOR BRAKING PERFORMANCE winced 9 3 FAULIY FRONT FORG 9 3 UNS TADEETIANDEING a 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 28450 TROUBLESHOOTING EAS28460 GENERAL INFORMA
306. roke align the TDC mark on the pickup rotor with the crankcase mating sur face b Q zs QP on the compression stroke can be found when the camshaft lobes are turned away from each other DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Remove Camshaft caps 1 CAMSHAFTS ECA13720 CAUTION To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 4 Remove e Intake camshaft Exhaust camshaft NOTE To prevent the timing chain from falling into the crankcase fasten it with a wire 1 NOM lt 1 5 1 THE CAMSHAFTS 1 Check e Camshaft lobes Blue discoloration pitting scratches Re place the camshaft 2 Measure Camshaft lobe dimensions and b Out of specification Replace the camshaft Camshaft lobe dimensions Intake A 33 725 33 875 mm 1 3278 1 3337 Limit 33 675 mm 1 3258 in Intake B 25 225 25 325 mm 0 9931 0 9970 Limit 25 175 mm 0 9911 in Exhaust A 32 925 33 075 mm 1 2963 1 3022 Limit 32 875 mm 1 2943 in Exhaust B 25 082 25 182 mm 0 9875 0 9914 Limit 25 032 mm 0 9855 in 3 Measure Camshaft runout Out of specification Replace Camshaft runout
307. rottle valves open or short circuit detected No 15 Throttle position sensor for throttle valves coupler con nection is loose EXUP servo motor circuit 17 open or short circuit detect ed or loose connection EXUP servo motor is stuck Open circuit is detected in the input lead from the sid estand switch to the ECU When the main switch is turned to ON the atmo spheric pressure sensor voltage and intake air pres sure sensor voltage differ greatly Coolant temperature sen sor open or short circuit detected FUEL INJECTION SYSTEM Diagnostic Probable cause of malfunction code No Open or short circuit sub wire harness 1 Open or short circuit in wire harness Defective cylinder identification sensor Malfunction in ECU Improperly installed sensor Open or short circuit in wire harness Defective crankshaft position sensor Malfunction in pickup rotor Malfunction ECU Improperly installed sensor Open or short circuit in wire harness Defective intake air pressure sensor Malfunction in ECU Intake air pressure sensor hose is de tached clogged kinked or pinched Malfunction ECU Open or short circuit in wire harness Defective throttle position sensor for throt tle valves Malfunction ECU Improperly installed throttle position sensor for throttle valves Open or short circuit in
308. s end of the plastic locking tie to 0 20 mm 0 0 79 in Be sure to route the wire harness above the negative battery lead and the starter motor lead Route the turn signal relay lead and relay unit lead so that they are cushioned against the damper Be sure not to pinch the leads between the battery cover and the frame 2 60 CABLE ROUTING CABLE ROUTING 2 61 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC 1 2 2 41 3 1 6 O M 3 1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL E 3 1 GENERAL MAINTENANCE AND LUBRICATION CHART 3 1 ENGINE MEN ET 3 4 ADJUSTING THE VALVE CLEARANCE 3 4 SYNCHRONIZING THE THROTTLE 3 6 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 8 CHECKING THE SPARK PLUGS 3 8 MEASURING THE COMPRESSION 50 3 9 CHECKING TRE ENGINE OIL EE Pide texts ERE 3 10 CHANGING THE ENGINE OIL 3 11 MEASURING THE ENGINE 50 3 12 ADJUSTING THE CLUTCH LEVER FREE 3 13 REPLACING THE AIR FILTER 3 14 CHECKING THE THROTTLE BODY JOINTS
309. section title 1 is shown at the top of each page Sub section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc Jobs 7 requiring more information such as special tools and technical data are described sequen tially CLUTCH CLUTCH CLUTCH Removing the clutch cover 5 12 Nm 1 2 kg 8 7 ft Ib Refer to GENERAL CHASSIS on page 4 1 Drain Refer to CHANGING THE ENGINE OIL on page 3 11 Drain Refer to CHANGING THE COOLANT on page 3 19 Disconnect Disconnect For installation reverse the removal proce dure EAS25070 REMOVING THE CLUTCH 1 Remove Friction plates Clutch plates NOTE Be sure to mark the friction plates and clutch plates or note the position of each part so that they are installed in their original positions 2 Loosen Clutch boss nut 1 NOTE While holding the clutch boss 2 with the univer sal clutch holder
