FZ09 Service Manual OCR

2014
1RC-28197-10
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FZ09E ..-<)
FZ09EC
SERVICE MANUAL
2013 by Motor Corporation,
August 2013
All i1ghts reserved. "
Any reproductiO'q,or unauthorized use
without the writfl!.n permission of
Yamaha Motor CorP,Qration, U.S.A.
Is expressly prCSbJblted.
Printed in U.S:AJ,
PIN
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0% EA$20071 %
IMPORTANT

c:-.s> This manual was produced by the Yamaha Motor CompanW.!.td. primarily for use by Yamaha dealers
.@nd their qualified mechanics. It is not possible to include all of a mechanic in one man
Therefore, anyone who uses this book to perform and repairs on Yamaha vehicles
have a basic understanding of mechanics and the techniqueSl.t, o repair these types of vehicles.
Repaifaod maintenance work attempted by anyone without this is likely to render the vehi
cle unfit for use.
6

This model been designed and manuPct ,stured to perform within certain in regard to
performance attq,emissions. Proper service wi\1:1 the correct tools is necessary'fu/ ensure that the vehi
cle will operate as designed. If there is any quesli1;ln about a service procedure, it is imperative that you
contact a Yamaha dealer for any service informaftO,n changes that apply to this model. This policy is

intended to provide the customer with the most satisaction from his vehicle and to conform to federal
environmental quality objectives.
v Yamaha Motor Company, Ltd. is continually striving to impi"QYe all of its models. Modifications and sig
nificant changes in specifications or procedures will be forwarefe:d to all authorized Yamaha dealers and
'&iy appear in future editions of this manual where applicable.
'
Manual contains information regarding periodic to the emission control sys
tem. read this material carefully. ..-'l,
Designs cfft!i!, specifications are subject without notice.

EA$20081 1:Y;.S
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in'1Bis manual by the following notations.

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F! Sf4i;Ui!NtJ
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' NOnCE!

TIP
This is the safety alert used to alert you to potential per
sonal injury hazards. Obey all saf1!ty messages that follow this symbol
to avoid possible injury or death.
6
,
A WARNING indicates a hazardous which, if not avoided, could
result in death or serious injury.
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A NOTICE precautions that taken to avoid
damage to the vehicl%or other property.

A Tl P provides key informatlb!). to make procedures easier or clearer.
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EA$2()($1 CO..., CO...,
HOW TO USE THIS MANUl\

This manual is intended as a handy, reference book for the mechanic. Comprehensive v.so
explanations of all installation, removal, assembly, repair and check procedures are laid <>
out with the individual steps in sequential
The manual is divided into chapters and each c'frag ter is divided into sections. The current section title
"1" is shown at the top of each page.
Sub-section titles in smaller print than title.
6
To help identify parts a'I)Q clarify procedure steps, there exploded diagrams "3" at start of each
removal and disassemb1ih.ection.
Numbers "4" are given in of the jobs in the exploded diagram. A number
sembly step.
Symbols "5" indicate parts to be fU.Il;icated or replaced.
Refer to "SYMBOLS".
A job instruction chart "6" exploded diagram, providing the order of jobs, names of "! v
parts, notes in jobs, etc. This step explall\'s and disassembly procedure only. For installation
and assembly procedure, reverse the
Jobs "7" requiring more information (such as tools and technical data) are described sequen-

1
CLUTCH
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CLUTCH
EA$20101 co
SYMBOLS
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The following symbols are used in for easier understanding.
TIP
The following symbols are not relevant vehicle.
'
SYMBOL DEFINITION

l?_rYMBOL
DEFINITION

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engine mounted Gear oil
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Filling fluid

Molybdenum disulfide oil



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Wheel beanng

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Tightening

Lithium-soap-based grease

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Wear limit, clearance
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Molybdenum disulfide grease

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Engine speed Silicone grease
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Electrical Apply locking agent (LOCTI<J$) .

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Replace the part with a new one.
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Silicone fluid
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EASroUO TABLE CONTENTS
SPECIFIC
PERIODIC CHL_Li,.
ADJUSTMENTS
CHASSI
ENGINE
COOLI
FUEL SY
ELECTRICAL SYS
AND

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INFORMATION

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IDENTIFICATION ............ ................ .................. ........ ........ ................. ....... .... 1-1
VEHICLE NUMBER ................. ........ ........................... 11
MODEL LABEL ..................

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FEA"FitRES ...................... ................... i?.( . . . . . ... 'b -12
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OUf'h.INE OF THE Fl SYSTEM ........
Fl sv'SlJ; _EM .......................................... ................. ........ ..................... .... l-3
INSTRUtl,i:;NT FUNCTIONS .................................. ............................... "'1(, 14
YCCT Chip Controlled Throttle) ..................... ........ ........ ............
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IMPORTANT INFORMAJ ION ................................................................ ....... .. 1-11 v.s>
:::: ::: :: :::::
GASKETS, OI L SEALS 0-RINGS ........................ ......... ........ ........ 1-11 <:>"<1
LOCK WASHERS/PLATES COTTER PINS .......... ....................... 1-11
Bj:ARINGS AND OI L SEALS ..... ............ ....... ... .. ........... EI .......... 1-11
CI F-l /CLIPS ..................................... ............. ........ ........ ............. "hr .. .... .. 1-12
PARTS ................. ......... .... 1-12 '
' ..
BASIC INFORMATION ........................ ........ ......................... .........
QUICK ......................... ....... ................ ....... ..............
ELECTRICAL ......... ........ ................. ........ ................. ........ ........ 1-13 % ..
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SPECIAL TOOLS ............ .. >Y_, . . . . . . . . . . . . 118 >y_,

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EA$20130
IDENTIFICATION

IDENTIFICATION NUMBER
identification number "1" is stamped
into side of the steering head pipe.

IDENTIFICATION
1-1
FEATURES

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EA$20170
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EA$1Acuo IS'
OUTLINE OF THE Fl SYSTEM -9 <?> <?>
The main function of a fuel supply is to provide fuel to the combustion chamber at the
air-fuel ratio in accordance with the operating conditions and the atmospheric temperature.
the conventional carburetor system, the ratio of the mixture that is supplied to the combustion
chamber is by the volume of the air and the fuel that is mete.red by the jet used in the
respective ca'fb.a,Jretor. "!>,.?
Despite the of intake air, the fuel vold'fne requirement varies by the operating con-
ditions, such as deceleration, or operating under a heavy load. that meter the
fuel through the use oftebs have been provided with various auxiliary devices, so that aftoP,timum air-fu-
el ratio can be achieved fq,accommodate the constant changes in the operating conditi'is'"ll! of the en-
gine. ..
As the requirements for the eliine to deliver more performance and cleaner exhaust gases
it becomes necessary to control ratio in a more precise and finely tuned manner. To
modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in platlq
of the conventional carburetor system can achieve an optimum air-fuel ratio required by%"<1
the engine at all times by using a micropffo.eessor that regulates the fuel injection volume according to
the engine OJ?.erating conditions detected sensors.
6
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The the Fl system has resulted in precise fuel supply, engine response,
better fuel econd' s:cy, and reduced exhaust emissi6l)s.

4, 5, 6 7

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13 12
1. Engine trouble warning light
2. ECU (engine control unit)
3. Throttle position sensor
4. Accelerator position sensor
5. Intake ajJ; pressure sensors
6. Throttle s"l!tyo motor
7. Fuel pump
8. Lean angle
9. Battery
10. Speed sensor
11. 0
2
sensor
"' 12. Crankshaft position sensor v.s>
13. Coolant temperature sensor <?>
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1-2
14.1njectors
15.1gnition coils
16. Spark plugs
17.1ntake air temperature sensor
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Fi'svsTEM
v The fuel pump delivers fuel to the fuel Injector v1a the filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel 1njector at a certa1n le'V.el. Accordingly, when the energ1zing Signal
<\J.rom the ECU energizes the fuel injector, the fuel passage causing the fuel to be injected into
intake manifold only during the time the passage remain
the longer the length of time the fuel injector is duration), the greater the
volum""ecflf fuel that is supplied. Conversely, the shorter the length of the fuel injector is energized
the lesser the of fuel that is supplied.
6
"!>
The and the injection are controlled by the ECU. Si!fl'!gls that are input from the '.?
throttle positia'n sensor, accelerator positioifi<:Jensor, coolant temperature lean angle sensor,

crankshaft position sensor, intake air pressure intake air temperature sensor, speed sensor and
0
2
sensor enable the ECU to determine the inje&tion duration. The injection timing is determined
through the signals from the crankshaft position As a result, the volume of fuel that is required
v by the engine can be supplied at all times in accordan&. t'ith the driving conditions.
.5'-9 Illustration is for reference only. .5'-9

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9
15
13
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12

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1.
2.
3. ECU control unit)
4. Throttle pt sition sensor
6. Speed sensor
7. Lean angle sensor
8. Intake air temperature sensor
9. 0
2
sensor
6"!>
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16. Throttle servo motor

1-3
Fuel system
Bv.f-i r system
c. system
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EA$1AC1103
FUNCTIONS
Multl-functf6!) meter unit
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1.
2.
1 2

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1. Trans;;q,.s_fion gear display
2. Tachomeietr
3. Drive mode aiplay
:>
4. Fuel meter Y.?-.,_
5. Eco indicator "EC<J' "o1
6. Multi-function dis
...
6
7. Sell-diagnosis device <t>b
"!>,.? 8. Clock
Speedometer

F!fkQ;JtlldCi ___________ _
Be stop the vehicle before making
any changes to the multi-function
meter unit. settings while riding
can distract ttie,..,Qperator and Increase the
risk of an acclden&-.,,
The multi-function is equipped with
the following:
6"!> a speedometer
'.? a tachometer y.?-.,
f.., clock "
.. 1
meter
an indicator
a gear display
a drive display (which shows the select
ed drive
a multi-function djSplay
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a self-diagnosis
a brightness contrOt -wode
TIP .
Be sure to turn the key
"SELECT' and "RESEr'
To switch the " '"lti-fllnl'tinn
displays between kilometers
the button for at least onia'.G>Jecc,nd.

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1.
2. red zone Y-?

The tachomf#er allows the rider to monitor the
engine keep it within the ideal power

range.
When the key is to "ON", the tachometer
will sweep across the
0
'TlJ;nin range and then re
turn to zero r/min in orderf e test the electrical cir-
cuit. >Q>Y.?
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NOTICE "<1
Do not operate the engine in the
red z'&ge.
Red zon\ , 11250 r/min and above Y-?'!4
Clock
1
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1.
The clock d11],1ays when the key is turned to
"ON". In additiotl-.d_he clock can be displayed for
10 seconds by p'fis_bing the "SELECT' button
when the main switc"ff oil> in the "OFP', "LOCK" or
"pe" position. c:-.s>
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To set the clock
This indicator comes on when the be-

l. Tum the key to "ON". ing operated in an environmentally
2. Push the "SELECT" button and but- el-efficient manner. The indicator goes off wheq,..
ton together for at least two the vehicle is stopped. <?>
3. When the hour digits start flashing, TIP
"RESET" button to set the hours. Consider the following tips to reduce fuel con-
4. Push the "SELECT" button, and the sumption:
digits will start <t>b Avoid high engine speeds& uring acceleration. <t>i
;..:)...
5. Push the button to set the minutes. .. Y Travel at a constant speed:",.?
6. Push the "S and then release 'S.l'llect the transmission gear is appropri-
it to start the clock. ate for the vehicle speed. -t..
Fuel
Transmission gear display 'b
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1 2
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1. Fuel meter
2. Fuel level warning indict-lj;); "il"
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The fuel meter indicates the amOI;[lt of fuel in the
fuel tank. The display segments fuel meter
disappear towards "E" (Empty) as ttfes.fuel level
decreases. When the last segment and
warning indicator "i l" start flashing,
soon as possible.
TIP
This fuel meter is equipped with a self-diagnosis
system. If a problerths detected in the electrical
circuit, the following is repeated until the
malfunction is level segments
and fuel level warning indicaw "il" flash eight
times, then go off for 3 seconds.
(Refer to "CHECKING THE
EL LEVEL WARNING LIGHT" on paw 8-105.)
1. Transmission gear display
2. Neutral indicator light " N "

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This display shows the selected gear.

tral position is indicated by "- " and by the neufr;:ll
indicator light. <?
Drive mode display >y.?

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Eco indicator
1 . Drive mode display -9

1
1. Eco indicator "ECO"
This display indicates which drive mode has
been selected: "STD", "A" or "B". For more de-
tails on the modes and on how to select them,
to "0 -mode (drive on page 1-8. <t>i
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FEATURES
Multi-function display
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AVE __ ._ U1 00 km or AVE __ ._ M PG --?
0
P Air __ F 4 000 --? TRIP 1 4 TRIP 2 --?
F-TRl!i/
1
'-9
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To reset a '!ug meter, select it by pushing the "SE-
LECT" then push the "RESET" but-
ton for at least second.
If you do not the fuel reserve tripmeter
manually, it resets automatically and the
display returns to the pfi9r mode after refueling
and traveling 5 krn (3 rni).
1. Multi-function display Instantaneous fuel consumption display
% A 1
The multi-function display is equipped with the
00
<1 v following:
.sof an odometer .sof N """' J, a
tripmeters (which show the distance trav-
l?eiW} since they were last set to zero)

1
1li11iilill!'i
11.,1 . '- a reserve triprneter (which shows the dis- JJ _
since the left segment of the fuel _
meter flashing) e"b , tE:J!!,tjl
a coolant teqjperature display 'l? .:=I .:=I :,t y.?.
an air intake temperature display

. .
an instantaneous fuel consumption display 1. Instantaneous fuel consumption d1splay
an average fuel consumption display The instantaneous fuel consumption display can
Push the "SELECT" button to switch the display
set to either :km/L", "U100 km" or "MPG".

%,. between the Instantaneous fuel consumption The distance that can be traveled on
v .so mode "km/L", "U100 km" or "MPG", average fuel 1.0<'ts.of fuel under the current riding conditions

mode "AVE __ ._ km/L ", "AVE __ ._ is shoWQ.
km" or "AVE __ ._ MPG", coolant temper- "U100 klTh" q;, The amount of fuel necessary to
"F", air intake temperature mode travel 100 k''\ under the current riding condi-
"Air _ _:"1", odometer mode "000'' , and tripme- lions is
ter 1" and "TRIP 2" in the "MPG": The that can be traveled on
order: 'b,l? 1.0 US gal of fuel the current riding con-
ditions is shown.
krn/L, U100 km or MPG --? AVE __ ._ To switch between the instantaneous fuel con-
AVE __ ._ U100 km or AVE __ ._ MPG--? F--? sumption displays, push the "SELECT" button
Air __ F--? 000 --?TRIP 1 --? TRIP 2 18.r one second when one of the displays is
TIP sl\'own.
"' ,.
v .so Push the "RESET" button to switch the display in TIP_, c/ 4---------------
<?the reverse order. If travelfi;!Q at speeds under 20 km/h (12 milh), "_
> '% _ -_-_" _________ _
If level warning indicator "iil" and left
segmell\_of the fuel meter start flashing, the dis-
play changes to the fuel
trip meter TRIP" and starts countinJ!JAhe y.?.
distance traveled from that point. In that
push the "SELECT" button to switch the
between the various tripmeter, odometer, in-
stantaneous fuel consumption and average fuel
.
consumption modes in the following order: %,.
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1-6
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Average fuel mode

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1. Average fuet.c.onstJmtltion
The average fuel display can be
set to either "AVE_ "AVE __ ._ U100
km" or "AVE . MPG"
--- . f
This display shows the fuel consump
tion since it was last reset.
"AVE __ ._ km/L": The that
can be traveled on 1.0 L of fuel is
_._ U1 00 km": The average of
fuel ne'ej1ssary to travel 1 00 km is showrr.?.
"AVE_ !."?b
1
MPG": The average
can be on 1.0 US gal of fuel is shown.
To switch the average fuel consump
t1on displays, "SELECT" button for one
second when one of11i.e displays is shown.
To reset the average fu'EIJ. consumption display,
select it by pushing the "SEj..ECT" button, and
then push the "RESET" at least one
second.
TIP
After an average dis
play, _ ::r"' IS shown for that diSplay ve
hicle has 1 km (0.6 mi).
" 1. display
This display the coolant temperature from
104 F to 242 F fti.ql F increments.
If the message stop the vehicle,
then stop the eng1ne, anl:!,.let the engine cool.
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1-7

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When the coolant below 104 F,
"LO" will be displayed. v.r
The coolant temperature varies w'ftt;J> changes
1n the weather and engine load.
Air intake temperature display

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1. Air intake temperature display
The air intake temperature display indicate't"'Jae
temperature air drawn into the air filt&f.. b
case. "!>,
This display air intake temperature
from 14 F to 210 increments. "
TIP .
14 F will be displayed if the air intake
temperature falls below 14
The air intake temperature mgy01ary from the
ambient temperature. .rf
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1. Error code display <?>
2. Engine trouble warning light"
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This model is equipped with a
vice for various electrical circuits.
If a problem is in any of those
the eng1ne light will come on and Y.?.
the display will an error code.
If the display indicates error codes, note the
code number, and then the fuel injection
system. (Refer to "FUEL INJI!.CTION SYSTEM"
on page 831.)
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If display Indicates an error code, the ve-
be checked as soon as possible
in orderct o avoid engine damage.
c
the switch.
Mode
v
Mode "STD" for various riding condi-
tions. <?>y
This mode allows f%rider to enjoy smooth and
mode sporty drivability low-speed range to the
.. 1 high-speed range.
6"!> Mode " A"
N Y'%! 9 """ J (' '";, Mode "A" offers a sportier response in
" low- to mid-speed range compared to mode
"STIQ".

0
Mode response that is somewhat less
sharp to mode "STD" for riding situa-
tions that requ[J? especially sensitive throttle op-
eration. -<?>
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1. level display
0
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This you to adjust the brightness
of the multi-funoUgn meter unit panel to suit the
>, outside lighting col\@tions.
6
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To adjust the brightness
%-o 1. Turn the key to "OFF". %-o
2. While pushing the "SELECT" button, turn the
. key to "ON" and continue pushing the button .
the display switches to the brightness v
c8fltrol mode. .s>
11
3. PuSI\the "RESET" button to set the bright- <?>y
ness "'%
4. Push the.o.r .WELECT" button to return to the
original
>, D-mode (drive iil'o$!e) 6"!>
., ;, D-mode is an controlled engine '";, Y"oo

performance system wrth three mode selections

"
("STD", "A", and "B").
Push the drive mode switch "MODE" to switch
0 0
modes.

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'o 1. Dri ve mode switch "MODE"
'<o
' I.P-----------
Befqre using D-mode, make sure you under-
stan!-.i.t operation along with the operation of
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EA$1AC11t
YCC-T (Yamaha Chip Controlled
"
Mechanism characteristics v
Yamaha developed the YCC-T system emploY,ing the most advanced electronic control technologies.
t?. Electronic control throttle systems have been automobiles, but Yamaha has developed a fast-
er, more compact system specifically for the a sports motorcycle. The Yamaha-developed
system has a high-speed calculating capacity that computations of running conditions every
1/1 OOOth of a second.
The YCC-T system is deSi'g_ned to respond to the throttle of the rider by having instan-
calculate the ideai wrottle valve opening and genef&,l
0
e signals to operate the m6!'0Jdriven
tt1rottle valves and thus the intake air volume. "

The ECU contains two CPUs wittfii..Rapacity about five times that of conventional units, making
sible for the system to respond extreffi.!!IY quickly to the slightest adj ustments made by the rider. In paf -9 .s>-9
Increased engine power
By shortening the air intake path, higher engine is possible Increased engine power.
Improved driveability
Air intake volume is controlled according to the operatfri Improved throttle response to
meet engine requiremerrt. e"b
Driving force is controlled
0
at_Ahe optimal level according to t'lfll>.gansmission gear position a1a.s1 engine
Improved throttle c8\lrol. "

Engine braking control
Due to the throttle control, optimalo?eegine braking is made possible.
Simplifi ed idle speed control (ISC)

The bypass mechanism and ISC actuatBipare eliminated A simple mechanism is used to maintain ..
a steady idle speed. v.s> v.s>

Reduced weight
Compared to using a sub-throttle mechanism, w"e!9ht is reduced.
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3
3. Throttle position sensor
4. Throttle valves

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5
"' v.s> 1. Throttle position sensor
-9. <?,. Throttle servo motor
>
3'.?.:-_ccelerator position sensor
4. Etu (engine control unit)
.....
5. Sens.er input
...
6. Gear plJJ;ition sensor
7. Cranksh:teposition sensor
8. Speed
9. Coolant temperature sensor
6
7
8
9
1-10
FEATURES
-"!>
IMPORTANT

EA$20180
IMPORTANT

EA$201QO
PREPARATION FOR REMOVAL
9
A:fliD
DISASSEMBLY
1. Before removal and disassembly, rertio.<Ye all
dirt, mud, dust and foreign material.
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2. Use only the proper tools and cleanin(J.:tl;QtJip-
ment.
Refer to "qfECIAL TOOLS" on page 1-
E.A$20210
GASKETS, OIL SEALS AND dfijiNGS
1. When overhauling the all
gaskets, seals and 0-rings. All surfac-
"
es, oil seal lips and 0 -rings must be cle_aned.
2. During reassembly, properly oil all ni'ftting
parts and bearings and lubricate the oil
lips with grease.

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3. When always keep
parts includes gears, cylinders,
pistons and othel"i!D,erts that have been "mat-
ed" through Mated parts must
always be reused or as an assem-
y.?.

bly.
<I
1. Oil
2. lip
3. Spring
4. Grease e"b
4. During disassembly, all of the parts and
place them in trays in thf!j'<oncJer of disassem-
bly. This will speed up and allow for
the correct installation of all
'
yo.?. ..,h.
COTTER
PINS
After removal, replace all lock
"1" and cotter pins. After the bolt or been
tightened to specification, bend the r69k tabs
along a flat of the bolt or nut. v.s>
f
5. Keep all parts away from any
""""'

y.?

REPLACEMENT PARTS

<t>b

Use only gerlJiine Yamaha parts for all
ments. Use grease recommended
Yamaha for all jobs. Other brands
may be similar in and appearance, but

y.?.

inferior in quality. -o

.s>
f

y.?

<t> ..
1-11
1

Cb

,_,
BEARINGS AND OIL SEALS v
Install bearings "1" and oil seals "2" so thifm8e
>
y.?

<t> ..
c
marks or numbers are visible.
When oil seals, lubricate the oil seal
lips with a Gijght coat of lithium-soap-based
grease. Oil liberally when installing, if
appropriate.
CA13300

6
Do not spin the compressed air
"!>, because this will damage i'l1e bearing surfac-
.?;, y.?.

-"!> "<0<
'it
INFORMA'ft.ON

%,
c
low any items o1Q,er than the specified one to
contact the parts. ..
1-12
v
.s>
''9
'<?>
y.?
'%

<t>b

y.?.

"
BASIC

<o

BASIC SERVICE INFORMATION
Cb

15' EA$303510
QUICK FASTENERS
type

fastener

To the quick fastener, push its a
pull the fastener out.
'-9 :..n;
'.(?> '!l:l

'%

"t>

2. Install :

=

Quick fastener

the quick fastener, insert the fastener
into to be secured and tighten the screw
"a".

2. Install: Cb%
Quick fastener
<? i-n-st_a_ll-th_e_q_u- ic _k_f_a_ s-te_n_e_r.-p- u_s_h-it_s_p-in_s_o __ th-at ..
protrudes from the fastener head, then insert .. <?>y1Jf!:;
a.t!e fastener into the part to be secured and push
tfi"e-nin "a" in with a screwdri ver. Make sure that
...,.
the pill, is flush with the fastener's hegd. .....,.,.
6
"!>
ELECTRICAL

Electrical parts ha'f1JA11ng
e;;;.ICE -------------

'9.J Never disconnect a battery lead while the en-
1IT
..

<o

Screw type
1. Remove:
Quick fastener
ill
TIP-------------

.s> To remove the quick fastener, loosen the screw
<?> with a screwdriver, then pull the fastener out.

'%

<t> ..
Is running; otherwise, the electrical
Components could be damaged.
1-13
EC,.. I$7'61)
TICE -----------
WMn disconnecting the battery leads from
'"' >

'%

<t> ..
c;,
the battery, be to disconnect the nega-
tive battery lead the positive bat-
tery lead. If a tool or siml!flr item contacts the
vehicle while only the battery lead
is connected, a spark generated,
which is extremely
>
TIP Y.?_.,
If a battery lead is difficult to due to
rust on the battery terminal, rust us-
ing
"+"
When connecting41J<e battery leads to the
battery, be sure to the positive bat-
tery lead first, then the battery lead.
If a tool or similar Item ccitltacts the vehicle
y.?
'%

"!:>.
-"!>
'v
BASIC SERVIOJS INFORMATION

%,
c
while only the negative ba'tWry lead is con-
nected, a spark could be which is
extremely dangerous. v.s>

...... ._ ... c;,

EC,.. I$$1()
NOTICE ________________
Turn the main switch to " OFF" dis-
connecting or connecting an
ponent.

y.?.

Electrical are very sensitive to
and can be damagelf-t9 Y static electricity.
Therefore, never touch terminals and be
sure to keep the contacts
1-14
6"!>
'.?

TIP

When resettin'$,; he ECU by turning the main
switch to "OFF", to wait approximately
5 seconds before turf.ti!lg the main switch back
to "ON"
. .so

Cb

Checking the system
TIP c:-
Before checking the eledll'iJ;al system, make
sure that the battery voltage least 12 V.

-'>.
Never Insert the tester probes'<le_to the cou-
pler terminal slots. Always probes
from,tae opposite end " a" of the tak-
.
ing carEi'J)Ot to loosen or damage the

Cb

.so
f
".(?>
y.?
'%

"!:>.
-"!>
y
BASIC SERVIJ; INFORMATION .?"0

ECA19&$0
NOTICE
For waterproof insert the
tester probes directly Into
When
performing any checks using .a waterproof
.so
coupler, use the specified test liar))ess or a
suitable commercially available har-
ness. '%
"
<?
Checking the connections
Check the leads, couplers, and for
stains, rust, moisture, etc.
...
1. Disconnect:
6
<t>b
Lead "!>,.?
Coupler .?"0
Connector
NOTICE
When disconnecting a coilpler, release the
b
coupler lock, hold both secti<SI}S of the cou-
pler securely, and then disconnect the cou-
'<?
pier. >y.?
There are many types of coupler"<l@.cks;
therefore, be sure to check the type
pler lock before disconnecting the coupltfr,.,.

"", v:>
1-15
..,h. yo.?.

.so
'-9
'.(?>
y.?
'%

"!:>.

..

BASIC SERVICE INFORMATIGltJ

Make sure all connections are tight.

If
When disconnecting a connector, do not pilll
the leads. Hold both sections of the connec-v.s>f
tor securely, and then disconnect the con-
nector. \ \ I 1
1
<:) ' ,
2. Check:

, '
/ / 1\\
.?.
4. Check:
Continuity
(with the pocket tester)
Poe ket tester
9089()..()3112
Analog pocket tester
VU-03112-C
:
:

.l?
Lead
Coupler
0 If no continuity, clean the terminals.
Connector
4 Dry with an
4 Connect and di_P.connect sev-
When the wire harness, cp,erform
steps (1) 15;;&3). 'l?;,

.s>
"f.
eral times.

c
As a quick Pemedy, use a contact
available at most part stores.

If

.l?

6"!>
3. @&nnect: 'l?
Lead

Coupler ..,

Connector Cb

When connecting a coupler or connector, pus'hc:-
both sections of the coupler or connector to- .s>f.
gether until they are connected securely.

1-16
...
<t> ..
Cb

.s>
"f.
tester
'90890-03112
AnMQ,Q pocket tester
YU-03>j.12-C
Y.>.
TIP
The resistance values were obtained at
6
the standard measuring of 20 c
"!>,.? (68 F). If the measuring is not 20
(68 F), the specified measu'Fiag conditions
.,.
wihll?g; shown.
"'
air temperature sensor re-

51.40,-6.60 k.n at o c (32 F)
29ikJ90 n at 80 c (176 F)
'"' >
...

u
"'.o
0

Q
'b ....
1'-'
"
- -
- -
- -
-
'h .
z-
-"!> " The following special tools are necessary for complet &.-,?nd accurate tune-up and assembly. Use only
-9. <> the appropriate special tools as this will help prevent caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or may differ depending on the country.
placing an order, refer to the list provided below to mistakes.

and Canada, use part starting with "YM", "YUi>A; or "ACC".
For use part number with "90890".

6
"!>

"!v
.s>
"f
"<}>
Tool name/Tool No. Illustration
Reference
pages
461
.?

<f!adiator cap tester
0
38
, 62
lre900 1 325
cooling system tester kit
6
YU-24' "\.flOA "!>,
., .? ;,

"!v
.s>
"f
"<}>
y.?
Radiator cap tester adapter

tester adapter

yo.

..
>>
62
1-18

Cb

name/Tool No.

Flywheel pullef <>
90890-01362
Heavy duty puller
YU-33270-B

6"!>
Steering nut wrench

<t>b

flange nut wrench

"'
Damper rod t(Jder
90890-01423 <>>
Damping rod
YM-01 423

<t>b
6
Oil filter wrench
/.90890-01426

Rod holdei"' v
90890-01434"''9
Damper rod double ended
YM-01434

y,
SPECIAL TOOLS
Illustration
11
YMA8703

00 0
1-19
Reference
pages
5-32
3-18 4-61 -?-
,
4-52, 4-53
4-51 ' 4-56,
4-57
'
c.
Tool name/Tool No.

Illustration
Reference

pages
'
Rod puller
-<J
4-55, 4-56,

90890-01437

4-57
Universal damping rod bleeding tool set

YM-A8703

...
b
6"!>

"tot,
6"!>

y.?. 'v> y.?. 'v>

YMA8703
\

000

Cb

oo.,
Fork spring compressor
v.s> e55 v
4-51 ' 4-56,
90890-01441

4-57
YM-01441
'%.,

=
"to,;
=
seal driver "!>,"' 4-54 4-55"!>,
' v>
9089g-01442
6
\..
\
Adj ustable fork seal dri ver (36-46
/
YM-01442 .o
./

0
10-:b ..

Pivot shaft wrench adapter
0 ..
5-7, 5-8
c:-
90890-01476
.so
"' 0

!?l

.<>.
'6)vot shaft wrench
6"!>
"'t>
5-7
6"!>
95'890-01485
'v>

'v>
Fraifte mount insert wrench

.?.
\
YM-01485

Cb
Pivot shaft wrench 5-7, 5-8
90890-01 51 8
oo ..
0 c:-
Frame spanner socket
.so
-<J
YM-01518

yv>

..

'9,J:ive chain cut & rivet tool
6"!>

4-71 4-73>
96'890-0 1550
' "!>
'v> 'v>
YM::'&550

\

Tool name/Tool No.
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
Pressure gauge
90890-03153
YU-03153
Illustration

'
ft;}
>

'%

SPECIAL

Reference
Tool name/Tool No. ?6 Illustration
pages
.s>
'-9
'{ Mechanical seal installer
90890-04078
Water pump seal installer
YM-33221-A
njY,ersal clutch holder
908"90-04086
YM-91042
Valve spring compressor attachment
90890-041 08
Valve spring compressor adapter 22 mm
YM-04108
6-11
5-42, 5-45
5-23, 5-28

Valve guide remover (04.5) 6"!>
11 6
5-25
'
ft;}
>

'%
VafQe guide remover (4.5 mm)
YM-04116

Valve guide installer (04.5)
90890-04117
Valve guide installer (4.5 mm)
YM-04117
04.5
5-25

Valve guide reamer (04.5)
6"!>
5-25
guide reamer (4.5 mm)
YIVf-il4118

% %

oS' oS'

{

'%
1-23
...
"!:>.

Tool name/Tool No.

.s>
-9. <> Extension
>y.? 90890-04136
'Z!

<t>b

Piston ins !I!Jing tool
90890-041 6'1
YM-04161
lgniti
90890-06754
Oppama spark checker
YM-34487
Yamaha bond No.1215
(Three bond No.1215)
90890-85505
6"b

Illustration

Cb

1-24
.?.;;,
"
Reference
pages
5-1
5-68
5-1 2, 5-14
8-100
5-34, 5-57
"!>,
.?;,

o,

1-25
-"!>
'.?

% '

GENERAL SPECIFICATIONS ............. .................... ........................... ....... .... 2-1

ENGINE SPECIFICATIONS ........ ........ ................. ....... .... .................. ....... .... 2-2

6
"<'-., "!> .. -
SPECIFICATIONS ''"' '' ''"' '""""' '"' '"' '"' '"' '' ''"' '"' ' ' '" ' ' '' '' '"' '' '''"2 7
-?.. ;, -? .

ELECTRICAL SPECIFICATIONS ...... ..................... .................................. 2-1 0

TIGHTENING TORQUES ......................... ..... .................. ........ .. ... .... .2-13
GENERAL TIGHTENING TORQUE SPECIF<1,9ATIONS ....... ....... ..... .... 2-13
-9. ENGINE TIGHTENING TORQUES ................ ........................... ......... 2-1 4
CHASSIS TIGHTENING TORQUES .................... ..... .. .................. 2-1 8

' '

POINTS AND LUBRICANT TYPES .......... . ?-ie- ................ .2-22
........................... .. ......... .. ..... 2-22
IS ............................ ............ 2-23

LUBRICATION SYSTEM CHART AN{f..niAGRAMS .. .................................. .2-25

ENGINE OIL LUBRICATION ........................................ .2-25
LUBRICATION DIAGRAMS ................... ..... .... . .2-27

. COOLING SYSTEM DIAGRAMS ........................... .... ................. ... ..... .... .2-37
y.?&. .?&.

' '
ROUTING ........... ................................................... ?.-<> ..... ..... ... ..... .... .. 2-41

<t>b 6 <t>b
"!>

f

y.?

<t>b

y.?.

-"!>
GENERAL

%,
EA$202180 CO...,
GENERAL SPECrFI&ATIONS
"!
Model
Model

<?> FZ09E 1 RC4 <?>
FZ09EC 1 RC5

Overall & ngth <t>b 2075 mm (81.7 in)
6
<t>b
Overall llii\Jth 815 mm (32. 1 in) "!>,
Overall heiQI;Ij 1135 mm (44. 7 in) .?
Seat height 815 mm (32.1 in)
Wheelbase 1440 mm (56.7 in)
Ground clearance 135 mm (5.31 in)
Minimum turning 3037 mm {119.6 in)
Weight
Curb weight
Maximum load
2-1
FZ09E 188 kg (414 1b)
FZ09EC 189 kg (417 1b)
FZ09E 177 kg (390 lb)
FZ09EC 176 kg (388 lb)
co,.., co%
ENGINE

Engine .s>f .s>f
Engine type <?> L1qu1d cooled 4-stroke, DOHC <?>
3
Displacement 847 em
Cylinder arrangement lnline 3-cylinder
Bore x stroke x 59. 1 mm (3.07 x 2.33 in)
Compression ratio 6"!> : 1
Standard (at sea level) r/min {15.3 r/min,
r/ min)

Minimum-maximum 133o-171 0 kPa/680 r/min (13.3-17.1
kgf/cm
2
/680 r/ min, 189.2- 243.2 psi/680 r(ft1j n)
Electric starter

Starting system

.s>f Premium unleaded gasoline (Gasohol (E1 0) ac- .s>'9
Fuel
Recommended fuel
Fuel tank capaci ty
Fuel reserve amount
ceptable)
14.0 L (3.70 US gal, 3.081mp.gal)
2.8 L (0.74 US gal, 0.62 lmp.gal)
.<>.
Engine oil 6
Recommended
Type

Recommended engine oil
'1
6
YAMALUBE "bv
10W-40, lOW-50,
20W-40 or 20W-50
API service SG type or higher, JASO
Lubrication system
Engine oil quantity
'%

MA '1%
Wetsump

.s>
Quantity (disassembled) '9 <?
Without oil filter cartridge replacement
With oil filter cartridge replacement
Oil filter
Oil filter type 6"!>
'
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip
Limit
Outer-rotor-to-oil-pump-housing c'i' e%"ance
Limit

3.40 L (3.59 US qt, 2.99 lmp.qt)
2.40 L (2.54 US qt, 2.1 1 lmp.qt)
2.70 L (2.85 US qt, 2.38 lmp.qt)
...

Trochoid
Less than 0.120 mm (0.0047 in)
0.20 mm (0.0079 in)
0.09-{).19 mm (0.0035-D.0075 in)
0.21 mm (0.0083 in)
0.06-D.13 mm (0.0024-0.0051 in)
clearance
Limit 0.16 mm (0.0065 in)
Oil pressure 230.0 kPa/5000 r/min@ 100 c (2.3 kgf/cm
2
/
Bypass valve openi'ng pressure

Relief valve operating

Cooling system o%
Radiator capacity (including all rout%)
Coolant reservoir capacity (up to the m\l)<i-
mum level mark) '9 <?
->{iOOO r/min, 33.4 psi/5000 r/min @212 F)
kPa (0.8o-1.20 kgtfem
2
, 11.6-1 7.4
psi) y.?.
<?....
670.Q-=810.0 kPa (6.70- 8.10
97.2-t 17.5 psi)

1.93 L (2.04 US qt, 1.70 lmp.qt)
0.25 L (0.26 US qt, 0.22 lmp.qt)
>

...

.s>
f
.<?>

-"!>
ENGINE SPf'CJFICATIONS

93.3-122.7 kPa (0.93-1.23
psi)

.s>
'-9
340.0 mm (13.39 in)
222.6 mm (8.76 in)
22.0 mm (0.87 in)
'.(?>

'%

<t>b

y.?.

Cylinder head v.s> v.s>
Combustion chamber volume <? 19.09-20.69 cm
3
(1.16-1.26 cu.in) <?>
Warpage limit 0.10 mm (0.0039 in)

Camshaft
Drive system Chain drive (right)
"t> <t>b
Camshaft inside diameter 24.500-24.521 mm in)
Camshaft joutl)pl diameter y.?. 24.459-24.472 mm in)
clearance 0.028-0.062 mm (0.00114.{)j)24 in)
Camshaft lobe
Lobe height 36.290-36.390 mm in)
Limit
36.190 mm (1.4248 in)

Base circle diameter (IJ' ii\(e) 27.950-28.050 mm (1.1 004-1.1043
Limit v.s>f 27.850 mm (1.0965 in) v.s>-9
Lobe height (Exhaust) <?> 35.720-35.820 mm (1.4063-1.4102 in) <?>
Limit 35.620 mm (1.4024 in)
Base circle diameter (Exhaust) 27.978-28.078 mm (1.1015-1.1054 in)
Limit 27.878 mm (1.0976 in)
Camshaft limit 0.030 mm (0.0012 in) 6"!>
Timing chain
Tensioning syste"!li " Automatic

Valve, valve seat, guide
Valve clearance (cold)

Intake 0.11-0.20 mm (0.0043-0.0079 in) ..
Exhaust v.s> 0.26-0.30 mm (0.01 02-0.0118 in) v.s>

Valve head diameter (intake) 30.90-31.10 mm (1 .2165- 1.2244 in)
Valve head diameter (exhaust) 24.90-25.10 mrn (0.9803-0.9882 in)
Valve seat contact width (intake) 0.90-1.10 mm (0.0354-0.0433 in)
Limit
6
1.60 mm (0.06 in)
6
<t>b
Valve width (exhaust) 1.1 Q-1.30 mm (0.0433i' 'I'J.,P.512 in)
Limit 1.80 mm (0.07 in)
Valve stem (intake) 4.475-4.490 mm in)
Limit 4.445 mm (0.1750 in)
Valve stem diameter 4.460-4.475 mm (0.1756- 0.1762 m1o
Limit 4.430 mm (0.1744 in)
Valve guide inside 4.500-4.512 mm (0.1772-0.1776 in)
Limit <? 4.542 mm (0.1788 in) <?
> >

'% '%
2-3

<t>.. <t> ..
Valve dimensions
c
inside diameter (exhaust)
limit
"' Valve-sterii' 1o-valve-guide clearance (intake)
limit
Valve-stem-to-valYJ;J-guide clearance (ex-
haust)
limit
6
Valve stem runout
"!>
spring
length (intake)
t-t9)it
(exhaust)
(intake)
Installed leK!iJlh (exhaust)
Spring rate Kl<(intake)
Spring rate K2
Spring rate K 1 (
Spring rate K2 (exhauSt')
6"!> Installed compression force (intake)
... ,h; yo.
compression spring t3' rce (exhaust)

s) neg tilt (intake)
Sprin'9llilt (exhaust)
(intake)
Winding di(e"ction (exhaust)
Cylinder
Bore
.-9
>
Y.r
Taper limit
'%

<t>
Out of round limit
6
"!>,., Piston
clearance

point (from piston skirt bottom)
Offset
Piston inside diameter
limit
Piston pin outs1dfil diameter
limit '%
Piston-pin-to-piston) R_;;bore clearance
6 Piston ring
Top ring
Ring type
gap (installed)
it
clearance
..
2nd ring
.-9
Ring type <?>
Y.r
'%

<t> ..
2-4
-"!>E'f\GINE SPECIFICA

c
4.50o-4.512 mrTf-(9..1772--0.1776 in)
4.542 mm (0. 1788 ft>Q.,
0.010--0.037 mm (O.Oo6.fl--0.0015 in)
0.080 mm (0.0032 in) <?>
0.025-0.052 mm in)

0.100 mm (0.0039 in)
0.01.9 mm (0.0004 in) <t>b

39.31 in)
37.34 mm in)
.
37.78 mm (1.49dn)
35.89 mm (1.41
32.90 mm (1.30 in)
32.00 mm (1.26 in)
32.15 N/mm (3.28 kgf/mnwJ 83.58 lbflin)
43.93 N/mm (4.48 kgf/mm, 84 lbflin)
30.11 N/mm (3.07 kgf/mm, 17.<1\l;i. lbflin)
41.48 N/mm (4.23 kgf/mm,
N (19.58-22.43 kgt,

N (16.52-18.97 kg!,

1.7 mm (0.07 1f.l.b
1.6 mm (0.06

Clockwise ..
Clockwise
.-9
>
Y.r
78.000-78.010 mm (3.0709-3-x\1713 in)
0.050 mm (0.0020 in)
0.050 mm (0.0020 in)

y
mm (0.0004--0.0014 in)
0.150 mm'(0.0059 in)
77.975-77.99'Q.)!lm (3.0699-3.0705 in)
12.0 mm (0.47
0.00 mm (0.0000 ii'f);- -6
17.002-1 7.013 mm (l1,P694--Q.6698 in)
.!'
17.043 mm (0.6710 in)
16.990-16.995 mm in)
16.970 mm (0.6681 in) <:!
0.007-0.023 mm
6"!>
,.,
),
Barrel
0.15--0.25 (0.0059-0.0098 in)
0.50 mm (O.Ol 9t, in)
0.030--0.065 mm
0
-w..oo12--Q.0026 in)
0.115 mm (0.0045 i71).,
c:-
Taper
<1'
.-9
.<?>
Y.r
'%

<t> ..

ENGINE SPECIFie ATIONS

c
End gap (installed) 0.30-0.4%nm (0.0118-0.01 n in)
.. Limit 0.80 mm in)
R,ing side clearance 0.020-0.055 rTIQ'I (0.0008-{).0022 in)
0.115 mm
Oil ring
End gap 0.10-0.40 mm in)
Connecting rod"'<t.. "'.it..
6
"!> Oil clearance
6
"!> 0.027- 0.051 mm (0.0011-D.60.?., 0 in)
Bearing color code Blue 2. Black 3. Brown 4. Gree9
0
Crankshaft
Runout limit 0.03it.r:pm (0.0012 in)
end side clearance mm (0.0063-{).01 03 in)
oil clearance 0.014-0.0:m.J.llm (0.0006-{).0015 in)
B1!i:!gng color code O.White 3.Brown 4.Green
Balancet>
method
Balancer sfi'&V. runout hm1t
Balancer to balancer shaft bear
ing clearance
6"!>

Bearing color
?4
Clutch

Clutch type
Clutch release method
lever free play
F'ti.lion plate 1 thickness
Wei r,limit
Plate
Friction 2 thickness
Wear limit
Plate quantity
6"!> Clutch plate thickfless
Plate quantity

Warpage limit "
Clutch spring free length
Limit
quantity
X)
TrallsJll lsslon
type
ratio
ratio
Final drive
Operation
6
"!> Gear ratio
v ?
'
2nd

"' 3rd

4th
"0

Mafl\,axle runout limit
runout limit

<t> ..

>y
Gear
0.030 mm (0.0012 in)
0.024-0.048 mm in)
'!:>
6"!>
2.Biack 3.Brown
... ?4 .;.S

Outer rack and pinion pull
(0.39-D.59 in)
2.92- 3.08 in)
2.82 mm (0.111'1!'1)
7 pes
2.92-3.08 mm (0. 115"%/.121 in)
2.82 mm (0.111 in)
2 pes
"t>
6"!> 1.90-2.10 mm
?.?.
O?<l,_,Q mm (0.004 in)
(2.07 in)
(1.96 in)
6 pes
b"
v
Constant
1.681 (79/47)
2.813 (45/16)
Chain
...
Left foot operation
6"!>

2-5
1.61 9;.(,34/21)
1.381 (2'9}21)

1.037 (28/21)'1 v
0.08 mm
0.08 mm (0.0032

<t> ..
?.?.

Shifting mechanis'hi .
Shift mechanism tyP\ v Shift drum and guide bar "! v
Shift fork guide bar beri6if1Jl limit 0.050 mm (0.0020 in) .s>f
Shift fork thickness >Y.?_,., 5.76-5.89 mm (0.2.268-0.2319 in) <?"Y.?_,.,
Air filter
Air filter element Oil-coated paper element

Fuel . p ' ' '
y.?.;;, Electrical '.? y.?.;;,
Maximurlii&onsumption amperage " 3.3 A

"

Fuel inject or
Model/quantity
Throttle position sensor

Output'V,P.Itage (at idle)
..,
sensor
Resistance
Output voltage
':!>
Air induction v
Reed valve bending limit,
Solenoid resistance <?>y
.?
Idling condition
Engine idling speed
(AI system OFF, exhaust
lntaK'ey acuum
Water
Oil
Fuel line at idling
Throttle grip fre.Qiay
"0

"!v
.s>
f
.<?>
y.?
'%

y.?.

2-6
297500-1 110/3
FZ09E EACW41-61/1
FZ09EC EACW41-B3/1
FZ09E 1 RC1 00
FZ09EC 1 RC5 1 0
1.2o-2.80 kn
0.63-0.73 v
1.08- 2.52 kn
0.63-0.73 v
0.4 mm (0.02 in)
2o-24 n

110o-1300 r/min
...
1.50-3.50%
30.5-34.5 kPa mmHg, 9.o-10.2 inHg)
90.0-110.0 oc F)
75.o-95.0 oc F)
300-390 kPa (3.0- 3.9 k{j'tlfm
2
, 43.5-56.6 psi)
. -"'c
3.o-5.0 mm (0.12- 0.20 m)

"!v
.s>
f
.<?>
y.?
'%

y.?.

"<0< -"!>
'.?
-?,HASSIS

%,
'
CHASSIS

Chassis .s>f .s>f
Frame type <?> Diamond <?>
C
' 25.00 "
aster angle
Trail 103 mm (4.1 in)
.<)
<
Front wheel
Wheel type
Rim size
Rim material
Wheel travel
6"!>
'.?

Radial wheel runout limit
Lateral wheel runout limit
<t>b
wheel
Y.
x MT3.50
'
Aluminum
137.0 mm (5.39 in)
1.0 mm (0.04 in)
0.5 mm (0.02 in)
Rear wheel
Wheel type
Rim size
Rim material
Wheel travel
.s>
Radial wheel limit
Lateral wheel runollt,jjmit
;,
Front tire
Type
Size
Manufacturer/model
Manufacturer/model
Wear limit (front)
Rear tire
Type
Size

Manufacturer/model>,
Wear limit (rear) .?
f
.<?>
y.?
Cast wheel
17M/C x MT5.50

Aluminum
130.0 mm (5.12 in)
<t- 1 .0 mm (0.04 in)
(0.02 in)
Tubeless
120/70 ZR17MIC (58W)
BRIDGESTONEIS20F
DUNLOP/ D214F
1.0 mm (0.04 in)
-y.?
Tubeless
180/55 ZR 17MIC (73W)
-><t- J!RIDGESTONEIS20R
Ef.(,J NLOP/ D214
1.d'ra;n (0.04 in)
Tire air pressure on cold tires)
Loading condition o-90 kg (o-198 lb)
Front
250 kPa (2.50 kgf/cm

2
, 36 psi)
Rear 290 kPa (2.90 kgf/cm
2
, 42 psi)
Loading condition FZ09E 9o-177 kg (198- 390 lb)
f
Front
Rear
High-speed riding
Front
Rear
Front brake
Type
Operation
%

%.0

Front disc brake .
<?> FZ09EC 9o-176 kg (198-388 1b)
2
, 36 psi)
2
, 42 psi)

kPa (2.50 kgf/cm
2
, 36 psi))
290-?.kPa (2.90 kgf/cm
2
, 42 psi)"!>,.?
'?; \;
Dual disc brake
Right hand operation
Disc outside diameter x v
Brake disc thickness limit .s>f
.<?>
y.?
298.0 x 4.5 mm (11.73 x 0.18 in)
4.0 mm (0.16 in)

""2.-7

<t> ..
c
disc runout limit (as measured on

Brake paQ,Iining thickness (inner)
Limit
Brake pad (outer)
Limit
Master cylinder
6
Caliper cylinder inside diameter
"!>,.? Caliper cylinder inside dia(llle$er
brake fluid
Relij' brake

"''-'
Rear
Disc diameter x thickness
Brake disc tl'tickness limit
Brake disc limit (as measured on
wheel)
Brake pad lining (inner)
6"!> Limit
'.? Brake pad lining
Limit "0
cylinder inside diameter
CiffiJ2er cylinder inside diameter
Spec'Hi!;ld brake fluid

Steering v
Steering type
Center to lock (left)
Center to lock (right)
Front suspension
..
6
Type
"!>,.? Spring/shock absorber
fork travel
spring free length
Lifujt

Fork sPr'-igp installed length
Spring
Spring
Inner tube
Inner tube bendinQ' <IJ[Iit
Recommended oil
Quantity (left) ..
6
"!>, Quantity (right)
.? y
Level (left)
(right)
preload adjusting positions

M11)imum

MaximClQ:J
,s>
'-9
'.(?>
y.?