310. shed Lean angle sensor 11 Cylinder identification sensor 30 latch up detected n Lean angle sensor 12 Crankshaft position sensor 41 open or short circuit 19 Sidestand switch 50 ECU internal malfunction open circuit in the wire to the ECU memory check error Checking the engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main switch has been turned to ON and it comes on while the start switch is being pushed If the warning light does not come on under these conditions the warning light may be defective 8 35 FUEL INJECTION SYSTEM a a Main switch OFF d Engine trouble warning light on for 1 4 b Main switch ON seconds c Engine trouble warning light off EAS27380 SELF DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven the ECU illumi nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating depending on the conditions Self Diagnostic Function table Able un Fault Able un symptom able to start pe rive No normal signals ar
311. sition sensor for throttle valves signal 2 Item components and probable cause Installed condition of throttle position sensor for throttle valves Connections Throttle position sensor for throttle valves coupler Main wire harness ECU coupler Open or short circuit in wire harness Defective throttle position sensor for throttle valves Check or maintenance job Reinstatement method Check for looseness or pinch ing Check that the sensor is in stalled in the specified position Turning the main switch to ON Check the couplers for any pins that may be pulled out Check the locking condition of the couplers f there is a malfunction repair it and connect the coupler se Repair or replace if there is open or short circuit Between throttle position sen sor for throttle valves coupler and ECU coupler black blue black blue blue blue blue blue green green Execute the diagnostic mode Code Nos 01 13 Replace if defective Refer to CHECKING THE THROTTLE POSITION SEN SOR FOR THROTTLE VALVES on page 8 97 8 52 FUEL INJECTION SYSTEM Fault code No Symptom EXUP servo motor circuit open or short circuit detected Diagnostic code No 55 EXUP servo motor Check or maintenance job Reinstatement method Connections Check the couplers for any pins Reinstated au e EXUP servo motor coupler that
312. so that the front wheel is elevated Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that the front wheel is stationary Remove the brake caliper Hold the dial gauge at a right angle against the brake disc surface b 4 22 FRONT BRAKE e Measure the deflection 1 5 mm 0 06 in be low the edge of the brake disc 4 Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Brake disc thickness limit 4 0 mm 0 16 in 5 Adjust Brake disc deflection a Remove the brake disc b Rotate the brake disc by one bolt hole c Install the brake disc NOTE Tighten the brake disc bolts in stages and crisscross pattern Brake disc bolt 18 Nm 1 8 m kg 13 16 LOCTITE d Measure the brake disc deflection e If out of specification repeat the adjustment steps until the brake disc deflection is within specification f Ifthe brake disc deflection cannot be brought within specification replace the brake disc DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 6 Install Front wheel Refer to FRONT WHEEL on page 4 4 EAS22270 REPLACING THE FRONT BRAKE PADS The following procedure applies to both brake Calipers NOTE When
313. ssembly reverse the disassembly pro cedure NO 4 21 22220 INTRODUCTION EWA14100 Disc brake components rarely require disas sembly Therefore always follow these pre ventive measures Never disassemble brake components less absolutely necessary If any connection on the hydraulic brake system is disconnected the entire brake system must be disassembled drained cleaned properly filled and bled after reas sembly Never use solvents on internal brake com ponents Use only clean or new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get im mediate medical attention EAS22240 CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 4 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Brake disc deflection limit 0 10 mm 0 0039 in a Place the vehicle on a suitable stand
314. start charging c Make sure that the current is higher than the standard charging current written on the bat tery NOTE If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the MF battery A vari able voltage charger is recommended d Charge the battery until the battery s charg ing voltage is 15 V NOTE Set the charging time at 20 hours maximum e Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 6 Install Battery e Battery band 7 Connect Battery leads to the battery terminals ECA13630 CAUTION First connect the positive battery lead 1 and then the negative battery lead 2 ENN 8 Check Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate Battery terminals Recommended lubricant Dielectric grease 10 Install Fuel tank bracket Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester If the continuity reading is incorrect re place the relay Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Disconnect the relay fr
315. surfaces Damage pitting wear Replace the starter clutch gear 4 Check e Starter clutch operation a Install the starter clutch gear 1 onto the gen erator rotor 2 and hold the generator rotor b When turning the starter clutch gear clock wise A the starter clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear counter clockwise it should turn freely otherwise the starter clutch is faulty and must be re placed 24600 INSTALLING THE STARTER CLUTCH 1 Install e Starter clutch 1 NOTE sure to install the starter clutch so that its side with the arrow mark a is facing inward away from the rotor GENERATOR AND STARTER CLUTCH 5 Yamaha bond No 1215 2 90890 85505 Three Bond 12159 EAS24500 INSTALLING THE GENERATOR 1 Install Generator rotor Washer Generator rotor bolt NOTE Clean the tapered portion of the crankshaft and the generator rotor hub Lubricate the generator rotor bolt threads and washer mating surfaces with engine 2 Tighten Generator rotor bolt 1 Generator rotor bolt 70 Nm 7 0 m kg 50 ft lb NOTE While holding the generator rotor 2
316. t 5 49 INS TALLING THE SHIFT SHAFT 5 49 OIL PUNDP res e 5 50 REMOVING TIE OIBIPAIN 5 53 CHECKING THE Ol PUN 5 53 CHECKING THE RELIEF VALVE priis 5 53 CHECKING THE Ol PIRES 5 MM RE Rs 5 54 CHECKING THE OIL 4 440 5 54 ASSEMBLING THE OIL PUMP 5 54 INSTALLING THE OIL PAN 5 54 5 55 DISASSEMBLING THE 5 57 CHECKING THE CRANKCASE 5 57 CHECKING THE OIL PIPE pionierii eee 5 57 CHECKING THE TIMING CHAIN iie bu pio ERE Mente quint taU 5 57 ASSEMBLING THE CRANKCASE 5 57 CONNECTING RODS AND 6 5 59 REMOVING THE CONNECTING RODS AND PISTONS 5 60 CHECKING THE CYLINDERS AND 5 60 CHECKING THE PISTON RING 5 61 CHECKING THE PISTON PINS eta Une Peor ues 5 62 CHECKING THE CONNECTING 5 63 INSTALLING THE CONNECTING RODS AND PISTONS 5 64 CRANKSHAF E oaa 5 67 REMOVING THE
317. t 13 Nm 1 3 m kg 9 4 ft lb Sidestand assembly and frame 3 26 Nm 2 6 m kg 19 ft lb E bolt Coupler holder and right M6 4 7 Nm 0 7 m kg 5 1 ft lb and frame bolt 10 Nm 1 0 m kg 7 2 16 1 Shift arm bolt Locknut shift rod upper side 7 Nm 0 7 m kg 5 1 ft lb Locknut shift rod lower side 10 Nm 1 0 m kg 7 2 ft lb 2 Front wheel axle pinch bolt 1 Insert the front wheel axle from the right side and tighten it with the flange bolt from the left side to 91 Nm 9 1 m kg 66 ft lb without performing temporary tightening 2 In the order pinch bolt 2 pinch bolt 1 pinch bolt 2 tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening 3 Check that the right end of the front axle is flush with the front fork If necessary manually push the front axle or lightly tap it with a soft hammer until its end is flush with the front fork However if the surface of the front axle end is not parallel to the surface of the front fork align a point on the outer edge of the axle with the fork making sure that the axle does not protrude past the fork 2 23 TIGHTENING TORQUES 4 In the order pinch bolt 4 pinch bolt 3 pinch bolt 4 tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without performing temporary tightening NOTE Lower ring nut 1 First tighten the lower ring nut to approximately 52 Nm 5 2 m kg
318. t POWER EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the di rection of wheel rotation Align the mark 2 with the valve installation point EAS21670 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check Wheel Damage out of round Replace EWA13260 Never attempt to make any repairs to the wheel NOTE After a tire or wheel has been changed or re placed always balance the wheel EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables EWA13270 CHASSIS EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand Recommended lubricant Lithium soap based grease EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Lithium soap based grease Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Ro