<t> ..
2-8
-"!> -....
SPECIFICATI'G.NS
..

c
0.10 mm (0.0039'1g\

"'
4.5 mm (0.18 in) c/"'
0.5 mm (0.02 in) <?>
4.5 mm (0.18 in)
0.5 mm (0.02 in)
15.00 mm (0.59 in)
mm (1. 19 in) <t>b
(1.06 in)
DOT 4

Single disc
Right foot
oo,.
c:-
245.0 x 5.0 mm (9.65 in)
4.5 mm (0.18 in) <?>
0.15 mm (0.0059 in)

<t>b

6.0 mm (0.24 in)
1.0 r:run (0.04 in)
6.0 in)
1.0 mm in)
12.7 mm (iJ.'S.g in)
38.18 mm (1.50dfl)
DOT4
y.?.
"0
Angular bearing
32.0
32.0

Telecopic fork
Coil ifP!;jng/oil damper
137.0 in)
300.3 mm {1> J .82 in)
294.3 mm (1 in)
120.0 mm
295.3 mm (11.63
7.35 N/mm (0.75 41.971bllin)
0.0-137.0 mm (O.OQ-5.39,lf:J)
41.0 mm (1.61 in)
0.2 mm (0.01 in)
Suspension oil 01
472 . .Q cm
3
(15.96 US oz,

(15.48 US oz,
147 mrfi.tg;.8 in)
148 mm "

19.0 mm (0.75 iii},
16.0 mm (0.63
4.0 mm (0.16 in)
.s>
'-9
'.(?>
y.?

<t> ..
Cb
, Rebound damping adjusting positions '<o
Minimum .. 3 tum(s) out
v.s> Standard '1s. 314 turn(s) out
-9. <?> Maximum screw fully turned in
adjusting screw fully turned in
'%ijear suspension
'l,ype Swingarm (ftli!k suspension)
Spnng/shock absorber type
6
"!> Coil damper
absorber assembly traveJ, 60.0 mm (2.36 in f .?.;;,
Spring ifee length

191.4 mm (7.54 in) "
Spring installed length 179.8 mm (7.08 in)
Spring rate K1 99.96 N/mm (10.19 kgf/mm, 570.77 1bf/in)
Spring stroke K1 0.0--60.0 mm in)
.. v Enclosed gas/air pressure (STD) .. J 80 kPa (9.8 kgf/cm
2
, 139.4 psi)
.s>f Spring preload adjusting positions .s>f
<?>y Minimum 1 <?>
Standard 4
Maximum 7
damping adjusting positions
6"!> 3 turn(s) out
'.? 1 1/2 turn(s) out? Y.?.
Maximum

Adjusting screw fu!fr turned in
'With the adjusting screw fully turned in

>

.s>
Drive chain
Type/manufacturer
Number of links
525V10/DAIDO

-9 Drive chain slack
. <?>Y.? 15-link length limit

""4?hlft pedal
shift rod length
<t>b

y.?.

.%15.0 mm in)
(9.42 in)

' '
SPECIFICATIONS

c
SPECIFICATIONS

Voltage'f
System
.?X.
Ignition systlltJJ
Ignition
Ignition timing (B:'l-;t, D.C.)
6"!>
'.?;, Engine control unit "Y.?.

Model/manufacturer

%-o Ignition coil
ignition spark gap
"l:><l'jmary coil resistance
coil resistance
.s>
Lean sensor output voltage
Less than?-6!
More than
AC magneto ..
6"!> Standard output
'.? Stator coil resistance
Rectifier/regulator "
Regulator type
voltage (DC)
R\ctifier capacity
"!
Battery.rf
Model -<?>
Voltage,
Specific
Manufacturer
6"!> Ten hour rate current
'.?
Headlight
Bulb type "
%
voltage, wattage x quantity

light
Tail/l!r!iake light
Front signaVposition light
>
Rear turn light
License
Meter lighting
6"!> Indicator light
'.?;, Neutral indicator light Y.?.

Turn signal indicator
Oil level warning light
High beam indicator light
temperature warning light
trouble warning light
v.s>
'f
. -<?>
y.?
'%

"!:>.
12 v
TCI
6
5.0 / 1200 r/min
'.?;,

?"
'%
ob
6.0 mm in)
1.19-1.61
9.35-12.65 krr' c,
.s>
0.4-1.4 v
3.7-4.4 v
6
"!>14.0 V, 415 W@5000 r/min
0'"!52-0.228 n (WW)
...

Semi JBI!Jductor-short circuit

50.0A
YTZ10S
12 V, 8.6Ah
1.310
GS YUASA
6"!>0.86 A

Hant!il,en bulb
"

"!
c
12 V, 60.ffVi./55.0 W X 1
12 v.
LED v.s>
12 V, 21.0 W/5.0
12V,21.0Wx2
12 V, 5.0 w X 1 ""<1
LED
2-10
Electric
System type "! v
Starter motor
Power output
Armature coil resistance
Brush overall length
LiQ)it
Brlfs,S spring force
Mica (depth)
Starter relayo
Amperage
Coil

q;.,
Horn 'v
.s>
Horn type <?
Quantity "Y.?
Maximum amperage '%
Coil resistance
-'?.
Turl}) signal/ hazard relay
RefHy,JYpe
device
-"!> "
y.?
'%

12.0 mm (0.47 in)
6.50 mm <t>b
6.03-6.52 N gf, 21.71- 23.47 oz)
), y.?.
0.70 mm (0.03 in
180.0 A
4.18-4.62 n
Plane
1
3.0A
1.07-1. 11 n
Oil level sv.irtlih
Oil level switctill{.esistance (maximum level po-
sition)
484.o-536.o o
Oil level switch (minimum level po-
t ) oS'
SI IOn .
Fuel sender unit Y.?
Sender unit resistance
Sender unit resistance
...
Fuel'(injection sensor
position sensor resistancl-"Y.?.
Intake sensor output
Intake air''f'Wlperature sensor resistance

Cb
Coolant sensor resistance
'!><!
Fuses
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
fan fuse
lighting fuse
Fuel injee;).ion system fuse
Auxil iary
Backup fuse
Electronic fuse
Spare fuse v
Spare fuse .s>f
Spare fuse <?>y

<t> ..
2-11
114.o-126.o n
9.o-11.o o
213.o-219.o o
6"!>
228- 342 0 (Gy-B)..
3.57-3.71
540o-6ooo o@o F)
290-390 o@80 c
251o-2780 o@20 c (68
210-221 o@100 c (212
50.0A
15.0A
7.5A
15.0A
15.0 A
10.0 A
10.0 A
2.0A
7.5A
7.5A
15.0 A
10.0 A
7.5A
-"!>
ELECTRICAL

Spare fuse 2.0A
2-12
EA$20320 CO...,
TIGHTENING

EA$20331
GENERAL TIGHTENING T(i).RQUE
SPECIFICATIONS
This chart specifies tightening for stan-
dard fasteners with a standard ISO!t-JJ.ead pitch.
Tighteaing torque specifications for com-
poneni-:pr assemblies are provided fdr?each
chapter manual. To avoid warpage, 'light-
en assemblies in a crisscross pat-
tam and stages until the specified
tightening torque Unless otherwise
specified, specifications re-
qui re clean, dry threads.C<;;.omponents should be
at room temperature.
>
?.?
'%

0
<t>

?.?.

B

torqli'E:
A (nut)
(bolt)
...
6"!>
Nm m-kgf

?
?,
10mm
6 0.6
12mm 8 15 1.5 11

14 mm 10 mm''
<o,. 30
3.0 22
17 mm 12 mm

5.5 40
19mm 14 mm 85 8.5 61
22mm 16 mm 130 .. 94
..,
2-13

EA$203-CO
ENGINE TIGHTENING TORQUES

.,
Item

>?
Sparfo_elug

bolt
't>
Cylinder
?
Intake camshatt'Bap bolt
Exhaust camshaft cap bolt
Camshaft cap bolt
.,
Cylinder head cover bolt
O,y. Jinder head stud bolt (exhaust
pip'
Reed cover bolt
.<>.
Camshaft S) Jocket bolt
"'
Cylinder breather
plate bolt "
Timing chain bolt (right side of
cylinder head)
Connecting rod bolt
., -<lenerator rotor bolt
-c>,
chain tensioner bolt
tensioner cap bolt
Oil pump
Oil pump bolt
Oil pump cover screw
Water pump housing cover bolt
Water pump drain bolt
' :Jater pump bolt

jacket joint bolt
"''"
Oil coole; union bolt
.<>
Engine oil bolt
"'"
Oil strainer
Oil filter cartridge union bolt
Oil filter cartridge
Oil pan bolt
' :Jhrottle cable nut
Thread
size
M10
M9
M6
M6
M6
M6
M6
M8
M6
M7
6
'
M5
M6
M8
M12
M6
M6
M6 6
'
M6
M5
M6
M6
M6
M6
M20
M14
6
M6
M20
M20
M6
M6

?,
TIGHTENING TORQUES
c:-
Q'ty torque Remarks
-c>>
?
3 13 Nm (1.3 9.4 ftlbl)
8 --<1]
.. 4
10 Nm (1 .0 mkgf,

10 Nm (1 .0 mkgl, 7.2 tlibt) --<1]
4 10 Nm (1.0 mkgf, 7.2 ftlbl) --<1]

8

See TIP. --<1]
4 10 KII!P (1 .0 mkgl , 7.2 ftlbl)
oS'
' f
6 15 Nm ( 11 ftlbl)

4 10 Nm (1 .0 7.2 ftlbf)

4 24 Nm (2.4 mkgf,'t;tl ftlbf)
"'
,.,

-y;:>
4.0 Nm (0.40 m kgf, 2.9 lt$Jbf)

1 10 Nm (1.0 mkgf, 7.2 ftlbf)

6
..
"! /,
See TIP. --<1@
1 75 Nrli;<l.?,5 mkgf, 54 ftlbf) --<1]
2 10 Nm 7.2 ftlbf)

1 7 Nm (0.7 ftlbl)
4 10 Nm (1.0 mkgf,
.. {
0
15 Nm (1. 5 mkgf, 11

1
,
3.8 Nm (0.38 mkgf, 2.8 ftlbf)
%
1 0 Nm (1.0 mkgf, 7.2 ftlbf)
1 1 (1.0 mkgf, 7.2 ftlbf)
4 12 NmP-(,1.2 mkgl , 8.7 ftlbl)

2 10 Nm (1 7.2 ftlbf)

1 35 Nm (3.5 25 ftlbf) --<1]
.<>
1 43 Nm (4.3 ftlbf)
iS>,<
'.>_R

10 Nm (1.0 mkgl , 7.2it,.Jgt)

1 "'1
1-%,
70 Nm (7.0 m kgf, 51 ftlbl) --<1]
1 17 Nm (1 .7 mkgl, 12 ftlbf)

15 1 0>-t!m (1.0 mkgl , 7.2 ftlbl)
"'
2 4.5 Nrlls(p-45 mkgf, 3 3 ftlbf)
2-14
-"!> "<0<
'.?
TIGMJENING TORQUES

%
' '
c. c.

Thread

lteJ:u Q'ty Tightening torque Remarks

size

' '
Throttle body joint clarnr?, screw M5 6 3.0 Nm (0.30 mkgf, 2.2 ftlbf) <>
Air filter case cover M5 10 1.6 Nm (0. 16 mkgf, 1.2 ftlbf)

Air filter case joint clamp sere"':, M5 3 2.8 Nm (0.28 mkgf, 2.0 ftlbf)
.
... ...
FQ,el injector adapter bolt

2 12 Nm (W6 mkgf, 8.7 ftlbf)

" "

Air case bolt

3 7 Nm (0.7 5.1 ftlbf)
nut
M8 6 20 Nm (2.0 4 ftlbf)
Muffler bolt M8 2 20 Nm (2.0 mkgf,
Muffler protectof.b,91t M6 3 10 Nm (1 .0 mkgf, 7.2 ff.'fi3Jl
Crankcase bolt M8 8 See TIP.
.so

Crankcase bolt
-y.?

M8 6 24 Nm (2.4 mkgf, 17 ftlbf)

Crankcase bolt

M6 16 10 Nm (1.0 mkgf, 7.2 ftlbf)

cover bolt
<to
M6
11 12 Nm (\f mkgf, 8.7 ftlbf)

i$)4
position sensor bolt

2 10 Nm (1 .O' f'%kgf, 7.2 ftlbf)
-G
Crankslfa4, end cover M36 1 10 Nm (1 .0 ftlbf)
Timing bolt M8

1 15 Nm (1 .5 mkgf, Y'bftlbf)

Drive sprocket ce.ger bolt M6 3 8 Nm (0.8 mkgf, 5.8
Generator cover M6 8 12 Nm (1 .2 mkgf, 8.7
Generator cover bolt
"">
y.?.;,
M6 2 12 Nm (1 .2 mkgf, 8.7 ftlbf)
"':
r.?.;, -G
Main gallery bolt M16 2 8 Nm (0.8 mkgf, 5.8 ftlbf)
SJ:1b gallery plug
...
<to
M14 1 6 Nm (o.g mkgf, 4.3 ftlbf)
...

Cllltc.\\ cable holder bolt 2 12 Nm (1 8.7 ftlbf)
-G
--
"'
Timing"' e.tJain cover bolt M6 8 12 Nm (1 .2 8.7 ftlbf)
Starter M8 3 32 Nm (3.2
-G
Clutch boss M20 1 125 Nm (12.5 mkgf,
-G
Clutch spring bolt v.so.., M6 6 10 Nm (1 .0 mkgf, 7.2 ftlblf .so
4
Clutch cable locknut
>Q>
M8 1 7 Nm (0.7 mkgf, 5.1 ft lbf)
>Q

Drive sprocket nut 'Z>"<1
't9
M22 1 95 Nm (9.5 mkgf, 69 ftlbf)

axle bearing housing bolt M6 3 12 Nm (1.,:,2 mkgf, 8.7 ftlbf)

Stiilt;rum retainer bolt

10 Nm (1 .'O' 'fl);kgf, 7.2 ftlbf)
.

2
-G
"'-
Shift spring stopper MS 1 22 Nm (2.2 16 ftlbf)
-G
" "
Shift arm M6 1 14 Nm (1.4 mkgf,
Gear position bolt M5 2 4.0 Nm (0.40 mkgf,
-G
Coolant
'"'
M10 1 16 Nm (1.6 mkgf, 12 ftlbf)&.so
'"'
2-15

TIGHTENING TOBQUES
....
'
c. c.

Thread

Item Q'ty Tighte'hing torque Remarks

size

' '
Intake aW,pJessure sensor screw M5 2 7 Nm (0.7 ftlbf)
...
Stator coil b'61b M6 3 14 Nm (1.4 m-kgf, -(J
" "
Oil level switch b'blt M6 2 10 Nm (1 .0 m-kgf, 7.2 ft'ib!)
Starter motor bolt
K)

M6 2 6"!> 12 Nm (1.2 mkgf, 8.7
Starter motor lead nut "oo
"
M6 1 Nm (0.7 m-kgf, 5.1 ft-lbf)

Speed sensor bolt M6 1 10 m-kgf, 7.2 ftlbf) -(J
rod locknut (front) M6 1 8 Nm mkgf, 5.8 ftlbf)

Left
Shift'Ted locknut (rear) M6 1 8 Nm (0.8 rii'lsgf, 5.8 ft lbf)
thread ,SO ..
'-9 '-9
Shift rod [oi'Rt bolt
..-,
M6 1 10 Nm (1 .0 m-kgt,"-1.2 ftlbf)
..-,
-(J
Adapter bolt (te(!Lright) M6 2 12 Nm (1.2 m-kgf, 8.7<ft. 4bf)
"
Oil filler cap
..,..
M20 1 1.5 Nm (0.15 mkgf, 1. 1 ftietl
<t>b
'""
"'
Starter motor assem61Y,,Qolt M5 2 ... 5 Nm (0.5m-kgf, 3.6 ftlbf)

"'
y
Starter motor insulator nuf M6 1
(1.1 m-kgf, 8.0 ftlbf)

"
..
J hrottle position sensor screw M5 2 3.5 Nrrt,,l-?.35 m-kgf, 2.5 ftlbf)

M5 2 3.5 Nm
m-kgf, 2.5 ftlbf)

"'"'
Clutc'ttcable and adjust nut M8 1 7 Nm (0.7 5.1 ftlbf)
,SO
Throttle cat;>le and throttle body
-;,.
M6 2 4.5 Nm (0.45
ft lbf)
Coolant bolt M5 1 0.5 Nm (0.05 m-kgf, ftlbf)
Coolant M6 1 9 Nm (0.9 m-kgf, 6.5
Radiator bolt
K)

M6 2 6"!>,. 10 Nm (1 .0 m-kgf, 7.2
Radiator fan cover bolt M6 1 (0.7 mkgf, 5.1 ftlbf)

-(J
Radiator cap bolt M5 1 m-kgf, 3.6 ftlbf)
stay bolt M6 1 10 Nm f4.<o0 m-kgf, 7.2 ftlbf)
..
Camsha'f$ cap bolt .so-9
Tighten to 10 Nm (1.0 m-kgf, 7.2 ftlbf) following the tightening ord'ef.
" "
2-16

?,
TIGHTENING TeRQUES
ilinder head bolt
TidhiAn the bolts to 25 Nm (2.5 m-kgf, 18 fllbf) with a torque wren6t.J, following the tightening order.
PA1rfmm the following procedure to all the bolts one by one in the tig'fl'tt;ljling sequence as shown in

'%

the
a. Loosen bolt.
b. Tighten to 16 Nm (1.6 m-kgf, 12 ftlbf) with a torque wrench.
c. Tighten the to reach the goo.
2-17
-"!> -"!>

' '

%
TIGHTENING TORQUES

TIGHTENING TOBQUES
v
Thread
v
.s>
Item Q'ty Tightenin!f-torque Remarks "f
size
"<}
<>>
>y
y
Engine bolt (front upper
M10 4

45 Nm (4.5 mkgf, 33 J.bf)
and front

-<>. -<>.
Engine mounting nilb.[ear upper) M10 1

45 Nm (4.5 mkgf, 33
Engine mounting nut (rif<!&)ower) M10 1 /., Nm (4.5 mkgf, 33 fllbf)

Engine mounting adjust bolt
"'1
M18 1 7 (0.7 mkgf, 5.1 fllbf)

mounting adjust bolt

M16 2 7 Nm 5.1 fllbf)

Main frifr:ne and rear frame nut
<>
M10 4 50 Nm (5.0 m:ifgh 36 ftlbf)
-<lt
Pivot shaft M14 1 110 Nm (11 mkgf,
Relay arm and"irame nut
.<>.
M10 1 61 Nm (6.1 mkgf, 44 fM!:>J)
Relay arm and corine_ting arm
'"'t;>.
nut .
M10 1 6"!> 55 Nm (5.5 mkgf, 40 fllbf)

Connecting arm and swiri'Qarm
(5.5 mkgf, 40 fllbf)
"
M10 1
assembly nut

shock absorber assembly
c

M10 1 44 Nm mkgf, 32 fllbf)

0
Rear st:\Ock absorber assembly
v
nut (lowe'Q,
M10 1 44 Nm (4.4 m:l('gf, 32 fllbf)
>
"<}>
Drive chain bolt M6 2 7 Nm (0.7 mkgf,
Rear fender M6 3 7 Nm (0.7 mkgf, 5.1 fl.rek)
Swingarm bracket {Mf!,land
6 ;o
M6 4 "b 7 Nm (0.7 mkgf, 5.1 fllbf)
-<lt
swingarm bolt Y.,.,._
y
Swingarm bracket (right) and

I"-'
swingarm bolt
M6 4 7N.Ji1 (0.7 mkgf, 5.1 fllbf)
-<lt
-b
' eJ;lain puller adjusting locknut M8 2 16 mkgf, 12 ftlbf)
Upperi racket pinch bolt M8 2 26 Nm (2.6'"<mc,kgf, 19 ftlbf)
nut M22 1 110 Nm (11 m'kg_t,,SO fllbf)
Upper holder bolt M8 4 22 Nm (2.2 mkgf,
(')
Lower ring nut .
-<>.
M25 2 See TIP.
...
-<>.
Lower handlebar nut M10 2

40 Nm (4.0 mkgf, 29
Front brake master cyliif<ij,3r
/.,
ftl,
holder bolt "
M6 2 Nm (1 .0 mkgf, 7.2 ftlbf)
..
brake hose union bolt M10 3 30 t\rr'ijp.o mkgf, 22 ftlbf)
t"e.wer bracket pinch bolt
"'"'
M8 4 23 Nm mkgf, 17 ftlbf)
.. "'
and upper bracket M8 2 23 Nm (2.3 ih;kgf, 17 fllbf)
.s> .s>
Grip end' <>>
v,
M16 2 26 Nm (2.6 mkgf>) 9 fllbf)
v,

2-1 8
'
c.
Item

r;,Q'ty Tightening torque Remarks
size

'
Front brake master cylinder res-

ervoir cap screw
M4 2

1.5 Nm (0.15 mkgf, 1.1 ft lbf)

Clutch lever holder pinch bolt M6 1 ' 1 Nm (1. 1 mkgf, 8.0 ftlbf)
Horn bolt
6
M6 1 7 mkgf, 5.1 fllbf)
6
fender bolt

;,
M6 4 10 Nm"' (l!,,R mkgf, 7.2 ftlbf)

;,
Meter bracket bolt

M6
2 7 Nm (0.7 m-kgf, 5.1 fllbf)

"
Meter assembly screw 3 1.3 Nm (0.13 mkgf, 0.94 ftlbf)
Headlight stay and lower bracket
-'0
M6
r;. 1
7 Nm (0.7 m-kgf, 5.1 fllbf)
bolt

Headlight stay, horn bracket and
'f
lower bracket bolt
M6
1 .

Front brake hose holder and
M6 1 (0.7 m-kgf, 5.1 fllbf)
headlight stay bolt
..
t uel pump bolt
6"!> M5 4 4.0 Ni'Wi(l.40 mkgf, 2.9 ftlbf)
6"!>
? ?
F' del tank stay and fuel tank M6 4 7 Nm 5.1 fllbf)
Fuel tank stay and frame
.ft,!'16
2 7 Nm (0.7 m-kgf, 5.1 fllbf)

Fuel tank and fuel tank bracket
MS.. -<o
2 7 Nm (0.7 m-kgf, 5.1 fllbf)
Fuel tank bracket and fuel tank
M6

bracket assembly bolt .s>
'f
Fuel tank cap bolt MS 4 6 Nm (0.6 mkgf, 4.3 ftlbf)
...
Air scoop stay and frame bolt M6 4 Nm (0.7 mkgf, 5.1 fllbf)
Fuel tank bracket assembly and

M6 4 7 mkgf, 5.1 ftlbf)
l ear frame bolt 6"!>

6"!>
bracket and rear frame bo lt..,_, M6 4 7 Nm 5.1 fllbf)
..
Seat lock assembly and battery
.ft,.f.16 2 7 Nm (0.7 m-kgf, 5.1 fllbf)
"1;
box bolt

Front wheel axle 1 65 Nm (6.5 mkgf, 47 ftlbf)
Front wheel axle pinch bolt M8 23 Nm (2.3 mkgf, 17 ft-lbf)
Front brake caliper bolt M10 4

35 Nm (3.5 m-kgf, 25 ftlbf)
Front brake disc bolt M6 10 ... <>"<118 Nm (1 .8 mkgf, 13 fllbf)
-<ll ,.
Rear wheel axle nut M18 1 (15 mkgf, 108 ft-lbf)
brake disc bolt
"!>
M8 5 30 mkgf, 22 fllbf)

.>. ... .>.
Rear wheel sprocket nut

M10 6 80 Nm mkgf, 58 fllbf) ..
Brake caliper bleed screw 3 5 Nm (0.5 m-kgf, 3.6 ftlbf)
Rear brake master cylinder bolt

2 23 Nm (2.3 mkgf, 17 ftlbf)
Rear brake hose union bolt M10
'-
30 Nm (3.0 mkgf, 22 fllbf)
Footrest bracket bolt M10 2"'
'
y
55 Nm (5.5 m-kgf, 40 fl lbf)
-<ll

"
TORGlJES

' '
c. c
Item

Q'ty Tightening torque Remarks
'
Passenger footrest and rear
'"/
M8 .t> 28 Nm (2.8 mkgf, 20 fl lbf) -(J
frame bolt
Y,;>
'
r,/.
Rear brake fluid reservoir nut M5 1 Nm (0.38 mkgf, 2.8 ftlbf)
Sidestand bracket bolt
6
M10 1 (4.8 mkgf, 35 ftlbf)
switch bolt
v,.,

M5 2 4.3 mkgf, 3.1 fllbf)
v,.,

Adapter bracket and frame M6 2 12 Nm (1 .2 mkgf, 8.7 ftlbf)

" "
Battery box and rear frame bolt 2 7 Nm (0.7 mkgf, 5.1 ft lbl)

0
Mudguard assembly nut

2 7 Nm (0.7 mkgf, 5.1 ftlbf)
Rectifier/regulator bolt M6
,J>42
7 Nm (0.7 mkgf, 5.1 fllbf)
Rear side cover and rear frame
'>Q>
7 Nm (0.7 mkgf, 5.1 ftlbf) M6
4 Y,;>
bolt '
%
Rear frame and tail/brake light
M6 2
(0.7 mkgf, 5.1 fllbf)
nut
6

. Battery terminal bolt "",.,
;,
M5 2 2.2 Nfu., J?.22 mkgf, 1.6 ftlbf)
1"",.,
;,
Headlight unit side cover bolt (faU
/

side and right side)
M6 4 7 Nm (0.7 mkgf, 5.1 ft lbl)

<> -6
Headlight unit side cover bolt
'oM
0
(upper side)
4 0.8 Nm (0.08 mkgf, 0.59 fllbf)
"'
Front brake lever pivot bolt M6 ,J> 1
'"/
1.0 Nm (0.10 mkgf, 0.72 fl lbl) -t
Front brake lever pivot nut M6
>
1 Y,;>
'
6 Nm (0.6 mkgf, 4.3 ft lbl)
Front brake light switch screw M4 1 Nm (0.12 mkgf, 0.87 ftlbf)
Brake pedal nut
..
M8 1 S'J; Nm (3.0 mkgf, 22 fllbf)
. Rear brake master
"-?:> o,
M8 1 18 Nr'ltsJ1.8 mkgf, 13 ftlbf)
"';,
\lut ...
"
...
Rear brake caliper bolt (front) , M12 1 27 Nm (2.7 mkgf, 20 ftlbf)
<>

-t
0
Rear brake caliper bolt (rear) M& 1 22 Nm (2.2 mkgf, 16 ftlbf)
"'
and -(J
'!>"!
Rear brake pad retaining bolt M10
,J> 1

17 Nm (1.7 mkgf, 12 ftlbl)
Rear brake caliper screw plug M10
1 Y,;>
' [>/.
2.5 Nm (0.25 mkgf, 1.8 ftlbf)
Rearview mirror (left/right) M10 2 17 Nm (1.7 mkgf, 12 ftlbf)
Throttle cable housing M5 2 (0.38 mkgf, 2.8 ftlbf)
..
. Handlebar switch screw v,.,;,
M4
v:>y "v?,;>
" eft/right)

4 2.0 NW-(9.20 mkgf, 1.4 ftlbf)

Front fork cap bolt

, M46 2 23 Nm (2.3 mkgf, 17 fllbf)

Front fork cap bolt locknut

2 15 Nm (1 .5 mkgf, 11 ft lbl)
0
Front fork damper rod assembly
"

,J> 2
23 Nm (2.3 mkgf, 17 fllbf) -(J
bolt
'"/
"

TIGHTENING

'
c.
Thread
"0
Item
size

Tightening torque Remarks

Thermostat assembly bolt M6 2 10 Nm (1.0 mkgf, 7.2 fllbf)
Fuel rail bolt M6 2 (0.5 mkgf, 3.6 fl lbf)
A ir scoop bolt M6 2 1.5 Mn;,..(0.15 mkgf, 1.1 fllbf)
'
bolt (for California M6 2 7 Nm mkgf, 5.1 fllbf)
6"!>
CaniSJ,er bracket bolt (for Califor-
"'
<.

2 7 Nm (0.7 5.1 fllbf)
ma only)

TIP
Lower ring nut

1. Tighten the ring nut to approximately 52 Nm '{&.2 mkgf, 38 fllbf) with a torque wrench, then loosen
the lower ring nut completely. v.so
2. Tighten the lower ring nut to 18 Nm (1.8 mkgf, 13-f.tj bf).
2-21

.,
-"!> "<0< -"!> "<0<
'.?
LUBRICATION LUBRICANT TYPES
'

co,.., co%
LUBAlGJHION POINTS AND LUBRICANT TYPES

ENGINE
EA$20370
? ?

Lubrication point

Oil seal lips

<t>b

0-rings

?.?_.

}-.

hose insertion part
"/
Water or_,,]
"
""
Be<ift (1gS
v.o
-]
0

cover bolt gasket and timing chain bolt gasket
-@
Camshaft i&b{ s and journals (intake and exhaust)
v.

_ ,@
Valve stem sea'fS:;Q,ntake and exhaust)
v>
?.?.;,
-@
Valve lifter outer (intake and exhaust)

Valve stems and stem eflgs (intake and exhaust)
...
6
..
Crankshaft big ends "'?.?. '.? -([]"'?.?.

surfaces
-([]

-]

Connedtlg.,p rod bolts
"!
_,@
Crankshaft
'<,

-]
.,_
Balancer shaft
?.?

-([]
" Generator rotor asseii).bly
.<>.
.<> .
Water pump impeller

Oil pump rotors (inner and
'.?

... _
.
e*'_pump assembly
-.. ,

-]
Oil c6o_J,er bolts
c
0%
-([]
Oil filter union bolt

"! (,
-([]
"f
Oil nozzle
>?.?00, -]
".?.;a,
Main gallery bolt
:;.,

Oil cooler sub gallery
6<'!
..

""
Drive axle sub gallery 0 -ring?-?
00
'.?
....,.or -2;(jl
...
.
journal bolt 0 -rings
v ..
-]
inner surface and end

- ([]
Starter outer assembly
"! /,
-([]
Starter

-([]
y y
2-22
-"!>
.
LUBRICATIOWPOINTS AND TYPES

%
' '
c. c.
Lubrication point
Primary driven gear end
v
.s>
f f
Crankcase cover and clutch
--:..
"'>

Clutch housing spacer
- 1
Clutch conical washer
"-it-.
--<([!
, 6,
Transmissiori>9ears inner surface
..
v:>
.?.
;;a

-<I@
Transmission co11' a.L_ 4.<. -<I@
Transmission gears ooJer surface (shift fork contact parts)

Drive sprocket washer

"!

Shit drum moving surface
.s>
f."'
-1
.s>
f."'
Shift fork pin
- .?

-I
- .?

Shift forks guide bar outer surface
.<>.
-I
Shift
"t>
-I
<'!
6<'!
Shift shaft surface
.?.

...
- 1

bond No. 1215
Crankcase mating (T bond No.
f%5)
(6.,
Yamaha bonlf.f'.J:o. 1215
Stator coil assembly lead gr6ir:}met (Three bona.No.
.<?> 1215) f.<?>
- -
"'"'""
CHASSIS
6"!>
Lubrication P'q;pt
6"!>
Lubricant

Steering bea1ib.Jls, seal lip and ball race lip
y.?.;;,
"

Tube guide inner surface and throttle cables
-6
Brake lever pivot bolt 'if!W metal-to-metal moving parts

Clutch lever pivot bolt, mefull-to-metal moving parts and clutch cable end

Swingarm collar outer surface;'?QiJ seal lip
v,
--=a a
f
.<?>
v,
Pivot shaft
'%
--:..

"<!>,
Swingarm pivot bush outer surface, oil

Swingarm thrust cover inner surface

... , .
.? .,
Relay arm surface, oil seal inner

Sidestand and metal-to-metal moving parts

0.
Sidestand switch conta&,Roint
'!>
Sidestand hook and spring 6tmtact point
f
...:zaav<l'
f
"' "'
' '
. .
?
LUBRICATION POINTS LUBRICANT TYPES

c. c.

Lubrication point

Lubricant
Shift pedal parts
v
.s>
f.
.....
Rear footrest bali"alll .g_ metal-to-metal moving parts

Shift shaft joint rod parts

Front wheel oil seal (left an"' d;J.ight)
""

{ i!ear wheel oil seal
-y.?.

'l?
...
.......
-y.?.

drive hub oil seal

-,,_

Rear dri ve hub mating surface
.,c

Brake caliptr eiston seal

v
Master cylinderi q,sJde
f
-<1@1
-y >y
Brake caliper piston seal

Caliper bracket slide retaining bolts

2-24
.
LUBRICATrQN SYSTEM DIAGRAMS

'
c
EA$203510 1:?,
LUBRICATION SYSTEM CHART AND .

.s>
'f
'<?>
y.?
'%

.<>.

2-25
. .
' '
LUBRICA'flON SYSTEM CHAFtt AND DIAGRAMS .?"0

c
1. Oil strainer
0
%
2. Oil pump ..
3. Relief valve . v.s>
f
4. Oil cooler . <?>
5. Oil filter cartridge Y.?
6. Main gallery
7. Dri ve axle
8. Main axle
<t>b
fork (upper)
10. shower Y.?.
11.

13. Oil
14. Balancer
15. Timing chain
16. Intake camshaft "! v
.s>
17. Exhaust camshaft <?
>
y.?

<t>b

y.?.

2-26
. .
'.?
L:'WBRICATION SYS CHART AND DIAGRAMS

c

DIAGR.AMS

' '

1
2-27
<t<b

?.?.

.
LUBRICAf.JQN SYSTEM DIAGRAMS

1. Oil level switch
2. Oil filler cartridge union boll
3. Oil filter cartridge
Crankshaft
'

2-28
- . . . ~
LlJBRICATION c-v<c:-TI:ta
- . . . ~
?,
CHART AND DIAGRAMS
2
3
2-29
. .
'.? ,,
LtJ'BRICATION SYST'i::u CHART AND DIAGRAMS
'

c

chai n tensioner '<o

2. ln'f8J5e camshaft
3. camshaft "! v.s>
4. Balance1' -9. <?>
5.
6. Oil cooler "
7. Oil strainer
8. Oil drain bolt
9. Oil pump driven 6"!>

2-30

'<o

"!v
.s>
"f
"<?>
y.?
'%

<t>b

y.?.

3
1. Oil cooler
2. Oil filler cartridge
3. Oil level switch
4. Oil strainer
5. Oil pump
Main gallery boH
2-32
~ . ~
~ ~ ' ""'
LuBtiiCATION SYSTEM 'GHART AND DIAGH>4 MS
~ ~
~ ~
. .
v 1

LBBRICATION SYS CHART AND DIAGRAMS

1 shaft '<o
2.
3. MairY.!jXIe v.s>
4. Shift bar (shift forkC side) -9. <?>
5. Drive axle
6. Sub gallery IJ(;j \
'

6"!>

2-34

Cb
'<o

.s>
f
.<?>

y.?.

-"!> "<0<
't ,,
CHART AN'D DIAGRAMS

%,
7
2-35
-"!> "
LUBRICATION CHART ANIY't>IAGRAMS

"

1. Cylinder head
2 Exhaust camshaft
o,. .
V,f>. Intake camshaft
passage to the timing chain tensioner
5. Qi!,passage to the cylinder head
6. to the clutch chamber
7. Oil rellr..n_JJassage from the cylinder head
8. Crankshafl't, .
9. Main
?.?.

2-36

?

COOLIN& SYSTEM DIAGRA'Pv!S

.._0

COOLING SYSTEM

-c
2
"
~ y - ? 0 COOLING SYSTEt1 DIAGRAMS
~ ~
~ '
1. Water pump
2. Thermostat
3. Radiator
2-38
'
... , &

C QJ:ING SYSTEM DIAGRAMS

% %

2 ' 3

<t>b

y.?.

2-39
4
1. Water j acket
2. Thermostat
3. Radiator
4. Water pump
5. Oil cooler
6. Coolant reservoir
2-40
CABLE ROUTING
Handlebar (top view)
A
\
2-41
Cb
1. Front brake
2. Throttle cable % ..
3. Rubber cover v.s>
4. Handlebar <>
5. Front brake hose
A. When installing the rubber cover, water or
soapy water may be applied to the insttle .of the
rubber cover. ""<t>.
B. Defai!ed drawing of around the front brake
cylinder;, "Y.?.
C. Straight parallel to the front brake master
inder cap
D. 3-13'
E. Center of the metal fitting tor the front brake hose

oo ..
c:-
.s>
'-9
'<}>
y.?
'%

"t>b

y.?.

-"!>
ROUTING

2-42

CABLE ROUl..ING
0.
HandieJaar (front view)

.s>

2-43
Cb
1. Thro"'e cable '<o
2. Meter lead
3. Meter assembly v.s>
4. Left handlebar switch lead
5. Horn lead Y.?
'% 6. Wire harness
7. Right handlebar switch lead
8. Main switch lead
9.

<t>b

10. HandletSljt; switch coupler y.?.

11.

12. Front brake
13. Turn assembly (lefVri ght)
14. Flap
0
%

A. Route the right lead to the rear of
the meter lead. .s>
B. Fasten the throttle cables aniff{P.nt brake hose at
the center of the metal part withii:J.e clamp as
shown in the illustration. Face the of the
clamp on the front brake hose side
C. Route the main switch lead to the cable from
the top of the vehicle. ->"l:>.
D. meter lead behind the throttle
E. Fasten fA.e. left handlebar switch lead with the
clamp so the jointed part is facing upward. "
F. Fasten the le'1P,toandlebar switch lead and right
handlebar switC1\Jead with the clamp.
G. Fasten the horn to the stay with the clamp so
that the mating sectfclq.Jaces downward.
H. Align the horn lead anait}e brake hose with the
brake hose protector and l d.'i!\en them to the stay
with the cl amp. -9
I. Fasten the brake hose and the'fi9!:n lead with the
headlight clamp.
J. Clamp the wire harness, and then it to the
stay.
Hook the either catch of the clamp onto tRet-stay.
K. drawing of around the meter lead
L. To Mefe'l>;, Y.?.
M. To handle!\\ switch (left/right)
N. To turn light (lefVri ght)
To auxiliary lignt>-o
0. Front of the
P. Fasten the left switch coupler to the
headlight. ..
Q. Route the brake hose thro6Q.h the inside of the
headlight cover.
R. Fasten the right handlebar to the
headlight. The order and connectioQ_.Qf the leads
on the wire harness behind not mat
ter. .,....o
S. Fasten the auxiliary light coupler to the cotipler
to the headlight.
T. Make that the lead of the wire harness
trude froriii.!f:le bottom side of the vehicle.
U. Insert the fia'MP to the sides of the arrow .
.fi-b

0%

.s>
'-9

y.?
'%

<to ..
2-44
-"!>
ROUTING

CABLE
2-45
t . Radiator cap
2. Radiator
3. Radiator fan
Cb

.s>
4. Radiator outlet hose -9. <?>
5. Thermostat assembly
6. Water j acket joint
7. Coolant reservoir
8. Radiator inlet hose
6
A. lnstalflh$ radiator outlet hose with its white
mark facu'\,Q inward.
0
B. Install the raiiiJ_\ltor outlet hose up to the base of the
bend in the ra'6i%tor pipe.
C. Point the hose ci['{'P installation bolt inward.
D. Point the end of the'l:\ese clip downward.
E. Align the yellow paint of the radiator outlet
hose with the ri b of the th'?ifP1ostat assembly, and
then install it. .s>f
F. Install the radiator outlet hose SO) hat the tip of the
hose contacts the rib of the therme&iat assembly.
G. Install the radiator inlet hose so thart\ e tip of the
hose contacts the rib of the water
H. Install the radi ator inlet hose with its yell 0\%.gaint
mar!Vacing downward.
I. Point clamp installation bolt upward.
J. Install thitl'.@.diator inlet hose up to the base of
bend in pipe.
K. Install the inlet hose with its white paint
mark faci ng inwaRlc
L. Install the radiator up to the base of the bend
in the radiator pipe.
M. Point the end of the clip o'O!)vard.
N. Install the cool ant reservoir i'f' o,se up to the base of
the bend in the radiator pipe. <?>
o. Point the end of the clip
P. Install the grommet on the coolant r.fsw oir drain
hose to the hole in the coolant reservo,19.c,gver.
a. go -><t..
R. lock of the hose clamp withi n the
shown iil>Jtte illustration, placing as close to the Y.?.
center as p?:sible.
S. Point the tip 1l'f,the clamp rearward.

.s>
f
.<?>

<to>!)

y.?.

2-46
c
Fuel tank (left and botto'i'q, view)

.s>

-"!>
ROUTING

1. Frame
2. Fuel tank
3. Fuel pump
4. Fuel tank drain hose
5. Fuel tank breather hose
6. Clip
7. Fuel hose assembly
A. Insert the fuel tank(jrain hose up to the section
where the fuel tank Oloe increases in diameter.
Install it so that the wliife.. J.'aint mark faces the
rearward.
B. Install the clip so that the on the paint mark.
Do not put it on the clip spool" ard). Point the
end to the rear, and store it insi bo the fuel hose.
C. Align the fuel pump positioning to panel
marking (visual guide during installati .
D. Insert the fuel tank breather hose up tot
where the fuel tank pipe increases in
Install it so that the yellow paint mark faces tnll>>
rearward.
""<1

y.?.

-"!>
,.,
CABLE RQUTING

%,

CABLE ROUTIN'Q

Canister (for California only)
IIl -
IKl
t
'o "
%

Cb
1. Canister '<o
2. Bracket ..
3. Canister purge hose to canister)
4. Clip
5. Frame
6. Fuel tank drain hose
7. Fuel tank breather hose (rollover canister)
8. Clamp
9. valve
10. Fuel taril< J!reather hose (fuel tank to rollover
11. Fueltank

"
12. Rear shock
13. Canister
14. Rivet

A. Right side of the vehicle
00
<1 v
B. Point the end of the clip forwar.d.
Make sure not to install the cii' P(pn the raised por
lion of the hose fitti ng of the canrs,w .
C. Face the yellow paint mark on the upward.
D. Point the end of the clip downward.
Make sure not to install the clip on the raiS)ld por-
ti on the hose filli ng of the canister.
E. Face white paint mark on the hose
F. Install up to the base of the bend in
hose "
G. Route the drain hose between the canis
ter and the
H. Install the fuel tank'b.: ather hose to the rollover
valve, making sure th fuel tank breather hose
contacts the rollover va \1ij.
I. To fuel tank . v.s>
J. Point the end of the clip
Make sure not to install the clip oi).the raised por-
ti on of the hose filli ng of the canisfo!)><::!
K. To throttle bodies
L. Front side of the vehicle
M. In seQ, the fuel tank drain hose up to the
wherelll]e fuel tank p1pe 1ncreases in d1ameter Vi.ith
its faci ng rearward.
N. Route the C1jQ1ster breather hose under the rear "
shock absorfre>to
0. Atmosphere
P. Face the white on the hose forward.
Q. Install the hose up to i'l'f%bend in the hose fiHi ng of
the canister.
0
<! v
.s>
f
.<>>

y.?.

2-50
-"!>

1. Air filter case j oint clamp
2. ECU (engine control unil)
v.s> 3. Air filter case
"f
. <?> 4. Thronle body
5. Clip
6. Cylinder head breather hose
7. Thronle cable (decelerator cable) (white plating)
8. Throttle cable (accelerator cable) (black plating)
lead 6"!>
1 O.'lt)j,ector coupler
11. FIYel rail .

12. Fuel hose (black side)
13. Canister purge hose (for Californi a only)
Cb
A. Install the breather hose on the yellow paint .
side to the air fi lter case, with its yellow paint mark ..
voS' facing toward left side of the vehicle. . voS'
-9 Point the end ol the clip toward left. -9
<?> B. Install the breather hose so that the tip touches the <?>Y
pipe of the cylinder head.
"<1 Install the breather hose on the whit e paint mark <::>"<1
side to the engine.
Install the breather hose so that the white paint
mark is in the rear of the vehicle parallel to the
head mating surfaces. "b
" llilstall the clip so that the end is in tb'l,.rear of the Y.?.
and parallel to the cylinder hea\ mating
surfaces.
C. Install the ECU harness by storing it in
in the air filter case. _..c
D. Install the ECU so that the hooks on the air
case go over the ECU edges.
v.s> E. Store the throttle cables on the protrusion of the air "! v
-9 finer case. .s>f
<?> F. Insert the injector coupler all the way in. <?>
G. Instructive drawing for assembling the throttle
cables "
H. Install the throttle cable so that the nut of the throt-
tie cable touches the stay. ..

6"!>

Cb

"!v
.s>
"f
"<?>

2-52

y.?.

-"!>

c
Air cut-off valve (left side

.s>

q,
1. RadiaiW,jan cover
2. Air filter
3. Clip c:-.s>
4. Air induction hose (air fi lter case to air
cut-off valve)
5. Air induction system (air cut -off valve to reed
valve cover #1)
6. Air induction system hose {aj ,[ cut-off valve to reed
valve cover #2/#3) <t>b
6
"!> 7. Air cut-off valve
v y
Air cut-off valve holder
"
A. the a1r induction system hose (air filter case
10 cut-off valve) so that the tip of the hose con-
ta sa.!J.e a1r finer case.
B. Insert tl'fll,_protrusion on the radiator fan cover into
the hole i11'1)he air cut-off valve holder.
'?
C. Point the en<:tg( the clip for the air induction sys-
tem hose (air Cl!J-off valve to reed valve cover
#2/#3) forward.
D. Point the end of for the air induction sys-
tem hose (air filter air cut-off valve) to the
teft.
E. Point the end of the clip for"ftr$, air induction sys-
6 tern hose (air cut-off valve to valve cover #1)
"!>, diagonally left forward.
Install the hose so that the tip of th"e'4)ose touches
protrusion of the pipe. "

.s>
f

'%

<t>b

y.?.

Y,
CABLE ROUTING
2-54
ngine (right side view) Frame and e
2-55
Cb
1. Clamp '<o
2. Rear brake light lead
3. Positioning tape . voS'
4. 0
2
sensor coupler -9. <>
>
5. Radiator fan motor coupler
6. Auxiliary DC jack
7. Headlight relay .<>
8. Radiator fan motor lead -><t..
9.

sensor lead
10. y.?.;;,
11. Engiife>1 "
12. Adapter""rncket
13. Bracket

A. Insert the the long hole in the battery
box.

B. Route the rear brake 'frglJt switch lead outside the
wire harness branch to th>0
2
sensor lead.
C. To the ECU coupler Y.?.;;,,
D. Install the wire harness clamp vehicle before
performing "Q".
To install the clamp, refer to (front
6
view)". :6<9:
E. W)len performing the "Q", turn the to
the r<ght and position the wire harness as in
the "
F. ConnecP1.lle 0
2
sensor coupler, and then fasten to
the brackefb.Make sure that the top of the coupler
does not protf4de. It is okay if the cover is
deformed.
G. Fasten the 0
2
senS"9r lead with the clamp, and
then install it on the IS'!'cket.
H. Route the 0
2
sensor the rear brake light
switch lead through the guide.
1. Route the rear brake light sw'ffcn lead outside
brake ftuid reservoir hose.
J. It does not matter whether the 0
2
lead or
rear brake light switch lead is on
'"}he area shown in the illustration.
K. Cffrtgect the radiator fan motor coupler. Y.?.;;,
L. rubber bracket for the headlight rel.i;, so
that it the rib of the air scoop stay on the
vehicle.
M. Install the fus'S>,!;!ox to the rubber bracket, and then
insert the so that it touches the rib
of the air scoop on the vehicle.
Make sure that the box is not removed from
the rubber bracket. -9
N. Route the radiator fan mo'fo* lead behind the fuse
box.
0. Route the radiator fan motor rear side ol the
vehicle respect to the wire harness:,
P. Insert the clamp so that it touches ttil\:{im of the

Q. the grommet of the wire harness ifnd main
switeQ. lead with the clamp at the rear side oflyle
and the center of the positioning tape.
Point of the clamp outward, and then cut it.
R. for the main switch lead.
S. Fasten the 0
2
11Snsor lead wi th the holder.
T. Route 0
2
inside to the protrusion of
the adapter bracket: voS'
U. Inside vehicle -9. <>
>
y.?
'%

"!:>.
2-56
-"!>
,.,
CABit{; ROUTING

c
1. Air induct feu system hose (air fi lter case to air
cut-off
2. Air filter case "! v
.s>
3. Throttle cables
4. Stator coil assembly
5. Speed sensor lead
6. Clamp
7. Positive battery lead
6J Starter motor lead
Stator coil lead
1 harness (to rectifier/regulator)
11. sensor lead
12. switch lead
13. Oil level lead
-<0
: :: cable'\! v
16. Intake air tempera!ljre sensor coupler
17. Air scoop stay
18. Wire harness
19. Coupler cover
20. Main switch coupler I
6
21. Main switch coupler 2 <t>,o
<$).?<,.
Sponge .,Y
23!$_;onge edge
24. breather hose

A. Route iJw, air induction system hose (air fitter case
to air cuf-()J!, valve) inside the throttle cable.
B. To speed
"
C. Route the fuel faok drain hose/breather hose out-
side to the wire ha'1-9esses.
D. Fasten the lead, stator coil
assembly lead, starter 'iil,otor lead, oil level switch
lead, and the speed sens%) lead with the clamp.
The order of the leads matter. Align the
clamp with the tape on the sta'ttllr motor lead. Do
not cut off the clamp end and it forward.
6
,oJ:. Route the gear position sensor lef t!<.\gside to the
arm. Y.?.
F. bending edge
G. Aligl),the sidestand swijch lead, oil level switch
tank drain hose, and breather hose with
the ben(!jgg edge of the hose, and then install
them. clamp opening to the rearward.
H. 30-50 mm in)
I. Point the tips o7 tank drain hose and breather
hose as shown illustration .
. ,.
J. Place the stator coil as;;embly lead so that bare
copper wires do not from the boots.
K. Route the intake air sensor lead
above the throttle cable in thi!'..f@me, and feed it
outside the vehicle through hole in the
6
frame.
Install the clamp to the hole in the stay.
M.'ilastall the intake air temperature senso' rt\>oupler
ri b of the air scoop stay.
N. clamp to the hole in the bottom of the
couple1' 1_c;>ver.
0. Fasten switch coupler to the coupler
cover with
P. Make sure main switch coupler does not
protrude from the<S,vonge edge.

y.?