319. t value Power supply is not normal ECU memory is faulty When this malfunction is detected in the ECU the fault code number might not appear on the meter Throttle position sensor for throt tle cable pulley open or short circuit detected Throttle position sensor for throt tle cable pulley coupler connec tion is loose Throttle servo motor open or short circuit detected Motor is defective or ECU internal malfunction Communication error with the meter ECU internal malfunc tion output signal error Symptom No signals are received from the ECU 8 38 Able Un Able Un able able Able Un Able Un able able Able Un Able Un able able Able un able to drive Able un able to start Unable Fault code No ECU internal malfunc tion output signal error ECU internal malfunc tion input signal error ECU internal malfunc Er 3 tion output signal error EAS27400 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on 1 Check e Fault code number a Check the fault code number displayed the meter b Identify the faulty system with the fault code Refer to Self Diagnostic Function table c Identify the probable cause of the malfunc tion Refer to Fault code table FUEL INJECTION SYSTEM Able un able to drive
320. tatic balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 8 ET2C01004 CHECKING THE REAR BRAKE DISC Refer to CHECKING THE REAR BRAKE DISC on page 4 34 EAS22160 INSTALLING THE REAR WHEEL REAR BRAKE DISC 1 Install Rear brake disc Rear brake disc bolt 30 Nm 3 0 m kg 22 ft lb LOCTITE NOTE Tighten the brake disc bolts in stages and in a crisscross pattern Rear brake disc Refer to CHECKING THE REAR BRAKE DISC page 4 34 3 Lubricate Rear wheel axle Wheel bearings Oil seal lips e Collars Recommended lubricant Lithium soap based grease 4 15 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 25 Drive chain slack 35 0 45 0 mm 1 38 1 77 in 5 Install Rear brake caliper Rear brake caliper bolt M12 27 Nm 2 7 m kg 19 ft lb Rear brake caliper bolt M8 22 Nm 2 2 m kg 16 ft lb LOCTITE EWA13500 Make sure the brake hose is routed properly 4 16 REAR WHEEL FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 5 Nm 0 5 kg 3 6 ft Ib 35 Nm 3 5 m kg 25 ft Ib ow the front brake calipers Reflector assembly Brake hose holder oo For installation reverse the removal
321. te set the engine If more than one code stop switch from R to number is detected the dis O play changes every two seconds to show all the de tected code numbers When all code numbers are shown the display re peats Actuator operation table Diag nostic code No Cylinder 1 ignition coil Cylinder 2 ignition coil Cylinder 3 ignition coil Checking method Actuates the cylinder 1 igni tion coil five times at one second intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker Actuates the cylinder 2 igni tion coil five times at one second intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker Actuates the cylinder 3 igni tion coil five times at one second intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker 8 46 Cylinder 4 ignition coil Primary injector 1 Primary injector 2 Primary injector 3 Primary injector 4 Secondary injector 1 Secondary injector 2 Secondary injector 3 Secondary injector 4 FUEL INJECTION SYSTEM Actuates the cylinder 4 igni tion coil five times at one second intervals Illuminates the engine trou ble warning light Actuates the primary injector 1 five times at one second intervals Illuminates th
322. ternal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals Recommended fluid DOT 4 22670 INSTALLING THE REAR BRAKE CALIPER 1 Install e Rear brake caliper 1 temporarily Copper washers Rear brake hose 2 e Rear brake hose union bolt 3 Syr Rear brake hose union bolt 30 Nm 3 0 m kg 22 16 EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 47 CAUTION When installing the brake hose onto the brake caliper 1 make sure the brake pipe touches the projection b on the brake Caliper NU 77 1 XA 2 Remove Rear brake caliper 3 Install Rear brake pads Brake pad springs Brake pad pin Rear brake caliper Refer to REPLACING THE REAR BRAKE PADS on page 4 34 Rear brake caliper bolt M12 27 Nm 2 7 m kg 19 ft lb Rear brake caliper bolt M8 22 Nm 2 2 m kg 16 ft lb LOCTITE 4 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid REAR BRAKE Recommended fluid DOT 4 EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in
323. ters 1 VALVES AND VALVE SPRINGS NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment 90890 04108 Valve spring compressor adapt er 22 mm YM 04108 4 Remove e Upper spring seat 1 e Valve spring 2 Valve 3 Valve stem seal 4 Lower spring seat 5 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place s Xe E 3 it N EAS24290 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 5 19 VALVES AND VALVE SPRINGS 1 Measure Valve stem to valve guide clearance Out of specification Replace the valve guide Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear B E ance intake b Install the new valve guide with the valve D 0 0 037 mm 0 0004 0 0015 guide installer 2 and valve guide remover 4 Limit 0 080 0 0032 Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 Limit 0 095 mm 0 0037 in Valve guide position 15 80 mm 16 20 mm 0 622 0 638 in a gt a Valve guide position c After installi
324. ters and miles press the SELECT button for at least one second Tachometer 1 Tachometer 2 Tachometer red zone The electric tachometer allows the rider to mon itor the engine speed and keep it within the ideal power range When the key is turned to ON the tachometer needle will sweep once across the r min range and then return to zero r min in order to test the electrical circuit EC2C01020 CAUTION Do not operate the engine in the tachometer red zone Red zone 17500 r min and above Clock mode 1 Clock Turn the key to ON set the clock 1 Push the SELECT button and RESET but ton together for at least two seconds 2 When the hour digits start flashing push the RESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET button to set the minutes 5 Push the SELECT button and then release it to start the clock Odometer tripmeter and stopwatch modes 1 Odometer triometers fuel reserve tripmeter stopwatch Push the SELECT button to switch the display between the odometer mode ODO the tripme ter modes TRIP A and TRIP B and the stop watch mode in the following order TRIP A gt TRIP B gt ODO gt Stopwatch TRIP A If the fuel level warning light comes on the odometer display will automatically change to the fuel reserve tripmeter mode F TRIP an
325. tester YU 03112 C Positive tester probe gt horn terminal 1 Negative tester probe gt horn terminal 2 c Measure the horn resistance 2 Check Horn sound Faulty sound Adjust or replace a Connect battery 12 V to the horn b Turn the adjusting screw in direction a a or until the horn sound is obtained AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ELECTRICAL COMPONENTS EAS28190 CHECKING THE OIL LEVEL SWITCH 1 Drain Engine oil 2 Remove Oil level switch from the oil pan 3 Check Oil level switch resistance Out of specification Replace the oil level switch Oil level switch resistance Maximum level position 484 536 Q Minimum level position 114 1260 8 95 a Connect the pocket tester Q x 100 to the level switch terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Minimum level position A Positive tester probe connector white 1 Negative tester probe gt body earth 2 Maximum level position B Positive tester probe connector white 1 Negative tester probe body earth 2 b Measure the oil level switch resistance
326. the screw 3 4 turn in and be sure to synchronize the throttle body NOTE Intake vacuum 20 0 kPa 5 9 inHg 150 mmHg The difference in vacuum pressure between two throttle bodies should not exceed 1 33 kPa 10 mmHg 7 Stop the engine and remove the measuring equipment 8 Allow the engine to cool and then start the engine and check that the engine speed does not rise abnormally high 9 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on page 3 8 Throttle cable free play 3 0 5 0 mm 0 12 0 20 in 10 Install e Caps Fuel tank Refer to FUEL TANK on page 7 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20630 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idling speed and carburetor synchroniza tion should be adjusted properly ENGINE 1 Check Throttle cable free play Out of specification Adjust Throttle cable free play 3 0 5 0 mm 0 12 0 20 in 2 Adjust Throttle cable free play Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained Direction a Throttle cable free play is increased