<t> .
2-58

CABLE
c
Q. Align the wire with the edge of
the Velcro tape and However, the tape sur-
face may protrude
R. For California only .s>f
s. Route the canister breather hos@.to the inside of
the stator coil assembly lead and Sl%ter motor
lead, also outside to the sidestand sW1tll;h lead and
the oil level switch lead.
T. It does not matter whether the oil level swit\.lead
or switch lead is on top. ,o
u. It matter whether the fuel tank drain
or the brE!attler hose is on top but make sure
these not twisted each other. "

"%

oo ..
v
.s>
''9

y.?

<t>,o

y.?.

- . . . ~
CABLE ROtJTING
2-59
i1

1. Injector coupler #1
2. Inj ector coupler #2
3. Clamp
.s>
f
. 4. Ignition coil #1 coupler
5. Ignition coil #2 coupler
Air cut-off valve coupler
coil #3 coupler
8. F!i!ll. inj ector coupler #3
9. position sensor coupler
10. motor coupler
11. Cross tubl!'
12. Accelerator posit ion sensor coupler
13. Pressure sensor coupler
i1

14. Air induction system hose (air fi lter case to air
cut-off valve)

15. Clutch cable
16. Air cut-off valve
.s>
f
17. Air filter case
ECU (engine control unit)
ECU (engine control untt) coupler

;:9,,
A. ro[d back the intake air pressure sensor lead by
the"awpler, and then fasten it with tape.6'!>
B. lnserl 'ffi$. clamp into the fuel rai l hole. '.?
C. Fold injector lead #1 by the coupler,
then fasten it with tape.
D. Connect the sub-lead to the inj ector coupler #2. %.0
i1 Fasten the injector coupler on the wire harness
side with tape.

E. For the air cut-off valve lead, ignition coil lead #3,
v and fuel injector lead #3, it does not matter which v
.s>f is routed above the others. .s>f
F. Route the coolant temperature sensor sub-lead
Y.? between the cross tube and the wire harness. Y.?
Fasten the fuel hose at the mark and the wire har-
at the positioning tape with the clamp. The
dll.ening of the clamp can face either way.
H. the clutch cable above to the air iuduction <tob
syste'li}. .hose (air finer case to air cut-off
I. Route lead for the front of the Y.?.;;,
through rib of the air filter case.

"

Cb

.s>
f

y.?

"tob

y.?.

2-60
c
Frame (top l e w
0
~
~ ~
"!
m
10
2-61
-"!> -"!>

' '

CABLE RQUTING

'<a . Stator coil assembly lead '<o
switch coupler
3. Re,ilr brake light switch coupler "! v.s>
4. switch coupler -9. <?>
5. Gear sensor coupler t
6. Gear posilla,g_ sensor coupler 2
7. Negative bail'ew. lead coupler
8. Lean angle
6"!>

9. Starter motor 6"!>
10. Cover Y.?. Y.?.
11. Canister purge hose j oint to canister)

12. Fuel tank breather hose (fuel tank to rollover valve)

Cb A. Leads on the front of the battery box are, from the
top of the vehicle, in the following order: starter
lead, stator coil assembly lead. The orders
1% other leads do not matter.

B. the speed sensor read on the cutout of the
as shown in the illustrati on. Make sure
to front of the oil fever switch coupler.
C. Fasten harness side of the oil level switch
lead to the bli'!l_.ery box.
D. Fasten the light switch lead on the wire
6.,_ harness wi th
E. Fasten the lead of the wire har-
ness to the battery
F. Route the negative batte,Y lead inside to the
branch of the 0
2
sensor lead and the rear brake
light switch lead, and through between the wire
harness and the frame. For rear side of the vehi-
cle, route it above the wire harness.
the wire harness side of gear position sen-
SG(slead 1 to the battery box.
H. the wire harness side of gear position sen-
sor lea<t- J to the battery box.
I. After the speed sensor coupler, make
sure that th oupler edge on the lead side does
not protrude rem the cover.
J. Route the wire hfruess between the canister
purge hose (hose jijlot to canister) and the fuel
tank breather hose to rollover valve).
K. For California only
2-62
Cb
'<o

"!v
.s>
'f
'<?>

<t>b

y.?.

-"!>
CABLE RhijTING
~ ~
~
Frame (top view)

ROUTING

0% 1.
2.
Positive battery lead
Starter relay
v
.s> 3. Fuse box
Positive battery terminal
s>?Jaattery
6. fan motor relay
7. battery lead
8. terminal
9. Turn relay
10. Relay unit ?.?.;;,
11. Clamp "
,_ 12. TaiVbrake light coupler
13. Yamaha diagnostic tool coupler
14. Battery box
15. Starter motor lead
v 16. Stator coil lead
Wire harness (to rectifier/regulator)
'fs,.?Wire harness

A. the rubber bracket of the starter relay in the

B. Install rubber bracket of the radiator fan motor
relay in box. Make sure to route
negative under the relay. '.?
C. Install the of the turn signat/hazard
relay in the battery box.
D. Install the clamp into the hole in the battery box.
E. Connect each rear turn signal coupler to the cou
pier with the same color. After connecting the

license plate light connector, store the turn signal
<> v light coupler (left/right) furthest to the bottom of the <! v
.s> vehicle. After the other couplers. store .s>
t.>, them below the tait/brake light lead. <>
f':'"yJ.3oute the tail/brake light lead, turn signal light >?.?
and license plate light lead through the cut
the battery box. The order of the leads does "01
not i'ffaJier.
G. wire harness side of the tail/brake light "'-it-.
lead to box. 6"!>
H. Insert the rubber bracket of the Yamaha
tool coupler to battery box.
I. Instructional drawing for routes in the front of the
battery
J. Fasten the crankshaft position sensor lead of the
wire harness with tape.

.s>
f
.<>>
?.?
2-64

?.?.

-"!> -"!>

' '

c
Fro'nt,brake (right side view and left sld" e ----"----..,.

OF 4 .

CABLE ROtJTING
2-65
1.
2.
3.
4.
5.
6.
7.
A.
!>
B.
y.?.

c.
D.
E.
F.
G.
H.
!>
I.
y.?.

Headlight assembly
Right brake caliper
Front brake hose
Clamp
Lett brake caliper
Left reflector
Right reflector
Cb

.s>
f.
.<?>

'%

To left
To front cylinder
Install the front hose with its blue paint mark
facing outward.
Install the brake the right brake caliper so
that the brake pipe the projection on the
brake caliper. Install braki1}
0
se lrom the master
cylinder so that it aligned direction of the
brake pipe to the right brake cal iper.
Install the brake pipe so that it ooh\.acts the projec
lion on the brake caliper. -9. <?,
Face the catch of the clamp backward, 1\P,d then
close the clamp until three clicks or
heard. "<1
Same for three clamps .<>
...
Insert the into the front fender securely. <t>b
When installing_ the rellector, make sure that the
rellector contae\s. the brake caliper. Y-?

.s>
f.
.<?>

'%

<t>b

y.?.

2-67
-"!> -"!>

' '

Y.
CABLE ROUTING

j:Q, Rear frame '<o

3. Rear,prake caliper "! v.s>

4. Rear hose <?>
5.
A. Install the the direction in the iltustra-

B. Make sure to clamp all the way in the "t>,o
6
"!> rear frame.
6
"!>
'.? C. Fasten the protector of tlf&J?rake hose with the '.? Y.?.
clamp. Install the mating seG!ion on the top of the
vehicle.
"'.o D. Make sure to install the clamp all the way in the "'
.,..Cb swingarm assembly. .... <1
S,,rstall the brake pipe so that it aligned with the cut- '<o
'IY.t in the caliper. ..
<!v v
oS' oS'

' '

6"!>

2-68
"'1

Cb
'<o

"!v
.s>
f
.<?>
y.?

"t>,o

y.?.

- . . . ~
?,
CABLE ROUTING
2-69
PERIODIC CHECKS AND

............... ......................... ........ ................... :r.- .. .... 3-1
> >
INTROI}l;JCTION ..................................................................................
CHART FOR THE EMISSION CONTROL
SYSTEM .... :..o ............................................................................................ 3!\,
6
GENERAL MAtf'ti ENANCE AND LUBRICATIQN CHART ...................... 3-2.,<t,b
"!>,.? CHECKING THE LINE ......................... 't>o(;>- ... ........... .... ....... 3-4
CHECKING THE PLUGS ..................... .............. ......... 3-4
ADJUSTING THE VALVE CLEARANCE ................... ................... 3-5
CHECKING THE ENGINE IDLING SPEED ..................... *_.,. ....................... 3-7
SYNCHRONIZING THE THROTTLE BODIES ................... ................... 3-8
'<HECKING THE THROTTLE BODY JOINTS ........................ ... ............ 3-9
THE CANISTER (for California only) ...................... .......... 3-9
THE AIR INDUCTION SYSTEM .................................. .. 3 10
CHEC'RWG THE CYLINDER HEAD BREATHER HOSE ..................... r.;. ,2 10
THE AI R FIL TEA ELEMENT ............ ................... .. .. .. ........
CLUTCH LEVER FREE PLAY ....................... ............. 3-'m-<>
.
CHECKING T OPERATION ................................................... 3-11 <t>b
6
"b CHECKING THE'13f;lAKE FLUID LEVEL .........

. . ... ..... ....... ..... ... ........... 3-11
ADJUSTING THE FRQNT DISC BRAKE ............. ................................ 3-12
" " CHECKING THE FRONT BRAKE PADS .. ............... ............... ........... 3-12
ADJUSTING THE REAR DISC BRAKE ......................

........ ... ..... ..... 3-13
CHECKING THE REAR BRAKE PADS ........................ .. ................ 3-13
THE HYDRAULIC BRAKE SYSTEM ............... ........ 3-13
CfiECKING THE FRONT BRAKE HOSES .................. ............ 1.
0
........ . 3-14
-
CHE!i:KING THE REAR BRAKE HOSE ...................... .. ................. ..; ....... 3-14
0
CHEvFWJG THE WHEELS ....................................... .. ....................
THE TIRES ......................................... ................................
CHECKINdq):tE WHEEL BEARINGS ................... ......................... .........
CHECKING Tf'l_g SWINGARM OPERATION ................. ................. .........
6
"b LUBRICATING SWINGARM PIVOT ....... .. .. .. ... ........................... 3-16
ADJUSTING THE 0Ji31VE CHAIN SLACK ........... ............ .. ...... .... ........ 3-16

LUBRICATING THE !5RIVE CHAIN .. ..................... .................. .......... 3-17 "
CHECKING AND ADJUSTING THE STEERI NG ........................ 3-18
LUBRICATING THE STEERI NG HEAD .......................... .................... 3-1 9
THE CHASSIS FASTENERS ........... .. .............. ................ 3-19
..
UJ3RICATING THE BRAKE LEVER ................... .. .................... '\:; ......... 3-19
THE CLUTCH LEVER ........... ...... .. ........ ................ <!''9 ....... 3-19
LUBRIGATING THE PEDAL ................................ .. ...... .. ...... .. .......... ... 3-19

ADJUST11ij,G THE SHI FT PEDAL .......... ...... .. ............... .. ...... .. .............. >"4}19
SIDESTAND ..................... ....... .. ...... .. ............... .. .........
SIDESTAND ................................ .. ................. ......... 3-20\ .
e"b CHECKING SWITCH ......... ................... ...... .. ......... 3-20
CHECKING THE FORK ....................... .............. .. ........ 3-20
ADJUSTING THE FRl'd>NT FORK LEGS ............... .............. .. ........ 3-20 "
CHECKING THE REAR SHOCK ABSORBER Y ..................... 3-21
ADJUSTING THE REAR SHOCK ABSORBER ASSEMI:J"t'( ................... 3-21
CHECKING THE CONNECTING ARM AND RELAY ARM ....... .......... 3-22
THE ENGINE OIL LEVEL ............. .. .................... ........... 3-22
v THE ENGINE OIL .................... .. ...... .. ........ ................ .,. ........ 3-23

MEA"'-'::( RING THE ENGINE OIL PRESSURE ....... ........ .................. ... 3-24

' '

<t>.. <t> ..
c
CHECKING THE COOLANT LEVBJo .......... ........ .... ................... .. ............. 325
CHECKING THE COOLING .............. .... .... ............. .... .... .... ..... 3-25
G
v
CHAN lNG THE COOLANT ......... .... .... . "" ................ ............. ......... ......... 3-26
CHECKING THE FRONT BRAKE LIGHT '$WITCH ................ .... .... .... ..... 3-27
ADJUSTING THE REAR BRAKE LIGHT SWI1;fH .................................. 3-27
CHECKING AND LUBRICATING THE CABLES"'%1 ......................... .......... 3-28
CHECKING THE THROTILE GRIP ..................... ............ .................. 3-28
CHECKING AND THE BATIERY ........ ............... .. ........ 3-29
-
CHECKING THE FUSES ................................................. ,v ........ ... .. ... .... .. 3-29
"',.,, >.
REPLACING THE BULB .................. ........... ................. 3-29
ADJUSTING THE HEADLI(ji;i{ BEAM ......... ............................... ......... 3-30

Cb
%

oo,.
v
.s>
'-9

'%

<t>.6

yo.

-"!>
)!'...?. ... ,

0% %
PERIODIC MAINTENANCE

fNiAooUCTION -9

Thiss;ghapter includes all information necessary to perform recomrYfEl!Jded checks and adjustments. If
preventive maintenance procedures will ensure vehicle operation, a lon-
ger life and reduce the need for costly overhaul work. This applies to vehicles al-
ready in sll'i(i,Re as well as to new vehicle\ that are being prepared for All service technicians
should be fam'iliar with this entire chapter. '.?
TIP
From 24000 mi (37000 km) or 36 months, maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
0
% Items marked with an asterisk require special tools, <ffite. and technical skills, have a Yamaha dealer
perform the service. ...
c:-

,
MAINTENANCE CHART FOR THE EMISSION SYSTEM
""<1 INITIAL O'D,!?METER READINGS

No.

ROUTINE
600mi 4000 mi 8000 mi 16000 mi 20000 mi

6"!>
(1000 km) (7000 km) (13000 km) (TSOOO km) (25000 km) (31000 km)
y.?.
'
or or or or or

6 months 12 months 18 mori.!!Js
24 months 30 months
"
Check fuel hoses for cracks or
1
.
Fuel line damage . -J -J -J -J -J

Replace it necessary.
. (
Check condrtion.
2
Spark plugs
Adjust gap and clean.
Replace. -J Replace. -J

Replace every 8000 mi

J,
(13000 km) or 12 monlhs.

:?,
3 :-
clearance
Check and adjust valve clear .?.,
ance when engine is cold,
mi (42000 km)

Check breather hose for

4

cracks or damage. -J -J
<t>b -J
-J -J
breathe
6"!>

Replace it necessary.

5
.
Fuel Adjust synchronization.
.... -J
-J -J

-J -J
Evaporative eml s Check oonttol system for

6
si on control sys-
damage. -J -J
tem (for Cali forni a
Replace if necessary.

only)
f:<,
Check the air cutoff valve,

oo,.
7 Air induction sys
reed valve. and hose tor dam
4
c:-
age.

-J -J
'<
tem
Replace any damaged parts if

:?>
y
necessary.
y.?
"'

"<0< -"!>
'.?
PERIODIOoMAINTENANCE

"
EA$1AC1W
GENERAL MAI NTENANCE AND LUBRICATION
"
INITIAL
v
ODOMETER READINGS .s>
'-9
\i No. ITEM ROUTINE
600 mi 4ooo" .n 8000 mi 12000 mi 16000 mi 20000 mi
%
(1000 km) (7000
o! 3000km)
(19000 km) (25000 km) (31000 km)
or or .., or or or or

1 month 6 months 18 months 24 months 30 months
.<>
.<>
1
.
element Replace. Every 24CS? mi (37000 km)
6
Clutc;-:-Y.?.
Check operation.
0
1'.,
.
2
.
y.?.

Adjust orreptace cabl e. ..,_

Check operation, fluid tevet.

3
.
Front brake
and for fl ui d leakage.

Replace brake pads ff neces-

sary.
"0'9.
Check operation, fluid tevet.
v
4
.
Rear brake
and for fluid leakage.

Replace brake pads if neces

\j
sary.
Y.?_.
'
Check for cracks or damage. o.
Check for correct routing and

5
.
-B$ake hoses
clamping.
...

<t>
Replace.

'
6
.
Brake nUff:!., Replace. Every 2 %!)IS
Check runout and fOl dam-
,
7 Wheels age.
Replace If necessary.

Check t read depth and l or

damage.
v.s>
8
.
Tires Replace If necessary.
Check air pressure.
'-9

\i
Correct if necessary.
y-?0:
.
Check bearings for smooth
o
9 ' )heel bearings operation.
...
Replace If necessary .
...
<t> <t>
.. Check operation ancifor
"'1

y
excessive play. h;
y
0

bearings
Moderately repack with lith
tum-soap-based grease.
%,
Every 32000 mi (50000 km)
Check chain slack. alignment
Cb
and condition.
1 Drive chain Adjus1 and lubri cat e chain
mi (800 km) and after washing the motorcycl e. riding in the
wi th a special 0-(ing chain
C/ rain or riding in wet areas
.s>
lubricant thoroughly.
'f.""

Check bearing assemblies tor
..
looseness.
"
'
Steering bearings

Moderately repack with lith
mi (19000 km)
<t>,
tum-soap-based grease.
<t>,

Check all chassi s fitti ng )!nd "'1

3.
fasteners. i

"

"
4
Brake lever pivot Apply silicone grease lightly.

shaft

15
Brake pedal pivot
Apply lit hium-soap-based

shalt grease lightly.
Clutch lever pi vot Apply lithium-soap-based "'.s>
16
shaft
grease lightly.

"
v .
3-2

No. ITEM
<?>

'
7
illi)J.I pedal pivot
shaft:,o.
. ..,,!)
8
y.?.

9
Sldestand switch
0 .
Front fork
2il
Shock absorber
Y.; assembly
'
-
2.
Rear suspension
llni<"-P. Ivots
":';:
3
y
4
Engine oil f iltef'l
cartridge
5
Cooling system

Front and rear
y
brake switches
'
'Z>,.
7 .
COQ}Jol cables

8 .

y.?.
Throttle grip
9
Lights, signals
and switches
ROUTINE
Apply lithium-soap-based
grease lightly.
Check operation. 6
Apply lithium-soap-based "!>,
grease lightly. 'v
Check operation and replace
if necessary.
Check operation and tor oil
leakage.
Check operation and tor oil
leakage.
Check operation.
Change (warm engine befgre
draining) . "!>,
Replace.
Check hoses for cracks or
damage.
Replace if necessary.
Change coolant
Check operation.
Apply Yamaha cable lubricant
or other suitable cable lubri
cant thoroughly.
Check operation. 6"!>
Check throttte grip free pl ay, ?,;
and adjust if necessary.
Lubricate cable and grip
housing.
Check operation.
Adjust headlight beam.

'
c.
INITIAL

ODOMETER READINGS
600mi 400o<' O:W, 8000mi 12000 mi 16000 mi 20000mi
(1000 km)
(7ooo
!13000 km) (19000 km) (25000 km) (31000 km)
or or , or or or or
1 month 6 months 18 months 24 months 30 months

<
l"',o

y.?.

"'1'

o6
c

oo,.
/.
ol'

>

<.

y

"'l

>y,

<

"

/,

' (

0%

TIP
ol' .
fil ter <?
model's air filter is equipped with a disposable oil-coatedmaper element, which must not be
with compressed air to avoid damaging it.
The 'ail; filter element needs to be replaced more frequently when nEl]!;lg in unusually wet or dusty

areas. <t>,o <t>,o
Hydraulic b'taJ e service
6
"!>,
After disasse'l!;lbling the brake master cyltf'i9.ers and calipers, always the fluid. Regularly
check the brake fluid levels and fill the reserv"'&i&s as requi red. "
Every two years replace the internal of the brake master cylinders and calipers, and
change the brake fluid.
Replace the brake hoses every four years and if or damaged .
.,
3-3
EASZIIW co 2 A
CHECKING THE FUEL LI NE emove:
.'o Ignition coils
The following procedure applies to all 01Jhe fuel, Spark plugs
vacuum and breather hoses. .s>f "'''"'"
1. Remove: . NOTICE
Rider seat Before re_ m_o_v-in_g_t_h_e_s_p_a_r_k_p-lu_g_s_ b-lo_w_ a_w_a_y
Refer to "GENERAL CHASSIS" on page 4-1. dirt accumulated in t he spark pl ug wells
Fuel tank "' ,."tM!ith compressed ai r to it from falling
Refer to "FUEL T on page 7-1. iltto the cylinders. "!>,
2. Check: '\
Fuel hose " 1"

3. C'fi>eck:
Fuel tank breather hose Spark plug type
Fuel tank drain hose "3" Incorrect --t Change.

Cracks/damage --+ Replace. . Manufact urer/model
Loose connection --t Connect NGK/CPR9EA9 .., . v
ECA14940 '---""---------------' ,s>
NOTICE 4 Ch k -9. .......,........,:;,.:::.o ___________ ec :
Make sure t he fuel tank breather hose is roll% Electrode "1"
ed correctly. Damage/wear --t Replace the spark plug.
TIP Insulator "2" '
Before removing hoses, place a few color --t spark plug.
rags in the area under it will be removed. color is medium-to-liglit) an.
5. Cle'an:

Spark plug
(with a spark plug cleaner or wire brdi'U,
6

. Measure:
Spark plug gap "a"
(with a wire thickness gauge) v.s>
Out of specification --+ Regap.

Spark plug gap
0.8-0.9 mm (0.031-{).035 in)
3. Install:
6"!>

Fuel tank \ .
Refer to "FUEL TANK" 7-1.
Rider seat

y.?.

,__

.

.
.
.

a +
Cb
'---1
'<o

Refer to "GENERAL page 4-1.
EAS206e0
I
"!
CHECKING THE SPARK PLUGS v.s>
The following procedure applies to all of:;,) he 7. Install :
spark plugs. Spark plugs
1 . Remove: ""<1 Ignition coils
Rider seat r---r--------------,
Refer to CHASSIS" on page 4-1. ->-i Spark plug
"!> 13 Nm (1.3 ftl bf)
Fuel tank "Y.
Referto "FUEL TIP "'.1
Air filter case . . <l
Refer to "GENERAL CHAS"S.J.::;" on page
4
_
1
_ Before 1nstall1ng the spark plug, clean
Air cut-off valve plug and gasket surface.
Refer to "AIR INDUCTION SY'%TEM" on 8. Install :
page 7-15. "!v" Aircut-offvalve "!v
u .s>
-9 Refer to "AIR INDUCTION SYSTEM" on -9

+
1 2
'

'
'
"!:>.
6"!>
... , h; ...?.
4. Measure:
Valve clearance
Out of specification --+Adj ust.
Cb

.s>
'f
'<?>

'%

"!:>.

TDC compression stroke can be found
when the lobes are turned away from
each other.
"'
c. Measure the va1e clearance with a thickness
gauge "1 ". <?>

Thickness
<?- 90890-03180
6
Feeler gauge set -><t.b
' VU-26900-9
Y,
/

6"![ p
valve clearance is incorrectl>o; ecord the
readi ng.
3-5
the valve clearance in the following

Valve clearaoce measuring sequence
.s>
Cylinder #1 ""f #2 --+ #3
>Q>o

#1 #2 #3

A. Front
.0
Valve tapper
9089()-()4101
Valve lapping tool
YM-A8998
d. To measure the valve of the other
cylinders, starting with at TOG,
tum the crankshaft countercl;;&ttise as
specified in the following table. .s>
11
TIP----------------------------
B
#1
c #2
#3
>y
o 240 4ao Cover the timing chain opening with a rag to
f- 1----+1-----+1-----ll prevent the valve pad from falling into the
c:ft

.. D

c
D
crankcase.
a note of the position Qj each valve lifter
and valve pad "2" so thaf'tj)ey can be in-
stclfl.ed in the correct place.
"0

B. Degrees that the crankshaft is turn'El4,coun-
terclockwise .s>
'f
C. Cylinder
D. Combustion cycle

1
<t>
6"!>
the difference the speci-
valve clearance and the valve
clearance.
" Example:
Camshaft
Specified valve clearance =

TIP (0.004-Q.008 in) ..
Refer to "CAMSHAFTS" on page 5-9.</.s> Measured valve clearance= 0.25 mm (0.01 0 v.s>
When removing the timing chain -:am- in) 11
shafts, fasten the timing chain with a wire tcf.ijl- 0.25 mm (0.01 0 in)-Q.20 mm (0.008 in) =
trieve it if it falls into the crankcase. 0.05 mm (0.002 in)
- 6--A-d-. -- t -------------------------- "l.. c. Check the thickness of the current valve pad.
. JUS :
Valve clearance 6"!>
TtfeJhickness "a" of each valve is marked in
a. Remove the valve and the valve pad hunCfredths of millimeters on the touch-
"2" with a valve tapper es the valve lifter.
Example:
If the valve pad is marked "158", the
"! v thickness is 1.58 mm (0.062 in). v
oS' oS'

');'
...
<t> ..
Cylinder #2 240
Cylinder #3 6"!> 480
I
6 '
"!>,
d. t>a)fulate the sum of the values in
and (c) to detennine the required
valve Pa.s! thickness and the valve pad num-

ber.
Example:
1 .58 mm + 0.05 mm (0.002 in) =
1 .63 mm (0.064 <>
The valve pad numl:ie'FJ.s 163.
e. Round off the valve paCf 'l(J,umber according to
the following table, and tfie.n select the suit-
able valve pad.
""
'b.
"'o,.? ._ Last digit Rounde'O;,value
"'
1, 2 0
"
..
6
5
7, 8,

10
"' TIP v
Refer to the for the available
>
valve pads. y.?-.,
'
Valve pad range Nos:,..ao-240
...
pad thickness
1.20-2.4'Glm
(0.047--0.094J.n)
.?;,
"'

pads
25 thicknesses in
0.05 mm (0.002 in)

increments
Example: ..
Valve pad numb% = 163
Rounded value =
New valve pad 165
f. Install the new valve and the valve lift-
e
r ot211. .....

TJP. <t>
t 'flbricate the valve pad with molybpenum di-
"'
oil.
the valve lifter (Top side) with molyb-
denum dfs,\Jifide oil.
Lubricate tlfe- .qyalve lifter (Outer side) with en-
gine oil.
Install the valve fittw and the valve pad in the
correct place. <>
>
y.?
'%

<t> ..
3-7
c
The valve lifter must t6f9. smoothly when rotat-
ed by hand. ..
Camshaft cap bolt '<>>
10 Nm (1.0 m-kgf,
"

Refer to on page 59.
Lubricate camshaft lobes and camshif4
. I ;, .?..,
JOumas. "
First, install the camshaft .
with the camshaft
Turn the crankshaft coul\!erclockwise several
"' full turns to seat the parts. v.s>
h. Measure the valve clearance
i. If the valve clearance is still
tion, repeat all of the valve
ment steps until the specified clearim%e is
'b .. ""
v, v:>
..,h. )!'...?.
........................................ ................................................................................
7. Install :
All removed
TIP

For installation, reverse th procedure.
.s>
'-9
. (),
CHECKING THE ENGINE
TIP a
Prior to adj usting the engine idling the
throttle bo<zy synchronization should be
properly, the> filter element should be cle'fi'li\
and the have adequate
sion. ..
"
1. Start the engine ai\'Q_,Jet it wann up for several
minutes.
.
2. Check: ..
Engine idling speed v.s>
Out of specification --+ Go to step.
y.?
'%

<t> ..
Engine idling speed
110Q-1300 r/min
:F.-}; heck:
IS; (idle speed control) learning value
"01" Check the intake system.
"02" the throttle bodies.
Refer ECKING AND
on page 78. '.?
a. Connect the Yamaha diagnostic tool.

4. Install :

0%
Use the diagnostic code number "67".
Vacuum gauge "1"

Refer to "SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE" on page
oo ..
v
.s>.., 95.
the ISC (idle speed control) leaning

<t>b 6
EASIAC1318
Vacuum gauge
9089().()3094
1
THE THROTTLE
TIP "
Before synchronizing the throttle bodies, check
the following items:
0
Valve clearance
Spark plugs .
v.s>.; Air filter element
5
1 t l.s> l'9.
.c[-httl b d . . t .nsa. <?
? ro e o Y JOin s Air fil ter c'a.e
FUeJ.,hose Refer to CHASSIS" on page 41.
system F 1 t k
ue an ..-..o
Refer to "FUEL on page 71.
Checking tiTh<Jhrottle body synchronizati9n 6. Check:
1. Stand the ve'ii191e on a level surface. .? Throttle body synchrorti2jltion
TIP """'"""'"'""""'"'"""'"'"""'"'"'"""'"'"""'"'"'""
Place the vehicle on a suitable stand. Start the engine, warm it up for several min

2
R and then let it run at the specified en
v . emove: -<o.
Rider seat -----------.,
. v.s> Refer to "GENERAL CHASSIS" on page 41. .s>
4
Engine idling speed
tank V ): <?J 10Q-1300 r/min
to "FUEL TANK" on page 71. ,....---------__J
case b. Check the pressure.
CHASSIS" on page 41. The dlffEffeJ!ce In vacuum pressure
3. 6 between thirhrottle bodies should
Caps "1" "!>, "'
?.?. .?;, not exceed (10 mmHg).
"
If out of specifi cation Adjust the throttle
body synchronization.
'<o
3-8

.s>
....
".(?>
?.?
'%

<t> ..
.

MAIN 1 ENANCE

..,, ..,,
c c
Adjusting the throttle body syn'q_hronization 2. Stop the engine and remove the measliri[lg
1. Adjust: equipment. ..
Throttle body synchronization v.s> 3. Install : v.s>

., ., ., ., .,.,., ., .,., ., ., ., .,., ., ., .,., ., ., .,., ., ., ., "'"'"''!: .,., Caps
a. Start the engine, warm it up for several 4. Install :
utes, and then let it run at the specified Air fil ter case
gine idling speed. Refer to "GENERAL CHASSIS" on page 4-1.
= <t>b Fuel tank
6
Engine idilo.Q speed to "FUEL TANK" on pifge 7-1 .
IV Alder seat
b. Using the throttle body th:a'\ltJas the bypass air
5
"GENERAL CHASSIS" 4-1.
screw "1" with a white paint itfark as the stan- ThJUSttl. .
1 1

. . ro e gnp ree p ay
dard, adJust the. other throttle by turn- Refer to "CHECKING THE
rng rts bypass arr screw rn or out. "! GRIP''
3 28
"!
.oAC"" v.s> on page - . v.s>
NOTICE
Throttle grip free play "">
Do not turn the bypass ai r screw (white v 3.Q-5.0 mm (0.12-Q.20 in)
mark) of the throttle body that is the
dard. Otherwise, the engine may run roughly . ....,,,,,
at idle and the thro!Jie bodies may not oper- <t>& HECKING THE JOINTS
ate properly. "!>,.? 1":">-{lemove: "!>,.?
TIP--------"lr.:------
Turn the bypass air screw ir@g the carburetor
angle driver.
After each step, rev the or three
times, each time for less than a slfeond, and
check the synchronization again. . v.s>f
If a bypass air screw was removed,
screw in fully and be sure to synchronize
throttle bodies.
If the throttle body synchronization can not be
adjusted using air screw, clean or
replace the throttle b0di9s.
The difference in v"c'UUI(I..l
the throttle bodies should fuk_<exceed
(10 mmHg).
Carburetor angle rlri11t>r9,
90890-03173
ThJC>ttle bodies
Refer to "THROTTLE BODIES" 7-5.
2. Check:
Throttle body joints "1"
"0
Cracks/damage Replace.
"!v
.s>
3. Install :
Throttle bodies
Refer to "THROTTLE BODIES" on page
'""""'
CHECKING THE CANISTER (for California
only)
1. Remove:
Rider seat
v"i>RAIArto "GENERAL on page 4-1 .
.?
tank
to "FUEL TANK" on
2. Check:

Canister
Canister purge hose
'-9

y.?

"!v
.s>
Fuel tank breather hose
Canister breather hose '-9

y.?

Cracks/damage -> Replace.
3. Install:
Cb

"' Fuel tank v
.s>
Refer to "FUEL TANK" on page 7-1. <>
Rider seat
2

"t>
Refer to "GENERAL CHASSIS" on page 4-1.

EAS1AC130&
CHECKING THE AIR SYSTEM
Y.?. Refer to "CHECKING Tblf AIR INDUCTION
on page 7-18.

EAS2'10:.0
CHECKING THE CYLINDER Air filter element "1"
BREATHER HOSE Air filter seal
1. Remove: Damage -> Replace.
Air filter case v.s> TIP---------------
Refer to "GENERAL CHASSIS" on page4Cj. Replace the air filter element every 37000 km
2. Check: (24000 mi) of operation.
Cylinder head breather hose "1" The a1r filter needs more frequent service if you
Cracks/damage -> Replace. riding in unusually wet or dusty areas.
Loose connection -4>,Qonnect properly.
y ECA14920 Q?
NOTICE y.?.
'A
Make sure the cylinder head"'b.re.ather hose is
routed correctly.
c.
3. Install:
Air filter case
Refer to "GENERAL CHASSIS" cir'b,oacJe 4-1.
Never operate the engine without the ai?'fjJter
element Installed. Unfiltered air will ca.fse
rapid wear of engine parts and may
EAS20!ir01 (, v
THE AIR FILTER
Rider seat ies synchronization, leading to poor engine
Refer to "GENERAL CHASSIS" on page 4-1. performance and possible overheating.

.. <t> Fuel tank 'li.IP
Refer to "FUEL on page 7-1. installing the air fil ter into the air
2. Remove: cover, make sure that sur-
" ECU (engine control unith f' faces are aligned to prevent any air
Air filter case cover "2" s. Install :
Refer to "GENERAL page 4-1. Fuel tank
%
Refer to "FUEL TANK" on page 7-1 .
v Rider seat ..
.s>-9 Refer to "GENERAL CHASSIS" on page 4-1. v .s>-9
<},
-

"

<t> ..
EA$20870 CO...,
ADJUSTING THE CLI}li,&H LEVER FREE
PLAY
1. Check: .s>f
Clutch lever free play "a" .
Out of specification Adj ust. ...
Clutch lever free play
e 10.G-15.0 mm (0.39-0.591n)6,.
"b "'<{;,_

2. .. -i-b
free play
y

Handlebar
"
a. Turn the adjusf r!)_Q bolt "1" in direction "a" or
"b" until the Clutch lever free play is
obtained.
..
Direction " a"
.:9
Clutch lever free play Is lne..reased.
Direction " b"
Clutch lever free play i s

1
f
.<?>

TIP
If the specified clutch lever free play 'aannot be
obtainecwn the handlebar side of the use
the adjusfih9 nut on the engine side.
"

6

Engine side
a. Loosen the locknut "1 "\1.
b. Turn the adjusting nut "2'iqpirection "a" or "b"
until the specified clutch levetfree play is ob-

3-11

"!:>.
-"!>

tained.
Direction "a" '-! v
Clutch lever free play Is Increase-a,
Direction " b" <?>

Clutch lever free play is decreased.
'1<>

................ ............. .

E.ASIAC1307
CHECKING THE BRAKE
1. Check:
Brake operation '-! v
Brake not working properly CheJ k the
brake system.
Refer to "FRONT BRAKE" on page
"REAR BRAKE" on page 4-32.
TIP '
Drive on the dry operate the front and rear
brakes separately anCf to see if the brakes
are operating properly. "
"-o
E.AS21240 .... C!
CHECKING THE BRAKE FLUl Bi EVEL
1. Stand the vehicle on a level surface.
TIP
Place the vehicle on a suitable stand. <?>
Make sure the vehicle is upright.
2. Check:
Brake fluid level
Below the mark "a" Add the
specified brake fluib-J_.? the proper level.
Front brake
V Specified brake flui d
DOT4
Rear brake
Specified brake fluid '-! v.s>
DOT 4
>
<t>b
""Front brake
B. brake Y-?._

EWA\ 3000 1:YQ.
F!fii;RIIIlfl -----------
Use only brake fluid. Other
brake fluids rifll cause the rubber seals to
deteriorate, cai1si ng leakage and poor
brake
Refill with the same of brake fluid that
is already in the system. brake fluids
may result in a harmful reaction,
leading to poor brake
refilling, be careful that does
noi'Wlter the brake fluid Water
will s1gp ificantly lower the boiling point of
'.o
the bral<eWuid and could cause vapor lock.
NOTICE
Brake fluid may 't>dsmage painted surfaces
and plastic parts. always clean up
any spilt brake fluid
.;,
TIP " .,.
In order to ensure a correct of the brake
fluw level, make sure the top of ill!!, brake fluid
is horizontal.
"
AS2'1 U50 11Y;.S
ADJUSTING THE FRONT DISC BRAKE
.
1. AdjUSt:
Brake lever
(distance "a" throttle grip to the brake
lever) .s>f
. <?>
Y.;
-"!> "
Be sure to align the setting on the a'1J&sting dial
with the arrow mark "2" on the brake hold-
er

Position # fO,.;
Distance the largest.
Position #5
Distance " a" is

A WARNING
After adjusting the lever position,
make sure the pin on the 'Srt! ke lever holder
is firmly inserted in the hole iil,the adjusting
dial.
A soft or spongy feeling in the lever
can Indicate the presence of air In tfi"e.r,Prake
system. Before the vehicle is operated};the
air must be, removed by bleeding the bra'l<e.
system. brake system will
erably reduce 'bsjke performance resulting "
in loss of possibly cause an ac-
cident. Therefore, and if necessary,
bleed the brake
After adjusting the brake leilei position,
make sure there is no brake drag."''%

E.A$212$0
FRONT BRAKE PADS
The followin9' ;.procedure applies to all of thEPy
;,
brake pads. "
1. the
2. Check.
Front brake pad
Wear indicators "1" touch the brake
disc -7 Replace the brake as a set.
Refer to "FRONT BRAKE" ori1l.@jle 4-20 .
Y.;
'%
3-12

'%

<t> .. <t> ..
6"!>
'.?

EA$ZI I QO
THE REAR DISC BRAKE

6"!>
'.?
l3rRke pedal position
o,.

oS'
a. Looserr locknut "1 ".
b. Tum bolt "2" in direction "a" or
"b" until the brake pedal position is
obtained.
...
Direction " a"
Brake pedal is
Direction " b"
Brake pedal is lowered.
A wARNING
After the brake pedal position,
check thS''Jhe end of the adjusting bolt "c" is
visible through the hole " d".
c. Tighten "1" to specifi cation.

...
Locknut <t>>O
18 Nm (1.8-kgf, 13 ftlbf)
-y,

EWAIRCI30a

A WARNING
soft or spongy feeling in the brake pedal
0
the presence of air in the brake
Before the vehicle is operated, the
air removed by bleeding the brake
system. Ait>in the brake system will consid-
erably performance.
After adjusting pedal position,
make sure there is no drag.
-"!>
MAINTENANCE

1
6"!>
'.?

1
EAS21360 ..... 'b...,
BLEEDING'lt1E HYDRAULIC BRAKE
SYSTEM

v
EW"13100 l.fl
"-9
. <:>_,
A WARNING
Bleed the hydraulic system whenever:
the system is
a brake hose is or
-<'
6"!> replaced.
l j:!e brake fluid level is very
operation is faulty. "

Be to spill any brake fluid or allow
the brake cylinder reservoir or brake
fluid reservoir
0
tQ,overflow.
When bleeding 'tl;te hydraulic brake system,
make sure there is<?always enough brake fluid
..
3-13

<t> ..
-'"' -"!>

PERIODIC..-: MAINTENANCE

0,..
Cb

before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic
brake system, considerably lengthening the
c
0
Cqi. Repeat steps (e) to (h) until all of the air bub-

.s>
<?> bleeding procedure.
bleeding is difficult, it may be necessary to let
brake fluid settle for a few hours. Repeat
procedure when the tiny bubbles
in the,.'f.\Qse have disappeared.
6

:>
1. Bleed:
Hydraulic orake system
have disappeared from the brake fluid in
plastic hose.
j. the bleed screw to specification.
caliper bleed screw
(0.5 mkgf, 3.6 ftlbf)
.<>..
k. Fill the cylinder reservoir or 6"!>
brake fluid reserv6i!; .,to lhe proper level with
the specified brake tl&id.

Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-1 1.
a. Fill the brake master cylinder reservoir or
brake fluid reservoir to the proper level with
the specified brake fluid.
b. Install the diaphragm (brake master cylinder
reservoir or brake fluid reservoir).
a clear plastic hose "1" tightly to the
CHECKING THE FRC>NT BRAKE HOSES
6
"!>
1: The following applies to all of the
brake hoses and brake holders.
1. Check:
Brake hose

--> Replace.
2. <Check:
v
hose holder
Laos&,-> Tighten the holder bolt.
3. Hold ttf&<'{ehicle upright and apply the brake
several
4. Check:
Brake hose 6"!>
Brake fluid Replace the damaged

hose. "

Refer to "FRONT BRAKE" on page 4-20.

Cb
%
THE REAR BRAKE HOSE

v A. Front 1 :O'<(.tleck:
.s>-9 B. Rear hose
. <?>'\,Place the other end of the hose into a con- Replace.
2.
e. apply the brake several times. Brake
f. the brake lever or fully down Loose -->Tighten the holder bolt.
the bra9(e pedal and hold it in positioiTP, 3. Hold the vehicle-.tupright and apply the rear 6"!>
g. Loosen screw. brake several
TIP ,.
1
4. Check: "

Loosening the bleed screw will release the Brake hose
o,..Cb sure and cause the brake lever to contact the Brake fluid leakage --> Replace the damaged
. <o hose.
v throttle gnp or the brake pedal to fully extend. to "REAR BRAKE" on page 4-
32
.
.s>-9 h. Tighten the bleed screw and then release the .s>f
<?> brake lever or brake pedal. <?>

3-14

"!:>. "!:>.
EA$Z1610 CO...,
CHECKING THE
The following procedure to both of the
wheels. .s>f
1. Check: . <?>y.,
Wheel
Damage/out-of-round --+ Replace.
EWAI$260
-"!>
,.,
PERIODIC

%,
Tire air pressure cold
v tires) v
Loading condition .s>f
G-90 kg (G-1981b) >
Front
2
, 36 psi)
Rear
F!U i;UIIdi
v
Never attempt'-tJl make any repairs to the Y"'oo
290 kPa (Z:,90 k.gflcm
2
, 42 psi)
Loading con'ajtion
FZ09E 9G-1n1sJ.! (198-390 lb)
wheel.

"
FZ09EC 9G-176 kg (198-3881b)
TIP %
After a tire or wheel changed or re- 250 kPa (2.50 psi)
placed, always balance Rear
------------'""'!- . .,.. v----- 290 kPa (2.90 kgflcm
2
, 42<psi)
.s> High-speed riding
EA$ZI&SO -f
7
CHECKING THE TIRES <?>y Front <?>
The following procedure applies to of the 250 kPa (2.50 kgflcm
2
, 36 psi)
"<1 Rear ""<1
tires. 290 kPa (2.90 k.gflcm
2
, 42 psi)
1. Check: '"'>
., Maximum load <t>b
Tire pressati FZ09E 177\g (390 I b)
Out of speci
*Total cargo
"".() and accessories "\,.
c
"f
"<?>
Yy>

2. Check:
T1re surfaces
Damage/wear --+ Replace the tire. "! v.s>
..,
"<?>
A wARNING

EWAt 3180 ""'
F!j41;Jtlld:t _
It is dangerous to ride with a worn-out
When the tire tread reaches the wear limit, re-
place the tire immed ..

The tire press&'1:11, should only be checked
and regulated the tire temperature
equals the ambient 'fii.r. temperature.
(">
The tire pressure and tJ1% suspension must
be adjusted according t&Jhe total weight
"' (including cargo, rider, and ac-
cessories) and the riding
speed. y.,
Operation of an overloaded vehic'fd><ifould
cause tire damage, an accident or an iffiWY
NEVER OVELOAD THE VEHICLE.
0
... , )!'...?.

Cb

"!v
.s>
"f
"<?>
Yy>

3-15

"!:>.

1. Tire tread depth
2. Side wall
3. Wear indicator
Wear limit (front)
1.0 mm (0.04 in)
Wear limit (rear)
1.0 mm (0.04 in)

.s>
-<J
.

'%

'%
EWA\ 4090

<t>
A wARNING
After extensive tests, ti;Ml tires listed below
have been approved by Motor Co.,
-?fltd. for this model . The frdht and rear tires
should always be by the
and of the same design. No gua1:3ntee con-
cerning handling characteristics giv-
en if a tire combinat ion other than.; one
approved by Yamaha is used on this velfi!!!

Front tire
Size
120/70 ZR17M/C (SSW)
Manufacturer/model

'
Manufacturer/m6i;lel
0
DUNLOP/D214F

o,

Rear tire

Size

180/55 ZR17M/C (73W)

Manufacturer/model
.s>
-<J
6"!)
)!'...?. /',

E.ASI FC1308
CHECKING THE WHEEL BEARINGS
The following procedure applies to all of
wheel bearings. .
1 . Check: v
Wheel bearings
>y Refer to "CHECKING THE FRONT WHEEL" .
on page 4-10 and "CHECKING THE REAR
on page 4-17.
THE SWINGARM OPE8JmON
1. Check)-
0

Swingahn operation
Swingarm not working properly
swingarm.
Refer to "SWINGARM" on page 4-67.
2 . Check:
.s>
-<J Swingarm excessive play
BRIDGESTONE/S20R

Manufacturer/model

Refer to "SWINGARM" on page 4-67.

DUNLOP/D214
RICATING THE SWINGARM PIVOT

<t>. ,w.,,.. 1.
____
6
..:; "1> ;:,...------- o ff w als
6
"!>
,. 1',
tires have a relatively{I_Qw grip on the CollarS-
0

road surface until they slightly .,
" Recommended lubricant
worn. Therefore, 100 km -t Lithium-soap-based grease
should be traveled at normal before
any high-speed riding is done. Refer to "INSTALLI NG THE SWINGARM" on
TIP v page 4-69. v.s>
For tires with a direction of rotation mark "1": -9. ....,,,. -9.
Install the tire with the mark pointing in the di - ADJUSTING THE DRIVE CHAIN SLACK
rection of wheel rotation.

Align the mark "2" with the valve installation N TICE - -------------
<t>b point.
6
A afi.e chain that Is too tight wJII overload
the engme and other vital parts, ai'rqpne that
Is too 1o8'Se can skip and damage
arm or cause an accident.
the drive chain slack within the specified ITIT).-
Cb "t Cb
IS.
v 1. Stand the vehicle on a level surface. v
oS' oS'

3-1
...
<t> ..
EWAt 3 120
A wARNING
Securely support so that there is
no danger of it falling
TIP
Place the vehicle on a suitable'$!and so that the
rear wheel is elevated.
2.
slack "a"
Adjust.
NOTICE v.s>
posi-
Improper drive chain sFacJ will overload the
engine as well as other vitibparts of the mo-
torcycle and can lead to ch"aln slippage or
breakage. If the drive chain is more
mm (0.98 in), the chain c:all?Pamage
the frii''Ve, swingarm, and other pre-
vent thfsj from occurring, keep the "drive
chain the specified limits.
4. loosen:
Wheel axle
/ "!
5. Adjust:
Drive chain
a. Loosen both
0.
b. Turn both adjusting bol'h!,"2" in direction "a" or
"b" until the specified slack is ob-
tained.
Direction "a"
Drive chain Is tightened.
Direction " b"
Drive chain is loosened.

To maintaimthe proper wheel alignment, auJ'"":i<..
both sides
There should clearance between the ad-
justing block and aa4!sting bolt.
c. Tighten the wheel to specification.
""
'\,., Wheel axle nut "'(6,.
150 Nm (15 ftlbf)
d. Tighten the locknuts to specificatf0!k
'\,., locknut
16 Nm (1.6 mkgf, 12 ftlbf)
""" 'b.
""o '\'1:>
?., h. yo.?.

E!A$2t 440
LUBRICATING THE CHAIN
The drive chain many interacting
parts. If the drive chain is proper-
ly, it will wear out quickly. There_tore, the drive
chain should be serviced, when the
vehicle is used in dusty areas.
This vehicle has a drive chain with
0-rings between each side plate. Steam
ing, high-prEftt>ure washing, certain
and the use Of>Jfi coarse brush can damage y.?.
these 0 -rings. Tife,J:pfore, use only kerosene to
clean the drive the drive chain dry
and thoroughly it with engine oil or
chain lubricant that is suit%8-!, e for 0-ring chains.
Do not use any other on the drive
chain since they may contain sorvents that could
'-</
damage the 0 -rings. <?>

'%
3-17

<to ..

Recommended lubricant
Chain lubricant suitable for "! v
0-ring chains <.s

'%

EA$Z1510
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the vehicle on a
surface.
/'<
lf4,f&i;Jtlldri
Securely support the vehicle there is
no danger of it falling over.
TIP %
Place the vehicle on a suitable stand so
front wheel is elevated. .s>
11
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472

'%
2. Check:
'\,..,

Lower ring nut (initial tightening
torque)
Steering head
52 Nm (5.2 mkgf, 38 ft-lbf)
Grasp the bottom of the front fork legs and

gently rock the front
f'l,z--"-'

c. the lower ring nut "6" es mpletely,
Blind1ngllooseness -t ft:giust the steering
)!'...?. \$>h;

3. Remove:
Upper bracket
4. Adjust:
Steering head
then '\iQQten it to specification.
EWA13\ '0 \blllifl
F!Ui;Uii$lCJ

Do not overtighten the lower ring nut.

r- '<o

a. Remove the lock washer "1", the upper
Lower ring nut (final tightening
torque)
"!v
.s>
nut ''2", and the rubber washer "3". '--------------------'
Check the steering head for looseness or
by turning the front fork all the way in
directions. If any binding is f81t, remove
the f6_wer bracket and check the ueyer and
lower
Refer to "STEERING HEAD" on page 4'f!J.
e. Install the rubber washer "7'. %-o
f. Install the upper ring nut "8".
g. Finger tighten the upper ring nut, then align
v.s> the slots of both ring nuts. If necessary, hold "! v
'f

'(;
b. Loosen the lower ring nut "4" and then tighter?. the lower ring nut and tighten the upper ring .s>11
\ it to specification with a steering nut wrench nut until their slots are aligned.
'% "5". %Ja: Install the lock washer "9".
"<1
TIP
,.. the lock washer tabs "a" sit correctly
Set the torque wrench at,a right angle to the
steering nut wrench. "!>, in the olrt,l( nut slots "b".
6
"!>,,
the steering to the left right a couple
of times to check that it moves Si\;1_2othly.