327. throttle body assembly UP EE For installation reverse the removal proce dure 7 10 THROTTLE BODIES Removing the primary injectors 3 5 Nm 0 35 kg 2 53 ft Ib 5 Nm 0 5 kg 3 6 ft Ib 3 5 Nm 0 35 m kg 2 53 ft Ib Job Parts to remove Q ty X Intake air pressure sensor coupler ovine iecore 1 1 _ GER 0 Primary injector fuel rail 5221 E 5 10 Primary injector Throttle position sensor for throttle valves Throttle position sensor for throttle cable pulley Throttle bodies ECA14600 CAUTION The throttle bodies should not be disas sembled For installation reverse the removal proce dure 7 11 26980 CHECKING THE PRIMARY INJECTORS 1 Check Injectors Damage Replace EAS26990 CHECKING THE THROTTLE BODIES 1 Check Throttle bodies Cracks damage Replace the throttle bod ies as a Set 2 Check Fuel passages Obstructions gt Clean Wash the throttle bodies in a petroleum based solvent Do not use any caustic carburetor cleaning solution Blow outall of the passages with compressed DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA CHECKING THE ROLLOVER VALVE for California only 1 Check Rollover valve 1 Damage faulty Replace NOTE Check that air flows smoothly only in
328. tion coils Spark plugs e Cylinder head cover Refer to CAMSHAFTS on page 5 7 3 Remove e Pickup rotor cover 1 4 Measure e Valve clearance Out of specification Adjust ENGINE Valve clearance cold Intake 0 12 0 19 mm 0 0047 0 0075 in Exhaust 0 16 0 23 mm 0 0063 0 0091 in a Turn the crankshaft clockwise y 2 W L X Y b When piston 1 is at TDC on the compres sion stroke align the TDC mark on the pickup rotor with the crankcase mating sur face b on the compression stroke be found when the camshaft lobes are turned away from each other gauge 1 NOTE e f the valve clearance is incorrect note the measured reading e Measure the valve clearance in the following sequence Valve clearance measuring sequence Cylinder 1 2 4 3 3 4 A Front d To measure the valve clearances of the other cylinders starting with cylinder 1 at TDC turn the crankshaft clockwise as specified in the following table 180 360 540 720 A Degrees that the crankshaft is turned clockwise B Cylinder C Combustion cycle Cylinder 2 Cylinder 4 180 360 5 Remove Camshafts 3 5 ENGINE N
329. ts are defective the engine trouble warning light will come on and then the odometer trip meter fuel reserve trip meter stop watch display will indicate a two digit error code e g 11 12 13 If the display indicates an error code note the code number and then check the vehicle Refer to FUEL INJECTION SYSTEM on page 8 33 2 01022 CAUTION If the display indicates an error code the ve hicle should be checked as soon as possible in order to avoid engine damage FEATURES Display brightness and shift timing indicator light control mode 1 Display brightness 2 Shift timing indicator light activation deactivation 3 Shift timing indicator light This mode cycles through five control functions allowing you to make the following settings in the order listed below Display brightness This function allows you to adjust the bright ness of the displays and tachometer to suit the outside lighting conditions Shift timing indicator light activity This function allows you to choose whether or not the indicator light should be activated and whether it should flash or stay on when activat ed Shift timing indicator light activation This function allows you to select the engine speed at which the indicator light will be acti vated Shift timing indicator light deactivation This function allows you to select the engine speed at which the indicator light will be deac tivated Shift timing i
330. uction system hose air filter case to air cut off valve Air cut off valve Air induction system hose air cut off valve to cylinder head cover Reed valve assembly Exhaust port 7 16 AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM Removing the air cut off valve Order Job Parts to remove Fuel tank Refer to FUEL TANK page 7 1 Air filter case Refer to AIR FILTER CASE page 7 5 221 Canister for California only Refer to THROTTLE BODIES on page 7 8 3 Air induction system hose air filter case to air 1 cut off valve A Air induction system hose air cut off valve to 2 cylinder head cover NOE dure 7 17 AIR INDUCTION SYSTEM Removing the reed valves 10 Nm 1 0 m kg 7 2 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Job Parts to remove Q ty gt Reed valve assembly 2 4 NN LE For installation reverse the removal proce dure 7 18 27060 CHECKING THE AIR INDUCTION SYSTEM Air injection The air induction system burns unburned ex haust gases by injecting fresh air Secondary air into the exhaust port reducing the emission of hydrocarbons When there is negative pressure at the exhaust port the reed valve opens allow ing secondary air to flow into the exhaust port The required temperature for burning the un burned exhaust gases is approximately 600 to 700 C 1112 to 1292 F Ai