% %

"!v "!v
oS' oS'

'%
3-18
...
<t> ..

?,
PERIODIC MAIN'fENANCE
E.A$213&0 CO...,
ADJUSl"Jklt THE SHIFT PEDAL
TIP
The shift is determined by the in-
stalled shift rod IPnrnth
6
1. Measure:
Installed shift rod

,.,

Install:
bracket
to "HANDLEBAR" on page 4-44.
f
EAS1RCI 321 {>>? ..
THE STEERING HEAD
1.
Upper
Lower bearing

,.,

Bearing races
""
-t


CAECKING THE CHASSIS FASTENERS
that all nuts, bolts, and screws are
properlfvliJlhtened.
Refer to "0JrlASSIS TIGHTENING TORQUES"
on page 2-1
.<)
EASIRCIXC
LUBRICATING LEVER
Lubricate the and metal-to-metal
moving parts of the
0 ..
Silicone grease

LUBRICATING THE CLUTCH LEVER
pivoting point and metal-to-metal
moving the lever
"'
a. LoiJsefii,jl,oth locknuts "1 ".
b. Tum rod "2" in direction "a" or "b" to
obtain the shift pedal position.
"
ReCOI),:Jmended lubricant c. Tighten both locknuts.
-t Lithium-soap-based grease

,.,

_______ .....J e"b d. Make sure the installed s.tWt rod length is
Y.?. '" .1-! within specification. ?-?
EAS:tl110 \$0.1 -?....,..:
LUBRICATING THE PEDAL "l,
Lubricate the pivoting point and metal-to-metal
parts of the pedal.
..

CO...,
SIDESTAND
1. Check:
Sidestand
Check that the1 idestand moves smoothly.

3-19

<t> ..
c
Fbwgh movement 4 Repair or replace.

EAS21nl /
LUBRICA'J:.\f'IG THE SIDESTAND
Lubricate point, metal-to-metal mov-
ing parts and contact point of the sides-
land.

6"!>
'.?
lubricant
grease

EASIACIJIO ':1
THE SIDESTAND SWITCH
to "ELECTRICAL COMPONENTS" on

EA$2'1$31 (/
CHECKING;, THE FRONT FORK
1. Stand the on a level surface.
EWAUI120
""o1 A wARNING
Securely support u1&i(ehicle so that there is
6"!> no danger of it falling av_;,r.
2 Ch k y.?.
. ec :
Inner tube
%-o Damage/scratches 4 Replace.

'iOJont fork leg
between inner tube and outer tube
4 the oil seal.
3. Hold upright and apply the front
brake. "Y.?
4. Check:
" Front fork
Push down hard handlebar several
times and check if fork rebounds
smoothly. Y-?
00
Rough movement 4 Repai'r.
Refer to "FRONT FORK" on page 4-48.
6"!>
'.?

THE FRONT FORK LEGS
following procedure applies to both of the
front{Qrk legs.
EWAI31;0n
,,,n.!;JtUda -----------
securely the vehicle so that there Is
y.?
-"!> "<0<
'.?

%,
c
no danger of1! falling over.

A WARNING
Always adjust both fr(fQ_h fork legs evenly.
Uneven adjustment can reliult in poor han-
dling and loss of stability.
Nevei"<go beyond the maximum or m1nimum
positions.
1. Adjust: <14,
Spring prelol!:!il,
"'

a. Tum the "1" in direction "a" or
"b" >y
. l?.;o,
Direction " a"
Spring preload is increase6,Jsuspension
6 is harder).
BiJection " b"
Sift: ,J.ng preload is decreased (sus'f;ension
is
/.
1
TIP ---.::!2:,,...----------
The spring setting is determined by
measuring the "c" shown in the illustra-
tion. The shorter "c" is, the higher the
spring preload; the "c" is, the
lower the spring preload.

3-20

"!:>.

'

'

Cb
Spring preload adjusting positions
Minimum
' .., 19.0 mm (0.75 in)
<?>y Standard
16.0 mm (0.63 in)

mm (0.16 in)

""!>
y y

Rebound damping (right side only)
CA13590 '\..AA..A.&AA.&A.&A..&..t,.&,A.,6._.&..t,,&.A..&..t,.&,A.A,.A.&AAAA.&

rc
Cb
Never go beyond the maximum or minimum
"! ,jtdjustment positions.

..
THE REAR SHOCK ABSORBER
ASSEMBL.Y
1f. e.jljust: 1. Stand tti'&.v,ehicle on a level surface.
Re1;!ound damping eviA""' -y_,

_________ , ___
a. Tum screw "1" in di rection "a" or Securely support the .vehicle so that there is
"b" no danger of it fallin!i',gver.
. e.,,
Direction " a" ;, 2. Check: "-'y.?.
Rebound dampfng is increased (suspen-

Rear shock absorber
slon Is harder). Gas leaks/oil leaks 4 Replace the rear shock
Direction " b" assembly.
Rebound damping is decreased (suspen- R'e1er to "CHECKING THE REAR SHOCK
slon Is softer). AB'QRBER ASSEMBLY" on page 4-64.
3.
' 'f
Rear absorber assembly operation
Rebound damping adjusting posi- Rear link pivots
Z! tions
(soft) Push down se t.gn the vehicle several times
':3"turn(s) in direction " b" * and check if the rew shock absorber assem-
e"b bly rebounds
1 3/4>1M,"n(s) in direction " b" * ;. ;, Rough movement 4 Re,aair.

Maximum (hard) Refer to "REAR SHOCR' 0ABSORBER AS-
Adjusting screw fully turned in SEMBL Y" on page 4-63 .
direction " a" .o
Cb
* With the adjusting screw fully turned in THE REAR SHOCK ABSORBER
direction " a"
ASS MPLY
<;y: ew ... ,:mo (.,
=if F! Vii;Ufif[ti _____________________ _
Alilfu,)Jgh the total number of turns of a damping """
mechanism may not exactly Securely the vehicle so that there is
match specifications due to small dif- no danger of it ffll!jng over.
ferences iri<' ..oroduction, the actual number of Spring preload
I

turns a ways the entire adjustlt:J_.g
range. To obtain adjustment, it woul d>;, Y; .
be advisable to the number of turns of

Never go beyond the maxitnum or minimum
each damping force adjusting mechanism and positions.
to modify the specifi cations as necessary. 2t
1
. ......:.. __________ _
3-21
preload

a. Adjust 'fl;,e spring preload with the special
wrench extension bar ''2" included in

<!:> .
6"!>
'.?
the owner's tool kit.
b. the adjusting ring "3" in direction "a" or
c. desired position on the adjusting
stopper "4".
Direction
Spring increased (suspension
is harder).
Direction " b"
Spring preload is (suspension
is softer).
Spring preload adjusting positions
Minimum
1

Rebound
CA13590 yo.?.

Never go beyond the maximum or minimum
positions.

Re!JPund damping
'-9

..
a. Tum the a1ij,Jsting screw "1" in direction "a" or
''b" .....
.
"'""-
6
"!> Direction " a"
Rebound (suspen-
slon Is harder). "
Direction " b"
Rebound damping is decreased (suspen-
' o. slon Is softer).

Y,
Min (soft)
3 turn'(lil in direction "b"*

1 1/2 direction " b" *
Maximum (hard).
Adjusting scre\'isjully turned In
direction " a"
the adjusting screw fuHY' <lJurned in
"lil r .,rtlnn "a"
TIP
To ot adjustment, it is advisable to
check the total number of turns of the
damping fon:e'<'a<;jjusting mechanism. This ad-
justment range exactly match the spec-
ifications listed small differences in
production.

E.ASIAC1312
6
"!> CHECKING THE CONNECTII\G ARM AND
'.?f!ELAY ARM
to "CHECKING THE CONNE" CTING ARM

ARM" on page 4-64.

EAS20?3l

ENGINE OIL LEVEL
1. Stand the on a level surface.
TIP -9
Place the vehicle 613!.? suitable stand.
Make sure the upright.
2. Start the engine, for several min-
e'!> utes, and then tum it off.
Check:
oil level
engine oil level should be between the
level mark "a" and maximum level

Below tfi"(!; .. minimum level mark Add the
engine oil to the proper level.
'-9

y.?
'%
3-22

"!:>.
>

'%

c
2. Place a container under the engine oil drain
bolt.
3 R

.s> emove: .s>
<?> Engine oil filler cap "1" <?>
Recommended
Y AMALU BE
Type
SAE 10W-30, 10W-40,

15W-40, 20W-40 or 20W-50 v.s>
Recommended engine oil grade -
API service SG type or higher,
JASO standard MA
0 10 30 50 70 90 110 130 .F
! ! ! t
:SAe, 101'!30: : {? :
. l oW-40; ;
' . . '
: s.:,: 10W59 1
S[I.E ISW-40 l .... C
20\it40i
Engine oil drain bolt "2"
<::> Gasket "3"

; SAE 20w.S()
b io 4
1
o c </ 4. Drain:
<? Engine oil
===:.1-------------- (completely from the crankcase)
If the oil fil ter cartridge is also to be replaced,
the following procedure.
Engine oil also lubricates the clutch and the
wrong oil types or additives could cause

<t>b clutch slippage. Therefore, do not add any
chemical additives or oils with a
y-?s.Jijrade of " CD" or higher arfft1o not use oils
labeled " ENERGY CONSER1NG II" or
"1
b
a. the oil filter cartridge an oil
higher.
Do not allow foreign materials the
crankcase.

filter w"mnch "2".
. "f.!!' 1$)-?.
>

'%
Before checking the engine oil level, wait a few <?
minutes until the oil has settled.
""<1

.<)
.. utes, and then turn it off.
5. Check the engine oil leV'$,1, again.
"ij s'!ef h k' h "!e 1 f
e ore c ec mg t e engme 01 a)Je , wa1t a ew
minutes until the oil has settled.
4. Start the engine, warm it up for several min-
Cb

<t>b

y.?.

2 1

b. Lubricate the 0 -ring "3" of the new oil
cartridge with a thin coat of engine oil.

EA$201\l1 %
CHANGING THE ENGINE OIL ..
1. Start the engine, warm it up for several riift;J,
utes, and then turn it off. <?>

'%

...
<t> ..
.s>
f
.<?>

0-rlng "3" Is positioned cor-
"''"""' of the oil filter cartridge.
3
6"!>
'.?

Cb
%

oo ..
c. Tighten il'ie. new oil filter cartridge to specifi-
cation with a'l'l>_oil filter wrench.
Oil filter"tJlrtridge
17 Nm 12 ftlbf)
":&:
'\, oil drain bolt
Nm (4.3 m-k.gf, 31 ftlbf)
oQ>
7. Fill: Y.?
Crankcase
(with the of the recom
mended engine oil)
6
"!>,.? Engine oil quantitf:'Y.?.
" U Quantity (disassembled)
r:z, 3.40 L (3.59 US qt, 2.99 lmp.qt)
Without oil filter cartridge re-
placement
2.40 L (2.54 US qt, 2.11 lmp.qt)
oil filter cartridge replace-
meq t
2.1IF.\:. ) 2.85 US qt, 2.38 lmp.qt)
"
8. Install:
Engine oil filler cap
6 (along with the 0 -ring nr.)
"!>,.? 9. Start the engine, warmii'ifp.?.tor several min
utes, and then turn it off.

Ea&l1ne
(for
0
SD.gine oil leaks)
11 ..
Engine oil'1,evel
Refer to ''<:lt;JECKING THE ENGINE OIL
>y

<to ..
-"!>
MAINTENANCE

c
LEVEL" on pil!J!l 3-22.

"""""" "'
MEASURING THE OIL PRESSURE
1. Check: <?>y
Engine oil level
Below the minimum level "a" -+ Add the
recommended engine oil to level.

When engine is cold, the engine '01J will
have a higl],er viscosity, causing the engine
oil increase. Therefore, be sure
to measure engine oil pressure after
warming up the e"llgine.
4 . Install :
gauge "1"
Ad'ai3Jer "2"
3-24
gauge
<7-
Vl:l'l).3153
Oil pr&JJure adapter H

6"!>
'.?

5. Measure:
Engine oil pressitre
(at the following coli'"t4j!ions)
Oil pressure
230.0 kPa/5000 'flqlin@ 1 oo c
(2.3 kgf/cm
2
/5000 rfmin, 33.4
psi/5000 r/min@212
Out of specifi cation Check.
''-'-
Engine &ib_wessure
.?
Possible
?
Faulty oil pump t'0

Clogged oil filter

Below specification
Leaking oil pas-
f<o-. sage
or dam-
oil seal
oil pas-
sage
Above specification Faulty oil lllt!)r
Oil viscosity
6"!> high
,,_

6. Install.
Main gallery
Main gallef.Y, bolt
8 Nm (0.8 5.8 ftlbf)
o
EA$:2'1110 ,.()
THE COOLANT LEVEL
1. Stand t@,_yehicle on a level surface.
TIP ;,
Place the pn a suitable stand.
Make sure the vefiiG)e is upright.
2. Check: %
Coolant level ..
The coolant level shoul&.sbe between the
maximum level mark "a" antl(;\llinimum level
?.?

-"!>

PERIODIC

mark "b".
Below the minimum level
recommended coolant to the
Adding water Instead of coolant lowers the
antifreeze concentration of the coolt rit. If
"'
water Is used Instead of coolant check, an'd
if necessary, correct the antifreeze
tration of the coolant. ..
Use only However, if di s-
tilled water i s not soft water may
be used. "
3. Start the engine, warm it several min-
utes, and then tum it off.
4. Check:
..
Coolant level v.so
TIP
Before checking the coolant level, wait
minutes until it settles.

E!A$2\120
CHECKING THE CelQLING SYSTEM
<t>b

'.?
1. Check:
?.?.

Radiator "1"
Radiator inlet hose "2"
Radiator outlet hose "3"
Oil cooler "4"
Oil cooler inlet hose "5"

v
Oil cooler outlet hose "6" .so-9
Water jacket joint "T'
Water pump inlet pipe "8"
Cracks/damage Replace.
Refer to "RADIATOR" on page 6-1, "OIL
COOLER" on 6-4, ''THERMOSTA r' on
page 6-6 and "WAl'Ef:l PUMP" on page 6-8. v-?._

.so
'-9

?.?

"!:>.
3-25

"!:>.
1
EA$211:)1

CHANGING"fJ;:IE COOLANT
"
1. Remove:

Radiator cap b31t;"1"
Radiator cap "2"
Cb
Radiator cap
EWAI$030 %

A wARNING
A hot radiator is under presS' ur,e. Therefore,
do not remove the radiator cap the en-
gine is hot. Scalding hot fluid and St!;.!lm may
be blown out, which could cause serlops in-
jury. Whe!) the engine has cooled,
radiator follows:
Place a thick or a towel over the
cap and slowly t11w the radiator cap counter-
clockwise toward l }te detent to allow any re-
sidual pressure to esllJY.>I!. When the hissing
sound has stopped, down on the radi-
"
ator cap and turn it counter,plockwise to re-
move.
2. Remove: v.s>
Coolant reservoir bolts "1" <>
>

'%
-"!>

PERIODIC

Coolant reservoir cover "2"
Coolant reservoir "3''
Collars "4"
3. Remove:
Coolant reservoir cap "1"
4. Drain:
Coolant
(from the coolant reservoir)
5. Remove:
Water pump drain bolt "1"
Copper washer "2"
1
6. Drain:
Coolant
(from the engine and radiator)
7. Install : e"b
Water pump drain b'OJ.!
Copper washer
.,
Water pump
10 Nm (1.0 mkgf, 7<!2 ft-lbf)
8. Install :
Collars
"<>,_

"!:>.
3-26
c
Coolant
Coolant cover
Coolant reservoir<Qplts
<7
Coolant bolt (M5)
0.5 Nm (0.05 0.37 ftlbf)
Coolant reservoi"'-9lt (M6)
9 Nm (0.9 mkgf,
'%
9. 1-'ill),

y.?.

Co61\gj! system
(with specified
mended
amount of the recom-
ReconYruended antifreeze
V High-qlta,!jty ethylene glycol anti-
freeze conf;lining corrosion
inhibitors engines
Mixing ratio l?'\,
1:1 (antifreeze: W,jj!ter)
Radiator capacity (TnJ,;Iuding all
6
routes) ..
"b,l? 1.93 L (2.04 US qt, 1.70q!J!p.qt)
Coolant reservoir capacit?-('YP to
maximum level mark)
L (0.26 us qt, 0.22 lmp.qt)

Handling for coolant
Coolant is harmful and should be
handled with spectat.care.
EWA\ 3040 {>>
A WARNING )1'"-s-...
If coolant splashes in thorough-
ly wash them with water anO.eJ;>nsult a doc-
'to
t%.
If COQiant splashes on your
with water and then wlfh soap
and waleJ..
If swallowed, Induce vomiting
and get 1mrlfu9.1ate medical attention.

Adding water insteadl.of coolant lowers the
antifreeze the coolant. If
water Is used instead of check, and
if necessary, correct the concen-
tration of the coolant.
ul e,.p nly distilled water. if dis-
Is not available, soft wa'fer may
be
If into contact with painted
surfaces, im'l:Q,ediately wash them with wa-
ter. ..
Do not mix differertt types of antifreeze.
1 O.lnstall:
Radiator cap stopper ..
Radiator cap v.s>
Radiator cap bolt -9. <?>
'\..., Radiator cap bolt '\,
5 Nm (0.5 mkgf, 3.6
. ..,.
11.Fill : 6"!>
Coolant res'e..Qtoir y.?.
(with the rec8fi')J"ended coolant to the maxi-
mum level

N..r
I- _@} I
V"

' ;,
12.1nstall :
Coolant reserv6lt.%ap
13.Start the engine, vial{" it up for several min-
utes. and then tum it 51[.
14.Check: ..
Coolant level v.s>
Refer to "CHECKING THE Gtl,QLANT LEV-
>
EL" on page 3-25.
TIP
Before checking the coolant level, waif ' a. few
minutes unm the coolant has settled.

'l?
EA.SIRC13l 3
CHECKING BRAKE LIGHT
SWITCH
Refer to COMPONENTS" on
page 8-85.
"'
E.A$21331)
ADJUSTING THE REAR
SWITCH
TIP
The rear brake light switch is operated bf -IJ30Ve-
ment of brake pedal. The rear brake .. 1\ght
switch is prop9rly adjusted when the brake iiQllb
comes on just the braking effect starts.
1. Check:
Rear brake light opefation timing
Adjust.

2. Adjust: ..
Rear brake light operation tft;ning
f
.<?>
yl?
'%

3-27

<to ..
'b

a. Hold the main body "1" rear brake light
switch so that it does not ro(<Ue and tum the
adjusting nut "2" in direction "a;
19
oJ; 'b" until the
rear brake light comes on at the pf og er time.
Direction " a"
Brake light comes on sooner.
Direction "ill'
"
Brake light if9.mes on later.

"

'
..,h. )!'...?.

"' .... ., 4>
CHECKING AND LUBRL!;.ATING THE
CABLES
The following procedure to all of the in-
ner and outer cables. .s>f
EWAl 3VO {>>
y"
A wARNING
-"!>
PERIODIC

c
Damage/deterioration -) Replac"eo
Throttle cable installation ..
Incorrect -) Reinstall the throttle cablel\,,
Refer to "HANDLEBAR" on page 4-44.
2. Check:
Throttle grip movement <::>"<1
Rough movement -) Lubricate or replace the
defective part(s).
6

y"oc
Suitable

TIP
With the engine stopped, turn the
0
1fMottle grip
slowly and release it. Make sure that ti'fE!, throttle
grip turns smoothly and returns properff.w en
released.
Repeat this check with the handlebar turned
the way to the left and right.
3. Check:
Throttle grip free play
0
"a"
Out of specification y"oc
Throttle grip freev1ltay
3.D-5.0 mm In)
c,
/
Damaged outer cable may cause the to
corrode and interfere with its movemenf.-1;!e- , a
place outer cable and inner 6
'
..._
1 . Check:
Ouler cable 4. Adjust:
Damage -) Throttle grip free play
2. Check: TIP------------"!$;------
Cable operation v Prior to adj usting the throttle grip free
Rough movement -) tie body synchronization should be ad)'listed
- properly. >Q>y,
Recommended
Engine oil or a suitable lu- .,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,
bricant a. Slide back the rubber cover "1".
b. Loosen the
TIP "!> . c. Tum the adjusting nuBta" in direction "a" or "b" .,y.?.
Hold the cable and pour a few drops until the specified throttfe--:9.rip free play is ob-
of lubricant into sheath or use a suit tained.
able lubricating device . .,_
Direction "a" , '-b...,
Throttle grip free play is

EAS30800
Direction " b"
Throttle grip free play is decreased.v.s>f

CHECKING THE
1 . Check: .s>f
Throttle cables
'%

"!:>.
3-28

PERIODIC
2
t
' 3
d. Tighten the locknut. ,
e. Slide the rubber cover to if'g,,qriginal position.
TIP
Make sure that the adjusting nut is &&ered com-
"' pletely by the rubber cover. v.s>

0"<1
--
y.?.

2. Disconnect:
Headlight coupler "1"
CHECKING AND CHARGING THE BATTERY
Refer to AND CHARGING THE
BATTERY" on page
, ..,,,. 3.
CHECKING THE FUSES Headlight bulb cover "1"
Refer to "CHECKING THE Ff1\ES" on page
8-93.

eAwm
REPLACING THE HEADLIGHT BULB -9.
>
1 . Remove:
Headlight unit side cover bolts "1"
TIP
Lift up the ''2", and then remove it "t>b
from the headlight st"a-y-?"3".

4. Lfnhook:
Headlight bul b holder "1"
5. Remove:
Headlight bulb ''2"
,&WARNING
Since the headlight bulb gets extremely tfot,
keep flammable products and your handsv.s>
away from the bulb until it has cooled down.
y.?
'%

.<)
q
c
6. Install:

Headlight bulb lmiJ ..
Secure the new headlight bu!Qr,with the head-
light bulb holder. <?>
CA13890 Y'..,
NOTICE
Avoid touching the glass part of the
light bulb toekeep it free from oil,
the of the glass, the life of
bulb and the lu'hi!nous flux will be adversely
affected. tf the bulb gets soiled,
thoroughly clean it''Y.tj th a cloth moistened
with alcohol or lacquer<Ulinner.
7. Hook: ..
v
Headlight bulb holder .s>
'-9
8. Install: <?>
Headlight bulb cover y.?""

9. Connect:
Headlight coupler "1"
-"!>
PERIODIC

''b".
Direction " a"
Headlight beam is raised.
Direction "b"
Headlight beam Is lowered.
6_
<t>

2. Adjust: '.?
1 O.lnstall:
Headlight unit "1"
TIP
Install the
1
11.1nstall: 6
Headlight cover bolts
side cover bolt
7 Nm (0.'7<Wkgf, 5.1 ftlbf)

EAS2'1810 %
ADJUSTING THE HEADLia fi,T BEAM
1. Adjust v.s>
Headlight beam (vertically) <?>
y.?
Headlight beam

TIP
To adjust the headlight beam (horii1lJJally), in-
sert a crosshead screwdriver into the 'hgle "a"
and turn the adjusting screw.
Direction "b"
Headlight beam moves to the right.
Direction " c"
Headlight beam mo4 es to the left.

3-30

<t> ..
3-31
3-32
CHASSIS

"'v

.
GENERAL t:.'!ASSIS ..... .. ................... .................. ........ ........ ....................... :r,-..<4-1
AIR SCOOPS .................. ........................ .. ...... .. ...........
AIR SCOOPS ...................... ....... ....... ................
INSTALLING TANK MOLES ................ ...... .. ...... .. .................. ..45

6"!> 6"!>
'.? FRONT WHEEL .............. .. ............ .................. ....... ... .................. ....... ... .4-8

REMOVING THE FRONi"WHEEL .............. ... ............ .... ...... .. .......... 4-10
DISASSEMBLING THE FRONT WHEEL .............. ......... ................. 4-1 0
THE FRONT WHEEL .............................. ... ... ............ . 41 0
iXC:EMBLING THE FRONT WHEEL ................................ ... ?q,. ........ . 4-11

AD::IWSTING THE FRONT WHEEL STATIC BALANCE ................. <!.</ .... 4-11
THE FRONT WHEEL (FRONT BRAKE DISCS) ...........

REAR WHEEL .......... ..................................... ........ ........ ................. ......... 4-'f4>"<1
REMOVING WHEEL ................. ................. ........ ........ ......... .4-17
.
DISASSEMBLIN\.:I"kt! E REAR WHEEL .............. ....................... ........ 4-17
6
"!>, CHECKING THE WHEEL ......... ................. ""o
7
... ........................ 4-17
CHECKING THE DRIVE HUB ......... .................. 4-17
CHECKING AND REPLACING THE REAR WHEEL SPf1Y.CKET.. ........ .4-18
ASSEMBLING THE REAR WHEEL ................................... ................. .4-18
s s c
TING THE REAR WHEEL TATIC BALAN E ............. <>r-............. 4-18

THE REAR WHEEL (REAR BRAKE DISC) ............ ....... .4-18

FRONT ............................................................ ........ ........ ............... : ..
INTRODU<f.'ij,ON ............................................................ ........ ........ ..........
CHECKING TH.E FRONT BRAKE DISCS ...................... ........ ........ .........
REPLACING BRAKE PADS ................................ .. ............ .4-26
6"!> REMOVING THE I%J2NT BRAKE CALIPERS ..... .. ............ ......... ........ .4-27
'.? DISASSEMBLING THE,.fRONT BRAKE CALIPERS,.-........................ .. .. .4-27 y

CHECKING THE FRON'!' ..BRAKE CALIPERS ........... 1 ...

...................... .4-28
ASSEMBLING THE FRONT BRAKE CALIPERS ............. ?.% .................. .4-28
THE FRONT BRAKE CALIPERS ................... n-
6
............... 4-29
'li3.MOVING THE FRONT BRAKE MASTER CYLINDER ........ ?% ........... .4-30
CHI;CKING THE FRONT BRAKE MASTER CYLINDER ............. '?v.;, ....... .4-30
THE FRONT BRAKE MASTER CYLINDER. ......... .. 430
THE FRONT BRAKE MASTER CYLINDER ................. 1,. -.ft-30

REAR BRAKE ..... ":% ....... .. ................................... ........................ ......... ..........

"' ., ................................................................................ .4-38 .. -'l,.
6"!> CHECKING THE RS1f! BRAKE DISC ................ ............ .... .... .... .. .... 4-38
REPLACING THE RE.%\BRAKE PADS .................. :o?,.;, ............. ... ..... .... .. 438

REMOVING THE REAR1lRAKE CALIPER ............... ......... ... ..... ..... 4-39 "

DISASSEMBLING THE REAR BRAKE CALIPER ............. -fo . ............... 4-40
THE REAR BRAKE CALIPER ......................... .............. 4-40
THE REAR BRAKE CALIPER. ....................... ", ........ 4-41
THE REAR BRAKE CALIPER ......................... ...... ... . 4-41
REMOWJNG THE REAR BRAKE MASTER CYLINDER ..................... :o.!':;t.4-42
THE REAR BRAKE MASTER CYLINDER .......... ..............

' '

ASSEMoUWG THE REAR BRAKE MASTER CYLINDER ...... .... .... .... .... . %43
INSTALLIN'&oJHE REAR BRAKE MASTER CYLI NDER ............ .... .... ....
v v

0 0
HANDLEBAR .............. :-',..; 4-44 "Y.;
REMOVING THE ..................................... ......................... .4-45
CHECKING THE ..... ........ .................... ..... .... .... ............ ..... A-45
INSTALLING THE ... .... .... ............................................. ..... A-45
6"!> 6"!>
? ?
FRORJ,FORK .................. ................ ..........................................
THE FRONT FORK LEGS .... ......... ........ .... ............. .... .... .4-51
THE FRONT FORK LEGS ... ........ .... ............. .... .... of!-
6
.4-51
THE FRONT FORK LEGS ...................... .... ............. .... .... ...
ASSEMBLiftl.Q THE FRONT FORK LEGS .... .... ................................. .....
INSTALLINGT<I:;j,E FRONT FORK LEGS ................... ......... .... ............ ......

STEERING HEAD .. ........
REMOVING THE BRACKET ... .... ................. .... ........ ..... .... .... .... .4-61
CHECKING THE STEER(IGHEAD .............................................. .... ..... .4-61
6,_ INSTALLING THE STEERINS.J.:i EAD ............... .................. ............ ...... 4-62

..,h. )!'...?. ..,h. )!'...?.

REAR '5,HOCK ABSORBER ASSEMBL ........ .... .... .... .... .... ............. ... ...... .4-63
THE REAR SHOCK ABSORBER ... .... .... .... ............. ..... .. A-64

DISPO OF A REAR SHOCK ABSORBER .... .... .... ..... .................... .iz4-64
REMOVIN REAR SHOCK ABSORBER ASSEMBLY .............. .... ..
CHECKING TliE REAR SHOCK ABSORBER ASSEMBLY ............... ...... 4-61f v

CHECKING ARM AND RELAY ARM ................ ...... 4-64
0
>
INSTALLING ARM ............................................................... 4-65 Y.;
INSTALLING THE SHOCK ABSORBER ASSEMBLY .......... ......... 465
' '

..................... ......... ............. ............................. ! &"6 ... .... .... .... . .4-67
'JiEMOVING THE SWINGARM?-,"' ................. .......................... ? .... .... ....... 4-68
THE SWINGARM .... ................... ........................

........ .4-68
THE SWINGARM ..................... ........ ........ ................. '?<!
0
..... 469

CHAIN
REMOVING li3E DRIVE CHAIN .. ..................... ................................. ..... .4-t r v
-
CHECKING CHAIN .. .... ......................... ......... .... ............ ..... .4-71 -9
o
CHECKING THE SPROCKET ............................ ................. ........ .4 72 "Y.;
CHECKING THE R SPROCKET ............... ................. ....... .4 72
CHECKING THE DRIVE HUB ............... ................. ....... .4 72
INSTALLING THE DRIVE ................................ ....................... 4-73
6"!> 6"!>
? ?
..,h. )!'...?. ..,h. )!'...?.

' '

' '

<t>.. <t> ..
EA$Z18l> CO...,
GENERAL
"!
Removing the seat
.<?>
'It 2.2 Nm (0.22 m. kgf, 1.6 ti"<lbl)
'L
2
3
4
5
6
Spacer . .,
Disconnect
Disconnect

4-1
-"!>
GENERAL f l t ~ S S I S
~ ~
to remove
- . . . ~ ?
GENER'AL CHASSIS
Removing the headlight and meter assembly
-"!>

2
4
1.5 Nm {0.15 m. kgf, 1.1 ft lbf)
Order Q'ty Remarks
2
3
4
5

EA$1AC1l1
REMOVING THE AIR SCOOPS
1. Remove:
Air scoop (left) "1"

A..&..t,.&,A..&..t,.&,A.A..&..t,.&,A..&..t,.&,A.A..&..t.AA..&..t,.&,A..&..t,.&,A..& E.AS1FC1404
.. INSTALLING THE FUEL TANK MOLES
'i.r Install :
EA$1AC1
INSTALLING THE AIR SCOOPS
.s>
"-9
1. Install:
-9
tank mole (left) "1"

a. hole "a" in the fuel tank mole onto
the "b" on the air scoop stay.
6"!>
'
Air scoop (left) "1"

the projection "a" on the air scoop into
"b" and insert the "c"
on th'e>.sir scoop into the hole "d".
b. Install tne air scoop bolt and quick
screws, and then tighten the bolts to
)!'...?. ..,h.

catlon. Cb

Air scoop bolt
1.5 Nm (0.15 mkgf, 1.1 ftlbf)

.s>
4-5
"-9
"<?>

"!:>.

Removing the air
tank cover
4-7
-"!>
{>
GENS!JAL CHASSIS

EA$Z1870
FRONT WHEEL
6
Order Job/Part s to remove
4-8
-"!> -"!>

' '

c c
the front wheel

.s>
f
.<?>

'%

...
"t>
Order -><t.. Job/Part s to remove
Oil seal
2 Wheel bearing,-
0
3 Spacer
6

6

6

6

EA$Z1900 CO...,
REMOVING THE
1. Stand the vehicle on a lev@!;.surface.
.s>
'-9
.<>>
EWAt 3120
A wARNING
Securely support the vehicle so t flabthere is
2.
Left
Right brake
CA1RCt4)g
NOTICE
Do not apply the bral{e],Jever when removing
the brake calipers.
3. Elevate:
v
.s>
Front wheel <>
>
TIP
Place the vehicle on a suitable stand the
front wheel is elevated.
...
4. Loosen: e"b
Wheel axle{J') jpch bolt
.
5. Remove.

Wheel axle

Cb

EA$21910
DISASSEMBLING THE FR0ftT WHEEL
1. Remove: .s>f
Oil seals <>>.
Wheel bearings
.,,
Front wheel

a. Clean the surface of the front wheel
b. Removettbe oil seals "1" with a
v, ""'
screwdrivef:? h ..
TIP "
To prevent wheel, place a rag "2"
between the the wheel surface.

c.
al bearing puller.
(
Wheel axle
Roll the wheel axle on a flat surface.
Bends Replace.
E'WA134&0
A wARNING
Do not attempt to striirQ_hten a bent wheel ax-
le.
II Ill
I
2. Check:
Tire
Front wheel
Damage/wear R' eP.Iace.
Refer to TIRES" on page
3-15 and WHEELS" on
page 3-15.
3. Measure:
Radial wheel runout "1"
Lateral wheel runout "2" "! v
Over the specified Replace. .s>-9
.,..
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (9_;02 in)
4-10
6"!>
'.?

4. 4...
Wheel btraJings
Front roughly or is loose -t Re-
place the wheet-&earings.
Oil seal v.s>
Damage/wear -t ReflJ., ace.
>
y.?
6"!>
'.?

y.?.

Cb

EA$21960
ASSEMBLING THE Ff;\ONT WHEEL
1. Install: <?>y
Wheel bearings m!IJ .?'%
Oil seals m!IJ
.<>

a. the new wheel bearing
ECA1ACl i :'i!l, )!',?,
(!tortCE-l
Do not cd'$.ct the wheel bearing inner race
"1" or Contact should be made

only with the olltf!r race " 3".

Use a socket "4" the diameter of
the wheel bearing outer
..
4-11

FRONT WHEEL
c. Install the new (left side).

Place a suitable washer "1" be{'it(.een the socket
"2" and the bearing so that botti1b! inner race
"3" and outer race "4" are pressed same
time, and then press the bearing until inner
race makes contact with the spacer "5".
b

+ y.?.

d. Install the new oil seals.

<t>
o,
.? y

ADJUSTING WHEEL STATIC "
BALANCE
TIP
After replacing the tire, or both, the front
wheel static balance shoulif-:b,l} adjusted.
Adjust the front wheel static with the
brake disc installed. <?>Y
1. Remove:
Balancing weight(s)
2. Find:
6
<t>b
Front wheel)? heavy spot
TIP .? ;, y.?.;;,
Place the front w'Rt;el on a suitable balancing "
stand. %-o

a. Spin the front wheel. ..
b. When the front wheel an "X
1
" mark
at the bottom of the wheel. <?>

%.0

y.?

"'
c. Turn the front wheel 9o so.tftat the "X," mark
is positioned as shown. -9. <?>
y.?
'%

<t> ..
c
d. Release the front wheel.
is balanced.
e. When the wheel stops, put an "X
2
" mark at ..
the bottom of the wheel.
heck:
wheel static balance

a. Tum wheel and make sure it stays at

Cb
%
f. Repeat steps (c) through (e) several times
v.s> until all the marks come to rest at the same v.s>
each poSttion shown.

Y.?. X
"'
X
'-9 t '-9
spo.
g. The spot where all the marks come to rest is
X
the front wheel's heavy spot "X".
b. If the l rQnl wheel does not remain stationary
at all of ihg positions, rebalance it.
6
3. "!> "!>
y
Fronb(wheel static balance

a. Install a balancing weight "1" onto the iNsTALLING THE FRONT WHEEL (FRONT
actly opposite the heavy spot "X". BRAKE DISCS)
TIP 1. Install :
Start with the lightest weight. v.s> Front brake discs
Front brake disc bolt
LOCTITE
6"!>
'.?

CO 2. Check:
c. If the heavy spot does not stay in that Front brake discs
lion, install a heavier weight. v.s> Refer to "CHECKING THE FRONT BRAKE
d. Repeat steps (b) and (c) until the front wheel '9 on page 4-25.
4-12
>
y.?
'%

"!:>.
3. Lubricate:
Oil seal lips
RecommendeCflubricant
Llthlum-soap-bi s,ed grease
"' "'
4. Install:
Collars
Front wheel
Whee7'a)lle
5. Tighten:

Wheel
Wheel axle pirfctl bolt
0

65 Nm (6.5 frt,kgf, 47 ftlbf)
Wheel axle piri&l bolt
23 Nm (2.3 mkg'ft,J7 ftlbf)
"'
o_
CA1RCI4(ll
NOTICE "'
Before<!jghtenlng the wheel axle,
hard orf
7
Jne handlebar several
check if th&ttont fork rebounds

Check that wheel end "a" is flush with front
folk surface "b" and tighten the wheel axle
pinch bolt. If end "a" is n"'tJiush with surface "b",
align the ends manually of.' .,with a plastic ham-
mer. '<\,
Front brake caliper
35 Nm (3.5 mkgf, 25 ft.f iJ.Q_
EWIH3500

F!Ui;UIIJ@ y\?. _
Make sure ttiibrake hose is routed properly.
,,_
4-13
,.,,,,..,
REAR WHEEL
Removing the rear wheel
4-14
Removing the brake rear wheel sprocket
6
mm
Order Job/Parts to Remarks
-"!>
REAR WHEEL

Order Job/Parts to re"lRve O'ty

1 "!> Oil seal "!>
2 ;, Wheel bearing
3 $ acer
Remarks
4 bearing
4-16

REMOVING THE REAR WHEEL
"! v 1. Stand the vehicle on a level surface.

__________ _
Secorgly support the vehicle so that there i s
no of i t falling over.
TIP "-it.
Place the vehflile on a suitable stand so that'il)e
rear wheel is elevaJed. '\
::-::::-____ ....:..._ __________ ....,...

THE REAR WHEEL

"' v,po not depress the brake pedal when remov-
11lg_, the brake caliper.

bearings
Refer .rto "DISASSEMBLING THE FRONT
WHEELP09. page 4-10.

""""'' ""<1
CHECKING THE RE;AR WHEEL
...
1 . Check:
Wheel axle
6"!>
'.?
Wheel bearings
Oil seals
y.?.

1
Loosen:
Refer to "CHECKING THE FRONT WHEEL"
Cb..g_n page 4-10.
2.
Tire<! &
.r
Rear
4 Replace.
Refer to THE TIRES" on page
3-15 and THE WHEELS" on
page 3-15. "-it-

3. Measure:
Radial wheel runout y-?
00
" Lateral wheel runout
Refer to "CHECKING THE FRONT WHEEL"
page 4-10.

"!v
.r
"0

THE REAR WHEEL DRIVE HUB
1. Check:11
a'.-Q!lemove:
axle nut "1"
Wagt)pr
"2"
""
RearwMeJ
Brake
6
"!>,.?
TIP .?.;;,
Rear hub "1"
Cracks/dam'\g,e 4 Replace.
,.
Rear wheel dampers "2"
Damage/wear 4

y.?.

Push the rear wheel forward and remove the

drive chain from the rear wheel sprocket.
Cb
4-17

"!v
.r
f
...
y.?
'%

<t> ..

<t>b
6'"
y.?. 1 2'.? .. 2

EA$1ACH-11
CHECKING AND REAR
WHEEL SPROCKET
1. Check. .....,, ..
Rear wheel sprocket <! v ASSEMBLING THE REAR WHEEL
More than 1/4 tooth "a" wear 4 1. Install :
drive sprocket, the rear wheel sprocket Wheel bearings Dm\!1
the drive chain as a set. Oil seal Dm\!1
Bent teeth 4 Replace the drive sprocket, the Refer to "ASSEMBLING THE FRONT
rear wheel sprocket and the drive chain as a on page 4-11.
6 6
set. "!> .....,,,. "!>
ADJUS'Il!J-IG THE REAR WHEEL
BALANCE
TIP
After replacing the tire, wheel or both, the rEla'r;,
wheel static balance should be adjusted.
1

'
b
Cb
V

\ (/
,SO
f
.<?>
Adjust the rear wheel static balance with the "! v
brake disc and rear wheel drive hub installed. .sof
.<?>
y.?
b. Correct

1. Drive chain roller
";0
<t>b 2. Rear wheel sprocket
6
"!>
y.?. 2. Replace: '.?;,
Rear wheel sprocket

a. Remove the rear wheel sprockefltuts and the
0
"
1. Adjust:
Rear wheel static balance
to "ADJUSTING THE FRONT WHEEL
A TIC BALANCE" on page 1 .
"!>
EAS2ZIGO Y',?, l'o ..J.!
INSTALI3iNG THE REAR WHEEL (RE'A.tl
BRAKE DISC)
1. Install :
Rear brake disc
0
%

oo,.
rear wheel sprocket.
b. Clean the rear wheel drive hub with
cloth, especially the surfaces that contacfdhe '\,.., Rear brake disc bolt
sprocket. '9. <?, 30 Nm (3.0 mkgf, 22 ftlbf)
- LOCTITE
c. Install the new rear wheel sprocket '---------------------------------'

Rear wheel sprocket nut ,
80 Nm (8.0 mkgf, 58 ftlbf) ____________ _
Repi11ce the brake disc bolts
ones.
y.?. TIP '.? TIP Y.?,._ ;,
the rear wheel nuts in stages Tighten the brake disc bolts in stages in a
and in a crisscross pattern. crisscross pattern.

v
,SO
f
.<?>
y.?
"
,

'%

,

<t>b

2. Check: A. Left side
Rear brake disc B. Right side
Refer to "CHECKING THE REAR0..RAKE
DISC" on page 4-38. 5. Install :
3 L b ate v Rear brake caliper
. u oo . .
Oil seal lips -9. Rear brake caliper bolts
6. Adjust:
'%

'% Drive chain slack
to "ADJUSTING THE DRIVE CHAIN
on page 3-16.
6
_
4. Install: 6"!>
Collars
Brake caliper bracket

Rear wheel
Adjusting blocks
Wheel axle '<o
Washer

TI
PWheel axle nut A Wheel axle nut
, '"'> 150 Nm (15 mkgf, 108 ftlbf)
Do not install the brake caliper. Rear brake caliper bolt (front)
Align the projection "a" in the swingarm with the 27 Nm (2.7 mkgf, 20 ftlbf)
slot "b" of the brake caliper bracket Rear brake caliper bolt (rear)
.. <t>c Install the adjusting that projection "c" 22 Nm (2.2 mkgf, 16 fu)t>f)
faces to the front of the vef.tide. LOCTITE
y
"
E'WA13000
chain slack
v "5.o-15.0 mm (0.2o-G.59

..
7. Tighten:
Wheel axle nut
Rear brake caliper bolts
A wARNING
Make sure the brake hose is routed

TIP
When tightening the wheel axle nut, there
-9. should be no clearance "a" between the adjust-
ing block "1" and adjusting bolt "2".

0 0 0
0
, " 0

Cb

EA$22210
FRONT BRAKE

.s>f Removing the front brake pads
. <>_ I

1 Brake pad clip
Cb

2 Brake pad pin

3 Brake pad spring
oo ..
c:-
4 Brake pad
.s>
f
5 Reflector
.
6 Front brake caliper

Bleed screw
4-20
5 Nm (0.5 m I@ .3.6 It lbf)

y.?.

4
2
3
Removi ng the front brake master cylinder
Right rear view mirror "!> "HANDLEBAR' on page 4-44."!>
Drain . .?.,

Refer to'1'BLEEDING THE HYDRAULIC '
<> " BRAKE SYSTEM' on page 3-1 3.

Brake Huid
.
2
Brake master cylinder reseNoir o%

) 1;).,
. v 3 Brake master cylinder reseNoir diaphragm . v . v
.s>-9 4 Brake lever .
11
. 5 Front brake light switch lead connector
6 Front brake light switch e>
7 Brake hose union boH 1

<!,.
Disconnect.
9 Brake hose "!>
'tB Front brake master cylinder )]older
11 Front brake master cylinder "

4-21

0%

-"!> -"!>

' '

"qj 4 assembling the front brake master cylinder

<t>b

y.?.

FRON'l0BRAKE
Order "t>b.. Job/Parts to remove Q'ty Renfl!!;kS
..
Brake cylinder kit
2 Brake master Iinder body
4-22
3
30 Nm (3.0 m gf, 22 It lbf)
Order Job/Parts to remove Q' ty
Brake fluid
1 Brake hose union boll ':q,
2 Brake hose gasket
35 Nm (3.5 m . kgf, 25 It -lbf)
5
6
v"b
'.?

The following procedure RPiies lo bolh of
the front brake calipers.
Drain.
Refer to "BLEEDING THE HYDifA!,ILIC
BRAKE SYSTEM' on page 3-13.
3 Brake hose . " 2
"f
4 Brake hose gasket 2
5 Reflector Y.?
6 Front brake caliper

y.?.

-
-
6
5
6
Order -><t.. Job/Parts to remove Q'ty

)!'...?.

1 Brake pad ip
2 Brake pad pin
3 Brake pad spring c
2

FRONT BRAKE
3
The following proced tg applies to both of
the front brake caHpers.Y.?.
'<o 4 Brake pad 2 -<0

.so 6 Brake caliper piston dust seal 4
o> Brake caliper piston seal 4
8 -.,, Bleed screw
4-24
c
d. Hold the dial gauge at a right angle against
,.,,,,,.,
INTRODUCTION
A WARNING
the brake disc surface.
v.s> e. Measure the runout 1.5 mm (0.06 in) below

c:-
.s>
EWA\ 4101
''9
Disc brake components rarely require disas-
'.(?_,

'% sembly. Therefore, always follow these pre-
ventive measures:
disassemble brake components un-
absolutely necessary. 6"!>
If any connection on the brake
Is disconnected, the brake
system must be disassembled, cfFQ.ined,
cleaned, properly filled, and bled after
edge of the brake disc.

'%

"t>

sembly.
Never use solvents on internal brake com- oo,.
v.s> ponents. v.s>
<?_, Use only clean or new brake fluid for clean-
ing brake components. 4. .
Brake fluid may damage painted surfaces diSC thickness . .
plastic parts. Therefore, always clean
'tQ any spilt brake fluid immediately. ferent
6
brake fluid coming with Out of Replace. "!>,,
the e'Ves as it can cause serioust llj,ury. thickness limit
FIRST AID FOR BRAKE FLUID v 4.0 mm (0.16 in)

Flush with water for 15 minutes and get ill;

c:-
.s>
mediate medical attention. ..
c:- .,
oS'
''9 , .,..,
. CHECKING THE FRONT BRAKE DISCS
'% The following procedure applies to both brake

wheel
6
"!>,
to "FRONT WHEEL" on 4-8.
2. Che6k 5 Ad. t
. jUS :
Front brake disc "'-o Brake disc runout
Damage/galling Replace. .,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,
3. Measure: a. Remove the brake disc.
\> v Brake disc runout . "! v .s> b. Rotate the brake disc by one bolt hole.
Out of spechcat1on Correct the brake d1sc 1:; Install the brake disc.
<?_,Y runout or replace the brake d1sc. .-"' ;.; -'::-.---.---------------.
,'% . . . Front brake disc bolt
Brake d1sc runout hm1t (as mea- <.., 18 Nm (1.8 mkgf, 13 ftlbf)
. sured on wheel) LOCTITE
0.10 mm (0.0039 inl, ________
i$)4 c:>...
:> ?o
1
ECAIAC\400 5l ?o
., .,., "'"' 0!'"'., .,., .,., ., .,.,., ., .,., .,., .,., .,., NOTICE
a. the vehicle on a suitable that Replace the brake disc bolts with new ones.
the front wheel is elevated.
b. Before measuring the brake disc runout, tw.m TIP . . .
the handlebar to the left or right to ensure T1ghten the brake diSC bolts 1n stages and 1n a
the front wheel is stationary. "! v cnsscross pattern. "!,
c. Remove the brake caliper. <?
....

'%

4-25

<t> ..
6"!>
'.?
I
d. Measure the brake disc runout.

If out of specification, repeat the adjustment
until the brake disc runout is within

f. If disc runout cannot be brought
within replace the brake disc.
>
y.?
.........

6. Install:
Front wheel .. -'l,b
Refer to "FRONT Wf'IJ:EL" on page 4-8.
y.?.
EA$::?2211
REPLACING THE FRONT BRAKE PADS
following procedure applies to both brake
the brake pads, it is not neces-
rli<!1rnrn<>.rt the brake hose or disassem-

FRONT"BRAKE
6"!>
'.?

3. M) a.ure:
wear limit "a"
Out of Replace the brake
pads as a
"'
Brake lining thickness (inner)
4.5 mm
Limit
0.5 mm (0.02'1.!U
Brake pad llnlngtl).lckness (outer)
4.5 mm (0.18 in)
Limit
0.5 mm (0.02 In)
61
6"!>
.{.? Jilemove:
ffi9ke caliper bolts
5. lnsfa\
Brake
Brake
TIP
a
lot
Always install new>.prake pads and new brake
pad spring as a set.

a. Connect a clear plastic "1" tightly to the
...
6
bleed screw "2". Put the of the hose
"!>,.?into an open container.
b. the bleed screw and push,the brake
calipj!r pistons into the brake caliper with your

.s>
f

y.?
'%
4-26

<t> ..
oS'-9

FRONT BRAK_g

2
% 8. Check: o%
Brake lever operation
"! v.s> Soft or spongy feeling --? Bleed the brake sys- "! v.s>
Brake caliper bleed screw
5 Nm (0.5 m-kgf, 3.6 ft-lbf)

<?> tem.
to "BLEEDING THE HYDRAULIC
'IBJ2AKE SYSTEM" on page 3-13.

E.ASZ2300
THE FRONT BRAKE CA!ftfERS
The applies to
brake calipers."

TIP
Before removing the brake caliper, drain the
brake fluid from the entire brake system.

1. Remove: "!v
.s>
f.
.<?>
y.?
6. Install:
Brake pad pin
Brake pad clips
brake caliper
Front brake caliper bdl\
35 Nm (3.5 m-k.gf, 25 ftlb.Q
,_
\

/7'-{,IC
7. Check: 1
Brake fluid level
Below the minimum level mark "a"--+ Add tha v.s>
specified brake fluid to the proper level. -9
<?>
Refer to "CHECKING THE BRAKE FLUID Y.?
LEVEL" on page 3-11 .
THE FRONT BRAKE

The folloWil;l_g procedure applies to the
brake calipers, '.?
1. Remove: "
Brake caliper pistons "1"
Brake caliper piston dust seals "2"

Brake caliper piston seals "3"
"!v
a
.s>
f.
pry out the brake caliper pis-
Do not
'

Cb

n
brake component
v replacement schedule
'
Brake pacfs<?>y,
If necessary
Piston seals
'%
Every two years
"
Piston dust seals Every two years
Brake hoses four years
Brake fluid
Evi:l"ey two years and
whenever the brake
.
.0
is disassembled
C!
1.
caliper pistons "1"
Rust/sq atches/wear 4 Replace the brake
. .,
caliper pls}gns.
Brake "2"
Scratches/weaft>..:t Replace the brake caliper
assembly.
Brake caliper
Cracks/damage 4 RePis,J.ce the brake caliper
.?.
assembly.
Brake fluid delivery passages
caliper body)
'el >struction 4 Blow out with compressed air.

-.s>
'

Cb
"f
"!,?>

c. Remove brake caliper piston dust sej l)s
and brake c<l\lper piston seals. "!>,.?
b
DraK., caliper is disassembled,
caliper piston dust seals
niston seals.
3
d. Repeat the pnt'VJous steps to force out
right side pistons from the brake caliper.
2

EASZ!391

0 0
-.s> -(CHECKING THE FRONT BRAKE CALIPERS
i i\'e._Jollowing procedure applies to both of the

"f
"!,?>
E!A.$22411 ....
ASSEMBLING FRONT BRAKE
CALIPERS

6"!>
'.? Before installation, all ihJ9,rnal brake com-
y.?.

ponents should be cleani d and lubricated
clean or new brake fluid.
use solvents on internal brake com-
as they will cause the brake caliper
pisto&. gust seals and brake caliper piston
seals tosy.tell and distort.
Whenever'B-wrake caliper is disassembled,

4-28

"!:>.-
-"!> -"!>

' '

c c
rifR!,ace the brake caliper piston dust seals 2. Remove:

caliper piston seals. Front brake
'r (/
brake fluid
'V
EAS224.CO .....
INSTALLING THE FffQNT BRAKE CALIPERS
6
"!> The following to both of the
brake calipers.
1 . Install:
"4r:,_; Front brake caliper "1"

hose gaskets mi!J
):lose "2"
Brake n"qse union bolt "3"
hose union bolt
30 mKgf, 22 ftlbf)
EWAI3$30 "':?4-.
6"!>
Proper brake hose routln'g. Js essential to ln-
sure safe vehicle operatlon."Refer to "CABLE
on page 2-41.
the brake hose onto the
brake caf iP.er " 1", make sure the brake pipe
" a" projection "b" on the brake
caliper. '%
Install the braife.. .Jlipe "c" so that it is
aligned with the brake pipe " a" .
3. Install : .s>
Brake pads
''9
. <?>

'%

Brake pad spring
Brake pad pin
Brake pad clips

6
Front brake caliper <t>b

-?
Front brake caliper bolt
35 Nm (3.5 mkgf, 25 ftlbl)
"
Refer i&t(.F.lEPLACING THE FRONT BRAKE
0
PADS" 4-26.
4. Fill: ..
Brake master cyrlflder reservoir
(with the of the specified
brake fluid)
Specified brake fruj,d
DOT4
>0 .. ,
:Q>
A wARNING
Use onw the designated brake fluid. Other
brake fhl if!!s may cause the rubber seals to
0
deterlorate/'O{ auslng leakage and poor
brake
'/
Refill with the same type of brake fluid that
is already In the Mixing brake fluids
may result in a chemical reaction,
leading to poor brake
When refilling, be carefuF'ttJat water does
enol enter the brake fluid Water
significantly lower the boil'i"n(! point of
fluid and could cause va'j;or lock.
Brake fluid Tm!y damage painted surfaces
and plastic Therefore, always clean up
any spilt brake fi Ufd.Jmmediately.
5. Bleed:
Brake system '%
Refer to "BLEEDING HYDRAULIC
BRAKE SYSTEM" on
Check:
fluid level
Bef o)!Y the minimum level mark "a" ....; Add the
brake fluid to the proper level.
Refer to<tCHECKING THE BRAKE FLUID
LEVEL" 3-1 1 .
%,.
v
.s>
''9
. <?>

'%
4-29

<t> ..
6"!>
'.?

7.
Brake operation
Soft or sp&F.lil Y feeling Bleed the brake sys-
tem.
Refer to "BLE1Zp 1NG THE HYDRAULIC
BRAKE page 3-13.
>
y.?
EASZ!t:90
REMOVING THE FRONT Bij_fKE MASTER
CYLINDER
<t>
Betgre removing the front brake maSleJ. cylinder,
brake fluid from the entire b-rake sys-
tem.
1. DisconnecJ:
Brake light connectors
(from the fronf't>f31ke light switch)
2. Remove: .s>f
Brake hose union
Brake hose gaskets
Brake hose "3" "o>L

T. 'Q collect any remaining brake 'il.yl.d, place a
under the master cylinder the end
of hose. "
6<'! 2
y
..?.$0.
THE FRONT BRAKE MASTER

1. Check:
Brake
Replace.
Brake fluid deliveP!fvpassages
(brake master cylinder body)
".?

FRONT
with compressed air.
2. Check:
Brake master cylinder kit c/.s>
Damage/scratches/wear R?_place.
3. Check:
Brake master cylinder reservoir "11!>"<1
Brake master cylinder reservoir
holder '6_' <t>b
Replace.
Brake masfe.r, cylinder reservoir
"3"
Damage/wear --!o.ijeplace.
Cb
V

1/
"!>,
.?;,

4. Check:
Brake hoses %-o
Replace.
-'0
....,.,.
ASSEMBLING THE FRONTfif!AKE MASTER
CYLINDER -9. <>
fVI,t,13620 >y

A wARNING
Before installation, all internal com-
ponents should be cleaned and
with clef n.or new brake fluid.
y
Never use on internal brake
ponents. "
fluid
'U DOT 4
v
"""""' oS'
INSTALLING THE FRONT BRTtKE MASTER
CYLINDER
1. Install : ""<1
Front brake master cylinder
Front b@ke master cylinder holder
V.?<,.
FrBI;)t brake master cylinder
mkgf, 7.2 ft-lbf) "

o
TIP 1b
Install the front brake rrfasi er cylinder holder
with the "UP" mark "a" facin!JSl;!P
Align the end of the front brake cylinder

'%

<t> ..
<::>
4-30
...
<t> ..
c
holder with the mark "b" on the handle-
bar. ..
First, tighten the uppertt?olt, then the lower bolt.
There should be more 11 mm (0.43 in) for
clearance between the switch
and the front brake master cyft'%!er holder. Al-
so, the punch mark should be
. ,
'-9

a >y..,
'%
2. Install:
Brake hose gaskets mi!J
hose
union bolt
hose union bolt
311>-l':!m (3.0 mk,gf, 22 ftlbf)
'D.
A wARNING
Proper brake hose routtpg Is essential to In-
sure safe vehicle operatioi:l, Refer to " CABLE
ROUTING" on page 2-41.
nP '
Attach the brake hose so that its is 3to
13ea!Jainst the straight li ne in the
ceiling.?pJane of the master cylinder.
While hoftlip_2 the brake hose, tighten the
bolt as show!\
Turn the to the left and right to make
sure the brake not touch other parts
(e.g., wire leads). Correct if
necessary. ..,'9

3. Fill:
Brake master cyli nder'fEQ>ervoir
>
".?
'%

"!:>.
4-31
c
(with the specified amo'h9.t of the specified
brake fluid) ..
Specified brake fluid -.,-9
DOT 4
0)..
EWA1:)64.()
A wARNING
Use only the>g eslgnated brake fluid.
brake fluids ma.}' cause the rubber seals to
deteriorate, calfsJ,rg leakage and poor
brake
Refill with the same of brake fluid that
is already in the system.<l'4).xing brake fluids
may result in a harmful crfe.91ical reaction,
leading to poor brake .
When refilling, be careful does
not enter the brake master
voir. Water will significantly lower
ing point of the brake fluid and could
vapor lock.
6
<t>b

ECAI $40 ?o yo.?.
NOTICE ______
Brake fluid may dafi:l9 ge painted surfaces
and plastic parts. always clean up
any split brake fl uid
4. Bleed: v
Brake system . .,f
Refer to "BLEEDING THE
BRAKE SYSTEM" on page 3-13. '%
5. Check:
Brake fluid level
Below the rliigimum level mark "a" -+ Add
specified brak!? to the proper level.
Refer to "CH THE BRAKE FLUID "
LEVEL" on page
a
6"!>
'.?
;,
6. Check:
Brake lever operaMlQ,
Soft or spongy the brake sys-
tem.
Refer to "BLEEDING HYDRAULIC
BRAKE SYSTEM" on page
'-9

".?
'%

"!:>.
EA$22550
REAR BRAKE
Removing the rear brake pads
17 Nm (1.7 m kgf, 12ft lbf)
Order to remove
.?.
1 Screw plug
'
v,
8 Bleed screw

the rear brake master
5
Order to remove
4-33
Removing the rear brake
Order Job/Parts to remove

Disassembling the rear master cylinder

.s>
f.
4
-
Order
1 B@ke master cylinder yoke
2 BraRe-,.master cylinder kit
3
4 Bushing
5 Brake master C1inder body
4-35
- . . . ~
?,
REAR BRAK'E
0'")
4-36
- . . . ~ y
REAR BRAKE .?"0
5 Nm (0.5 m kg!, 3.6 It lbf)
4
Q'ty Remarks
4-37
EA$22561

INTRODUCTION
EWA\ 4101
Brake disc thickness limit
4.5 mm (0.18 in)
A WARNING
.s>
f
Disc brake components rarely require disas-
Therefore, always follow these pre-
measures:
disassemble brake components un-
lesif-ag solutely necessary. e"b
If any C2_nnectlon on the hydraull9, brake
system fS disconnected, the
system must be disassembled,
cleaned, properly filled, and bled after 6. Install :
sembly. Rear wheel
v Never use solvents on internal brake com- Refer
10
"REAR WHEEL" on page 4-14.
.s>f ponents.
only clean or new brake fluid for clean- REPi''A.CING THE REAR BRAKE PADS
mg brake components.
fluid may damage painted surfaces TIP 'Z" . . .
t n,S;t p. lastic parts. Therefore, always clean When the brake pads, 11 IS not neces-
upliQ, y spilt brake fluid sary to the brake hose or
Avoid'hJ.ake fluid coming into with ble the brake "b,l?
the it can cause serious 1. Measure: "
FIRST AID FOR BRAKE FLUID Brake pad wear limit "a"
THE EYES: Out of specification Replace the brake
Flush with water for 15 minutes and get im-
pads as a set.

.s>
mediate medical attention. '<
c:. Brake pad lining thickness (inner)
f , .,,.,
. CHECKING THE REAR BRAKE DISC

wheel
IO "REAR WHEEL" on page 4-14.
2.
6
"!>
. 6.0 mm (0.24 in)
Limit
1.0 mm (0.04 in)
pad lining thickness (outer)
mm (0.24 In)
e<'l
1.0 rffJJJ, (0.04 in)

Read5t{jke disc 'l?
Damage'lgalling Replace.
3. Measure: %-o
Brake disc runout
Out of specification Correct the brake disc . a
v runout or replace the brake disc. v I
.s>-9 Refer to "CHECKING THE FRONT BRAKE
DISCS" on page 4-25. . .. ..

Brake disc runout limit (as mea- ""<1
sured on wheel)

0.1 5 mm (0.0059 in)
e.,, 2. Install :
y y
4. Brake pad insulai.ws
Brake drsc thickness Brake pad shims
Measure the brake disc thickness at a few-&iJ,- (onto the brake pads)
ferent locations. Brake pad spring
Out of specificalion Replace. (into the rear brake caliper)
Refer to "CHECKI NG THE FRONT BRAKE (J Brake pads
DISCS" on page 4-25.
install new brake pads, brake pad insu-

4-38
...
<t> ..

'b

'<

c
lators, brake pad shims, and brake as
a set.
Cb
3. Lubricate: %
Rear brake caliper bolts
.----r---------------------------,

a. Connect a clear plastic hose "1" tightly to -.
Recommended lubricant .s>f
Silicone grease

bleed screw "2". Put the other end of the hose '----'---------------'
C,. IACI41$
into an open container.
b. Loosen the bleed screw and push the brake
caliper piston into the 'B[ilke caliper with your
finger.
1

%

oo ..
v
.s>
f

NQTICE
D<P4:1ot allow grease to the brake
vh
excess grease.
4. Install :
Rear brake caliper
Brake pad retaining bolts
Screw plug
Rear brake caliper bolt (front)
Rear brake caliper bolt (rear)
22 Nm (2.2 m-kgf, 16 ftlbf)
"Q,

<t>
c. Tighten the bleed screw.
v:> <>.
.. LOCTITE
Brake pad retaining bOJt
17 Nm (1.7 m-kgf, 12 ft.fbJj

Brake caliper blefi:g screw
5 Nm (0.5 mkgf,

d. Install the brake pad insulators pad
shims onto each brake pads.
TIP
Apply silicone grease between the brake
sulator and brake pad shim.
" Screw plug

2.5 Nm (0.25 mkgf, 1.8 ftlbf)'%
-6
,,
5. Check: o%
Brake fluid level ..
Below the minimum level mark "a"-+ Add the v.s>
specified brake fluid to the proper level. '9
Refer to "CHECKING THE BRAKE FLUID

LEVEL" on page 3-11. '

<t>b Do not allow grease Jp contact the brake
pads.
)!'...?. ..,. '
Remove any excess
e. Install the brake pads and pad spring.
TIP
The longer tangs "a" of the brake
must point in the direction of the brake "Q91iper
piston. v.s>
6. Check:
Brake pedal operation a
or spongy feeling -+ Bleed the brake sys-
,.
tw.
to "BLEEDING THE
-
BRAK1; SYSTEM" on page 3-13.

"""""
REMOVING THE REAR BRAKE CALIPER
TIP
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system. v
.s>
f

"Q,
c
1. Remove:

Brake hose unio'P.-4/olt "1"
Brake hose gasket&:_2"
Brake hose "3" -9. <>
>
TIP Y_,
Put the end of the brake a container
and pump out the brake fluid carefwJIY.
6"!>
,_,

a. Blow compr-88sed air into the brake hose joint
opening "a" t<Y4,orce out the piston from the
brake caliper. ..
EWAUJ;SO (/
A wARNING
.s>
'f.

REAR BRAKE
Recommended brake
replacement schedule
.<>.
Brake pads If necessary
't>i
Piston seal
->;,
"
Every two years
Piston dust seal
4,
Every two years
Brake hoses 'Exery four years

Evef,y
0
two years and
Brake fluid whenffi&r the brake
is
-
1. Check:
Brake caliper piston "1"
RusVscratches/wear 4 Replace the
caliper <t>b""
Brake ''2''
Replace the brake caliper
assembly.
Brake caliper
Cracks/damage 4 Re8r"G.e the brake caliper
assembly. ..
Brake fluid delivery passages:/.s>
(brake caliper body) f.<>
Cover the brake caliper''l&ston with a rag.
Be careful not to get injurlf\ when the pis-
ton is expelled from the
Obstruction 4 Blow out with compFEtSSed air.
EWA1ACI402

Nel.er try to pry out the brake .. tfAiiper pis-
torl'h'-
4-40
A wARNING
Whenever a )?rake caliper is
replace the caliper piston dust

and brake seal.

.s>
'-9
'<}>
y_,

<t> ..
'.?

2. Check:

Rear brake caliper "1"
' c
Cracks/damage --+ Replace;- "0
Refer to "REAR WHEEL" on 4-14.
v
.s>
1 'f

y.?
'%

A WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to
ROUTING" on page 2-41. v

ECAoACO"' 'f
NOTICE -------------------------.
When Installing the brake hose onto the '%

brake caliper " 1 ", make sure the brake pipe
" a" passes between the "b" on <t>

brake caliper.
A wARNING
Before Installation, all Internal com-
ponents should be cleaned and
with clean or new brake fluid.
Never use solvents on internal brake \
ponents as cause the brake caliper 2. Remove:
piston dust seaf ?.cwd brake caliper piston Rear brake caliper
seal to swell and di%twt.
Whenever a brake caiipsr is disassembled, Brake pad insulators
replace the brake dust seal Brake pad shims
and brake caliper piston seal 1; (onto the brake pads)
Brake pad spring
Specified brake fluid v.s> (into the rear brake caliper)
' U DOT 4 -9. Brake pads
Rear brake caliper
,..,.,. Refer to "REPLACING THE REAR BRAKE
INSTALLING THE REAR BRAKE PADS" on page 4-38.
1. Install:
Rear brake cafi>per "1"
(temporarily) . '.?
..
Brake hose gaskets 'Om
Brake hose "2"

Brake hose union bolt "3" Cb
"'
Brake hose union /
Rear brake bolt (front)
27 Nm (2.7 ftlbf)
Rear brake caliper (rear)
22 Nm (2.2 mkgf, 16 ftdbf)
LOCTITE
Brake pad retaining bolt

Screw plug v
30 Nm (3.0 mkgf, 22 ff<l_bf)
'f 2.5 Nm (0.25 mkgf, 1.8 ftlbf)
'-
______________________________
y.?
'%

<t> ..
"<0<

BRAKE

q,
4. Fill:
"' v.s> (with the specified amount of the specified
<?> brake fluid)
Brake fluid reservoir
EWA\ 3090 6
F!i'&i;Uifdij
THE REAR BRAKE MASTER

1. Reri1Gve:
Brake union bolt "1"
Brake "2"
Brake hose ila','
TIP
To collect any rem'%1ojng brake fluid, place a
container under the cylinder and the end
of the brake hose. "
Use only the\lesignated brake fluid.
brake fluids may cause the rubber seals
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
v .s> is already in the system. Mixing brake fluids
<? may result in a harmful chemical reaction,
>
to poor brake performance.
W'%n refilling, be careful that water does
not the brake fluid reservoir. Water
...
will signit!cantly lower the boiling P9lnt of
the brake fl yJd and could cause

" ......,,.
" CHECKING THE REAR BRAKE MASTER
CYLINDER
Brake fluid may damage painted surfaces Ch k
and plastic parts. Therefore, always clean up eke t

1
. d
. . . . -sera e mas er cy 1n er
.. v any sp1lt brake flUid 1mmed1ately. BJw,age/scratches/wear
4
Replace .
.s>-9 5. Bleed: fluid delivery passages
<?_.., Brake system cylinder body)
to "BLEEDING THE HYDRAULIC Obstructi\3'1(!> 4 Blow out with compressed air.
BR4,KE SYSTEM" on page 313. 2. Check:
6. Cheek.i, Brake master kit
Brake flUid. level
6
"!> 4 Replace.
Below the""ro.[umum level mark "a" 4 AdcJ>the 3. Check: Y.?.
spec1fied brak'e flUid to the proper level.

Brake fluid
Refer to "CHECKING THE BRAKE Brake fluid reservoir diaphragm holder "2"

LEVEL" on page 3 11. Cracks/damage 4 Replace.
fluid reservoir diaphragm "3"
b al"age/wear 4 Replace.
'6 7. Check:
Brake pedal operation
Soft or spongy feeling 4 Bleed the brake sys

tem .
. v.s> Refer to "BLEEDING THE HYDRAULIC
-9 <?> BRAKE SYSTEM" on page 3 13.
y.?
'%

"!:>.
4-42
.s>
./'1

fluid reservoir hose
--) Replace.
-"!> -"!>

' '

THE REAR BRAKE MASTER brake fluid
'\_f 00! 4
EWAt 3520
F!j&.1Hfiri ---------------------
Before all internal brake com-
ponents sho'ilts! be cleaned and lubricated
with clean or ne"\brake fluid.
Never use solven(S, _gn Internal brake com-
ponents. Y.?.;,
Specified brake fluid
DOT4
1. lfutall:
master cylinder kit Bm!l
f
EA$2:11-CO () >
v,
INSTALLING?JHE REAR BRAKE MASTER
CYLINDER
1. Install:
Brake hose gaskErt$p
Brake hose y.?.
Brake fluid reservoir h1Jse
Brake hose union bolt
Brake hose union bolt
30 Nm (3.0 m-k.gf, 22 ftlbf)
EWAI3$30
,, il&.i;idijlri ---------------------
Proper routing is essential to in-
sure safe veh16le operation. Refer to " CABLE

ROUTING" on pa,e 2-41.
A wARNING
Use only the brake fluid. Other
brake fluids may cause tl},e rubber seals to
6"!> deteriorate, causing and poor
'.?.J?rake performance. y.?.
with the same type of bra'i?e fluid that
is in the system. Mixing brake fluids
may rei'.ult in a harmful chemical reaction,
leading brake performance.
When refflfiiJg, be careful that water does
not enter fluid reservoir. Water
will significantiY-<1.9wer the boiling point of
the brake fluid an&"Q
0
1:!uld cause vapor lock.

NOTICE
6"!>Brake fluid may damage surfaces
-a51d plastic parts. Therefore, clean up
brake fluid immediately."

5. Adjust:
6 Brake pedal position
to "ADJUSTING THf?YJ.l EAR DISC
on page 3-13.
6. Ai:!Lt;St:
light operation timing
Refer fQo"ADJUSTING THE REAR BRAKE
LIGHT on page 3-27.
v
.s>
f
.<?>
y.?
'%
4-43

"!:>.
HANDLEBAR
Removing the handlebar
3.8 Nm (0.38 m kgf, 2.8 ft lbf)
Grip end
9 iJ Throttle grip
6
i>

11 ft handlebar switch "
12 Handlebar grip ,,
13 Clutch cable Disconnect.
14 Clutch lever holder 1
15 Upper handlebar holder '6 2
v 16 Handlebar v'
.s>
-9 17 Lower handlebar holder

4-44

"!:>. "!:>.
REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
If
EWAt 3120
A wARNING
.<?>

Securely support the vehicle so that there is

Remove:
6
Handlebar grip "1" "!>
1',
Tl fi'?"0, .lc,
Blow compressed air between the 1JnJ]andlebar
and the handlebar grip, and the
grip off the handlebar.
INSTALLING THE HANDLEBAR
1. Stand the vehicle on a level surface .
A wARNING
..

.so11 Securely support the vehicle so that there is
<?_59_0 danger of it falling over.
6"!>

"'%
3. Remove:
Throttle cable housings "1"
Throttle grip "2"

Cb

2%g
2
tall :
LO' wer handlebar holders
...

"1"
Upper haffe!Jebar holders "2"
Upper handlebar holder bolt
22 Nm (2.2 mkgf, 16 fllbf)
"'
TIP
While removing the throttle cable housing, pull 11 <?> First, tighten the bolts on the front side of
back the rubber cover "3". upper handlebar holder, and then on
side.
2
Tui'hothe handlebar all the way to the left
and ?fQbt. If there is any contact With the
fuel the handlebar posiftCI_9;
TIP " "'
Align the punch mark "a" on the handlebar
the left side upper surface of the left lower han-
dlebar holder "3".

The upper handlebar holders should be in- ..
.so stalled with the punch marks "b" facing for- v.so
If
. () > EAS22890

<?> ward.
CHECKING THE HANDLEBAR
1. Check:
Handlebar
Bends/cracks/damage
V_,
A WARNING

..

Do not attempt to straighten a bent handle-
bar as this may dangerously weakeii'<i.t.
"

.sof 3. Tighten:
<?>y Lower handlebar holder nuts

4-45

<t> ..
9. Install:
Left handlebar switch ..
Left handlebar switctfscrew
2.0 Nm (0.20
TIP '
Align the projection "a" on the left handleBar
switch with "b" in the handlebar.
y.?.
b
10.Adjust:
Throttle play
Refer to THE
GRIP" on
,_
Throttle grip'ltee play
3.o-5.0 mm (0'::1.2-0.20 in)
.
..
11.Adjust: v.s>
Clutch lever free play -9. <?,
Refer to "ADJUSTING THE
FREE PLAY" on page 3-11.

0% EAS;.2aa50 %

y,
'F--RONT FORK
FRONT FORK

.s- Removing the front fork l egs
23 Nm (2.3 m. kgf, 17ft lbf)
Order -yo.?. Job/Parts to remove Q'ty
' 5 Front fork leg
4-48
.,
3'')
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
'
/--- s
/

'
'
'
'
'
'
'
'
'
'
'
'
'
The following procedure applies to both of
the front fork legs.
Refer to "FRONT WHEEl: on page 48.
- . . . ~
FRONT FORK y . ? ~
Job/Parts to Remarks
4-49
-"!>
~ ~ ~ R O N T FORK
~ ~
Disassembling the
18
u
.j
~ -
Job/Parts to
-"!> -"!>

' '
y,
FRONt FORK

c,- . c Q

REI\60VING THE FRONT FORK LEGS Locknut
The 1o!lowing procedure applies to both of the
front foi'l{-st egs. a. Press down on ihe,spacer with the fork spring
TIP
'<?> -
compressor "5". y.?""
Each front is equipped with a spring pre- "':>2>,
load adj'usting b'Bi the right fork leg is equipped b. Install the rod holder the locknut
.. "' "4" and the spacer "3".
with a rebound dartiging force adj usting screw
and compression force adjusting
screw Pay attention not fq-J,l1iStake the right and
left.
a suitable stand so that the
2. Remove:
Front brake caliper
Refer to "FRONT cHR".t: on page 4-20.
Front wheel
Refer to "FRONT WHEEL" on page 4-8.
locosenirtg1!be upper and lower brack
the front fork leg.
4. Remove:
Fork spring
9089().()1441
YM-01441
Rod holder
9089().()1434
rod holder double ended

Use the side of the roo;J;lolder that is marked "B".
c. Hold the cap
d. Remove the cap washer.
e. Remove the rod fork spring com-
pressor.
6 f. Remove the spacer and
"!>,
..,h. )!'...?.

2.

TIP

Stroke the d' azyper rod assembly "1" several
times while drairii@g the fork oil.
6"!> Front fork leg
'.?
EASIACUI3
DISASSEMBLING THE FORK LEGS
following procedure applies to both of the
fork legs.

damper rod assembly)

'%

<to ..
4-51
0
3. Removi.o
11
Dust seal
Oil seal clip "2':!-
(with a flat-head
y.?
'%

<to ..
Do not scratch the
4. Remove:
Outer tube

.s>
f

a. Hold the front fork leg
b. Securely clamp the brake in a
vise with soft jaws.
c. Sepa_r;, ate the outer tube from the tube
by pul ffo9, the outer tube forcefully but
ly.

%
Excessive force ,Ni.q, damage the bushings.
Damaged bushings iflyst be replaced.
F\ -
Cb

............... .............. .
5. Remove: v.s>
Damper rod assembly
Damper rod assembly
CA1Rc-l412
NOTICE
For rod assembly, the rf.l;l t side
is used fq5 the rebound operation. Pay
tion not the right and left.

While holding rod with the damper
rod holder ''1'", damper rod assembly
bolt.
Damper rod
9089Q-01423 
11
YM-01423 <?>

1
.s>
f
E.AS23011 <>
CHECKING THE FRONT FORK LEGS>Y.?
The following procedure applies to both
front fork legs.
1. Check:
6
..
Inner tube "1" "!>
'.? v:>
Outer tube "2"
Bends/damage/scr.;re,hes Replace. "
EWA13650

c A wARNING
Do not attempt to straighte'il; a bent inner
tube as this may dangerously lt.
f
1
I '%

6
"!>,,
.... _.)'------'-)---r- ' _})))
- \
2
Cb

2. Measure:
Spring free length "a'' v
Out of specification Replace. .s>1! <?,
4-52
6"!>
'.?
;,
3. Check:
Damper rod
Damage/wear
Obstruction all of the oil passag-
es with compressed a'l'b.; ..
CA1RCI40S (/
.s>
NOTICE -9.,
>
The front fork leg has a very Sf3 hlstlcated
Internal construction, which are'<" Perticular-
ly sensitive to foreign material.
When <lj,sassembling and assembliifg; the
front forRoJeg, do not allow any foreign 'fn.a-
terial to enl iu: the front fork.

1

= ::::::cc:>
>
y.?
'%

"t-
6"!>
?
AS1ACIU4 \1 )-:, yo.?.
ASSEMBLINt:}-fjtE FRONT FORK LEGS
The following applies to both of the
front fork legs.
EWAIRCI"'O 0%
A wARNING
Note that the amount of fork oil is differ-
ent in the left and right frorif(P-,rk legs. Make
sure to fill each of the left an{l<l!ight front
fork legs with the specified amou,nt of the
fork oil.
If both ft ont fork legs are not filled wit\ the
specifiedb{!mount of the fork oil, it
cause and a loss of
j
TIP
When assembling 'ltte front fork leg, be sure to
replace the following
-Oil seal ..
-Oil seal clip v.s>f
-Dust seal <?>
y.?
'%
Cb
-Copper washer '<o
-Oring ..
Before assembling the front fork leg, make
sure all of the components are clean. -9. <?>
1. Install :
Damper rod assembly "1"
ECAIACI406
NOTICE __
AIIow the damper t-9f! assembly to slide
slowly down the lnnef 1,Mbe " 2" until It pro-
trudes from the bottom Jr,tr.e inner tube. Be
careful not to damage the tube.
TIP
The lett side damper rod assembly fug; the two
holes of oil path, unlike the right side. .s>f.
6"!>
'.?
A. Left side

B. Right side
2. Tighten:
Damper rod assembly bolt .
(along with the copper washer dlll\!J)
Damper rod assembly bolt -9. <?>
LOCTITE

TIP
6

While holding the dam_Rer rod assembly with the
damper rod holder the damper rod
assembly bolt.
"
Damper rod
90890-01423
Damping rod holder v
YM-01423 .s>f
',:,

"!:>.
4-53
1

.s>
'f
'<?>

'%

<t>b

y.?.

3. Lubricate: 5. Install :
Inner tube's outer surface Outer tube
.----r----------'c"';%'!:""""---, (to the inner tube)
Recommended oil 6. Install :
Suspension oil 01 v" Outer tube bushing "1"
4. Install:
Dust seal "1" mill
Oil seal clip "2" mill
Oil seal "3" mill
. .., <? Washer "2"
(with the fork seal driver "3")
<:)
<
Fork seal driver
90890-01442
Washer "4" e
. <" Q
Outer tube bush1ng 5"

Adjustable fork sea! driver (36-46
mm)
Inner tube bushing
Make sure the numbered side ot..1rne oil seal
faces bottom side.

Before installing the oil seal, lubricate
with grease.
Lubricate the outer surface of the inner tube
with fork oil.
Before installing seal, cover the top of
the front fork leg bag to protect
the oil seal during

y.?.

<t>b

7.
"
YM-01442

3
2
1
Oil seal "1"
Fork seal driver

90890-01442
Adjustable fork seal driver (36-46 v.s>
mm) f<?
YM-01442
""<1

2
,--,,__.-

8. Install:
Oil seal clip "1"
Cb

1
"'
TIP v
Adjust the oil seal clip so that it fits into the oufeu;>
2
tube's groove.

1
9. Install:

<t>b

y.?.
3
6"!>
'.?

11.Fill :

-o Front fork leg

c (with the specified amount of the recorfi' ':<o
mended fork oil)
r----r---------------------------,
Suspension oil 01
.s>f Recommended oil .s>f

Quantity (left)
472.0 cm
3
(15.96 US oz, 16.65
% Dust seal "1"
Jib

lmp.oz)
Fork seal driy,er Quantity (right)
6
90890-0144:fo, 458.0 cm
3
(15.48 US 16.15
Adjustable fork.?S.. eal driver (36-46 lmp.oz)
mm) '
YM-01442
NOTICE
Be sure to use the recommended fork .
v Other oils may have an adverse effect on v
.s>f front fork performance. .s>f
When disassembling and assembling the
%

<t>b
1
front fork leg, do not allow any foreign ma-
!erial to enter the front fork.

6"!>
)!'...?. /',

1 O.lnstall:
Rod puller "1"

Rod puller attachment (M 1 0) "2"
1 filling the front fork leg, stroke the
da'ru,P.er rod "1" up and down least ten
times),Jo distribute the fork oil. .?
TIP '
"
Be sure to stroke the damper rod
(onto the damper rod "3")
Rod puller v.s>
cause the fork oil may spurt out.

.s>
90890-01437 'f..()
Universal damping rod bleeding
toolset
YM-A8703
Rod puller att achment (M1 0) ..
1
90890-0143flb 6"!>
Universal rod bleeding
' '
YM-A
8703
13.Before measuring the fork oil level, w:'fr><t_en
minutes until the oil has settled and the .flt,. <o
t
'f

y.?

bubbles have dispersed.
TIP
Be sure to bleed the front fork leg of any residual -9.
>
y.?

air.
14.Measure: v
Front fork leg oil level "a" .s>f
(from the top of the outer tube, the outer
tube fully compressed and fork
spring)
Out of specification Correct.
15.1nstall:
Fork spring (Left "1"

Spacer (Left side) "2"
Locknut (Left side) "3" v
Washer (Left side) "4" .s>f
Cap bolt (Left side) "5"
(along with the 0-ring DlliJ)

<t>b

y.?.

3
5
,
1
b
'.?

c. Install the locknut all the the damper
rod assembly.
d. Install the rod puller and rod
0
PJt,ller attach-
ment.
"'
e. Install the spacer. v.s>
f. Install the fork spring compressor. ''9
g. Press down on the spacer with the fork spriA9.
compressor "1". %"<1
h. Pull up the rod puller and install the rod holder
"2" between the "3" and the spacer ..
. '
y
Rod puller

9089G-01437
Universal damping fc:tQ bleeding
tool set
YM-A8703
Rod puller attachment (M10}.s>
9089G-01436
Universal damping rod bleedinlfy.?
tool set
YM-A8703
Fork spring compressor

YM-01441 Y.?.
Rod holder
9089G-01434
Damper rod ended
YM-01434

TIP -------------"-6-::--
Use the side of the rod holder that is "B" .

<1
'<o,.,_
..
"' i. Remove the rod puller and rod puller4%ttach-
ment.
>
y.?

4-56

<t> ..

y,
FRONT FORK

j. Install the washer and cap bolt, and then fin-

ger tighten the cap bolt.

(/ EWAI$670
t!i*i;UIIdri ------------

Alwa s use a new cap bolt 0-rlng.
k. Hoi t!e cap bolt "5" and tighten the locknut
"3" to
""!>
--- A
'.?
15 Ni'g)1.5 mkgf, 11 ftlbf)
L--'-'---------------' Install the locknut all the way onto the damper
I.
pressor.
rod assembly.
the rod puller and rod puller attach-
n1'e!;!t.
"' e. spacer.
f. Install fork spring compressor.
g. Press dowb:4.1n the spacer with the fork spring
compressor
h. Pull up the rod ifu.ll,er and install the rod holder
"2" between the "3" and the spacer
"4".
Y,
6"!>
holder and fork spring com,
1 Rod puller
v- 9089G-01437
................................................................................................ F;o,-....J Universal damping rod bleeding

16.1nstall:
Fork spring (Right side) "1"
tool set

%,. YM-A8703
v.s> Spacer (Right side) "2"
(Right side) "3"
Damper adjusting rod "4"
(Right side) "5"
Cap side) "6"
(along 0 -ring mill)

y.?.
.... 5
'!>
TIP <!
v .s> Rod puller attachment (M1 0)
_.!l089G-01436
U"rii,J!ersal damping rod bleeding

Fork spri'ns . compressor
9089G-01lf4{_
YM-01441 Y.?.
Rod holder
9089G-01434
Damper rod holder double ended
YM-01434
...
Use the sfc;le of the rod holder that is marked "B".
y.?
'%

............... ...................................................................... ...
a. Remove rod puller and rod puller attgch-
"!>
ment. y.?. '.?
b. Install the fork 'S"i!>ring.
\ TIP '
Install the fork spring with the smaller diameter
1
"a" facing up "A".

"' "' v.s> i. the rod puller and rod puller attach-

<> ment. <>
> >

'% '%
4-57

"!:>. "!:>.
c
j. Position the locknut "3" as specifii&\,"b".
--;.,
'0
Distance "b" <! v
v 12 mm (0.471n) Cap bolt
(to the outer tube)

tighten the cap bolt.
'WJJen to tighten the cap bolt specified
is after install ing the front feJIJ< leg to the
tightening the lower pinch
bolts.

""""""
INSTALLING THE FRONT FORK LEGS
v The following procedure applies to both of the

v
k. Set the cap bolt distance "c" to front fork legs.
.----...-------------::.:;,
0
,, 1. Install : <>>y,
Distance "c" Front fork leg
v 13 mm (0.51 in) Temporarily tighten the upper and lower '
pinch bolts.

6
Make the outer tube is flush wittl1he top of
the upper bracket.

..
2. Tighten:
Lower bracket pinch bolts "1"
Cb

<>>
'\...., Lower bracket pinch bolt "! v
23 Nm (2.3 mkgf, 17 ftlbf) .s>f
'<>>
yl?
Cap bolt ''2"
I. Install the damper adj usting rod, washer and .----...--------------.
cap bolt, and then finger tighten the cap bolt. Cap bolt
"t> ew .. ,.,. 23 Nm (2.3 mkgf, 17 ftlbf)
' 6

use a new cap bolt O-ring.
.
bracket pinch bolt "3" 'l?
m. Hold the cap bolt "5" and ti9't.ltgn the locknut
"3'' to specification.
Upper bracket pinch bolt

c
Locknut
15 Nm (1 .5 m-k.gf, 11

v

,A WARNING
Make sure the brake hoses are routed prop-
erly.
n. Remove the rod holder and fork c:nrir<i;, com-
pressor. v.s>
''9
'<>>
yl?

...
<t> ..

'
RING HEAD
9
4-59
-"!> ":.:; > __________ _
Securely support vehicle so that there is
no danger of it fallin%1}ver.
6
2. Remove:
"!>, Upper ring nut

Rubber washer
ring nut "1"
bracket

F!iitf;Jtjldri ___________ _
Securely S'tq?port the lower bracket so that
there is no of it falling.

Hold the lower nut with steering nut
wrench, and then refflQ, ve the upper ring nut
with the ring nut
Remove the lower ring nut the steering nut
wrench "2".
1
"
%., Recommended cleaning solvent

Kerosene
" .
2. ..
Bearings
Bearing

"'t>.
4-61

?.
STEERING H&AD
c
Replace the bearings and
bearing races set.
v
,SO
"f
"<}>

2

3. Replace:

Bearings ..
Bearing races v.so

2

a. Remove the bearing
the steering
head pipe "1" with a long roCP'.g" and hammer.
b. Remove the bearing race the lower
b.&acket with a floor chisel "4"
c. a new dust seal and new beaJ:ing rae-
;, -? .
es.

NOTICE %,_
If the bearing is not installed properly,
the steering could be damaged.
TIP v
.q
Always replace the beanl\l9S and bearing races
as a set.
Whenever the steering
replace the dust seal.

............................... .
"\;. Check:
bracket
bracket
the steering stem)
BendSla-qcksldamage Replace.
<t>b
EAS231otO
INSTALLING HEAD
1. Lubricate:
Upper bearing
Lower bearing
2.
ring nut "1"
"2"
Upper ring, nut "3"
<'
Lock e
Refer to "C1:it;._CKING AND
THE STEERIN<f--HEAD" on page 3-18.

Y,
STEERING HEAD

Cb
3. Install:
Upper bracket
Steering stem nut
TIP----------------
Temporarily tighten the steering stem nut.
Install:
'\Front fork legs
Al;jer to "FRONT FORK" on page 4-48.
TIP -.,,
Temporali.!y tighten the upper and lower bracket
pinch =
"!>,

5. Tighten:
Steering stem rfflJ

.s>
'-9
'>(?>

'%

<t>b

y.?.

Steering stem nut
11 0 Nm (11 m-kgf, 80 ftlbf)

4-62

.s>
'-9
'>(?>

'%

<t> ..
EA$2:) 1(10
REAR SHOCK ABSORBER ASSEMBLY
Order Job/Parts to remove
Rider seat
Air scoop/Fuel lank cover
4-63
. .

SHOCK ABSQRBER ASSEMBL

%,
EA$2:)180
HANDLING SHOCK ABSORBER
EWIH3740 (/
A WARNING
.s>
This rear shock contains highly
compressed nitrogen gii!b Before handling
the rear shock absorber, and make sure
you understand the following ,Jnformation.
T'b9 manufacturer cannot be
property damage or person.tl Injury
that result from Improper hanCIIIng of
the rear"!!bock absorber.
Do not or attempt to open the rear
shock absofb,.er.
Do not rear shock absorber to
an open flame ora.py other source of high
heat. High heat can e3use an explosion due
to excessive gas pres!iqre.
Do not deform or the rear shock
absorber in any way. Rear absorber
J.amage will result in poor da'lnQing perfor-
rtfQ'}.Ce. 'by

EAS23190
OF A REAR SHOCK ABSORBER
1. Gas must be released before dis-
posing of a shock absorber. To release
the gas presstfre;, drill a 2- 3 mm (0.08- 0.12
.!'
in) hole through ttie: rear shock absorber at a
point 2Q-25 mm in) from its end
asshown.
EWAl3700
A wARNING
eye protection to damage
froffl;released gas or metal chips.
20-25 mm
(0.79-Q.98 in)

<t>-
6"b
EAS232!9 :>
THE REAR SHOCK ABSORBER
ASSEP-l'B1 Y
1. Stand vehicle on a level surface.
EWAl3l20 q,
F!VIi;UIIIICt-'& .!l.,. ----------
Securely supporft l:le vehicle so that there is
no danger of it falliifgg ver.

TIP------""'-------
Piace the vehicle on a stand so that the
rear wheel is elevated. v.s>
2 R

. emove: Y.?
Connecting arm lower nut "1"
Connecting arm lower bolt
Relay arm nut "2"
Relay a-r-tg bolt
TIP '.? y
When removin!hJ;Je bolt, hold the swingarm
that it does not dr<fP<Qown.
3. Remove:
"
Rear shock absOf.iaer assembly upper nut
Rear shock absorbe'&,.?ssembly upper bolt
Rear shock absorber
TIP
Remove the rear shock g ssembly from
between the swingarm and frame:'y.?
..
" <!ASZ>200
CHECKING THE REAR SHOCK ABSORl!ER

1. Check: "'.? y.?.
Rear shock rod
Replace the rear shock
absorber assembitc
0
Rear shock absorbei'<o
Gas leaks/oil leaks the rear shock
absorber assembly. v.s>
"f
Spring
Bushings
Damage/wear Replace the ab-
" sorber assembly.
Bolts
Bends/dafuage/wear Replace. 'bY.?.

CHECKING THE ARM AND
RELAY ARM
C

1 . heck:
Connecting arms "1" ..
Relay arm "2" v.s>
"f
Damage/wear Replace.
y.?

4-64

<t> ..

.s>
'f
TIP -----------------------------
When installing the oil seals "2" to the relay
""<1 arm, face the character stamp of the oil seals
.
..
installing the connecting erms "4" to the
rel'lry;,arm, face the 1 RC mark of tite.?connecting
arrns'5J,Jtside.
4-65
3
1
5
"<0< -"!>
' -2
REAR SHOCK ASSEMBLY

%,
Rear sh0%J:soabsorber assembly
upper nut
44 Nm (4.4 32 ftlbf)
Relay arm nut
61 Nm (6.1 ftlbf)
Connecting arm lower.11ut
"
55 Nm (5.5 mkgf, 40

4-66
INGARM
EASZ)W
SWINGARM
Removing the swingarm
Order
-"!> .... -"!>

' '

THE SWINGARM
1. the vehicle on a level surface. "! v
EWAt 3 120 ,s>

F! f&fiMl!S'ri ---------------------
securely StlJli?Orl the vehicle so that there is
no danger of lf4.alling over.
TIP
6
"!> Place the vehicle on 'ff:iSuitable stand so that the
v y
6"!>
'.?
rear wheel is elevated .

2. Remove:
Connecting arm lower nut "1"
Connecting arm lower bolt

TI Ph'<!- . ,----------------
Whe.Y..r$moving the bolt, hold the swingarm so
that it doe. not drop down.
v,
v
3. Me<f!?ure:
side play
movement
"
a. Measure the flg!ltening torque of the pivot
shaft nut. 6"!>
'.?

Pivot shaft niJt
110 Nm (11 mkgf, 80 ftlbf)

q'% Check the swingarm side play "A" by moving
swingarm from side to side.
l f iJ;Ie swingarm has side-to-side play, check
.s>
the sp,ecer, bearings, and dust covers.
c. Checl<i!;le swingarm vertical movement "B"
by movinb e swingarm up and down.
If the vertical movement is not
smooth or if is binding, check the pivot
shaft, collar, and dust covers.
y.?.

4.
Drive chalil>
Refer to THE DRIVE CHAIN"
on page 4-71.
Swingarm
""<1

CHECKING THE SWINGA'ftM
6
"!> 1 . Check:
'.?;; Swing arm
-?;ijends/cracks/damage Replace.
2.
Pivdl(%haft
Roll shaft on a flat surface.
Bends '1i:leplace.
EWA13770
,A WARNING
'f.
Do not attempt a bent pivot
<::>
shaft. ...,.,
3. Wash:
Pivot shaft
Dust covers
6"!> Collars
'.? ;, Washer
..
c
Recommended cleaning solvent
Kerosene
4.
Dust coveFS&1"
Oil seals "2" .s>f
Damage/wear
'%
4-68

10 ..
6 .
'
6 .
'
6 .
'
6 .
'
c
Collars "3"

Damage/scratches ->
Bearings "4" v
.s>
Damage/pitting -> Replace. <>
>

'%
12 34
4 -------"=- ,-,.
3 "0

1

EAS233!1o "'"C
INSTALLING THE
1. Lubricate: ..
Dust covers v.s>
'f
Pivot shaft <>>
Oil seals
Collars

lubricant ..
'tiithium-soap-based grease
'

2. Install:

"0
Bearings "1"
(to the swingarm)
Oil seals "2" Ollll

(to the swingarm) v _
Installed depth " a" -9
'<}>
2.0 mm (0.08 in)
Installed depth " b" '%
9.0 mm (0.35 in)
Installed depth " c"
"0(,5-1.5 mm (0.02-o.os in)
lns(aJ!ed depth " d" ' "y.?.
7.0 (0.28 in) "0
" e"
1.5-2.5 in)
0
"!>:
TIP
When installing the oil seals< fQ, the swingarm,
face the character stamp of the ciif.,Jals outside.
A. Left side
B. Right side
3. Install :
Swingarm
Pivot shaft
Pivot shaft nut
v
110 Nm (11 mkgf, 80 ftlbf).s>-9
'<}
4. Install :
Drive chain
Refer to "INSTALLING THE DRIVE CHAIN"
on page 4-73. e"b
Connecting arm lowet>.llolt
Connecting arm lower

Connecting arm nut
55 Nm (5.5 mkgf, 40' <f41bf)
Rear wheel v
Refer to "REAR SHOCK ABSORBEA, AS-
SEMBLY'' on page 4-63 and "REAR
on page 4-14. "''%
5. AdjUSt:
Drive chain slack
Refer to THE DRIVE CHAIN
SLACK" on page
"0
Drive chain
5.o-15.0 mm in)
c
'%
4-69

"l;>,.
- . . . ~
CHAIN DRIVE
6

6

6

to remove
6

REMOVING THEtl@IVE CHAIN
1. Stand the vehicle level surface.
EWAt 3 120
A wARNING
.<>>
Securely support the that there i s
no danger of i t falling over.
TIP '
Place' qne vehicle on a suitable stand t6Wlat the
rear is elevated.
2. drive sprocket nut rib "a".

Cb
a
Be sure to put on goggles when work-
. "'
mg. c:-.s>

Cut the drive chain with the chain cut & riv-
et tool.
Drive chain cut & rivet t6bl
t?' - >;, 90890-01550 "\.?.
1-'-----' YM-01550

EAS2:\4.41 .....
CHECKING THiil.JtRIVE CHAIN
1. Measure:
15-link section "a" of,the drive chain
Out of specilicatiori.s>1'-t. Replace the drive
h . >Q>
c a1n. y.?""
-
15-link length
239.3 mm (9.421n)
<t-
..
}-. .?.
a. Measl'ifG the length "b" between the
sides o(1tJE pins and the length "c" between
the outer of the pins on a 15-link section
of the drive cffilil:1 as shown in the illustration.
b. Calculate the teli'b!Jl " a" of the 15-link section
of the drive chain uSigg the following formula.
Drive chain 15-link length "a" =
y.?
'%
4-71

<t-..
c
(length "b" between pin1gner sides + length
"c" between pin outer
TIP v
When measuring a 15-link sectici1l,p,f the drive
>
chain, make sure that the drive
Perform this procedure 2- 3 times, at a
location each time.
...
1 2 3 4 1213141516
rr IT 0
':Co
(o -(<
oHo oT(o o o!5DTio ol ( 0) OJ

oo ..
c:-
.s>
a
..,
1 2 5 61213141516
. '(,_ '
IT
(o oHo
3. Clean:
'
-m

_:
oHo"'<Q)Vo oTio O) 0) OJ

b o_,.,
c

"!
c:-
.s>
"-9

y.?
'%

Drive chai'6 <t-b

., .,.,., ., .,., .,., ., .,., .,., ., .,.,., ., .,.,., ., .,., .,., .,
a. Wipe the drive {il!?in with a clean cloth.
b. Put the drive chafi<t.Jt kerosene and remove
any remaining dirt.
c. Remove the drive chal 1lJrom the kerosene
and completely dry it.
"!v
.s>
"-9

y.?
'%

<t-..

y,
'GHAIN DRIVE

co% CA1RCI403
NOnCE -------------------------
. v.s> This vehicle has a drive chain with small
1
0-rings "1" between the drive chain
plates. Never use high-pressure water
or steam, gasoline, certain solvents
(e.g., mwzine), or a coarse brush to clean
the High-pressure metqods
could or water into the ifiixe
chain's internats, and solvents will deteri'&t
rate the A coarse brush can also s. Lubricate:
damage the 0-rings. Therefore, use only Drive chain
kerosene to clean the drive chain. __ .----------------------------,
Do not soak the drive chain in kerosene for Recommended lubricant
"! v more than ten minutes, otherwise the . v Chain lubricant suitable for
can be damaged.
6
0-rlng chains
=
I
I
1
6"!>

E.AS:23460 ........
CHECKING SPROCKET
1 . Check:
Drive sprocket
More than 1/4 tooth wear -7 Replace the
drive sprocket, the rea1twheel sprocket and
the drive chain as a set.
Bent teeth -7 Replace the drive sprocket, the
wheel sprocket and the drive chain as a
s1lt
"!v
,J> 1
"-9
".(?>

.. ?,'v'"--....