331. ugh movement Lubricate Recommended lubricant Engine oil or a suitable cable lu bricant NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers Recommended lubricant Lithium soap based grease EAS21710 LUBRICATING THE PEDALS Lubricate the pivoting point and metal to metal moving parts of the pedals Recommended lubricant Lithium soap based grease 3 34 21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to ELECTRICAL COMPONENTS on page 8 77 EAS21770 CHECKING THE FUSES Refer to ELECTRICAL COMPONENTS on page 8 77 EAS21790 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs 1 Remove 2 Disconnect Headlight coupler 1 3 Detach Headlight bulb holder 1 lt 6 1 ANN N 724 lt 4 Remove e Headlight bulb ELECTRICAL SYSTEM EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 5 Install e Headlight bulb Secure the new headlight bulb with the head light bulb holder ECA13690 CAUTION Avoid touching the glass part of the head light bulb to kee
332. unt of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 11 4 Check Cooling system Leaks Repair or replace any faulty part 5 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat a Air filter case ZEE Refer to AIR FILTER CASE on page 7 5 Canister for California only Refer to THROTTLE BODIES on page 7 8 NEN Drain Coolant Refer to CHANGING THE COOLANT on page 3 19 3 8 a dure 6 7 26450 CHECKING THE THERMOSTAT 1 Check Thermostat Does not open at 71 85 C 159 8 185 0 F Replace a Suspend the thermostat 1 in a container 2 filled with water b Slowly heat the water 3 Place a thermometer 4 in the water While stirring the water observe the thermo stat and thermometer s indicated tempera ture 8 0 31 71 85 159 8 F 185 0 F A Fully closed B Fully open NOTE If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling
333. uplers cylinder 1 ig f there is a malfunction repair it nition coil cou and connect the coupler se pler curely Repair or replace if there is open or short circuit Between cylinder 1 ignition coil coupler and ECU coupler red black red blue orange orange Execute the diagnostic mode Code No 30 Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IG NITION COILS on page 8 92 Fault code No Symptom circuit detected in the primary lead of the cylinder 2 ignition coil Diagnostic code No st Cylinder 2 ignition coil Reinstatement method Check the couplers for any pins Cranking the that may be pulled out engine Check the locking condition of Connect the the couplers cylinder 2 ig f there is a malfunction repair it nition coil cou and connect the coupler se pler curely Repair or replace if there is an open or short circuit Between cylinder 2 ignition coil coupler and ECU coupler red black red blue gray red gray red Execute the diagnostic mode Code No 31 Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IG NITION COILS on page 8 92 8 58 FUEL INJECTION SYSTEM Fault code No Symptom Open circuit detected in the primary lead of the cylinder 3 ignition coil Diagnostic code No 2 Cylinder 3 ignit
334. ut 3 at a cutout in the drive axle Drive sprocket nut 85 Nm 8 5 m kg 61 ft lb LOCTITE 4 72 CHAIN DRIVE 4 73 ENGINE ENGINE REMOVAL 5 1 INSTALLING THE ENGINE 5 6 CAMSHAFT 5 REMOVING THE CAMSHAFTS 5 9 CHECKING CAMSHAFTS tuit e pi aaa Re aA ET E 5 9 CHECKING THE TIMING CHAIN CAMSHAFT SPROCKETS AND TIMING CHAIN GUIDES 5 11 CHECKING THE TIMING CHAIN TENSIONER 5 11 INSTALLING THE RUM eR NR ER n 5 12 CYEINDER HEAD T 5 15 REMOVING TH CYLINDER ah 5 16 CHECKING THE CYLINDER HEAD 5 16 INSTALLING THE CYLINDER HEAD 5 16 VALVES AND VALVE SPRINGS 5 18 REMOVING THE VALVES 5 19 CHECKING THE VALVES AND VALVE GUIDES 5 19 CHECKING THE VALVE SEAIS csset osea 5 21 CHECKING THE VALVE Sr RINGS datu ptit 5 23 CHECKING THE VALVE 5 23 INSTALLING THE VAEVES iio RU ie Saut 5 24 GENERATOR AND STARTER CLUTCH 5 26 REMOVING THE GENERA TOP 5 28