\ ...
\ ..
a

b. Correct

'b

Dri ve chain roller
%
4. Check:
"' v.s> 0 -rings "1"
<?pamage -7 Replace the drive chain.
-I!)Jiive chain rollers "2"
Daf'b.,i;l ge/wear -7 Replace the drive chain.
Drive'taain side plates "3"
...
-7 Replace the &rive
chain. "!>,
yo.?. ..,h.

sprocket
'!>

CHECKl!II,G THE REAR WHEEL SPROCKET
Refer to "Ol=J.:CKING AND REPLACI NG THE
REAR on page 418.
"<1
.AS23.4&0 .....
CHECKING THE WHEEL DRIVE HUB
Refer to REAR WHEEL
DRIVE HUB" on page 4-
"

4-72

"!v
,J>
"-9
".(?>

'%

<t> ..
EA$1AC1l3
INSTALLif&,J HE DRIVE CHAIN
1. Install: v
Drive chain .s>f
.<?>

..,,
Be sure to put on safetYl!J;Pggles when work-
Ing.
0
<qrive chain cut & rivet tool
9Q890-01550
vi\f-.91550
.s>

a. When press fitting t1w connecting plate "1 ",
make sure the space the end of
the connecting pin ''2" the connecting
6
"!> plate is 1.2- 1.4 mm (O.Os-<f.'1.9, in).
'
y.?.

2
1
- --a
<? I
>y
b. After riveting, the diameter be-
tween the edges "b" connecting pin ''2"
is 5.5-5.8 mm (0.22-Q.2g>-<l{!)

y.?.

c. After riveting, make sure the space "c", which
is inside of the c8n9ecting link "3" and inside
of the connecting "1", is 14.1-14.3 mm
(0.56-0.65 in).

.s>
..................................... l1e ................................................... ...
>

CHAIN DRIVE
2. Lubricate:
Drive chain
RecommendeCflugricant
Chain lubricant for
0-ring chains '%
3. Install :

Washel>"1"
;,
Drive spr'f5ii;J<et nut "2" lmiJI
'1<..
Drive'fsprocket nut
95 mkgf, 69 ftlbf)
"'t><!

While applying the rear tighten the drive
sprocket nut.
Install washer "1" with the "a" lac-
. t "<1
1ng ou .
Stake the drive sprocket nut "2" at CO]P.UIS
in the . axle.
4.
5. Adjust:
sure to align the mark
the punch mark "b" of the
Drive chain slack
'%
4-73

<t> ..
Refer to "ADJUSTING THE DRIV!ii, CHAIN
SLACK" on page 3-16. ..
-.oS'
Drive chain slack -9
s.o-15.0 mm (0.2Q-0.591n) '>
'

'
NOTICE
A drive chain that is tog, tight will overload
the engine and other and one that y.?.
;s- 'fs too loose can skip and the swing-
arm or cause an accident. if,"el efore, keep
the drive chain slack within the si5lt.;:ified lim-
its.
-"!> -"!>

' '

'
ENGINE

"'c:-

INSPECTION ............................................................. ()_, .................. .... 5-1
THE COMPRESSION PRESSURE .............. ... 51

.............................................. ........ ........ ................ ....... 5-3
6
"!> REM6111NG THE ENGINE ........... ... 6.c
0
................. .. ... ... .. ...... .. ............ .... 5-7
THE ENGINE .. ........ ......

CAMSHAFTS .........................................................
REMOVING THE CAMSHAFTS ........... .............
CHECKING THE CAMSHAFTS ........... .................. ........... ................... 5-12
CHECKING THE TIMING CHAIN AND CAMSHAFT SI9Jl0CKET ........... 5-13
CHECKING THE TIMING CHAIN GUIDES .................. ... ..... 5-13
THE TIMING CHAIN TENSIONER ........... ... . ..... ........ 513
THE CAMSHAFTS ........................................ ........ 514

6"!> ..................................

.................. ........ .....................
THE CYLINDER HEAD .. :'.>._,., ........ ....... .............. ....... .....

CHECKING'lfHE TIMING CHAIN GUIDE'<t:XHAUST SIDE) .......... ......... 5'20
CHECKING THE CYLINDER HEAD ......... ... ....... ........ ... .. ... ..... 520
INSTALLING THE CYLINDER HEAD ........... ............. ................ 521
%

VALVES AND VALVE SPRINGS .................................... ................. ......... 522

REMOVING THE VALVES ............................................. :-1. ... ............. .... .. 523
"Y.? CHECKING THE VALVES AND VALVE GUIDES ........... >Q>.'V ... ..... 523
THE VALVE SEATS ....................... ........ 525
THE VALVE SPRINGS .............. ........ ...... . ............. .526
CHE'.1<1NG THE VALVE LIFTERS ................ ........ ........................... b., ..... 527
6
"!> THE VALVES ......... ..
6
<"
0
. . ... . ...... . .. ... . .. ... . ... .... . ......

GENERATOR AND STARTER CLUTCH ....... ...... . ................. ........ 530

REMOVING THE GENERATOR ................... ..... ....... .... ..... ... .. ... ..... 532
% REMOVING THE STARTER CLUTCH ............... .. .... .... ... .. ....... ..... .... .. 532
CHECKING THE STARTER CLUTCH . ... ............. .. ................ ........ 532
INSTALLING THE STARTER CLUTCH ..................... :f-tf 533
.
<>> INSTALLING THE GENERATOR ...................................... ()_, .................... 5-33

STARTER ..... ............................................. ........ ........... ............. 535
THE STARTER MOTOR ................... ....... ............ ... 537
6"!> THE STARTER ............................................
INSTALLII)IG THE STARTER ................................................
v..,_ .. "0 ol>..,_

CLUTCH ........................... ..................................... d;.. . .. .... ........ .... .... ... ... .... .. 539
REMOVING THE CLUTCH ........................... Cb% 542
CHECKING THE FRICTION PLATES .................... .............................. 5-43
CHECKING THE CLUTCH PLATES ......................... ............... .......... 5-43
CHECKING THE CLUTCH SPRINGS ............................

' '

6

6

6

6

CHECKING THE CLUTCH HOUSING .. .... ................. ........ ;'0 ... .. .. .. .. .. .... . 5-44
THE CLUTCH BOSS .... .... .................. .... .... ....... ............ .. 5-44
Cli,ECKING THE PRESSURE PLATE ...................................... :.Y..- .... ..... 5-44
w
CHt:<?J<ING THE PRIMARY DRIVE GEAR ............ .... .... ................. .. .. 5-44
THE PRIMARY DRIVEN GEAR ............. .... ..... ................ .
THE PULL LEVER SHAFT AND PULL ROD .. .... .................
INSTALLINt3'{.HE CLUTCH .....................................................................
<t>b 6 <t>b
6"!> "!>
SHIFT SHAFT ............. .......................................... .. ............. .................. 5-48

CHECKING THE SHfFT SHAFT .. ..... ..................... .. .. .. .. .................. .. .. 5-49
CHECKING THE STOPPER LEVER .......................... ..................... .... . 5-49
INSTALLING THE SHIFT SHAFT ...................... .... .... .... -o:"t.: ......... .. .. .. ..... . 5-49
% %

OIL P.I;JJ,JIP .. ...................... ............................................. ................... ......... 5-50
CHESKING THE SPROCKET AND CHAIN ................... ............... :f"' ..... 5-52
CHECKt NG THE OIL PUMP ........ ..... ................ ..... .... ........ ......... .......
THE RELI EF VALVE ............ ..... .... ........ ......... .... .................
THE OIL PUMP ............................ ............... ..... . 5!5!a
INSTALLING OIL PUMP ....................... .............. ........ ........ ........
6"!> "!>

OIL PAN ........................ ............................ ......... ....... .. ......... ......... ......... 5-54
REMOVING THE OIL PAN .................... ........ .... ........ .. ................ .... ...... 5-55
CHECKING THE OI L STRAINER ......... ....................... -o"'e ........... ........ 5 55
INSTALLING THE OIL PAN ......................... ........ ............ %oA ............... 5 55

CRANKCASE .................. ..................................... ........ ........ ............... .. ...... 5-56
THE CRANKCASE ................... ........ ........ .......... .. 5-57
CHECKING THE CRANKCASE ............................. ........ .......................
THE CRANKCASE ...... .......................... ........ ..................

6"!> 6"!>
'.? CONNECTING PISTONS .... .... .... ......... .... .... .... ................ .. 5-60

REMOVING THE CONNECTING RODS AND ............... .... ..... 5-61 "
CHECKING THE CYLINDER AND PISTON .............. -?
16
.............. .......... 5-61
CHECKING THE PISTON RINGS ............................. .................... 5-62
CHECKING THE PISTON PIN ......................................... o,.. '0 ................ 5-63

THE CONNECTING RODS ............................. ............ 5-63
"{, ? v
THE CONNECTI NG ROD AND PISTON ............... "' .......... 5-66

AND BALANCER SHAFT .............................................
CRANKSHAFT AND BALANCER SHAFT .................
OI L NOZZLES ............................................. ........
6"!> CHECKING THB.f:(.RANKSHAFT .................. 6"!> ........................... ........ 5-71
CHECKING THE SHAFT ............... ................ .................. 5-73

INSTALLING THE CfrANKSHAFT ....... ................

.. . .............. .. ........ 5-74 "
INSTALLING THE BALANCER ASSEMBLY .. .... .... .... ................. .... .... . 5-75

.............. ..................................... ........ ............ ............. 5-76
THE TRANSMISSION .. ...................... ........ ........... :.<:<J' ......... 5-80
Cf-l'f!r.KING THE SHIFT FORKS .................. ........ ........ ............... .... 5-80

' '

<t>.. <t> ..

THE SHIFT DRUM ASSEMBLY .............................. ...... ;q, ... . 5-81
THE TRANSMISSION ......................................................
THE MAIN AXLE AND DRIVE AXLE .......................... ..... 5"@1
TRANSMISSION .............. ..........................................

' '

6"!>

Cb

.s>
'f

y.?.

EA$1AC1506
%

15' EA$20110
MEASURING THE COMPRESSION
PRESSURE
procedure applies to all of the cyi-
"'
compression pressure in a
loss of
5. Measure:
1. Measure: Compression pressure
) Valve clearance 0u1 of specification Refer to steps (c and
v ALVE
.s>f ANCE" on page 3-5. Standard compression pressure
2. Start the engine, warm it up for several min-
5
s
3
e
0
a r/min (
15
_
3
utes, and then turn it off. kgf/cm2
1680
r/min, 217.6 psi/680
Remove:
seat M'rnJmum-maximum 6
Ft'ew r to "GENERAL CHASSIS'q;, JI page 4-1.

o kPa/680 r/min "!>,
Fuei\tank kgf/cm
2
/680 r/min,
Refer'6 "FUEL TANK" on page 7-1.

189.2-243.2 psi/680 r/min)
Air filter case
Refer to "G EN E RAL C HASSI S" on page "'"'"'"'"' "'"'"'"'"' "'"'"'"' "'"'"'"'"' "'"'"'"' "'"'"'"' "'"'"'"'"'
Air cut-off valve . a. Set the main switch to "ON".
% Refer to "AIR INDUCTION SYSTEM" on . h. With the throttle wide open, crank the engine

.s>f page 7-1 5. .s>f the reading on the compression gauge
Ignition coils "st<!bilizes.
Spark plugs
Refer to "CAMSHAFTS" on page 5-9.
'"" To the plug, remove all lg-
0. CE nition coil and fuel injector
Befor?, removing the spark pluglP,.. Jlse com- piers before crfn:lJ<ing the engine. '.?
pressedfair to blow away any dirt
ed in the spark plug wells to prevent difference in compression pressure be-
falling into the cylinders. .or tween cylinders should not exceed 100 kPa (1
4. Install: kg/cm
2
, 15 psi).
Compression gauge "1" oo,. .
v If the compression pressure is above the
.s>f Extension "
2
" .roaximum specification, check the cylinder
. Compression gauge valve surfaces and piston crown for
90890-03081
Engine compression tester Carboif-Q,eposits Eliminate. . .
. YU-33223 d. lithe conf'li!Jj!SSion pressure IS below the QJin-
Extension
6
"!> imum specifioi)tion, pour a teaspoonful of
90890-04136 gine oil into the"'Spark plug bore and
.
aga1n.

ENGINE INSPECTION
2
5-1
Compression oil applied into
the cylinder)
0
<! v
Reading
>
Higher than without Piston wear or
oil damage ---+
6
Piston, valves, a;yl in
Same oil
der head gasket JJ"lB

sibly defective ---+ Y-?s,
..
Repair.
Spark plug <\
2
13 Nm (1.3 m-kgf,
"' -..
7. Install:
lgnitiom coils
Refer on page 59.
Air cut-off 11aJve
Refer to "AtRtoiNDUCTION SYSTEM" on
page 7 15.
Air filter case

Refer to "GENERAL OlijASSIS" on page 41.
Fuel tank v.s>
Refer to "FUEL TANK" on pqge 7-1.
Rider seat
Refer to "GENERAL CHASSIS" 4 1.

y.?.

5-2
-"!>
INSPECTION

?,
ENGINIS'lREMOVAL
"

c
- ' ENGINE REMOVAL

the muffl er and exhaust pipe

<t>b
3
6
L- Order -yo.?. Job/Parts to remove Q'ty
....
1 0
2
sensor coupler bracket
2 0 2 sensor coupler 1 Disconnect.

o% 3 Muffler assembly

"! v 5 Muffler protector 1 v
- . . . ~ ?
ENGINE REMOVAL
the leads and hoses
Order to remove
Rider seat
5-4
-"!>
E N G l ~ E REMOVAL
~ ~
Disconnecting the hoses
5-5
-"!>
ENGINE R E ~ O V L
~ ~
Removing the engine
'
EA$1AC1501
REMOVING THE ENGINE
1. Loosen:
Engine mounting adjust bolt (front)
<?>y.? TIP---------------
the engine mounting adjust bolt with the
wrench "1".
shaft wrench
<?'-
Frame mount insert wrench

YM-01485
""""'"
INSTALLING THE ENGINE

1. Install :
1
Engine mounting adjust bolt (front) "1"
c&emporarily tighten)
mounting adjust bolts (rear) "2"
(temporarily tighten)
2.

3. Install : <t>
Engine bolt (rear upper side) "3"
Engine mountinif'twtt (rear lower side) "4"
4. Install : "
adjust bolts (rear) Adapter bolt (left) "5"

q, (temporarily tighten)
TIP--------------- Install :
/ Loosen the engine mounting adjust bolts with mounting bolt (left front upper side)
the pivot shaft wrench "1" and pivot shaft wrench "<".r.;
' adapter ''2".
<?>y.? Engif.!e mounting bolt (left front lower side) "7"
.s; bolt (right front lower side)
Pivot shaft wrench "8" "<>-c_
. . -'l_. 90890-01518
. TIP
!-'---""'" "! Frame spanner socket
6
;:,;,
YM-01518 "!>. Temporaril y tigme.9., the engine mounting
y: ;., "6"- 118" 51 I'.,
I<! Jvot shaft wrench adapter .?.;;,
90890-01476 6. Tighten:

Engine mounting adjust bolt (front) "1"
TIP
1
Tighten the engine mounting adjust bolt to "'
with the pivot shaft wrench.
5-7
sure that the flange on the engine
moun)JI)g adjust bolt contacts the engine .
.... -

Ehgine mounting adjust bolt
(frohtl
7 Nilil-(9.7 mkgf, 5. 1 ftlbf)
Y,
"'
Jib
Pivot shaft wrench
9089()..()1485
Frame mount Insert wrench
YM-01485
"'
7.
mounting adjust bolts (rear) "2"
'%

<t> ..
(,
TIP---....:.<t,:,-----------
Tighten the mounting adjust bolts to
specification with ll).e pivot shaft wrench and
pivot shaft wrench ad' agter.
Make sure that the on the engine
mounting adjust bolt the engine.
Engine mounting bolt
(rear)
7 Nm (0.7 mkgf, 5.1 ft-lbfY' 0
Pl'l.Qt shaft wrench
908!10-01518
socket
YM-015\11
Pivot adapter

8. Install:
Adapter bolt (right) "'9" ->-it.
tighten)
9.
mounting bolt (right front side)
"'10"

1 O.Tighten:
Engine nut (rear lower side) "'11"
Engine (rear upper side) "12"
Engine mol mJ ing nut
45 Nm (4.5 33 f11bf)
11.T1ghten:
6 Engine mounting bolt (right frO'l)l upper side)

E'hgj_ne mounting bolt (left front side)
"6"
Engine-ti'QQunting bolt (left front lower side) "'7"
Engine m6l:,inting bolt (right front lower side)
"8J'
..
Engine bolt
45 Nm 33 f11bf)

12.Tighten:
Adapter bolt (left) "5"
:,Adapter bolt (right) "'9" <t>b
.....
Jc Adapter bolt "'y.?.;,

12 Nm (1.2 mkgf, 8.7 f11bf)'

-"!> "-9
Refer to "RADIATOR" age 6-1 .
Refer to "AIR INDUCTIO on
page 7 15. """"
1 3 Disconnect.

6"!>
2
3
'
Spark plug
3
6

3
Y,

4 Cylinder head cover "

"

Cylinder head cover gasket
Timing chain guide (top side)
5-9
6
13 14
Q'ty
5-10
EA$23810
REMOVING THE CAMSHA1:;r,
"
1. Remove: <! v
Timing mark accessing bolt "1
Crankshaft end cover "2" <\
'
2. Align: .s>-9
Mark "a" on the generator rotor
(with the generator rotor cover
"

a. Tum the crankshaft counterclockwise.
4. Remove:
Camshaft cap "1"
Intake camshaft cap "2"
Exhaust camshaft cap "3"
b. When pistofl.,g1 is at BTDC12s on the
pression the BTDC12s mark "a" Remove:
on the generator"'fqJor with the generator rotor " Intake camshaft "1"
cover mark "b". Exhaust camshaft "2"
TIP TIP-------------<;Z:---
BTDC12S on the compres5in stroke can be To prevent the timing chain from the
found when the turned away crankcase, fasten it with a wire "3". v
from each other.
Timing chain tensioner "1"
Timing chain tensioner gasket
5-11
6. Remove:
Camshaft sprocket "1"

Use the camshaft wrench ''2" and the
camshaft sprocket bolt. .s>-9
.,

Camshaft wrench
90890-04162
YM-04162

.s>
CHECKING THE CAMSHAFTS
1. Check:
Camshaft runout limit
0.030 mm (0.0012 in)
f

Camshaft lobes
Blue discoloration/pitting/scratches --> Re-
the camshaft.
2. 6"!>
CarTlglaft lobe dimensions "a" amt)p"
Out of specification --> Replace the
A Camshaft lobe dimensions
y Lobe height (Intake) Cl:e..
36.29Q-36.390 mm
v.s> (1.4287- 1.4327 in) c:-6!. Measure:

36.190 mm (1 .4248 In) clearance
Base circle diameter (Intake) O'tq,2f specification --> Measure the camshaft
27.95D-28.050 mm jouiffqt diameter.
(1 .1004-1.1043 In)
Umit
6
A Cilglshaft-j ournal-to-cam-
27.850 mm (1.0965 y clearance
6
"!>
height (Ex haust) mm (0.0011-o.0024'"
35.72Q-35.820 mm in) "
(1.4063- 1.4102 in)
Ll mit c "'"' .,.,.,., .,.,.,.,.,.,.,.,., .,.,.,., .,.,.,.,., .,.,.,., .,.,.,., 'b
35.620 mm (1.4024 in) a. Install the camshaft into the cylinder head
Base circle diameter (Exhaust) (without the camshaft caps).
27.978-28.078 '!'m vii>"' Position strip of Plastigauge "1" onto the
(1.1015-1.1054 1n) journal as shown.

27.878 mm (1 .09761n) 1

5-12
:..c

"'
TIP-------------
Tighten the camshaft cap bolts in stages and in
v.s> a crisscross pattern, working frorn the inner
-9. <?> caps out.
Y,so not turn the camshaft when measuring the
journal-to-camshaft cap clearance
Plastigauge.
cap bolt "!>,.?),
1tbNm (1.0 mkgf, 7.2 ftlbf)
:..c

5. Measure:
"! v Camshaft journal diameter "a"
.s>f. <? Out of specification --> Replace the camshaft.
>y.? Within specification -t Replace the cyli nder
and the camshaft caps as a set.
it- Camshaft journal diameter
24.459-24.472 mm e'b
1--.., in)
c
Check:
.. camshaft sprocket
M>re than 1/4 tooth wear "a" --> Replace the
cam_!;laft sprockets and the timing chain as a
set.

'I .....

. <t>b
,__.--..,
1
5-13
v.s>
f.
.<?>

'%

<t>b
v.s>
f.
.<?>

'%

1

b K
. h . . h . d
. eep press1ng t e t1m1ng c a1n ro
by hand, remove the hexagon wrenBI'I. and .u.uu
slowly release the timing chain 3. Install : 'b%
c. Make sure that the timing chain tensioner ro&,; Intake camshaft sprocket "1" ..
comes out of the timing chain tensioner hous- "! v.s> Exhaust camshaft sprocket "2" v,
ing smoothly. If there is rough movement, re- -9.
place the timing chain tensioner. . Camshaft sprocket bolt
24 Nm (2.4 m-kgf, 17 ft-lbf)

EC,. IACI506 --:..0

Be sure the camshaft
bolts to the SPecified torque to avoid tft!i,
possibility of the bolts coming loose

damaging the engine.
'b

TIP----------------------------
wrench

'%

"!v
.,
.<)
-><t. p (\ -.J
6
a
"!>
'
MaEk, "a" on the generator
(with the generator rotor cover
"

a. Turn the crankshaft counterclockwise.
b. When piston #1 is at BTDC12s on the
pression stroke, align the BTDC125mark "a"
00
<1 v
on the generator rotor with the generator rotor .s>f.
cover mark "b
1
'. <>>)!'..,
'%
5-14

<t> ..

Cb
'<o 4. Install:
Exhaust camshaft "1"
0.
6' :<oTighten:
cap bolts
"' v.s> Intake camshaft "2"
'\,_, .s>f Camshaft cap bolt

Nm (1 .0 mkgf, 7.2 ftlbf)
sure the punch mark "a" on each cam-
shafi.Jpces up.
o.
the camshaft, no need to align
the mark"<' ,b" on the camshaft sprocket.
6

TIP
Tighten the cap bolts in the tightening
sequence as
'.?

%-o Lubricate the camshaft cap bolts with the
oil.
cap bolts must be tightened
eventy or damage to the cylinder head,
caps, and camshafts will result.
Do not tti1;_9. the crankshaft when installing
the camshafbto avoid damage or improper
valve
Lubricate tQ_e camshaft cap bolts with the
engine oil.

The camshaft ci!Q bolts must be tightened
IJ; evenly or the cylinder head,
"!>,.? camshaft caps, and will result.
Do not turn the cranksRaft when installing
the camshaft to avoid damage or improper

timing.
5-15
6"!>
'.?

""f,a. Check:
-ore Camshaft punch mark "a"
sure the punch mark "a" on the cam-
is aligned with the camshaft cap align-
ment<i'Jil.ark "b".

...
'f
b

9. lnSt911:
tensioner
Timing t ll!l)n tensioner gasket m1!J

a. Apply a few d' rq.es of engine oil to the inside
"a" of the timing ct}i!in tensioner.
't>b
a
6"!>
'.?

""f,
' ' --------
.Or
Cb

.s>
'f

y.?

b. While lightly the timing chain ten-
sioner rod by hai'\i. turn the timing chain ten-
sioner rod fully with a
hexagon wrench " 1".

"

CAMSHAFTS
6"!> 1
'.?

c. the timing chain tensioner rod
by remove the hexagon wrench, and
then the hexagon wrench "2" (Parts
No.: 1 into the timing chain ten-
. d "'
s1oner ro . v.s>
'f.
e. Tighten the timing ch<!ir11tensioner
specified torque.
Timing chain
10 Nm (1.0 mkgf, 7.2 ftUJ?f)
LOCTITE "
f. Screw hexagon wrench by hand until the
timing chffi\ tensioner rod touches the timing
chain guide, 'apd then tighten 1/4 turn by tool.
TIP v.s>
The timing chain teriSiOner rod is extended by
y.?
'%
516
...
<to ..

c
turning the hexagon wrench clockwiset <o

. .............................. .
10.Tum: e"b
end cover "2" =
Y.?. Crankshaft '"
(several turns
1t.Check:
Mark "a"
Make sure the mark "a" on the rotor
is aligned with the generator rotor cov&;111ark
"b" <(IS'
.
Camshaft punch mark "c"
'\,_., v'\;;, Crankshaft end cover "!>,.,
10 Nm (1.0 m-kgf, 7.2

Make sure the punch mark "c" on the cam-
shaft is aligned with the camshaft cap align-

Out of alignment Adkust.
Refer to the installation above.

'"
Timing"chain guide (top side)
Cylinder head cover gasket "1" mill

'b Cylinder head cover Cl,_
'

.s>
f

Y.r
'%

<t> ..
Cylinder head cover bolt
10 Nm (1.0 m-kgf, 7.2 ftlbf)

TIP---------'-<!,:,------
After installing the cylinder gasket "1" to the
cylinder head cover, cut off the section.
a
15.1nstall:
Spark plugs
Ignition coils " 1"
Spark plug
13 Nm (1 .3 mkgf, 9.4 ..
Tl P

Install the "1" in the direction shown
in the illustration. "
5-18
EA$24100
CYLINDER HEAD
Removing the cylinder head
EA$24120
REMOVING CYLINDER HEAD
'!>
1. Remove: "! v
Intake camshaft .s>f
Exhaust camshaft
Refer to CAMSHAFTS"
on page 5-11.
2. Remove:
head bolts
y
Looslllil the bolts in the proper as

shown.
Loosen ea!i:l:! bolt 1/2 of a turn at a time. After
all of the fully loosened, remove them.
EA$1AC1508
CHECKING TIMING CHAIN GUIDE
(EXHAUST v
. .s>
1. Check. -9
Timing chain guide side)
...
Damage/wear -4ReplaC:%

-<0

'!> ..
v
.s>
f
EA$t41$) {>>

"t>
CHECKING THE HEAD
1. Eliminate:

Combustion chamber carbof1Weposits
6 (with a rounded scraper)
Tlj9,
Do a sharp instrument to avoia?damag-
ing or
Spark plug-&ore threads
Valve

2. Check:
v
Cylinder head .s>f
Damage/scratches
'%

<t> ..
c
Cylinder head
Mineral deposits/rust
v
3. Measure: .s>
Cylinder head warpage <?>
Out of specification -4 cylinder
head.
Warpage limit
mm (0.0039 in)
,,

<t>

a. Place a "1" and a thicknes.?.
gauge "2" the cylinder head.

<7- 9089<Hl3"f.a0
1
Feeler
YU-26900-9 v
'
"b 0
a eO

b. Measure the warpage. ..
c. If the hm1t IS exceeded, res'i.'$3ce the cylinder
head as follows. <?>
d. Place a 4Q0-600 grit wet on the
surface plate and resurface the head
using a figure-eight sanding
TIP "" <t-b$;1
To ensure surface, rotate the
head several
5-20

"!v
.s>
f
.<?>

'%

<t> ..
CO...,
INSTALi!lftG THE CYLINDER HEAD
1. Install: v
Timing chaill,guide (exhaust side) "1"
Cylinder "2" mill
Dowel pins "3"

.... ,.() . :
'f
2. Install:
Cylinder head
Cylinder head bolts'M6)
Cylinder head bolts
e"b TIP
'l?;, Pass the timing chain throug t1m1ng cha1n
"
the cylinder head bolt (M9) thread
anCF1(!ating surface with engine oil.
0
3.
Cylinder nead bolts "1"- "8"
Cylinder bolts "9"-"12"
,
Cylindels.t!ead bolt " 1 " - " 8"
1st: 25 N'f1:1<(2.5 mkgf, 18 ftlbf)
*2nd: 16 mkgf, 12 ftlbf)
+90
Cylinder head
10 Nm (1 .0 mkgf, ftlbf)
RDJ!,owing the tightening order, loosen the bolt
one and then retighten it to the specific
the specific angle.
TIP
Tighten the c9)jnder head bolts "1"- "8" in the
tightening as shown and torque them
in 2 stages.
5-21
-....
y,
CYLINDER HBAD
c
4. Install :

Exhaust camshalt? ..
Intake camshaft v.s>
Refer to CAMSHAFTS"
on page 5-14.

y.?.

EA$.2-1210
VALVES AND VALVE SPRINGS
Removing t he valves and valve springs
.s>
'f
'<?>

11

<t>b
19

y.?.

14

lm16---e
Cb

2
1
<'/ \1\ l'N
4
3

c'<. 7 5

,\ >""'h . 8 -
<t>b . ,/;
6

y.?.
g

0
6 :
0

-
m oS'f<?>
r
15
'%

Q
....
<t>b
6"!>
<t>b

Order

Job/Parts to Q'ty

Remarks
Cylinder head Refer to "CYLINDER HEAD" on page 5-19.
1 Intake valve lifter

6
2 Intake valve pad
6
3 Intake valve cotter
... "'
12
4 Intake valve spring retainer v 6
5 Intake valve spring '"6,
6 Intake valve
6
"
7 Intake valve stem seal 6 Z>.,
yiS>_..,.() 8
Intake valve spring seat 6
. .,
.<>
<9,;
Intake valve guide

6 "t>,;

Exhaust valve lifter
"!>,_
6

11

Exhaust valve pad

6
"'00
12 Exhaust valve cotter
"'1 ..
12
13 Exhaust valve spring retainer
'bob 6
14 Exhaust valve spring

6
15 Exhaust valve

6
16 Exhaust valve stem seal ?v 6
17 Exhaust valve spring seat

18 Exhaust valve guide 6 >y
VA
5-22

-"!> "<0<
'.?
AND VALVE SPRINGS

%,

co EA$.2-1280
THE VALVES
c

Remov@OJ )le valve cotters by compressing the
valve sprfng,. with the valve spring compressor
"1" and the spring compressor attachment
"2" )!'..,
.
9"J;!e following procedure applies to all of the
and related components.
TIP-<> -"' "<>::--------------
Before the internal parts of the cylinder
head (e.g"?i\i;glves, valve springs, valve seats), ,.
make sure properl y seal. Valve spni'ig.compressor

1. 'b, VM-04019
Valve lifter "1" .? Valve spring corripJessor attach-
Valve pad "2" "' ment
TIP------------- %-o
Make a note of the position of each valve lifter Valve spring compressor adapter
valve pad so that they can be reinstalled in
22
mm
o .. VM-04108
original place. v
-..._
I-..._
-----.
I
5
<>" I
3 .........
i . 2

6 ---...
"!>
... , h; E!A$24290 Y'o.l<
THE VALVES VALVE

Tllecl ollowing procedure applies to all of the
valve guides.
1. Mea'we:
5-23
clearance
Out of sp9:8fication -t Replace the valve
y.?
'%

<t> ..
guide.
--;.,.
Valve-stem-to-valve-guide cf&1!ance =
Valve guide inside diameter "a
Valve stem diameter "b" <\,_
"'<

Valve-stem-to-valve-guide cle'llt,.
ance (intake)
mm (0.0004-Q.0015
in) '";,
Limit
0.080 in)
clear
0.025-o.052
in) v
Limit .s>f
0.100 mm (0.0039 in)
"'
o.
"<0< -"!>
'{-&-=:
'VALVES AND SPRINGS

%,
Valve guide position v
13.3-13.7 mm (0.52-Q.54 in) .s>f
. r.:!>
1
c
).,
<9 ""-

"'
a. Valve guide position . v.s>f
c. After installing the valve guide, bore the
guide with the valve guide reamer "3" to ob
tain the proper valve-stem-to-valve-guide
clearance.

,
Valve guide 1e!.Rover (04.5)
90890-04116 "! v
Valve guide removo/ (4.5 mm)
YM-04116 <?>y
Valve guide installer
90890-04117
Valve guide installer (4.5 mm}
6 YM-04117
VaJve guide reamer (04.5)
908:10-04118
Valve 9J.!Ide reamer (4.5 mm)
YM-04'ieJc8

.................. ............ .
3 El
. . t c,oS'
. 1m1na e: -9
Carbon deposits <?>
(from the valve face and valve
4. Check:
Valve face
-7 Grind the valve face.
Valve stertlJ}nd y.?.
Mushroom or diameter larger than
body of the va(q%Stem -7 Replace the valve.
5. Measure:
0
Valve stem runout '<o
Out of specification -7 the valve.
TIP v
When installing a new valve7 a.!, ways replace
the valve guide.
If the valve is removed or replaced, re-
place the valve stem seal.
stem runout
mm (0.0004 in)
"!>,.?

CHECKING SEATS
The following pr6'C' e.gure applies to all of the
valves and valve
1. Eliminate:
Carbon deposits v
(from the valve face and seat)
'<?>
y.?
'%
-"!>
'.?
VALVES AND SPRINGS

%,
c
2. Check:

Valve seat
"' Pitting/wear -7 Replace the
3. Measure: -9. <?>
Valve seat width "a"
Out of specification -7 Replace the cylinder"<1
head.
"t>b
Valve
Valve seat \YjS!th (intake)
0.90-1.10 In)
y.?.

Limit "'%.
1.60 mm (0.06

Valve seat width (exllctust)
1.1Q-1.30 mm in)
Limit ?c,.s>
1.80 mm (0.07 In) f.<?
>
0

b. Install the valve into the cylinder
c. Press the valve through the valve
onto the valve seat to make a clear
sian.
d. Measure the valve seat width.
TIP
6

Where the valve seat ffl)d valve face contacted
one another, the blue fluid will have been "
removed. "'%
'

"t>.
5-25
)

'%

<t>b

i
"

VALVES AND VALVE

f' '"I a

6"!>

2. Measure:
Compressed valve spring force
Out of specification Replace lfl valve
spring.

.s>
......,.
CHECKING THE VALVE LIFTERS
The following procedure applies to all of
valve lifters.
1 . Check: v
.s>
Valve lifter "-9

Damage/scratches Replace the valve lift-
"-9

b. Installed length
'% ers and cylinder head.

<t>b

?.?.

Installed compression spring
force (intake) ...,.,..
192.0G-220.00 N (19.58-22.43 THE VALVES
kgf, 43.16-49.46 lbf) following procedure applies to all of the
Installed compression spring vaKit s and related components.
force 1. Q!jiJ; w: 6"!>
end
kgf, (with a'!foil stone)
Installed length
32.90 mm (1.30 in)
Installed length (exhaust)::b
32.00 mm (1.26 in) "o,.,. "o,.,.

3. Measure:

Valve spring tilt "a"
Out of specification
spring.

Replace the valve
Spring tilt (int'!1<e)
1. 7 mm (0.07l o}
Spring tilt (exhauSV.
1.6 mm (0.06 in)

<t>
6"!>
2.
Valve slem "1"

Valve stem seal "2"
(with the recommended lubricant)

"o
Molybdenum disulfide oil

.s>
"-9

>
<0,

3. Install:
Valve spring seat "1"
o% Valve stem seal "2" 1m
"3"
spring "4"
Vai'Js spring retainer "5"
(into tl\ \';ylinder head)

Make sure e!i: valve is installed in its original
...
place. . . .. ,
6
5. To secure the valve r.olltP.rs
Install the valve wtth the larger pttch a stem, lightly tap the valve UJ'l.. JNnn
factng up.
<:>-5
>
<0,

0%

oo ..
v
.so
f

"%
b. Smaller

4. Install: <t>
Valve cotters
TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
"2" and the valve spring compressor attachment

N Jt;E
Hittin!fbt'e valve tip with
could the valve.
excessive force
lubricant
-t .. m disulfide oil
Valve lifter
6
"!> (with the recommended

Recommended lubrit ant
Engine oil
5-28

TIP- 4;;:--------------
The valv!}<ljJter must move smoothly when ro-
tated with a ligger.
Each valve valve pad must be rein
stalled in its originl!J- ,Osition.
-"!> " "
? ~
'%
~ ~ ~
to remove
Rider seat
Remarks
5-30
"<0< -"!>
GENERATo} -rAND STARTER ct,.,T'I""U
to remove Remarks
-"!>
.
GENERATOR AN'Q STARTER

EA$24$) CO...,
GENERATOR
"
1. Remove: "! v
Generator rotor"l301t "1"
Washer
.<?>

TIP
While holding the ''2" with the
sheave holder "3", loosen rotor

, Sheave holder "
r 90890-01701
r--..J 'eJimary clutch holder
'9.$:01880-A

-!>
c
2.
Generator "1"
(with the puller ''2")
Woodruff key <?
>

NOTICE
To protect the end of the c1'ill(lkshaft, place an
J PPropriate sized socket the fly-
wtJeel puller set center bolt aitc:J, the crank-

.?.
s .....
TIP
Install i Wec(lywheel puller bolts to the threaded
holes of clutch.
Make sure th\;f.lywheel puller is centered over
? '
the generator rotQF.

Flywheel
90890-01362 ".$_.
Heavy duty puller""
YU-33270-8

1

holder
'-9g890-01701
clutch holder

-!>

E.AS:2.1S10 I!J A.
CHECKING THE CLUTCH
1 . Check:
Starter clutch rollers
Damage/Wear -t Repla"' ce.s>
2. Check: <?
Starter clutch idle gear
Starter clutch gear ....
Burrs/chips/roughness/wear -t Re]:l.llce the
defectge part(s).
3. Check:<!>,
Starter d CJtqh gear contact surfaces
-t Replace the starter"
clutch gear. %-o
4. Check:
Starter clutch operail'G>.Q
"h

.!'
a. Install the starter clutch gear "1" onto the gen-
<?>

'%

"!:>.
"
GENEfmTOR AND STARTS!J CLUTCH

c
erator rotor "2" and generator rotor.
b. When turning the starter Cfatch gear clock-
wise "/l(', the starter clutch aFrf the starter
clutch gear should engage, the
starter clutch is faulty and must be
c. When turning the starter clutch gear coue.ter-
clockwise "B", it should turn freely,
the starter "iutch is faulty and must be

2
" "!>
placed. '.?

:...,,.
INSTALLING THE

1
1
key

Generator rotor "! v
.s>
Washer 1m!J
Generator rotor bolt >y.?
2 TIP
Clean the tapered portion of the crankshaft and
B
.. "l:> the generator rotor hub.
............................. u ..... ..................... u.u When installing the gen'a(lltor rotor, make sure
'.? y-? . the woodruff key is propeiiW::eated in the key-
"'"""" ' "'.?,_
nR way of the crankshaft.
INSTALLING THE S CLUTCH Lubricate the washer with enginil;oil.
1
clutch ..
1
.. Lubricate the generator rotor and
washer mating surfaces with engine
Starter clutch bolt v
2
. Tighten:
32 Nm (3.2 mkgf,

Generator rotor bolt "1"
LOCTITE .
y.?O}.
TIP
Install the starter clutch so that the side of tll'e
Generator rotor bolt
..,.
starter clutchtf811er assembly with the TIP. . . " .
mark "a" is generator rotor "2". y.?. While holdmg the 2" w1th the
While holding rotor with the '\heave holder "3", tighten ... generator rotor
sheave holder "3", tiQ@ten the starter clutch bolt.
bolts.
0

Sheave holder oo,.
90890-01701 v.s>-9
Primary cl utch holder
Y5-01880-A
7)
Sheave holder
9089()-()1701
Primary clutch holder
YS-0188Q-A
"
'if
GENERATOR AND

c
3. Apply:

Sealant
"' (onto the stator coil assembly lead gr,pmmet)
4. Install:
Yamaha bond No.1215
(Three bond No.1215)
90890-85505
Generator cover gasket 1m1!1
Generator cover e"b
Generat or cd:Y,er bolt "1"
12 Nm (1 .2 m"fkgt, 8.7 ftlbf)
LOCTITE
Generat or cover b0lt;: 2"
12 Nm (1 .2 m-k,gf, 8.7"-fllbf)
TIP
Tighten the generator cover bolts in stages.,and
in a cri sscross pattern.
Stator coil coupler
Crankshaft position sensor coupler
TIP--------,,...--------
To route the statorCQs>il lead, refer to "CABLE
ROUTING" on page

EA$2<11$0 CO...,
ELECTRIC ST A"FqER
"!
Removing the starter mo
.<>

12 Nm (1.2 m . kgl, 8.
r seat
Air scoo11/Fuel tank cover

Fuel tank
Air filter case v.s>
f .
Throttle bodies >y
1 Starter motor lead
2 Negative battery lead
-"!>
ELE'GTRIC STARTER

Refer to "GENERAL on page
41. o...,
Refer to "FUEL TANK" on e 7 1.
Refer to "GENERAL page
4 1. .s>-9
Refer to "THROTTLE BODIES" on
Disconnect.
Disconnect.
to remove
5-36
-.,_ - . . , . ~
"Q ? '
~ ~ ELECTRIC STAR'FER
~ 1 ~
/' 6
'-... ..... ;
'
',
'
'
I
I
I
I
I
EA$24XI<ib,..,
THE STARTER MOTOR
1.
Commut*-or
Dirt 600 grit sandpaper.
2. Measure:
Mica undercut
Out of specification the mica to the
6
"!> proper measurement a hacksaw blade
'.? that has been grounded to'"fitthe commutator.

Mica undercut (depth)
0.70 mm (0.03 in)
TIP
The mica commutator must be undercut to
ensure proper of the commutator.
6"!>
'.?

Cb

"' 3. Measurets-
Armature resistances (commutator
and insulatic(fl\
Out of specific3\in Replace the starter
motor.
...
6
"'- .
",.? a. Measure the armature res1stances
with the digital circuit
"'

Digital circuit tester
90890-03174
Model 88 Multimeter with tachom-
.. eter
vy u-A1927
'f.
v>

coil resistance
o.oo56!b_; Jl150 n
Insulat ion
Above 1 M t 20 oc (68 F)
"""
,,_
6"!>
'.?
If any resistance is out of"specification, re-
the starter motor.

Cb

.s-
'-9
'.(?>
y.?

ELECTRIC
6"!>
'.?

1. resistance
2. lnsuliftl@n resistance

Cb

-!>
4. Measure: v
Brush length "a" .s--9.
holder set.
Brush overall
12.0 mm (0.47
Limit
6.50 mm (0.26 in)

spring force
out "bJ specification brush

spring f orce
y N (615-665 gf,
oz)
.5'

6. Check: v
Gear teeth .s-f
the starter motor.

5-37

<t-.. <t-..
q,
7.
Bearin\;,.
Oil seal v.s>
Damage/wea r,>4 Replace the starter motor.

EAS2C&:O
ASSEMBLING MOTOR
1 . Install:
6"!> Brush holder set
Insulator "1"
;, -? .

l ffst.g.ll the insulator as shown in the illustration.
1
6"!>
... , yo.?.

Install: "
! m,gar cover "1"
Sl'aJ3er motor yoke "2"
"3"
TIP "6,.
Align the marks "a" on the starter motor
yoke with the nia!fh marks "b" on the front and
rear cover.

Y'-"
INSTALLING THE'SJ:ARTER MOTOR
1. Install:
Starter motor "1"
<t>
6"!> Negative battery lead
Starter motor bolts "3"
"
lnsw,)l the negative battery lead as shown in the

motor bolt
f2'._Nm (1.2 mkgf, 8.7 ftlbf)
....
-....
ELECTRIC
5-38

CLUTG.I;j

'o "
%
EA$25061
CLUTCH

.s>

2
12 Nm (1.2 m kgf, 8.7 It - lbf)
->Q der Job/Part s19,remove
Engine oil
1 Clutch cable
2 Cover
3
0 2 sensor coupler bracket
4 Clutch cover
5 Clutch cover gasket
l\l t2 Nm (-\,2m kgf, 8.7 It lbf) I
Q'ty Remarks

1
Refer to "CHANGING THE ENGINE Oil:' on
page 323.

0%
Disconnect.

oo,.
v
.s>

Order Job/Parts to remove -it.. Q'ty
1 Circlip "!> %1_,

3 Pull lever spring 1
Remarks
4 Circlip
5 Pull lever shaft
6 Oil seal
__ ,_ ____________________________
8 Bearing -9 .sof

'%

11 10
simi
8
R THE CLUTCH
1. v
Cover "1" .s>-9
Clutch
Gasket
TIP
Loosen each bolt 1/4 of at a time, in stag-
e'!> es and in a crisscross
all of the bolts are fully remove

"
.:e:.
y
Remove:
pump driven sprocket "1"
to "OIL PUMP" on page 5-50.
6"!>

7.
Clutch "1"
TIP
While holding the boss "2" with the univer-
sal clutch holder "3" :'roSJsen the clutch boss nut .
.. n
Universal clutck.,P.older
9089()..()4086
YM-91042
"'
5-42
)

'%
Conical spring washer
Washer
Clutch boss
Thrust plate
Clutch housing
Oil pump drive chain

Cb
%
<>>

'%

<t>b

y.?.
A. plate 1
B. Fricti on plate 2
E!A$2l$111
CHECKING THE CLUTCH PLATES

v The following procedure applies to all of the
.s>f clutch plates.
1. Check:
'% Clutch plate

EAS2SIOO
CHECKING THE FRICTIQN PLATES
-) Replace the clutch plates as a
.<>

The following procedure ap'(sl!e,s to all of the fri o-
iron plates.
1. Check:
Friction plate 1, 2
Damage/wear -) Replace the plates
2. Masure: 6"!>
Clut2ft"Qiate warpage
(with a J' Urtace plate and thickness "1")
Out of specification -) Replace the
plates as a set.

as a set.
2. Measure: "! v
.s>

"!v
.s>
)fb
Thickness gauge
9089()..()3180
Feeler gauge set
Friction plate 1, 2 thickness <>
Out of specification -) Replace the friction
'% plates as a set.
YU-26900-9
TIP--------------
,.<t>b Measure the friction four places.

Friction plate 1
y 2.92-3.08 mm (0.115.r.0.121 in)
Wear limit
2.82 mm (0.111 in)
Friction plate 2 thickness .
2.92- 3.08 mm (0.115-Q.121 Ffi:)v
Wear limit
2.82 mm (0.111 in) !<>>
"

Clutch plate thickness
. 'l, .
1.90-2.10 mm (0.075-Q;.083 in)
y Warpage limit
mm (0.004 in)
"'

'%

<t>
"' "" 6"!>
v:> '
E.AS:2S\40 Y'...?. .., h.
CHECKING THE CLUTCH SPRINGS

The following procedure applies to all ot' 4Pe
clutch springs.
1. Check:

Clutch spring %,.
''9
'<}>

Damage -) Replace the clutch springs as a v.s>f
set. <>>

c
2. Measure:
0
%
Clutch spring free length ..
Out of specification -t Replael the clutch
springs as a set.
Clutch spring free length
52.50 mm (2.07 in)

Limit
3. Check:
Bearing
Damage/wear -t
clutch housing.
""""' 60
CHECKING THE CLUTCH BOSS
1. Check:
49.1Ul mm (1.96 in) Clutch boss splines 6"!>
'-------"-' ''""r- ---------' Damage/pitting/wear -t>-Replace the clutch
..
' '
'0
EA$25150
CHECKING TH{j,CLUTCH HOUSING
1. Check: '.?
Clutch housing
Deburr the clutch
housing dogs or clutch housing.
TIP
Pitting on the clutch housing will cause er-
ratic clutch operation. v.s>f
0%

2. Check:
oo ..
v
.s>
Oil pump drive sprocket "1"
>
Pitting on the clutch boss splines w11bcause er-
ratic clutch operation.
0
%
Pressure plate "1"
Cracks/damage -t Replace.
Bearing "2"
Damage/wear -t Replace.
1
Cracks/damage/wear -t Replace.
""<1 .....,,.
CHECKING THE PRIMARY DRIVE GEAR
1

<t>b 1. Check:
Primary drive gear
6"!>
y.?.

' Damage/wear -t ReplacE!{P.e crankshaft and
clutch housing as a set.
Excessive noise during operati&F;), -t Replace
the crankshaft and clutch housinQ'&,li a set.
"0

.s>
''9

y.?

<t> ..
PRIMARY DRIVEN GEAR
1. Check: v
Primary drivEff\l .a ear "1"
Damage/wear 4,J3eplace the clutch housing
"'
and crankshaft as
Excessive noise duriifg.operation 4 Replace
the clutch housing and as a set.
b

y.?.

1
EA$25220 .()
CHECKING THE PULL LE'fR SHAFT AND
6
"!> PULL ROD
'.? .J!,. Check:
lever shaft pinion gear teetfl "1"
teeth "2"
Damq_J:!e!wear 4 Replace the pull rod and
as a set.

.s>

1
6"!>
'.?

2. Cheek:
Pull
DamageM ew 4 Replace.
"f
EAS2S2-CO () >
INSTALLING THE
1 . Install: . ''"
Oil pump dnve cha1n
6
Clutch housing "2"
"!>, TIP
the oil pump drive chain orito/ the oil pump
dnlle'!lprocket "a".
2. Install :
Thrust
Clutch boss
Washer
"' conical spring wasti
1
@ti\
Cl utch boss nut "3"
'
" Clutch boss nut
125 Nm (12.5 ftlbf)
LOCTITE
= "
"!>
TIP '
Install spring washer on the ffiain
axle with mark "a" facing away from
the vehicle.
While holding boss "1" with the uni
versal clutch tighten the clutch boss
nut. v.s>
Stake the clutch boss nu1,_pt cutouts "b" in the
...
main axle.
Universal clutch
<7- 6 9089()..()4086
t---"'', YM-91042
.?.
5-45
>
1:> ..
3. Install:
Friction plate 1
Clutch plate v.s>
Friction plate 2 <?>
TIP Yv
First, install a friction plate and then alternlit!1
between a clutch plate and a friction plate.
Install the last plate "1" offset from the 1:-b
other friction making sure to align a
,,;,..1r;,.,n plate with the punch
4. Install:
Bearing
(into the pressure plate)
Pull rod"1"
Pressure plate "2"

1:>

pins
Clutch cover gasket mill
Clutch cover
Cover
Clutch cover bolt
Clutch springs
Clutch spring bolts "3"
12 Nm (1.2 mkgf, 8.7 ftlbf)

Yv
'%

Clutch spring bolt TIP---------------
10 Nm (1.0 mkgf, 7.2 ftlbf) "o>
1
Apply engine oil onto the bearing.
Tighten the clutch cover bolts in stages and in
Oil pump "4"
Oil pump sprocket bolt
15 Nm (1 .5 'fn.kgf, 11 ftlbf)
LOCTITE

Tighten the clutch spring bolts in and in
a cnsscross pattern.
Apply lithium-soap-based grease onto 'ih9. pull
rod. '%
Position the pull rod so that the teeth "a"
towards the hole "b". Then, install the clutch
cover.
6
"!>
/
a crisscross pattern. 6
'6:.>-tJnstall : /v
Pull lever

Install the pull lever with the "0" mark fa;s::ing to-
ward lower side.
When installing the pull lever, push the puW4t-
ver and check that the punch mark "a" on
pull lever aligns with the mark "b" on the clutch <?>
Yv

cover. Make sure that the pull rod teeth and '%
pull lever shaft pinion gear are engaged.

5-47
~
5-48
6"!>
'.?

A$2tl&)1
THE SHIFT SHAFT

1. Install: o%
Shift shaft Sj:ffjng stopper "1"
Shift shaft
ol'
Stopper lever "2"
Shift shaft sp'tl.ng stopper
22 Nm (2.2 m Kgf 16 ftlbf)
LOCTITE
<t>

Ho6\_the end of the shift shaft sprirf\}''3" onto
the si11f!,_shaft spring stopper "1".
Hook of the stopper lever spring "2"
onto the s&P.Per lever "4" and the crankcase
boss "5".
Mesh the with the shift drum seg-
ment assembly. -9. <>
>
2. Install :
Bearing
Oilseal lm
Washer "1"
Circlip "2" 1m
TIP---------"!:,_ __ _
Lubricate the oil seal lithi-
um-soap-based grease.
Lubricate the outer periphery of the oil
the sil i fluid.
5-49
EA$2>1Q21
OIL PUMP
Removing the oil pump
Disassembling pump

.s>
f.
1
4
5
10
Order Job/Parts to re.reove O'ty Remarks -><t,.
2

3
Oil pump cover "!>

4
5
6
7
8
9
10
Circlip
"!
Washer .s>
Relief valve
Dowel pin 2
5-51
Hold down the washe
circlip.
removing the
"!
EA$25820 CO...,
CHECKING THE AND CHAIN
1. Check:
Oil pump drive sprocket
Refer to "CHECKING THE 6 1t!}TCH HOUS-
ING" on page 5-44.
2. Check:
Oil pump drive chain "1"
--+ Replace the oil
drive and oil pump drive
(clutch houS:iJJg) as a set. "
" 1
\

c::s.J
"'"'""
CHECKING THE OIL PUMP
1. Check:
Oil punw driven gear "1"
Oil pumP'.I:!ousing "2"
--+ Replace the defec<'
live part(s).

Cb

1
.s>
f
.

6"!> 2
l',h; yo.?.
2. Measure:

lnner-rotor-to9e..Yter-rotor-tip clearance "a"
Outer-rotor-to-o(f@ump-housing clearance
''b" 0%
Oil-pump-housing-to:'lnper-rotor-and-out-
er-rotor clearance "c" v.s>
Out of specification --+ Rej3iage the defective
part(s).
""<1

<t>b

y.?.

clearance v
Less than 0.120 mm (O.if0,47 in)
'
0.20 mm {0.0079 in) .?'\,
Outer-rotor-to-oil-pump-housing"<1
clearance
0.09-Q-19 mm (0.0035-0.0075 In) <t>b
"'-
Umit ",, ..,
" II y...?.
0.21 mm
in)

ner-and-outer-f' ator clearance
O.IMHJ.13 mm (0:Q..Q24-0.0051 in)
Limit
0.16 mm (0.0065 in)

1. Inner rotor
2. Outer rotor
3. Oil pump housing v.s>
f
3. Check: <>>
Oil pump operation
Rough movement --+ Repeat steps (1) <fn-li!
(2) or replace the defective part(s).
<t>b

y.?.

5-52
6"!>
'.?

I!; A-
CHECKING THE RELIEF VALVE
1. Check: Cb%

3. Check:
Oil pump operation
Refer to "CHECKING THE OIL PUMP" on
page 5-52.
oo ..
v
oS' """"""'
THE OIL PUMP
1y:?4t)stall :
Spring "2"
Damage/wear 4 Replace the oil pump as-
sembly.
2
EAS2$010
ASSEMBLING THE OIL PUMP
1. Lubricate:
2. Install:
Outer rotor "1"
:/
.s>-9 Inner rotor "2"
<>> Pin ''3"
y.?
Oil pump cover "4"
Oil pump cover screw

011 pump cover
3.8 Nm (0.38 ftlbf)
)-.
TIP .,
Align the pin "3" in the oil pump shaft the
groove in the inner rotor "2".
Oih,gump "1"
Oil PQ.[OP bolts ''2"
"'"
"'ai! pump bolt
6
"!>,
(1.0 mkgf, 7.2 ftlbf)

Oil pump driven sprocket "3"

011 pump driven sprocket bolt
0
%
15 Nm (1.5 m-kgf, 11 ft-lbf)
LOCTITE <!v
NO lCE
the oil pump drive chain and
driven "'$p.rocket, make sure the oil pump
turns 6"!>
TIP .?%
1 RC mark of the oil pump driven sprocket is
stalled at oil pump side.
.s:
Install the oil pump drive chain onto the oil Cb%
pump driven sprocket.
"!v
.s:
EA$1AC1W
OIL PAN
Remarks
on page
on page
5-54
' EA$2>1W
Engine oil drain bolt REMOVING THE OIL PAN
<! v 1. Remove: 43 Nm (4.3 mkgf, 31 ftlbf)
.s>-9 Oil level switch "1"
. Oil pan "2"
Oil pan gasket

each bolt 1/4 of a turn at a time, in stag-
es anifq@, a crisscross pattern. of the
bolts are loosened, remove them.

nghten the
cri sscross palttern

Lubricate the oil switch 0-ring with lithi-

0%

oo ..
v
.s>
'-9
um-soap-based grease.
1
'.(?>

Oil strainer "1"
Damage -+ Replace.
Contaminants -+ Clean with solvent.
1
INSTALLING THE OIL PAN
1. Install:
Oil pan bolt
Oil switch "2"
-
Oil level switch bolt

,
Engine oil drain bolt "3"
0
%

<!v <!v
oS' oS'

5-55

<to.. <to ..
2
to remove
5-56
EA$25550 CO...,
DISASSEMBLING
1. Place the engine &lawn.
2. Remove: .s>f
".(?>
Crankcase bolts

TIP
Loosen each bolt 1/4 of a tum at a ti;i:le, in stag-
es and in a crisscross pattern. After the
bolts ar@, ttJIIy loosened, remove them.
Loosen in the proper sequence
shown. "
The numbers on the crankcase in-
dicate the tightening sequence.

6"!>
3.
Lower
CA13$00 ,
NOTICE
Tap on one side crankcase with a
soft-face hammer. on reinforced
portions of the on the crank
case mating surfaces. Work slgwly and care-
fully and make sure the halves
separate evenly.
4. Remove:

5.
Crankshaft JQ.wnal lower bearing
.
TIP
Identify the position of eatitp,art very carefully so
that it can be reinstalled in place.
-"!>

E.AS2'56&0 CO...,
CHECKING THE
1. Thoroughly wash the crankcase9wlves in a
mild solvent. .s>f
2. Thoroughly clean all the gasket
crankcase mating surfaces.
3. Check:

Crankcase
Cracks!damage
6
w Replace.
Oil delivery passageQ
Blow o'!:JJ with compressed air.

E.AS:2S6SO ....
ASSEMBLING THE
1. Lubricate:
Crankshaft journal bearing inner
(with the recommended lubricant) t,>.
Engine oil
2. Apply:
6
Sealant
(onto the crankcasEf.l'pating surfaces)

Yamaha bond N'o, 1215
(Three bond No.1'2<1,5)
9089().85505
.,
v
TIP------------"o;,---
<tob

y.?.

Do not allow any sealant to come into !lntact
with the oil gallery or crankshaft journal
ings, or balancer shaft journal bearings.

3. Install :
Dowel pins
<tob

y.?.

...
v
.s>
'-9
'.(?>
Lower crankcase "1"
(onto the upper crankcase "2")
CA13$80
________________________ _
B'4Uore tightening the bolts, make
transmission gears sl\jtt correctly
shift drum assembly ii -twned by
hand.
6"!>
'.?

Crankcase bolts
TIP 6
Lubricate the bolts "1"- "8"' thread, mating
?o faces and washers with engine oil.
v.s> Lubricate the bolts "9"- "12" thread, mating sur "! v.s>
<?> faces and 0-rings with engine oil. . <?>
Y.? Lubricate the bolts "13"- "30" thread and mat- Y.?
Crankcase bolts " 1 " -"6"
1st: 25 Nm (2.5 m-kgf, 18 tt-lbf)
2nd: 15 Nm (1.5 m-kgf, 11 ftlbf)
3rd: +60
Crankcase bolts " 7"-" 8"
1st: 25 Nm (2.5 m-kgf, 18 ftlbf)
*2nd: 18 Nm (1 .8 m-kgf, 13 ftlbf)
3rd: +60
ing surfaces with engine oil.

x 100 mm (3.94 in) bolts with washers: * Followirl'q_the tightening order, loosen the bolt
"8" mill 6"!> one by then retighten it to the
M8'vJ:' 85 mm (3.35 in) bolts will), washers: torque. Yv. '.?
mill EWA1FICIS04
M8 x 78 mm (3.07 in) bolts with new '&. i ings:
"9"- "12" If the crankcase bolt is tightened more than
'b "
M8 x 60 mm (2.36 in) bolts: "13", "14" % the specified angle, do not loosen the bolt
0
%
1o M6 x 85 mm (3.35 in) bolt: "18" and then retighten it. Instead, replace the ..
v.s> M6 x 65 mm (2.56 in) bolts: "15", "16" v.s>crankcase bolt with a new one and perform <
<?> M6 x 65 mm (2.56 in) bolt: "26" procedure again.
M6 x 50 mm (1.97 in) bolts: "17", "19"-"21", _________ _
"23"-"25", "27"-"30"
M6 x 40 mm (1 .57 in) bolt: "22"
<t>b

y.?,

Do not a torque wrench to tighten the
to the specified angle. 6"h
>
TIP Yv, .?
Tighten the bolts the tightening sequence
on the crankcase.

5-58
0%

'<!(

'%

8.
Crankcasi:l""'lts "9"-"30" y.?.

Crank"e\ se bolts " 9"-"14"
24 Nm mkgf, 17 ftlbf)
Crankcase'b.Rits " 15" - " 30"
10 Nm (1.0 ITt>J.<gf, 7.2 ftlbf)
"!
.s>

Tighten the bolts in the cast
on the crankcase.
5-59
EA$1AC1503
Job/Part s to
.

ROD'S AND PISTONS

-
3

;..
'b
.

RODSAND PISTONS

'

.s>

3. Remove:
Top ring
2nd ring
Oil ring
TIP----------------------------

v 2. Remove:
Piston pin clips "1"
0%)(\'hen removing a piston ring, open the end gap
\liiiij) your fingers and lift the other side of the ring
oveYJhe piston crown.
o<J
Piston pin "2"
+tfiston "3"
ECA1
Do not a hammer to drive the piston pin
out. Y.?.

TIP
;..c For reference during installation, put
lion marks on the piston crown. 'b%
Before removing the piston pin, deburr the pis-
"'v ton pin clip groove and the piston pin bore ar-
ea. If both areas are debarred and the piston THE CYLINDER AND PISTON
pin is still difficult to remove, remove it with the
1

1
'liston pin puller set "4". 1ston w-5 1
"'& Cylinder
._ p t
11
t Vertical Replace the cylinder,
'b IS on pm pu er se d
1
h't;;,
1
d 1
<?'-

6"!> an rep ace t on an p1s on nngs as a 6"!>,
pin puller set.
vtl-01304

2. Measure: "

Piston-to-cylinder clearance
................................................................................................ .....
" c;
Measure cylinder bore "C" with the cylinder

gauge.
--------------------------
bore "C" by taking side, to-side

"%
5-61
...
<to ..
b
'.?

c
front-to-back measurements of the cylinder.
find the average of the measurements.
.n
> Bore
78.00o-78.010 mm
SQ.0709-3.0713 in)
limit
(0.0020 in)
Out o I"Qy nd limit
0.050 n1m,J0.0020 In)
"
"C" = maximum of D
1
- D
6
,Taper limit = maximum of D
1
or D
2
- maxi-
'Thl!:-m of D
5
or D
6
limit = maximum of D
1
, D3 or D
5
- D
2
, D
4
or Ds

c
following formula.
--:...
Piston-to:Bygnder clearance = Cylinder bore
"C" - Piston sRjrt diameter "P"
'A

clearance
0.01 o-o.035 mm (0.0004-o.0014
in)
Limit

0.150 mm
out of spec1ficat1on, replace the cylinder,
al'i"breplace the piston and piston rings as a

..,
"' ......................... ..................................................................... ....
'f
<> >
CHECKING THE RINGS
1 . Measure:
Piston ring side cleara-liJ,ce
6.,_ Out of specification the piston
v 'Q
'.? y.?. '.? and piston rings as a set. Y.?.
- - -
"l,
...--n, -----.._ measuring the piston ring side clearance,
' - I?_ - - - - any carbon deposits from the piston
ring and piston rings.

/
D Piston ring
b. If 60.1. of specification, replace the cylinder, v Top rf' ng
and the piston and piston rings as a Ring clearance
set. <:).._,1! mm (0.0012-o.0026
c. Measure skirt diameter "P" with the mi-
crometer.
6
"!> 0.115 mm (o.o8l\,5, in)
Piston '.? 2nd ring -y-?
00
Diameter Ring side clearance "
77.975-77.990 mm %-o o.o2o-o.os5 mm (0.0008-0.0022
(3.0699-3.0705 In) in)
Limit
mm (0.0045 in)
b
'.?

a. 12.0 mm (0.47 in) from the bottom edge of
the piston
of specification, replace the piston and
nngs as a set.
e. the piston-to-cylinder clearance
y.?
'%

"!:>.
' '
y y
CONN'fiCTING RODS AND PJSTONS

(' 'li!F.' --------------- C),
u;fe;the piston crown to level the piston ring near pin outside diameter
" 1'6._!}9G-16.995 mm
bottorf\s.of cylinder "a", where cylinder wear is

in)
lowest. -9. -<?> Limit <?>y
3. Measure:% 16.970 in)
Piston ring gap
Out of specifi6\lion ---+ Replace the piston
6 .
"b '
TIP Y

The oil ring expander spacer's end gap cannot
be measured. If the oil ring rail's gap is exces-
replace all three piston rings.

z
,M. Toprlng
v f End gap (installed)
1--....,.. -<?> 0.15-0.25 mm (0.0059-0.0098 in)
f:!l,mlt
mm (0.0197 in)
2nd
End gajS] Installed)
0.30-0.4S:.mm (0.0118-0.0177 in)
Limit
0.80 mm (O.OJ151n)
Oil ring
End gap (installed)
0.10-0.40 mm (0.0039-0.01571n)
6"!>
'.?

Cb
Upper of cylinder

CHEctqNG THE PISTON PIN
The folloWipg procedure applies to all of the pis-
ton pins.
1. Check:

.so
f
.-<?>
3. Measure:
Piston pin bore "b"
Out of specification 4 the piston.
6
"!> Piston pin bore diameter
17.002- 17.013 mm
1--"!>r ? -'-' (0.6694-0.6698 in)
Limit
6"!>
'.?

17.043 mm (0.6710 in)

%.0
4.
Piston:,Sigtopiston-pinbore clearance
Out of 4 Replace the piston pin
and piston set.
A
Piston-pin-to-pistomwn-bore clearance =
Piston pin bore insid meter "b" Piston
pin outside diameter
.<>.
Piston pin
6"!> Blue discolorati(;fJJrooves 4 Replace the 6"!>
'.? piston pin and then 'BQ,eck the lubrication sys-

;;a
'
2. Measure:
Piston pin outside diameter "a"
Out of specification 4 Replace the piston pin.

.so
f
.-<?>
y.?

<to ..
clearance

0.007-0.023 mm (0.0003-0.0009

in)
v .
E!AS1AC1!KU %
CONNECTING RODS
1. Measure: v.so
clearance
5-63
y.?

<to ..
6

6

6

6

"

CONNECTING RODS AND PIS:(ONS

c
Out of specification 4 Replace big end
bearings. ..

c
plastic-region tightening angle method. A\,
ways install new bolts. ..
v
.s>
Oil clearance .s>f TIP---------------
0.027-Q.051 mm (0.0011-Q.002if-. Clean the connecting rod bolts and lubricate
f
.<?>
y.?
?e.

in) the bolt threads and seats with molybdenum
disulfide oil.

The following applies to all of the
connecting rods. '.?
':1 ECA13000
Do not interchange the big end
connecting rods. To obtain
crankshaft-pin-to-big-end-bearing
ance and prevent engine damage, thl!f.s>plg
end bearings must be installed in their
?e. nal positions.
a. Clean the big end bearings, crankshaft pi ns,
and the inside of the connecting rods halves.
b. Install the big end bearing into the con-
necting rod and the big eb,9. lower bearing into
" the connecting rod cap.
TIP
Align the projections "a" on the big"egd bearings
with the notches "b" in the connectirt&rod and
connecting rod cap. .. v
tl.f1ake sure that the projection "a" on the con-
rod cap faces the same dlwction as the
"Y" mwk "b" on the connecting rocfo? h
After the big end bearing,
the connecting rod and connecting cap
without installing them onto the
6"!>
'.?

TIP
0
Install by carrying out the following procedureS;tp
order to assemble in the most suitable

.s>

e. Tighten the connecting rod bolt while check-
f
<?> ing that the sections shown "a" and "b" are
f
.<?>
y.?
c.
flush with each other by touching the surface.
Connecting rod bolt

TIP ''<>y
To insta'il the big end bearing, care be
taken not to install it at an angle and the Pbeition
should not be out of alignment.
a. Side machined face
b
6"!>
'.?

0

b. Thrusting faces
"0

I. Loosen the connecting rod bolt, remove the ..
connecting rod and connecting rod cap and v.s>
install these parts to the crankshaft with the '9 <?>
y.?

.

RODS AND PISTONS

'
"! v.s> Do not move the connecting rod or crankshaft
-9. <?> until the clearance measurement has been
a
sure that the projection "a" on the con-
neq ng rod cap faces the same direction as the <t.. t-
"Y'' "b" on the connecting rod.
6
\ /.
Make the "Y" marks "b" on the c<fflaecting 1ao
rods face -?fg,wards the left side of the
shaft. ew ......
A WARNING

If the connecting rod bolt is tightened more
the specified angle, do not loosen the
bQJt and then retighten it. Instead, replace
the.s> cconnecting rod bolt with a new one and
procedure again.
ECA I 55
NOTICE

00 not use a "fcuque wrench to tighten
connecting rod bal$ to the specified angle. "!>,.?
;,
j. After the installatiolt, check that the section

Connecting rod bolt (1st)
shown "a" is flush with each other by touching
the surface.
o,

"!v
.s>f h. Put a mark "1" on the corner of the connecting
<?>y rod bolt ''2" and the connecting rod cap "3".

r-- 2

6
it\--- 'lb,.?
\

k. Remove the connecting rod and big end
bearings. .

"! v i. Tighten the connecting rod bolts further to
.s>f reach the specified angle 17s- 1as.

Connecting rod bolt (final)
Specified angle 175- 185
1. Measure the compressed Plast1gauge

.. width on the crankshaft pin. If the crank-
clearance is out
select replacement big end

.
RODS AND PISTi$\MS
'

'
"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'l-4..,...,. INSTALLING THE CONNECTING ROD AND
S I
<!v PISTON <!v
2. e ect: .s> .s>
Big end bearings (P -P ) -9. The follow1ng procedure applies to all of the con- -9. <>
TI P
1 3
nect1ng rods and pistons.
Install :
The numbers "fl(' stamped into the crankshaft end bearings
web and the numbers "1" on the connecting rod cap
<t>b rods are used to determJ9e the replacement <-;,

big end bearings sizes. "!>,, ( om0$e connecting rod)
6
"!>
TIP Y
!i'1"-"P3" refer to the bearing\ shown in the Be sure to"reinstall each big end bearing11;! its
crankshaft illustration. '\ .. original place. %-o
For example, if the connecting roiii"c.f
1
" and Align the projections "a" on the big end
the crankshaft web "P { numbers are 2 ings with the notches "b" in the connecting rods .
respectively, then the bearing size for and connecting rod caps. v
"P " (connecting rod) "P " (crankshaft) = 5 k' Make sure that the projection "c'' on the con- .s>-9. <>
2 3 (brown)
1
necting rod cap faces the same direction as the
"Y" mark "d" on the connecting rod.
Bearing col or code
1. Blue 2. 3. Brown 4.
Green "!>,

p, p. p,
1
2. Tighten:
Tighten t he connect ing rod bolts using the
pl aS\igregion t ightening angle method. AI
ways fn.!all new bolt s. 6"!>
TIP >:>;,
Install by cafrying out the following in
order to assemble in the most suitable conditidi\,

'b "
% TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
0
%
v a. Replace the connecting rod bolts with new v
.s> ones. .s>
-9. <>> b. Clean the connecting rod bolts and lubricate -9. <>

5-66
...
<t> ..
-"!>
.
RODS AND PlSTONS

bolt threads and seats with molybdenum
Oil,
c. Aftef.ipstalling the big end bearing, assemble
the c61ieecting rod and connecting rod cap
.>
without install ing them onto the crankshaft.
d. Tighten the rod bolt while check-
ing that the sl ctions shown "a" and "b" are
6
flush with each by touching the surface.
"!> .,,<,
' -
'\ Connecting rod.,bolt

30 Nm (3.0 mi<gf, 22 ftlbf)

'\IP-----------
the big end bearing, care should be
takei'P.pot to install it at an angle and the position
should Yiot be out of alignment.
a
b
6"!>

' ..

a. machined face
.s>
b. faces
>
e. Loosen tffa<Bonnecting rod bolt, remove the
connecting Fa9., and connecting rod cap and
install these to the crankshaft with the
big end bearing in the current condition.
6"!>
?., h.

3. Install:
Oil ring expander "1"
0
-:;.J,.ower oil ring rail "2"
oil ring rail "3"
2nd <ri,Pg "4"
Top nn1J;'5"
(into the
TIP "
Be sure to piston rings so that the
manufacturer's numbers "a" face up.
6"!>

4. lnSl<!)l:
Pist6Tf,).'1"
(onto connecting rod "2")
Piston
"' Piston pin clips.;'4" 1m
TIP
Apply engine oil ont<f.\Qe piston pin.
:'kar
Make sure that the "Y" .. ''Q,.k "a" on the connect-
ing rod faces left when thE!:Ji1unch mark "b" on
6
the piston is pointing up as sl'tgwn.
"' ,! nstall the piston pin cl ips, so ttf&tjhe clip ends
3 mm (0. 12 in) "C:' or more froffi>Jhe cutout
in fife
b
1
6<'!
s.., Lubricate:

rings
Cylinder
(with lubricant)
lubricant
-.
'.6
6. Offset:
6"!>
'.?

Cb
a. Top ring '<o
b. 2nd ring ..
c. Upper oil ring. (cijl
d. Oil ring expande.(
e. Lower oil ring rail
""<1
A. Exhaust side

;z. Lubricate:
pins
C' o{lnecting rod big end bearing inrfey surface
recommended lubricant)
lubricant
-t
8. Install: &.s>
11
Piston
(into the cylinder "2" onto the crankshaft
pin)

Piston installing
90890-04161
YM-04161 .?.;;,
.. "
CA1RCI$02 o/

11 the " a" of the piston installing
tool damages, y;o8 cannot use it. Please han-
dle with care. .s>
11
>
TIP Y,
Fit the projection "a" of installing tool
"3" and blunt-edged part

the cylinder, fix
Jtle position of the piston installih!l, tool, and then
p'i:l)lh the piston up to the
9. Install : ,
Connecting
Connecting rod bdlf!ic,
TIP
Make sure the "Y'' marks
11
a('.s>on the connecting
rods face towards the left of the crank-
shaft. y.?
Make sure that the projection the con-
necting rod cap faces the same directf0,e as the
"Y" marts,"a" on the connecting rod.
Apply t\Je!lt,bdenum disulfide oil to the
threads anlh,eats.
b

1 O.Tighten. '.?
bolts "1"
a. Tighten the connecti1\'g, .&od bolts with a torque
wrench.
.s>
''9

y.?
'%
'

<t> ..
-"!> "<0<

CONNEOl;ING RODS AND PISTONS

& Connecting rod bolt (1st)
"! v 20 Nm (2.0 m-kgf, 14 ftlbt)
.s>
b. Put a mari0J" on the corner of the connecting
rod bolt "2" .l:'r'llbthe connecting rod cap "3".
2
6"!>
'.?

I
"'v
c. T1ghten'Wle connecting rod bolts further to
reach the angle 17s-1as .
EWAI$4100
.?.
rod bolt (final)
17s-1as
"'
A wARNING
6"!> If the connecting rod Is tightened more
'.?;, than the specified angle,YI(jo not loosen the

bolt and then retighten it. "Instead, replace
connecting rod bolt with a new one and
the procedure again.

[NOTtf EJ:
Do not u!le: a torque wrench to tighten the
connecting bolt to the specified angle.
d. After the check that the section
shown "a" is flustfw,j.th each other by touching
6
the surface.
EWAIACI 503
... ,h; )!'...?.

If the connecting rod and cap are not flush
each other, remove the connecting rod
boll$. and big end bearing and restart from
In this case, make sure to replace
the conngctlng rod bolts.
%,
5-69
Removing the crankshaft and balancer shaft
7
2
1
Orti )J Job/Parts to remove Q'ty "oo Remarks
"
? v 2 Balancer shaft journal lower bearing
.s>f 3 Balancer shaft journal upper bearing
4 Crankshaft
Y.;>
5 Crankshaft journal lower bearing
6 Crankshaft journal upper bearing

Lower crankcase Refer to "CRANKCASE" on page 5-56.
______
RODS AND PISTONS" on page 5-61 .

Balancer shaft 1
'-! 2 <!.:
2
5-70
%(6

REMOVING THE CRANKSHAFT AND
BALANCER SHAFT
1. Remove:
.s-
"-9
<?>y Balancer shaft "1"

Balancer shaft journal bearings
assembly "2"
"'@,cankshaft journal bearings
TIP
6
Identify of each balancer shell jour-
nal bearings and crankshaft journal so
that it can be reinstalled in its original
6"!>

EAS1RCI !iOS
CHECKING THE OIL NOZZLES
2. Check:
Crankshaft journal surfaces
Crankshaft pin surfaces
vo Bearing surfaces
oS'
--t Replace the crankshaft.
3.

nal-bea'FiQ9 clearance
Ou1 of --t Replace the crank-
shaft journaltlgarings.
6
"!>,
Y.. \/h.
Journal.'8i1 clearance

0.014-0.038 mm (0.0006-0.0015
In)
The following procedure applies to all of the
%(6 nozzles. eCAomo
v 1. Check: ____________ _

<? Oil nozzle "1" D<r. ,&ot interchange the crankshaft journal
Damage/wear --t Replace the oil nozzle. bearf1:!,2s. To obtain the correct crank-
Oil passage shaft-jO'tynal-to-crankshaft-journal-bearing
_,9bstruction --t Blow out with compressed air. prevent engine damage, the
.. -it.b crankshaft 1ii1Jlrnal bearings must be in-
stalled in their'li.rjginal positions.
6
"!>,
yo.?. /', i h.

a. Clean the crankshaft journal bearings, crank-
shaft journals, and bearing portions of the
crankcase.
%" .. b. Place the upper crankcase upside down on a
c:-
.s- bench.
oo ..
c:-
.s-
CHECKING THE CRANKSHAFT "-9
".(?
1. Measure:
Crankshaft runout
of specification --t Replace the crank-
l;laft.
b ""
5-71
c. 11(Jstall the crankshaft journal upper bearings
...
"1"' V{IJ!d the crankshaft into the upper crank-

TIP
Align the "a" on the crankshaft joy r-
nal upper bearinQ\with the notches "b" in the
per crankcase.

c/oS'
'f.
'<?>

'%
nal-bearing clearance is out of specification,
select replacement crankshaft journal bear-
ings.

<t>b

)!'...?. /',

d. Put a piece of Plastigauge
each
crankshaft journal.
TIP
Do not put the Plastigauge over the oil hole
the crankshaft journal. "! c-.so
-9. J Select:

0
journal bearings (J
1
-J
4
)

The 'fil.!,mbers "A" stamped into the crankshaft
web aif4; the numbers "B" stamped ir;!tO the
lower cralrk.case are used to determine re-
placement journal bearing
"J
1
"- "J
4
" refer"to the bearings shown in
crankshaft and lower crankcase illustration. %-o
0 t2 (J) !(.
e. Install the crankshaft journal lower ..
If "J
1
"- "J
4
" are the same, use the same size for
all of the bearings.
'<!c/

c/.so " 1" into the lower crankcase and assemble c/.so For example, if the crankcase "J { and crank-
'f. <?> the crankcase halves. -9. <?> shaft web "J{ numbers are 7 and 2 respec-
TIP then the bearing size for "J
1
" is:
Align the projections "a" of the crankshaft jour-
nal lower bearings with the notches "b" in the
c/oS'
'f.
'<?>
<t>i)Rwer crankcase. e
o'b,_Qot move the crankshaft clearance
meif:Surement has been
"J
1
- "J
1
" (crankshaft web) -1 = 7
- 2 - 1
-<'I>

Bea'I'JJ19 color code
O.White 1.Biue 2.Biack 3.Brow.;"'',
4.Green
., 'jl b
CJ (\ 6<b r
f. the bolts to specificati6l),in the tight-
enPrlg sequence cast on the
Refer to "CRANKCASE" on page
g. Remove the lower crankcase and the
shaft journal lower bearings. '<o
h. Measure the compressed
width "a" on each crankshaft journal. c/.sof
If the crankshaft-journal-to-crankshaft-jour- <?>

'%
5-72
...
<t> ..
Balancer shaft runout limit
0.030' t!lm {0.0012 in)

.so
y,
2. Check: f. f;}
Balancer shaft 1ob(rnal surfaces
Bearing surfaces ..
Scratches/wear ReJ?Iace the balancer
6
shaft.
"!> 3. Measure:
'l? Balancer shaft journal-to-balalli:lllr shaft jour-
bearing clearance "
0 6t-oof specification Replace the balancer
shaif1Qurnal bearings.

1ournal to balancer
t>
shaft bearin'g-plearance
0.024-{).048 rl\m (0.0009-0.0019
in) <?>

Do noj interchange the balancer sifa,.tt jour-
nal beHrmgs. To obtain the correct bal\Qcer
shaft-joufn.al-to-balancer shaft-journal
ing clearan'f:'e%, and prevent engine damage,
the balancer journal bearings must be
installed in their 8-liili! inal positions.
z-

a. Clean the balancer sti:9ft journal bearings,
balancer shaft journals, anljj bearing portions
of the crankcase.
b. Place the upper crankcase down on a
bench.
c. lnsf9)1 the balancer shaft lournal bear-

ings -tl),and the balancer shaft into the "l:rp.se,er
"
TIP ""
Align the projecfi\(ns "a" on the balancer shaft
journal upper with the notches "b" in the
upper crankcase.

.so
'f
'<?>
yl?

5-73

<to ..
"
AND BAUt'\!CER SHAFT
0.
e. Install the balancer sl'tft journal lower bear-
ings "1" into the lower cl1ifjkcase and assem-
ble the crankcase halves. v.s>
TIP

0.
If "J(- " J
2
" are the same, use
size for
all of the bearings.
Align the projections "a" of the shaft
journal lower bearings with the notcf!l{ "b" in
the crankcase.
For example, if the crankcase "J," af'ic;J bal-
ancer shaft web "J ( numbers are 5 anci
spectively, then the bearing size for "J ( is: '%

"J
1
" (crankcase)- "J
1
" (balancer shaft web) =
Do not mo,Y.e the balancer shaft until the 5 - 2 = 3 (brown)
6,
<t>b

ance measYlf$ment has been completed.

'
Bearing
y.?.

1
.0
0.
'\ 0%
a
oS'f (
t 0

f. Tighten bolts to specification in the
ening seque'Ace cast on the crankcase. Refery.?.
to on page 5-56.
g. Remove the and the balanc-
er shaft
h. Measure the Plastigauge
width "a" on each journal. If the
balancer shaft-journal-to-t:i aJancer shaft-jour-
nal-bearing clearance is out obpecification,
select replacement balancer journal
bearings.

'-
1

y.?

4. Select:
journal bearings (J
1
-J
2
) ..
TIP "b
The stamped into the
shaft web and trie numbers "B" stamped into
the lower crankcas'if&re used to determine the
replacement balancer'S9lft journal bearing siz-
es.
"J
1
"- " J
2
" refer to the bearing$:-shown in the bal-
ancer shaft and lower crankclse,dllustration.
>
y.?

1.Biue 2.Biack 4.Green
5.Yellow
<1_
""-
INSTALLING THE
1. Install : '.?
Crankshaft journal
(into the upper
Crankshaft journal lower beatif!gS
(into the lower crankcase)
0
Qo
Crankshaft ..
TIP v
Align the projections "a" on the crankshaftj_g,ur-
y.?
'%
5-74

'%

"!:>. "!:>.
"<0< -"!>
'v>
CRANKSHAFT AND SHAFT

%,
c
nal bearings "1" with the i're&tches "b" in the
crankcase. ..
Be sure to install each crankshaft(fQ.urnal bear-
ings in its original place. <?>
Balancer journal upper bearings
(into the upper crankcase)
Balancer jour{lal lower bearings
(into the
TIP
Align the & n the balancer journal
bearings "1" with the "b" in the crank-
cases.
Be sure to install each bearing
in its original place. v.s>
2. Install:
Balancer shaft
-"!> "

to remove Remarks
Collar
Bearing
Circlip
Drive axle
Drive axle assembly "1"
Shift drum retainers "2"
Shift fork guide bars
Shift fork-L
Shift fork-A
Shift drum%sembly
Shift fork-C '";,
2. Remove: 6"!>

,_,,.
CHECKING THE SHIFT
The following procedure applies to the shift
forks.
1. Check: v
Shift fork cam follower "1" .s>-9
Shift fork pawl "2"
Bends/damage/scoring/wear -7 Replace
shift fork.

Bearing "1"
y.?.

Main axle assem.tJiy "2"
...

a. Insert two bolts "3"-ot!!, the proper size, as
shown in the the main axle
assembly bearing
2
1
2. Check:
Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends -7 Replace. 6"!>
b. Tighten the bolts until
case surface.
c. Continue tightening the
axle assembly comes free
crankcase.
)!',?, EWA1281 /'< h;

Do not attempt to shift fork
guide bar.
6"!>
,.,

3. Check: ,_
Shift fork movement
(along the shift fork guide bar)
Rough movement -7 Replace the 'StJift forks
and shift fork guide bar as a set. v
.s>
'-9

y_,

5-80

<t> ..
..
3 19-0\\
'
EASleJ.!O Y'
THE SHIFT DRUM Y
1. Chifuk:
Shift drtu;n groove
c,
4 Replace the shift
drum
Shift drum segri;!ent "1"
Damage/wear the shift drum as-
sembly.
Shift drum bearing "2"
Damage/pitting 4 shift drum as-
6 sembly.
"b ..
... ,h; yo.?.

2 . f
.<}
1 y.?
'%
"<1
EAS2e280 ..... ,.()
CHECKING THE
6
<h Measure:
v y
l'ain axle runout
(Jitl$1 a centering device and dial gKuge "1 ")
Out 6f>ejlecification 4 Replace the main axle.
i.'tai!J axle runout limit
v (0.0032 in)

2. Measure:
Drive axle
(with a and dial gauge "1")
>
y.?
'%

5-81

c
Out of Replace the drive axle .
. ?>
Drive axle run6yt limit
0.08 mm
. <},
1
3. Check: v.s>-9
Transmission gears <>>
Blue Replace
the defective gear(s).
Transmission gear dogs
Cracks{damage/rounded edges 4 A'e:p) ace
the de&Qtive gear(s).

0 X 0 X "

4. Check:
Transmission gear engagement
gear to its respective
gear) .? ;, y.?.

Incorrect _,.,. 1,F.eassemble the transmission
axle
s. Check:
Transmission
Rough movement -) the defective
part(s). .s>f
6. Check: <>>y
Circlips .?'%
Bends/damage/looseness 4

""""""" .
ASSEMBloiNG THE MAIN AXLE AND
AXLE

1. Install :
Toothed
Circlip "2" 1m
TIP "0
Be sure the circlip comer "a" is
positioned opposite side t<i'\l;le toothed washer
and gear. <>>y.?
'%

)
'.?

Align the opening between the ends "b" of the
with a groove "c" in the axle.
the circlip so that a spline "d" is in the
of the gap between the circlip ends "e"
2 1
a
b
c
e
A. Main axle

A. Main axle
'<o B. Drive axle

2?- Jnstall: v
lock washer retainer "1" 2. Install : .s>f
To8lbJ.d lock washer "2" Main axle "1"
TIP Bearing
With the rofi)thed lock washer retainer in the "'
groove "a" in"\tle axle, align the projection on Bearing bolt
, the retainer with
0
'3Jil, axle spline, and then 1
2
Nm (1.2 8. 7 ft-lbf)
2
'.? the toothed lock '.? LOCTITE -<:>y.?""

Be sure to align the projection on the toothed
lock washer that is between the alignment
marks "b" with the alignment mark "c" on there-

<v
oS' oS'

5-82

"!:>. "!:>.
6"!>
'.?

Install:
fork-C "1"
l;)b.ft drum assembly "2"
Sh1ft4,ork guide bar "3"
TIP <!
The marks on the shift forks should
face towards tbt right side of the engine and be
in the following "R", "C", "L".
Carefully position th.g shift forks so that they
6
are installed the transmission
"!>, gears.
.? Install shift fork-C into the "a" in the 3rd
and 4th pinion gear on the main axle.
6"!>
'.?
4. Install:
Shift fork-R "1"
fork-L "2"
Sb)f.t fork guide bar
Shiff1Q.rum retainers "3"
Bearirilt .so
Oil seal Dm!J
Circlip "4" q
Drive axle "5"
Shift drum""q:tainer bolt
6"!> 10 Nm (1.0 7.2 ftlbf)
crankcase.
s. Check:

"d" on the shift fork guide
shift drum retainer.
the?.dlive axle bearing circlip "4"
hroovels "e" in the upper
Transmission v.so
'-9
Rough movement -"'>Jlepair.
TIP y.?
Oil each gear, shaft, and thoroughly.
LOCTITE

shift fork-R into the groove "a" in the 5th
gear and shift fork-L into the groove "b"
in thJ -&!h wheel gear on the drive axle.
Install ti<eso shift drum retainer with its "OUT'
mark "c" faCiJSl9 outward.
y.?
'%

<to ..
5-83
-"!>
)!'...?. ... ,

0.
COOLING

RADIATOR ...................... ............................................. -:;-.:;;_ ..................... ........... 6-1
CHECKING THE RADIATOR ............... ........ ........... , ................ .......... 62
INSTALLING THE RADIATOR ....................... ................ .," ......................... 62

................... ........... .. ........ ................. ............. 6-4
THE OI L
>- INSTALLING THE OIL COOLER.. . .. .................... ........ ............................ 65

THERMOSTAT .. .............. ............................. .. ........... .. ............... .. ........... 6-6

CHECKING THE THERMOSTAT ...... .... .... .. .. ................. .... .... .... .... ........ 6-7
INSTALLING THE THERMOSTAT ASSEMBLYc/
0
, .. .. .. .. .. .. .. .. .. .. .. ................ 6-7

WATER PUMP ................. ..................................... ............ . ................ ........... 6-8
DISASSEMBLING THE WATER PUMP .......................... '\, ........ .... .... .... . 6-10
THE WATER PUMP .. .... .... ................. .... .... .... .. .. .. .. .. ..... 6-10
THE .. ..................... .... .... .... ..... .. .. .. .. .. . 6-10

f

y.?

y.?.

EA$28SEIO
RADIATOR
Removing the radiator
8
Coolant Refer to "CHANGING THE
page 326.
RADIATOR

co%
CHECKING THE RADIATOR
v 1. Check:
.s>-9 Radiator fins
. <?>>Qbstruction Clean.
compressed air to the rear of the radia-

Repair or replace.
TIP 6
Straighten fins with a thin, flat-hea$f
d. " "
screw nver. b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
Cb
%

4. clfe-e":
..
Radiat9J fan
Replace.
Check and repair.
. Refer to co<YI:)J'JG SYSTEM" on page 8-27.
A
>V<9: 6 E!A$21!1400 >V<9:
"!>,.? INSTALLING THE RADIATOR
2. Check: 1. Fill:
Radiator hoses Cooling system
Radiator pipes (with the specified amount of the recom-
Cracks/damage -4 Replace. coolant)
3. Measure: to "CHANGING THE COOLANT' on
"'v Radiator cap opening pressure page.s>3-26 .
<? Below the specified pressure -4 Replace the 2. ChecW.<?
>YJgdiator cap. Cooling
Leaks -4 R'e"Qair or replace any faulty part.
, Radiator cap opening pressure
93.3-122.7 kPa (0.93- 1.23 .,.,.,.,.,.,.,.,.,.,., "\"""""""""""""""""""
1--..., 13.5-17.8 psi)
6
a. Attach the tester "1" and radiator
"!> cap tester adapter the radiator.
V'J.!
.,.,.,.,.,.,.,.,.,., .. 'Y''I''I''I''I''I''I''I''I''I''I''I''I''I''I''I''I''I''I''I' ' Radiator cap
a. Install the radiator cap tester "1" and radiator <?' -
9089
o-o
13
25
cap tester adapter "2" to the radiator cap ''3". .o Mityvac cooling system tester kit
% Radiator cap tester
YU-24460-A
v <?'- 90890-01325 oo.. Radiator cap tester adapter
.s> Mityvac cooling system tester kit v.s> 9089()-()1352
<?> YU-24460-A ,iressure tester adapter
Radiator cap tester adapter
""<1 90890-01352
tester adapter
"t-bYU-33984
i$>/.._
c
pressure.

c. Measure the in1!lts;ated pressure with the
v
gauge. .s>
''9
'.(?>
't
3. Measure:
Radiator cap opening
the specified pressure fitgg lace the
cap.
Relei-'- <tl], "CHECKING THE RADIATOF.l}; on
page

Cb
%

oo,.
v
.s>
''9
'.(?>

'%

<t>b

?.?.

6-3

OIL COOLER
v
to THE ENGINE Olt: on
323. .
6-4
Cb
,..,...., '<o 3. Fill:
CHECKING THE OIL COOLER Cooling system
1. Check: v.s> (with the specified
Oil cooler <?> mended coolant)
. Cracks/damage Replace. Refer to "CHANGING THE COOLANT' on
2. Check: page 3-26.
Oil cooler inlet hose
Oil cooler outlet hose .. the specified amount of, the recom-
Replace. engine oil)
Yo.?.
7
" h. ..?. N,.. 0
Refefs.!.o "CHANGING THE ENGI 1!?% IL" on
INSTALLING THE OIL page 3-23.
1. Clean: 4. Check:
Mating surfaces of the oil the Cooling system Cb%
crankcase Leaks Repair or replace any faulty part.
(with a cloth dampened with lacquer Refer to "INSTALLING THE RADIATOR" on v.s>
2. Install: <? page 6-2. <?
0-ring 1m 5. Measure:
Oil cooler "1" Radiator cap opening pressure <
Washer "2" 1m Below the specified pressure Replace the
Oil cooler union bolt "3" .. -'r-adiator cap.

""., to "CHECKING THE RAtl!)t-TOR" on
.., Oil cooler unioll>J?_olt e
' 35 Nm (3.5 ftlbf) pag

TIP
Before installing the oil cooler, oil o%
lightly to the oil cooler union bolt and ajgly lith-

ium-soap-based grease to the 0 -ring. . v n .s>
u ''9
Make sure the 0 -ring is positioned . <?>
Align the projection "a" on the oil cooler with
slot "b" in the crankcase. <
After installing the oil cooler union bolt, bend
...
the tab "c" of the <t>b

y.?.

1
,

Reri:lpving the thermostat assembly
'.(?>
_)
--(Djl v ---
\ I
"'\ 2
\ ___ \ '
Order -yo.?. Job/Parts to remove Q'ty

THERMOSTAT
1

Mulrler assembly

Refer to "ENGINE REMOVAL" on page 5-3.
",_
..., Drain .
Coolant Refer to "CHANGING THE COOLANT' on
'b% page 3-26.

v 2 Water pump inlet hose
''13 Oil cooler outlet hose Discor'l ect.
4 Thermostat assembly
EA$264.50 CO...,
CHECKING THE"\il!ERMOSTAT
1. Check: v
Thermostat
Cracks/damage Reptas.e.
'%

<t>b

6"!>
'.?

1
, . .,....,

Cb
%

oo ..
c:-
.s>
. ..,
INSTALLING THE THERMOSTAT
ASSEMBLY
1. Fill:
Cooling system
(wj!h the specified amount of recom-
mer.u1, ed coolant)
"CHANGING THE COOLANlr on
page 3-26- i\
2. Check:
Cooling
Leaks replace any faulty part.
Refer to "INSTALLifl:j.G THE RADIATOR" on
page 6-2. .., <?>
3. Measure:
Radiator cap opening presS\3&2
Below the specified pressure the
radiator cap. ..<t>b
Rel.er to "CHECKING THE RADIAi:QR" on
"'J.r.. .?.
page'".ii l

"%

oo ..
c:-
.s>
. ..,
'.(?>
y.?
'%

<t>b

y.?.

THERMOSTAT
6-7
EA$26500
WATER PUMP
Removing t he water pump
1
Job/Part s
Coolant
Q'ty
6-8
Remarks
Refer to "CHANGING THE COOLANT' on
page 3-26.

WATER
water pump
1m
8
4

Q'ty
6-9
EA$26520 CO...,
WATER PUMP
1. Remove: "! v
Mechanical seal (hollSjng side) "1"
TIP <:'>
Remove the mechanical se'fib (housing side)
from the inside of the water "2".
.<>.
2. Remove:
Bearing "1"

"!v
.s>
1 f

'%

2

Oil seal "2" <t>

TIP "b
Remove e oil seal and bearing from
side of the ter pump housing ''3".
6 1
"b,

3
3.
seal (impeller side) "1"
(from the f"'2_peller, with a thin,
screwdriver)

TIP
Do not scratch the impeller shaft.
flat-head

WATER PUMP
E.A$216641 CO...,
CHECKING THE WATER
1. Check: <!v
Water pump housing cover "1".s>-9
Impeller "2"
Cracks/damage/wear --> Replace. '%
Water pump housing "3"
Cracks/damage/wear --> Replace the
pump
l',h; yo.?.

3
1.
2
2. Check:
Bearing 6"!>
Rough --> Replace.
3. Check:

Water pump inlet
Replace.

E.AS26660
ASSEMBLING THE WATER fS4!JIP
1. Install : .s>f
Oil seal "1"
1
Bearing "2"

'%

(into the water pump housing "3")
Installed depth "a"
o.Sh;! .O mm (0.02-Q.04 In)
;,
TIP

"
Install the oil seal with lt6!ocket that matches its
outside diameter.
a
I
1mi!J

%
2. Install :
Mechanical seal (housiifg,side) "1" Dm!l

NOTICE "!
6-10
c
with oil or

TIP
Use the special tools and" press to press the
mechanical seal (housing side1 straight in until it
touches the water pump housirfl<>
'"
Mechanical seal
90890-04078
1-'---' pump seal installer
"
Miatlje driven shaft bearing driver
90800-04058
Middle 8!;j,ve bearing installer 40 &
50mm
6"!>

YM-04058 <!v
.s>
A
+
3

. . 11m!

. "'%o

2. Water pump housing v.s>
3. Mechanical seal installe1 <?>
4. Middle driven shaft bearing

A. Push down
...
3. lnstgll: ::::....
seal (impeller side) "1"
TIP
Before instaTiil?.JI the mechanical seal (impeller
side), apply or coolant onto 1ts outer
surface.