335. ves Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE 4 This Service Manual contains information regarding periodic maintenance to the emission control sys tem Please read this material carefully e Designs and specifications are subject to change without notice EAS20080 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death WARNING to the vehicle operator a bystander or a person checking or repairing the ve hicle A CAUTION indicates special precautions that must be taken to avoid dam CAUTION age to the vehicle NOTE A NOTE provides key information to make procedures easier or clearer 20090 HOW USE THIS MANUAL This manual is intended as a handy easy to read reference book for the mechanic Comprehensive explanations of all installation removal disassembly assembly repair and check procedures are laid out with the individual steps in sequential order e The manual is divided into chapters and each chapter is divided into sections The current
336. wire harness Defective EXUP servo motor potentiome ter circuit Open or short circuit in wire harness e Stuck EXUP servo motor mechanism e Stuck EXUP servo motor motor Open or short circuit in wire harness Malfunction ECU Relay unit diode e Atmospheric pressure sensor hose is clogged Intake air pressure sensor hose is clogged kinked or pinched Malfunction of the atmospheric pressure sensor in the intermediate electrical poten tial Malfunction of the intake air pressure sen sor in the intermediate electrical potential Malfunction ECU Open or short circuit in wire harness Defective coolant temperature sensor Malfunction in ECU Improperly installed coolant temperature sensor 8 41 FUEL INJECTION SYSTEM Diagnostic Symptom Probable cause of malfunction cade Open or short circuit in wire harness Defective air temperature sensor e Malfunction in ECU Improperly installed air temperature sensor Air temperature sensor open or short circuit detect ed Open or short circuit in wire harness Atmospheric pressure sen Defective atmospheric pressure sensor sor open or short circuit Improperly installed atmospheric pressure detected sensor Malfunction ECU Open or short circuit in wire harness No normal signal is re Defective sensor ceived from the sensor Malfunction in ECU
337. y Main wire harness ECU coupler Check the locking condition of normal signal is the couplers received f there is a malfunction repair it and connect the coupler se Open or short circuit wire harness Repair or replace if there is an and or sub wire harness 2 open or short circuit Between intake air pressure sensor coupler and ECU cou ler black blue black blue pink white pink white blue blue Defective intake air pressure sensor Execute the diagnostic mode Code No 03 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN page 8 100 Fault code No Symptom Intake air pressure sensor hose system malfunction clogged or detached hose Diagnostic code No Intake air pressure sensor Item components and probable Check or maintenance job Reinstatement cause method Intake air pressure sensor hose e Check the intake air pressure Cranking the sensor hose condition engine Repair or replace the sensor hose Defective intake air pressure sensor Execute the diagnostic mode Code No 03 Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN page 8 100 8 51 FUEL INJECTION SYSTEM Fault code No Symptom Throttle position sensor for throttle valves open or short circuit detected Diagnostic code No Throttle position sensor for throttle valves signal 1 Throttle po
338. y between the drive axle and the rear wheel axle 3 Adjust e Drive chain slack Loosen the wheel axle nut 1 b Loosen both locknuts 2 c Turn both adjusting bolts 3 in direction a or b until the specified drive chain slack is ob tained Direction a Drive chain is tightened Direction b Drive chain is loosened NOTE Using the alignment marks 4 on each side of the swingarm make sure that both chain pullers are in the same position for proper wheel align ment d Tighten the wheel axle nut to specification Syr Wheel axle nut 110 Nm 11 0 m kg 80 16 e Tighten the drive chain adjusting bolts in di rection to specification CHASSIS Syr Drive chain adjusting bolt 2 Nm 0 2 m kg 1 4 16 f Tighten the locknuts to specification Drive chain adjusting locknut 25 16 Nm 1 6 m kg 11 ft lb DAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS21440 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts If the drive chain is not maintained proper ly it will wear out quickly Therefore the drive chain should be serviced especially when the vehicle is used in dusty areas This vehicle has a drive chain with small rubber O rings between each side plate Steam clean ing high pressure washing certain solvents and the use of a coarse brush can d

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