If the top of the seal is dirty, clean
. v
II. .s>
4. Measure:

"!v
Impeller shaft tilt
Out of specification steps (3) and

'%

"!:>.
6-11
-"!>
WATER PUMP

Cb
(4).
ECAIAC160CI
NOTICE <!v
Make sure the mechanical
side) is flush with the impeller.
Impeller shaft tilt limit
0.15 mm (0.006 in)

V.
FUELSYSTEM

TANK .......................................................... ........ ............... ()-' .. ............ .... 7-1
THE FUEL TANK ..................... ................. ........ ... ......... 73
THE FUEL PUMP ........................... ........ .............. '%l ... ...... 73
THE FUEL PUMP BODY ................................ ... 73
6
"b THE FUEL PUMP ................................ . -3
,._, CHECKI I'J&,THE ROLLOVER VALVE (I&!? California only) ............ .........
INSTALLIN<fo3(J;HE FUEL PUMP ............. ............................. .........
INSTALLING THE FUEL TANK .................. .......... ........ ......... .......... 7-4

v :::: :::: ::: :::
.s>-9 REMOVING THE FUEL HOSE (FUEL RAIL SIDE) .......... :R'-v ................... 7-8
THE INJECTORS ....................................... ....... .... .... .... .... . 7-8
O.t;j,ECKING THE INJECTORS .................................................
AND CLEANING THE THROTTLE BODIES ............. ,;. ........ 7-8
REPLA.QING THE THROTTLE BODIES ............................................ '\,-.7-10
e"b INSTALL'ING THE INJECTORS .......... .... .... ........ ................................
CHECKIN<fvJ;HE INJECTOR PRESSUFfu;; ............................................. t "'\,ll

CHECKING lliE FUEL PRESSURE .......... ...................... ..................
INSTALLING THE FUEL HOSE (FUEL RAIL .. .............................. 7-12
ADJUSTING THE THROTTLE POSITION ............................... 7-12
ADJUSTING THE ACCELERATOR POSITION ....................... 7-13

"'v
dl .!'
AI!' INDUCTION SYSTEM .. ................................. .................... ... ... .. ... ... ... 7-15
-l!;(HECKING THE AIR INDUCTION SYSTEM .... ..................... ::-., ........ ...... 7-18
INTALLING THE AIR INDUCTION SYSTEM ............... ............ .......... 7-18
' '

e"b

'!>"
v
.!'
''9

. ..,
'%

<t>b

'.?.

EA$26820 CO...,
FUEL
"!
'll.lf. scoop/Fuel lank cover

Refer to "GENE& AL CHASSIS" on page
4-1. o...,
1 Fue se connector Disconnect
2 Fuel puropn coupler Disconnect
3 Fuel tank b:e ther hose Disconnect
f.
4 Fuel tank draitii(!.lose Disconnect
5 Fuel tank
6
7 Fuel pump
<t>
"!> 8 Fuel pump gasket

Wire harness assembly temperature
sensor) "
10

Air scoop stay (left)
11
'IY.ire harness assembly (headlight relay/fuse
o6 ! /radiator lan motor coupler)
12 Air stay (right)
7-1
FUEL
Removing the rollover valve and California only)
to remove Remarks
Rider seat
EA$1AC1101 co E.A$216640
REMOVING THE FUEL TANK REMOVING THE FUEL PUMP
1. Extract the fuel in the fuel tank thratl,gh the 1. Remove:
fuel tank cap with a pump. .s>f Fuel pump
2. Remove: <?>Y ECA,.,.
Rider seat NOTICE --:-----:----------
Air scoop/Fuel tank cover Do not drop the fuel pump or give It a
R -<>
<t>b efer to "GENERAL CHASSIS" on page 4-1. -><t, strong shock.
3. Disconnect:
6
"!>, not touch the base sectR;IJI of the fuel
Fuel hose (fuel tank siCfeJ 'l?;,
Fuel pump coupler

Fuel tank drain hose EAll"""""
Fuel tank breather hose CHECKING THE FUEL PUMP BODY
EWAIRClJW
0
% 1 . Check: co%
:-:---- Fuel pump body
Cover fuel hose connection with Obstruction --) Clean. v.s>
when disconnecting them. Residual pte.s- Cracks/damage --) Replace fuel pump as- -9 <?
A wARNING
sure in the fuel lines could cause fuel sembly. "Yl?
spurt out when removing the hose. .,..,..,.
THE FUEL PUMP OPERATION '
f' t>& heck: 6
Be sure to disconnect hose by hand. pump operation "b,l?
" Do not forcefully disconne$:t the hose with to "CHECKING THE FUI%6 PRES-
tools. SURE" on page 7-1 1.

Tl p Cb EA$1AC1118 .... c
To remove the fuel hose from the\l$ll pump, CHECKING THE ROLLOVER VALVE (for

slide the fuel hose connector cover "fR .pn the California only) v
end of the hose in the direction of the 1. Check: .s>f
shown, press the two buttons "2" on the Rollover valve "1" <?>
of the connector, and then remove the hose. Damage/faulty --) Replace.
Before removing the hose, place a few rags in . '
the area under where it will be removed. that a1r flows smoothly only in the direc-
It is prohibited to cotton work gloves ilq_Q_ of the arrow shown in the
or equivalent coverings:l?;, The-J.ollover valve must be in ai\'1'.1J?right posi-
_______ bon checking the airflow.
.

co

2
<t>b
6"!>
y.?. 4. Remove: 'l?
Fuel tank
TIP
Do not set the fuel tank down the instal-
lation surface of the fuel pump is under
the tank. Be sure to lean the fuel an up-
right position. v
.s>
.s>
'f
'<?>
yl?

'
'\v, Fuel

4.0 Nm (0.4g .. m-kgf, 2.9 ft-l bf)
TIP
Do not damage the of the
fuel tank when installing the
Always use a new fuel pump
Install. the fuel pump gasket so that th"&1jp side
turns fo!t'e inside of the fuel tank. y.?.
Install pump as shown in the
tion.
Align the proje'e!jon "a" on the fuel pump with
the slot in the bracket.
Tighten the fuel pumJi>., bolts in the proper tight-
ening sequence as sh.dwn.

A. Forward v
...
"-9
EAS1AC1104 ,
INSTALLING THE FUEL TA"N-l
1. Connect:
Fuel hose (fuel tank side)
CA1RCI?()8

When the fuel hose, make sure:tJ)at
it is securtl,y connected, and that the fuel
hose cover on the fuel hose is in
the correct posiii9n, otherwise the fuel hose
will not be proper!Y1i [!stalled.
TIP v
Install the fuel hose onto the fuel
pump until a distinct "click" isJ!;jeard.
To install the fuel hose onto fuel pump,
slide the fuel hose connector colfat> "1" on the
end the hose in the direction arrow
h

S '<>y
It is proKIQ.ited to wear the cotton work
or equivaiS'r'l.,t coverings.
"!>,

2. Connect:
Fuel tank breather
Fuel tank drain hose 'b%
Fuel pump coupler ..
1
c:-
...
"-9

'%

<t>b

y.?.

-"!>
,_,
THRO{TLE BODIES

Order
on page
7-5
- . . . ~
y . ? ~ THROTILE BOuu:::: . .,
Removing the sensors
Remarks

6 .
'
6 .
'
6 .
'
6 .
'

THR&TILE BODIES
6

Cb Cb
EA$1AC1106
CHECKING THE INJECTORS (BEFORE
<! v REMOVING)
.s>f 1. Check:
"<}
">$ Injectors
.s;l!;le the diagnostic code numbers "36"- "38".
R1lfer to "SELF-DIAGNOSTIC FUNCTION
ANif"'tJ,AGNOSTIC CODE TABLE" on page
9-5. 6"!>
)!'...?. /',
EASIAC1710
may cause the fuel to spray out. Place
or rag under the hose to catch
any-1uel that spills. Always clean up any
spilt immediately.
Turn switch to " OFF" and discon-
.
nect the battery lead from the bat-
tery terminal '&e.J.ore removing the injectors.
1 . Remove:
Throttle bodies
Fuel rail "1"
6

Cb

REMOVING THE FUEL HOSE (FUEL RAIL
SIDE)

Remove the fuel rail bolts "2" as shown.
1. Remove:
Fuel tank
<!v.s> Refer to "REMOVING THE FUEL TANK" on
page 7-3.
2>& Remove:
hose (fuel rail side)

Be sure the fuel hose bY'<4Jand.
Do not disconnect the hose 'with
tools. "
6
TIP %-o
To remove the fuel hose from the fuel rail joint, .. u ,u . ,u .. u,,u,u .. u ,u.
slide the fuel hose connector cover "1" on the
"'v.s> end of the hose in the direction of the arrow CHt:g KING THE INJECTORS
'9 <>> shown, press the two buttons "2" on the sides 1.
>@J the connector, and then remove the hose.
remov1ng the hose, place a few rags in Obstruct10l3 Replace and check the fuel
the under where it will be removed. pump/fuel system.
It is prllbl bited to wear the cotton Deposit Rej)}ace.
or equiva&.at coverings. "!> Damage Replap.g.
i$0 ' 2. Check: y.?.
"t Injector resistance
6
%-o Refer to "CHECKING THE FUEL INJEC-
Cb-A TORS" on page 8-1 11.
v o%

<! v.s> CHEgKING AND CLEANING THE THROTILE
'9 <>> BODl e-!;)
TIP .<>>,
Clean the iffrgttle bodies only if they cannot be
1 2 synchronized llsj.ng the bypass air screws. Be-
4
,..,.w., fore cleaning the 1tJ_rottle bodies, check the foi-
REMOVIN&.;i"HE INJECTORS
6
"!> lowing items:
ewAIACI101 "" Valve clearance
___________ Spark plugs "
6 Check the injectors in a well-ventilated Air fil ter element
.0
Cb free of combustible materials. Make sure Throttle body joints
that there is no smoking or use of electric
hose
"! v tools in the vicinity of the injectors. system
.s>'9,; Be careful when disconnecting the fuel Cylin1.pr head breather hose
Any remaining pressure In the fuel >

"
.<) 7-8

<t> ..
fh'r,pttle bodies are subjected to strong
shocks ,$1ropped during cleaning, replace
them as a silt,))
1. Check:
Throttle bodies
Cracks/damage the throttle bod-
ies as a set.
2. Clean:
the following precautions; other-
"' wise; throttle bodies may not operate

Do not su6j l!t the throttle bodies to exces-
sive force. <::>"<1
Clean the bodies in the recom-
...
mended cleaning
6
"!>,.? Do not use any caus11c
9
carburetor cleaning
solution.
Do not apply cleaning solvent directly to
%-o any plastic parts, sensors, or seals.
;'8_ careful not to remove the white paint
that identifies the standard throttle
"
bodY.v
Do the bypass air screws "a"; oth-
erwise, tfte.? throttle body synchronization
will be affec'fe;Q .
....
cleaning solvent
6
"!> -t Yamaha Oi"'-& Brake Cleaner
v

Cb

.... a
<t>-
6"!>
'.? .1-! a. Place the throttle bodies.;gn a flat surface with

the air filter case side factng up.
Install the caps (895-14169-00) onto the hose
fittings "a".

.s>
"f

y.?
'%

<t> ..

Y,
THROTILE BODIES
the throttle bodies, be careful
notto injure yoifiU,lelf on the throttle valves or
other the throttle bodies.
ECAIACI700
NOTICE
Do not open the by supply-
ing electrical power to the f flr.pttle bodies.
not use tools to open the ifii;P.ttle valves
keep them In the open
open the throttle valves quickly.
6"!>
'.?),
d. AI%>1Y the recommended to
valves and the inside of the throt-
tle to remove any carbon deposits .
TIP
Do not cleaning solvent to enter the
opening for the ((ljectors.
Do not apply solvent to the por-
tions of the throttle shafts between the
throttle bodies. ""<1
e. Remove the carbon the inside
6
"!> of each throttle body in a direction,
'.?Jmm the air filter case side of the 'UJJottle body
engine side. "
7-9

None
Do not u$l'" e.,{ tool, such as a wire brush, to
remove the ctiJbon deposits; otherwise, the
inside of the th'lottle bodies may be dam-
f
aged.
y.?
'%

<t> ..
c
Do not allow carbon deposits or other for-
TLE BODIES" on page 3-8.

eign materials to enter any of the passages Place the vehicle on a suitable stand so that
v.s> in each throttle body or in the space be- rear wheel is elevated.
-9. <?> tween the throttle valve shaft and the throt- 6. t':!;tjlck:
tie body. idling speed
removing the carbon deposits, clean the Start engine, warm it up, and then mea-
of the throttle bodies with the recom- sure the idling speed.
cleaning solvent, and dry the /"'-\. EngWi'V dling speed ,
thrott'fe;;Qodies using compressed v ; r/min
g. Make sil're that there are no carbon _______ __,

or other foreign materials in any of the ""'"""""
sages "a" in each throttle body or in the spactl-c INSTALLING THE INJECTORS
ECAIRCI102
"b" between the throttle valve shaft and the NOTICE
throttle body.
use new 0-rings.
WI}J!,n installing the injectors, do not allow
any-toreign material to enter or adhere to
the fuel rails, or 0-rings.
Be to twist or pinch the 0-rings
when instafiiQ-2 the injectors.
6
When inj ector, install it at the>,
y .?
same posit ion asttpe removed cylinder.
If an Injector Is subject to strong shocks or
excessive force, replace it.
If installing the original fuel rail and bolts,
remove the white paint marks using a
&:leaning solvent. Otherwise, paint chips on

3. Install the throttle bodies. .s>
'f
<?> 4. Reset:
ISC (idle speed control) learning values
the diagnostic code number "67".
1\efer to "SELF-DIAGNOSTIC FUNCTION
DIAGNOSTIC CODE on page
9-5. '.?),
ii1e bolt seats could prevent the bolts from
beif.Q, tightened to the specified torque.
1. seal onto the end of each injec-
tor.
2. Install the fQictors to the fuel rail, makiqg
sure to in the correct direction. "!>,.?
5.
Throttle bodies synchronizing
Out of specification -+ Replace the throttl&c
3. Install the to the adapter.

Fuel rail bolt

bodies.
Refer to "SYNCHRONIZING THE THROT- Check the injector pressure after the injectors
v.s> TLE BODIES" on page 3-8. installed to the throttle bodies.
f.<? Reter to "CHECKING THE INJECTOR
:.> .-
THE THROTTLE BODIES on page 7-10.
t \ Remove the throttle bodies from the vehicle. ""''RC""
a new throttle bodies to the vehicle. CHECKING 't\lE INJECTOR PRESSURE
3. TIP 6
ISC (@li e speed control) learning After installing the'j,Qjectors, perform the
Use the%iagnostic code number ing steps to check i11e injector pressure.

Refer to "SELF-DIAGNOSTIC Do not allow any foreign materials to enter the

AND DIAGNOSTIC CODE TABLE" on pag&c fuel lines.
' ' 4. Adjust: Check:
Throttle bodies synchronizing <1) nJector pressure
Refer to "SYNCHRONIZING THE THROT- f.<?>
7-10
y.?
'%

"!:>.

a. Connect the injector pressu?ei.}ldapter "1" to a. Remove the rider seat, air scoop fuel
the fuel rail joint "2", and then cBrmect an air tank cover. v.so
compressor "3" to the adapter. <?> Refer to "GENERAL CHASSIS" on page 4-f .<?>
b. Connect the pressure gauge "4" to tlfe-J,njec- b. Remove the fuel tank bolt and hold up the fuel

tor pressure adapter "1 ". tank.
Pressure gauge
908Q-03153
YU-03l 53
.., . c. Disconnect the fuel hose "1" from the fuel
pump. 6

Refer to "REMOVING TllF. FUEL TANK" on
Fuel injecftbJ: pressure adapter
90890-032'1'%
YU-03210
0

oo,.
c:-
.so
''9
4
;,
" page 7-3.
fVI,t,1RCI1(l2

r,.,
Cover fuel hose connection wltlto,. i! cloth
when disconnecting them.
sure in the fuel lines could cause
'.(?>
y.?
.so
spurt out when removing the hose. <?

1
'%
"<1
Be sure to disconnect the fuel hose by hand.
.. -it.b Do not forcefully discognect the hose with
'.?
3 2

c. Close the valve oif injector pressure
adapter.
d. Apply air pressure with compressor.
e. Open the valve on the inJt!ttor pressure
adapter until the specified is
reached. <?>
v,
Specified air pressure
490 kPa (5.0 kgf/cm
2
, 71 .1
"!>
v:>
9
tools. '.?,
6 d. Connect the pressur63jjauge "2" and
"!>,.? pressure adapter "3" to ll'le } uel hose.
Never exceed the air pressure or
damage could
"
A

Pressure gauge

90890-03153

YU-03153

Fuel pressure adapter
0%
f. Close the valve on ttl) njector pressure
"0
fuel

90890-03176
oo,.
c:-
adapter.
g. Check that the specified air is held
YM-03176
at least one minute. .so-9
Pressure drops Check the
and adapter. '%
Check the seals and 0 -rings and then Peip-
stall.
Out of Replace the fuel injec-
tors. '.?;,
9
.?.

EA$1ACI7
CHECKING THE FUEL PRE'S!JRE
1. Check:
v
.so
Fuel pressure ''9
'.(?>
y.?
'%
...
...
<to ..
e. Start the engine.
f. Measure the fuel pressure.
.so

y.?
'%
...

<tob
v
-"!>
'.?
THROTILE lapDIES

%,
c
Faulty --? Replace the fuel pumJ3<o 2. Adjust: '<o
F II
. Throttle position sensor angle
ue me pressure at 1 m!l v TIP----------------< v.s>
30G-390 kPa (J.o-3.9 '9
43
.
5
_
56
.
6
psi) <?>y Before adjusting the throttle position sensor, the -<?>
'Z! throttle bodies must be removed.
................................
uuu Temporary tighten the throttle position sensor
EAS1ACI111
INSTALLING THE (FUEL RAIL b. that the throttle valves afe.tully closed.
SIDE)

c. the main switch to "OFF".

1. Connect: %-o d. Connect the throttle position sensgfbt o the
Fuel hose (fuel rail side) wire harness.

No
'"CE .. e. Simultaneously press and hold the
,. '"- LECT" button "1" and "RESET" button "2"
00
..
When installing the fuel hose, make turn the rnain switch to "ON", and continue . v.s>f
it is securely connected, and that the f!Jel press the buttons for 8 seconds or rnore. -<?>
hose connector cover on the fuel hose is
the correct position, otherwise the fuel
will not be properly installed. , ., .,
<t>
TIP
Install the fuel hose seew.ely onto the fuel rail
joint until a distinct "click"
To install the fuel hose fuel rail joint,
slide the fuel hose connector "1" on the
end of the hose in the direction arrow

%.0

shown.

TIP-------------- .s> It is prohibited to wear the cotton work Qtoves
or equivalent coverings. <?>y
''9
"diAG" appears on the display. -<?>
y.?
1

'<o

.s>
.?
EAS1ACI11G -9
ADJUSTING THE THROTILE POSITION. <?>y.?
f. Simultaneously press the "SELECT" button
"1" and "RESET" button ''2" for 2 seconds or
SENSOR
EWA<RC<"" TIP---------------
diagnostic code number "1" appears on the
A wARNING
Handle the
special care. '.?
sensor with
Never subject the position sensor
to strong shocks. If the position
sensor is dropped, replace if t'c
0
1 . Check:
Throttle position sensor v
g. code number "1" is
h. Adjust the position of the throttle pol Ujpn sen-
sor angle so that 11-21 can appea'F'4p the
meter display.

Refer to "CHECKING THE THROTIL'&PO-
SITION SENSOR" on page 8-107. <?>y.?
i. After adjusting the throttle position sensor ail'l
gle, tighten the throttle position v.s>
screws "3'' . '9-<?
>
y.?

<t> ..
Throttle position sensor screw
"! v 3.5 Nm (0.35 m-kgf, 2.5 ft-lbf)
.s>
6"!>
'.?

3

Cb
%

oo ..
........... . 1;. .............................................................. ...
'"/

POSITION
SENSOR
EWAIRCl roG
<t>b
6"!>
'.? Handle the accelerator sensor with

special care. "
subject the accelerator position sen-
to strong shocks. If the accelerator po-
sensor is dropped, replace it.
1.
Accelei'alor position sensor
Refer to THE ACCELERATOR
POSITION on page 8-1 07.
2. Adjust:
Accelerator positio% ensor angle
6
"!> TIP
'.? Before adjusting the accelerajor position sensor,
.

the throttle bod1es must be removed.

a. 'f1[llporary tighten the accelerator position
bolts.
b. the throttle valves are fully closed.
c. Tum switch to "OFP' .
d. Connect position sensor to
the wire harne'..
e. Connect the to the throttle bod-
. ...
6 leS. <t>b
"!>, f. Simultaneously hold the "SE-
.? LECT' button "1" and button "2",
tum the main switch to "ON", and continue to
press the buttons for 8 seconds or more.

"!v
.s>
'"/

y.?
'%
-....
THROTILE BODIES
g. press the "SELECT' button
"1" and "RESr.T.' button "2" for 2 seconds or
more to set the dla,gnostic mode .

TIP
The diagnostic "1" appears on the
display.
y,
h. Diagnostic code is selected.
i. Turn the throttle grip to closed posi-

tion. <t>
1:'"1oAO.IUSt the position of the position
angle so that 12-22 can in the
display. "
aeJIUSlllnO the accelerator position sen-
tii ohten the accelerator position
I. Turn the throttle
mkgf, 2.5 ftlbf)

<t> ..
7-13
c
m. meter display value. If the meter
display is not 97- 107, adjust the accel-
erator positlgn sensor angle.
n. Select the diagji1ostic code number "15" .
...
o. Tum the throttleY.ggp to the fully closed posi-
tion.
p. Check the meter value. If the meter
6
display value is not 1 o-21t;l djust the acceler-
"b,.? ator position sensor angle.
..... , Tum the throttle grip to the position.
r. the meter display value. If the meter
value is not 95-109, adjust the accel-
eratOfi!OSition sensor angle.
s. Repeat<sseps (h) to (r) until the meter display
values are the specified ranges.
t. If the meter values are not within the
specified repeating steps (h) to
(r) several times, the accelerator po-
sition sensor.

e"b
... ,h; )!'...?.

.s>
''9
'.(?>
y.?
'%

<t>b

y.?.

7-14

Y,
THROTILE BODIES
4
7-15
-"!> - . . . ~
~ .
AIR IN&lJ}CTION SYSTEM . ? ~
~ ~
%,
Cb
1. Air filter case '<o
2. Air induction system hose (air fi ller case
cut-off valve) v
.s>
3. Air cui-off valve -9
4. Air induction system hose (air cut-off valve to ..
valve cover)

<t>b

y.?.

-"!>
,.,
INDUCTION SV<TEM

Order
1
Job/Parts to remove
Ffrder seat
"'J-.
Air sc8' tiPJFuel tank cover
,_
Fuel tank
0
Air litter case '<o

Radiator "! u
Q'ty
Air cut-off valve couplef-
11
1
-"!>
AIR SYSTEM

%,
Remarks
Refer to "GENEf!I\L CHASSIS" on page
4-1.
Refer to "GENERAL EZJ;j,ASSIS on page
4-1.
Refer to "FUEL TANK" on pllQ_e 7-1.
Refer to "GENERAL CHASSIS' .,gn page
4-1.
Refer to "RADIATOR" on page 6-1. "! u
Disconnect. "11
2
Air induction system hoseTaj,> cut-off valve to 1 v>y

Air induction system hose (air cufi;2ff valve to
1

3
4
5
6

induction system hose (air finer air
1 6
<t>,o
'al!,l-olf valve) "!>
valve ".;,. 1 ".1;9
Air cut<Qjf valve holder 1
7
Reed 1
8 Reed valve aSl!l!mbly 1 1
9 Reed valve . 1
10 Reed valve cover -v-<1 /, 1
11 Reed valve assembly 2"'.,. 1
12 Reed valve plate "'>v. 2
EA$270$0 CO...,
CHECKING THE AIR SYSTEM
Air Injection "! v
The air induction system buti'!S unburned ex-
haust gases by injecting fresh aif (i,econdary air)
into the exhaust port, reducing of
hydrocarbons. When there is
at the exhaust port, the reed valve
ing secorff@ry air to flow into the exhaust
0
p%rt.
The required;. Jemperature for burning the
burned exhaus1.>.sases is approximately 600 to"
700 c (11 12 to i'29J: F).
Air cut-off valve
The air cut-off valve is'ilw.trolled by the signal s
from the ECU in with the combus
tion conditions. Ordinarily, air cut-off valve
opens to allow the air to flow r.' ci,Y.ring idle and
closes to cut-off the flow when is be
ing driven. However, if the coolant tifr@.Perature
is below the specified value, the air cut-dlt,_ valve
remains and allows the air to flow int'G>)he
exhaust pipoeh until the temperature
higher than value. "0
""!v====--
A. From the air filter case
B. To cylinder head
1 . Check: "b,l? h
Hoses

Loose -t Connect properly.
Cracks/damage
2. Check:

Reed valve
"!v
Reed valve stopper .so
f
Reed valve seat <?>
yl?
'%
-"!>
{>
AIR SYSTEM

%,
c
Cracks/damage -t Replace
0
-\be reed valve
assembly. ..
v
3. Measure: .so
Reed valve bending limit "a" -9. <?>
Out of specification -t Replace the 'r@J;d
valve assembly.

Reed valve bending l imit <t>b
0.4 mritt0.02 in)
)!'...?.

CO,.., a
!
4. Check: e
Air cut-off valve "b,l?
Cracks/damage -t
5. Check
Air induction system solenei,(1
Refer to "CHECKING THE A1!i! INDUCTION
SYSTEM SOLENOID" on
v
,SO
f
INSTALLING THE AIR INDUCTION SYS.JJ:M
1. Install :
Reed valve plate "1"
TIP----------------------------
Align the projectie.Q_ "a" on the cylinder head
cover with the in the reed valve plate y.?.
"1".
Align the projection "c" cylinder head
cover with the hole "d" in tlle<r.eed valve plate
"1". '
1

"!:>.
7-18

.s>
Install the reed valve assembly 1 so that the
<> open side turns to the exhaust side of the en
> .

.s>
?.? g1ne.
' ...Jnstall the reed valve assembly 2 so that the
side turns to the intake side of the engine.
<> A. Reed valve assembly 1
>
B. Reed valve assembly 2
<::>"<1C. Exhaust side

3.
Ret!,g valve cover

V:ijeed valve cover bolt
LOCTITE "-E! c

"<0< -"!>
'.?
AIR INDUCTION SYSTEM

.s>
7-19
'f
'<}>
?.?
'%

"!:>.
-"!>
)!'...?. ... ,

'

'

ELECTRICAL

.
IGNITION SYSTEM .......... ................... ......................... :r.-y - 81
CIRCUIT DIAGRAM ..................................................
ENGINE STOPPING DUE TO SIDESTAND ...................... 83
TROUBLESHOOTING ....................................................... ............ ....... 84
<t>b 6 <t>b
"!>
STARTING SYSTEM ... ................................................ ......... 87

CIRCUIT DIAGRAM .................... ............................................... ....... 87
STARTING CIRCUIT CUT-OFF OPERATION ........................... 89
TROUBLESHOOTING ..........................
% %

CHARGING SYSTEM ...... ............ ........ .................. ........ .................. ......... 813
CIRCUIT DIAGRAM .............. ........ ....................... 1.,.. .... .... .... ..... ... .. ... .... .. 81 3
TROUBLESHOOTING ..............................................

Lf Q_HTING SYSTEM ........ ................... .................. ........ ............. :'\, ................ 817
DIAGRAM ............. .... .................. ........ ................. ..

..............
SIGNALING SYSTEM ...... ............ ............. . . . . . . . . 821
' C
CIRCUIT DIAGRAM .............. ........ ...........
TROUBLESHOOTING ........... ........ ..............

COOLING SYSTEM ..................... ........ ........................ :.'\?,.. ................... . ......... 827
CIRCUIT DIAGRAM .............. ........ ................. ....... .... ............. .. ......... 827
TROUBLESHOOTING ........... ........ ................. ................. !\.,. ....... .. .. ........ .. 829

<t> <t>
6
FUEt:::1!NJECTION SYSTEM .........
DIAGRAM ................... ................. ........ ........ .............. ...... 831
" 19. "
ECU SELF-DIAGNOSTIC FUNCTI .................. ........ .......................... 833
TROUBLESHOOTING METHOD ....... ;v-1);. ............. .. ...... .. ............... ..... .... .. 835
DIAGNOSTIC MODE ............................... ""-' 836
YAMAHA DIAGNOSTIC TOOL ........... ...... .. ............... .......... 837
TROUBLESHOOTING DETAILS .. ................... ?..(r 838

FUEL PUMP SYSTEM ................. ........ ................. ........... .. .... ..... ... .. ... .. .. .. 881
CIRCUIT DIAGRAM .............. ........ ................. ....... .........
TROUBLESHOOTING -9, 883
<t>b 6 <t>b
"!>
CAL COMPONENTS ....... ....... 885
CHEC:KING THE SWITCHES ........ ...... 889
CHECKING THE BULBS AND BULB S.2 CKETS ........... ........ .................. 892
CHECKING THE FUSES ....................... ":C',. ... .... .... .... ... .. ....... ..... ... ..... .... .. 893
REPLACING THE ECU (engine control .... ............. .......................... 893
CHECKING AND CHARGING THE BATTER?1.v .................................. 894
CHECKING THE RELAYS ............................. ... ............................. 897
CHECKING THE TURN SIGNAUHAZARD ......................... 898

<t> ..
c
CHECKING THE UNIT (DIODE) ... ................. ........ .... ............. ..... 8-99

CHECKING THE COILS ........................ .... .... .... .... ................ 8-100 -o,.
rl v
CHECKING THE IGNITivt\1 SPARK GAP ................. .... ......................... 8-100 .s>
CHECKING THE POSITION SENSOR .... .................. ... 8-101
CHECKING THE LEAN ............. .... .... ............. .... .... ... 8-101
CHECKING THE STARTER OPERATION .. .... ............. .... .... ... 8-102
CHECKING THE STATOR COIL .... .... ...................... ..................... ... 8-102
CHECtgNG THE RECTIFIER/ REGULJ\l[OR ............... ..................... '(;8-102
CHECKIN,9 THE HORN ................... ................ .................. '%103
CHECKING$J;.HE ENGINE OIL LEVEL ..........................
CHECKING fi\J_s FUEL SENDER ..................................................... 8-1
CHECKING THE'<f,:UEL METER/FUEL LEVEL WARNING LIGHT ........ 8-105
CHECKING THE Oit;,_LEVEL WARNING LIGHT.. ............................... 8-105
CHECKING THE SPE!ij! SENSOR .................................................. 8-105
CHECKING THE FAN MOTORS ............ ........ .... ......... .... ... 8-1 06 v.s>
CHECKING THE SENSOR .. .... ............. ... 8-106
CHECKING THE THROTTLE'P_,QSITION SENSOR .. .... .... .... ............. ... 8-107
CHECKING THE SENSOR ...................... 8-107 <:>"<1
CHECKING THE THROTTLE MOTOR ..................... ................ 8-108
CHECKING THE AIR INDUCTION S'f.SJ EM SOLENOID ..... ..............
6
8-108
CHECKltJp THE INTAKE AIR PRESSUI\!;; SENSOR. .. ....................... r8{;,109
INTAKE AIR TEMPERATl?JSE SENSOR ............... .... 8-'fP.9
A. 'l
CHECKING GEAR POSITION SENSOR ....... .... ......................... ... 8-1
CHECKING THE>J:UEL INJECTORS ....... ......... ......... ......................... ... 8-111

.!' .!'

' '

...
<t>b

y.?.

EA$27110
CIRCUIT DIAGRAM
c
3.
4.
9. Ignition tuS'e>
"-9
13. Battery <?>
14.Engi ne ground
15. Fuel injection syste<fQ, _Juse
18.Joint connector
e 19.Joint coupler
"!>,.? 20.Relay unit
(engine control unit)
214>Jgnition coil #1
coil #2
coil #3
27. Spark 1Jll!g
"' 33. Cranksh<itf'position sensor
38. Lean angle &e,Qsor
58. Gear position
61 .Sidestand switch
62. Right handlebar switc"F.:,
64. Start/engine stop switch .. -'l,b

y.?.

IGNITION SYSTEM
8-2
EA$1AC18G4 CO..., CO...,
ENGINE TO SIDESTAND OPERATION
When the engine is and the transmission is in gear, the engine will stop if is
moved down. This is becau?e:the electric current from the ignition coils does not flow to the when
both the gear position sensor circuit) and sidestand switch are set to "OFF", thereby
the spark plugs from producing a However, the engine continues to run under the following"' t:@n-
ditions:
The transmission is in gear (the of the gear position sensor is open) and the
is up (ffl!l sidestand switch circuit is
6
"!>
The transfuj ssion is in neutral (the neutral cTr.!buit of the gear position is closed) and the sides-
land is sidestand switch circuit is open).

"

12 2

v v
.,. ' ,.

' '

6"!>
yo.?. 4 ... , yo.?.

"'1

6
1.
2. Ma1n
3. Main
4. Ignition fuse
5. Start/engine
6. Ignition coil
7. Spark plug v
8. ECU (engine control
9. Sidestand switch <?>Y.?
10.Relay unit (diode)
11. Gear position sensor (neutral circ'llil)
12. Battery negative lead
6"!>
'
..,h. yo.?.

.,.
f
.<?>
y.?

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8
8-3

Cb

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f
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y.?

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IGNITION

EA$27150 .._0

TROUBLESHOOTING
The ignition system fails to operate (no intermittent spark). "! v
TI P
Before troubleshooting, remove the following . <?-)
1. Rider seat
2. Air scoop
3. Fuel tank cover
Fuel tank
6
"!>
filter case
1. Check the fuses.
(Main, ignition and fuel injection
system)
Refer to "CHECKING THE FUSES"

Replace the fuse(s).
on page 8-93.
<?
OK.!.

2. Check the battery.

Refer to "CHECKING AND the battery terminals.
<t>b CHARGING THE BATlERY" on 'hocharge or replace the ballel;.
"!> ' "!>
page 8-94. y, ...
'!.? OK.!.

'!.?
3. Check the spark plugs.
Refer to "CHECKING THE Re-gap or replace the spark plugs.
PLUGS" on page 3-4.
OK.!. "!v" "!v
u

<? 4. Check the ignition spark gap.

<t>b
Refer to "CHECKING THE IGNI-
TION SPARK GAP" on page 8-100.
Ignition system is OK. -l
,.

NG.l.
5. Check the ignition coiiS\b
Refer to "CHECKING THE;JGNI-
" TION COILS" on page

6. Check the crankshaft position sen-":
sor. oo,.
Refer to "CHECKING THE CRANK- . v.o..
SHAFT POSITION SENSOR" on

the ignition coils.
"
Replace the crankshaft position sensor.
page 8-101 .
OK.!.
7. Check the main switch.

<t>
Refer to "CHECKING
SWITCHES" on page

":?<t,
the main switch.
u:>
8. Check the starVengine stop swif61b
Refer to "CHECKING THE
0
SWITCHES" on page 8-89.
"'
OK.!.
'.(?>

Replace the right handlebar switch.

8-4

<t> ..
'
c.
9. gear position sensor.
Refer to THE GEAR
POSITION SE.fJSOR" on page
8-110. . <?>y,
10.Check the sidestand
Refer to "CHECKING
6
0,, SWITCHES" on page _
OK! "0
the relay unit (diode).
Refelli::!O "CHECKING THE RELAY
on page 8-99.
12.Check the leafl,angle sensor.
Refer to "CHEC'k1NG THE LEAN
ANGLE SENSORW' 'tt.-Q.page 8-101.
6 o, 13.Check the entire ignition
w1nng. ?.?.
to "CIRCUIT DIAGRAM"'lJn
8-1.
Replace
Refer to THE ECU (en-
gine control gn page 8-93.

8-5

IGNITION SYSTEM
'
c.

Replace the gear poSition sensor.
.,

Replace the unit.

"-& ..
'f
. <?>y,
'f
'<?,
Replace the lean angle
"""
6
P
"!>, . h . . .
roper,yJeconnect or repa1r t e 1gmt1on
!em's wiiiQlJ.

-"!> "<0<

ELECTRI.., TARTING

%,
EA$271(10 co
ELECTRIC SYSTEM

.s>
EA$27170 . ..,
c IRCUIT DIAGRAM .. <\,_
..
to>
'o
"
{>
:f-..

.<}
>y

,-

I
.- "'l;>.,

:_ .. , ..
0.
; i
: .

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ill!P

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h. ,J
.
. ,.
I'\
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I'
r' .. ;o.,<
- II 11,
lv,

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llil

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<8
I

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I'\
I

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6
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ro.,<q
-.
]f''

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. :

['j'c:i
'.;
; ....

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;
3 ...

8-7
""<1

:..co

3. Main switch

4. Main fuse
9. Ignition fuse .s>
'f
<?> 13. Battery
ground
injection system fuse
16.'S,Jil.rter relay
t?.Stl't19r motor
t 8.Joint '&>9.nector
t 9.Joint colff>ler
20.Relay unit
2t.Starting circuit cut-off relay
'<1
58. Gear position sensor
6t.Sidestand switch
v 62.Right handlebar switch
.s>
-9. <? 64.StarVengine stop switch
switch
""<1

y.?.

"<0< -"!>
'.?
ELECTRIC STARTING SYSTEM

8-8

'
v
STARTIN'G SYSTEM

'
c
EA$27180
CIRCUIT CUT-OFF SYSTEM OPERATION
f!Jlle main switch is turned to "ON" and the "(j)" side of the starVei'lgine stop switch is pushed, the starter
can only operate if at least one of the following conditions
is in neutral (the neutral circuit of the gear is closed).
The clfuh lever is pulled to the handlebar (the clutch switch is closedf <!i!nd the sidestand is up (the
is closed).
The starting .c'l' rf uit cut-off relay prevents the starter motor from operating of these condi-
tions has been In this instance, the startin1J,-s;ircuit cut-off relay is open so cannot reach the
starter motor. least one of the above coil'dj t ions has been met the cut-off relay
is closed and the engfne can be started by pushing fh.ll "(j)" side of the starVengine sfop switch.
"
13
M

,-----.

..
""<1

3
a
7

y.?.

.s>
"-9
".(?>
a. WHEN THE TRANSMISSION IS IN NEU-
TRAL
b. WHEN THE SIDESTAND IS UP AND THE
CLUTCH LEVER IS PULLED TO THE HAN-
DLEBAR

. Battery
fuse
3. switch
4. lgr\';'tipn fuse
5. stop switch
6. Starting circuit cut-off relay
7. Diode
8. Clutch switch
9. Sidestand switch
10.Gear position sensor (neutral circuit)
11.Diode
"

ELECTRIC STARTING SYSTEM

8-10

"0,
'
EA$271QO co
TROUBLESHOOTING
The starter motor fails to turn. "! v
.s>
TIP . ,
Before troubleshooting, remove the follbJ.!ing part(s):
1. Rider seat
'
3. Fuel tank cover
4. Fuel tank
6
"!>
5. Air filter case '.?
6. Throttle bodies "'1
"
1. Check the fuses. c;,1o
(Main, ignition and fuel
system) <!v
Refer to "CHECKING THE FUS6;s"
on page 8-93.

OK.!.

Refer to "CI<!ECKING AND <t>b"" Clean the battery terminals.
CHARGING't-I;IE BATTERY" on Recharge or battery.
page 8-94. .?.'l
OK.!.
3. Check the starter
Refer to "CHECKING THI-<TART-
ER MOTOR OPERATION" ifn eage
8-102.
NG.l.

c
Starter motor is OK. Perform the
starting system troubleshooting, stai\'llag
with step 5. 'v.s>
4. Check the starter motor.
Refer to "CHECKING THE START- Repair or replace the starter motor.
ER page 5-37.

OK.!. '.? Y.?. '.?

... 1,
5. Check the relay uflit (starting circuit
cut-off relay).

Refer to "CHECKING RE-
LAYS" on page 8-97.

6. Check the relay unit (diode).
Refer to "CHECKING THE RELAY y \
UNIT (DIODE)" on page 8-99.

OK.!.
Replace the relay unit.
Replace the relay unit.
7. Check the sr arter relay.
<t>b

0%

Refer to "CHEC!$;1NG THE RE-
LAYS" on page
Replace the starter
/ '
"
Refer to "CHECKING THE %,.
SWITCHES" on page 8-89. . v.s>
,..,

Replace the main switch.
'
c.
9. Check the gear position se?isor.
POSITION SENSOR" on page. v.s>-9
8-110. "< >0

OK.i
1 o.Check the sidestand switch.
SWITCHES" 8o,page 8-89.
11.Check the clutch swif' el:l.
Refer to "CHECKING TAt;
SWITCHES" on page 8-8'- .<o-&.
12.Check the start/engine stop switclf.<
NG-t

"
STARTING-.YSTEM

'
c.
Replace the gear position sensor.
Replace the sidestand switch.
e"b
'
Replace the clutch switch.
Replace the right handlebar switch.

"'
" (-
OK.i
<t>
e"b 13.Check the entlw starting system's
wiring.
Refer to on
page 8-7.
The starting system circuit is
1
... connect or repair tfW starting sys-
NG-t wiring.

- . . . ~ ?
CHARGING SYSTEM
---
II
I"
8-13
-"!> " CO...,
TROUBLtS!jOOTING
The battery is"Qpt being charged.
TIP .s>
Before troublesh&t.J!:!g, remove the following part(s):
1. Rider seat
2. Rear side cover
.<>.
6 "t>,;
"!>,, 1. Check the fuse.
(Main)
Refer to "CHECKING THE FUSES"
page 8-93.

Refer to AND
CHARGING lli;iE BA TIERY" on
page 8-94.
6
3. Check the stator coil.
"!>, Refer to "CHECKING
TOR COIL" on page
4. the rectifier/regulator.
"CHECKING THE RECTI-
FIERIRI;GULATOR" on page
8-102. c/<1'
'"'
5. Check the entire"lmarging system's
wiring.
Refer to "CIRCUIT on
page 8-13.
OK.!.
It charging system circuit is OK.
,_

8-15
-"!> "<0<
v
CHARGING SYSTEM

'
't>-?
Clean the battery
Recharge or replace battery.
?.?

the stator coil assembly.
..,h. )!'...?.

Replace the rec:Yit.i,er/regulator.
0 ..
c:-
.s>
'"'
'%
Properly connect or repair
system's wiring. "'-it..
6"!>

- . . . ~ ?
CHARGING SYSTEM
8-16

3. Main switch
4. Main fuse
9. Ignition fuse
10.Signal fuse
11. Headlight fuse
13.Battery
14.Engine ground
18.Joint
19.Joint coupler "!>,.?
23. ECU (engine
45. Meter assembly

47. Meter light
54.High beam indicator light 'b%
69. Left handlebar switch
74. Pass switch v.s>
75.Dimmer switch
78. Front right turn signal/position light
79.Front left turn signal/position light
80.Headlight
81 .Auxiliary light
6
82. License plate
83.TaiVbrake light
84.Headlight relay

0%

"-9

y.?
'%

<t>b

y.?.

.s>
"-9

y.?
'%

<t>b

y.?.

-"!>

Any of the fail to light: headlight, high beam indicator light, taillight, light or meter light.
TIP
Before troubleshooi mg, remove the following part(s): .
1. Rider seat ""%
2. Air scoop
3. Fuel tank cover
Fuel tank 6"!>

side cover '.?
6. assembly

1. each bulbs and bulb
socketS<l;ondition.
Refer to re!:;IECKING THE BULBS
AND BULB on page
8-92.

2. Check the fuses.
6 (Main, headlight, ignition signal)
'"',.? Refer to "CHECKING THE
\,,on page 8-93.
3. Cheels, the battery.
Refer AND
CHARGif<l<s THE BATTERY" on
page 8-94.
4. Check the main
Refer to
SWITCHES" on page 8-8$).

vh OKl
51>{; heck the dimmer switch. '
rfet_er to "CHECKING THE
SWl<fi,CHES" on page 8-89.

6. Check the switch.
Refer to THE
>
SWITCHES" on 8-89.

8-19
(,.0%

Replace the bulb(s) aod bulb socket(s).
.so
f

RePl!}ce the fuse(s).
'.?

Cb
Clean the batti '1%jerminals.
Recharge or repla'eevthe battery.
.so

"t>

The is faulty. Replace the '
left handlebarcpwitch.

c-
The pass switch is faultY;. Replace the left
handlebar switch.
.?-.,,
Repl!}ce the headlight relay.
'.?

8. Check the entire lighting system's
wiring.
Refer to "CIRCUIT DIAGRAM" on
page 8-17.
R!Wiace the ECU or meter assembly.
Reter to "REPLACING THE ECU
gine "' 6Qptrol unit)" on page 8-93. "!>
'
'
Cb

Properly connect or repair the lighting sys-
NG-t wiring.
"{?>y.
8-20
-"!>
S I G N ~ ~ I N G SYSTEM
~ ~
~
CIRCUIT DIAGRAM
c
3. Main
4. Main fuse ..
8. Parking lighting i 6' s.e
9. Ignition fuse f.<?>
tO.Signal fuse
13. Battery
14.Engine ground
1;Jl.Joint connector
t 9:4oint coupler
unit
23. ECIY(!!1gine control unit)
35. Coolanf telrperature sensor
39.Speed
45. Meter ..
46. Neutral indicator ft(!llt
48. Tachomet er -9. <?
49.Multi-function meter
50. 0 il level warning light
51 . Fuel level indicator light
trouble warning light .. -'l,b
53?-Soolant temperature warning
55.Ulf1turn signal indicator light
56. signal indicator light
57.0illeveP.witch
58. Gear sensor
59. Fuel sender
62.Right handleba1'1$Yitch
.s>
65. Hazard switch -9
66. Front brake light swiidR,.?
67.Rear brake light switch
68.Turn signal/hazard relay
69. Lefl handlebar switch

switch Y.?.;;,
73. switch "
76. Rear turn signal light
77.Rear left fctin signal light
78. Front right t&'@"-signal/position light
79.Front left turn light
83. TaiVbrake light .s>f
"<?>
y.?

<t>b

y.?.

8-22
-"!>
>,. )!'...?. ... ,

?,
SIGNALING SYSTEM

c
EA$272510
TROUBLESHOOTING
of the following fail to light: tum signal light, brake light or indicator light.
r'f..e hom fails to sound. .sof
TIP .<?> . <?>
remove the following part(s):
1. Rider s1fat
2. Air scoop
3. Fuel tank e"b

5. Air filter case
>;,

6. Throttle bodies

>;,

0%
1. Check the fuses.
v (Main, ignition, signal and parking
.so'9 lighting)
to "CHECKING THE FUSES"
8-93.
2. Check

Refer to "CftECKING AND
CHARGING Ti'le BATIERY" on
page 8-94.
OK-I-
>;,

v Refer to "CHECKING THE
.so-9 SWITCHES" on page 8-89.
A
4. entire signaling system's
w1nng. 1;
Refer to DIAGRAM" on
page 8-21.
OK.!. 0
This circuit is OK.

Check the signaling system

horn fails to sound.
(/
11 :heck the hom switch.
r'l$lfer to "CHECKING THE
SvV!{CHES" on page 8-89.

2. Check the't\gm.
Refer to THE HORN"
on page 8-1
OK.!.

8-23

Clean the battery terif1UJ.als.
Recharge or replace the"i:battery.

the main switch.
,SO
f
A

Properly connecf 'bpepair the signaling
system's wiring. <t>b

f
.<?
Replace tli&Jeft handlebar switch.

v<!,
b

Replace the horn. ?.?.

'
c.
3. Check the entire signaling system's
wiring. ..
Refer to "CIRCUIT DIAGRAM" on N'(,.'"
page 8-21. <?>
7
'<?>

OK.i
I This circuit is OK.
"t>

tail/brake light fails to caw,e on.
Check the front brake light
NG-t
Properly connect or repair the signaling
system's wiring.

Replace the front brake light switch. -1;
OK.i

7
'<?>

r-::--:,.---:-:----:--:--::-:-...,.,--,----,
2. Check the rear brake light switch. "! v
Refer to "CHECKING THE .r
SWITCHES" on page 8-89. NG; >

'%
Replace the rear brake light switch.

w1nng.

connect or repair the si99aling
Refer to "CIRCUIT on
page 8-21. ....
NG-t
wiring. "!>,
" !>.?.
....
This circuit is OK.
co
The turn signal light turn signal indicator both fail to blink
'
.r
7
'<?>

;.,.
1 . Check the front tum signal/position
'f
'<?>
light bulbs, rear turn signal light
bulbs and socket.

Refer to "CHECKING THE BULBS
NG-t
AND BULB SOCKETS" on page
8-92.
6"!>
"'
2. Check the tum signal switch.
SWITCHES" on page 8-89. Cl NG-t
OK.!. ..
3. Check the hazard switch.
OK.!.
v
.r
'f
'<?>
NG-t

4. Check the tum signal/l'@zard relay.
Refer to "CHECKING TURN
SIGNAUHAZARD RELA Y''k>J4page
8-98.
NG-t
Replace the front turn signaVposition light
rear turn signal light bulb(s), sock-
or both.

6"!>
"'
Replace the left handlebar switch.
Replace the left handlebar switch.
6
.. "!>
Replaca the turn signal/hazard relay?;,

"!v
.r
'f

'
Cb
'%
wiring.
NG-t
>
page 8-21.
I the meter assembly. I
fee.
The indicator light fails to com@,gn.
'
1. Check Yful gear position sensor.
Properly connect or repair the signaling
wiring.

<t
v

;..c

Replace the gear position sensor.

Refer to "CHECKING THE GEAR
POSITION SENSOR" on page
8-110. Cb
0%

oo ..
v
'%
OKi
2. Check the relay unit (diode).
.s>
'-9
. Refer to "CHECKING THE RELAY
UNIT (DIODE)" on page 8-99.
NG-t
3. Cf\:eck the entire signaling system.;;
"b
Refer DIAGRAM" on
page 8-21.
.s>
'-9
Reralace the relay unit.

<t
'-9
The oil level warning light fails to come on.
. 1. Check the oil level switch.
on page 8-89.
-.()
2. entire signaling system'sv ;,
NG-t

.s>
'-9
'"'>y
'
the oil level switch.

<t<

""y.?.
c;
;..c
Properly connect &trepair the signaling

system' s wiring.

page 8-21.
0%

oo ..
Cb
OKi
oo ..
v
Replace the meter assembly.
.s>
'-9
fuel !eye! warning light fails to come on.
'\ Check the fuel sender.
to "CHECKING THE FUEL
on page 8-104. =
,., v,
NG-t
8-25
v
.s>
'-9

c;
'
c.
2. Check the entire system's
wiring.
Refer to "CIRCUIT DI)I;GRAM" on
page 8-21.
'f
. <?>y,
Replace the ECU or meter assemol y,
Refer to "REPLACING THE ECU (eri' .it .
NG--t
gine c3otrol unit)" on page 8-93.
,, y
.?.;;,
The speedoilleter fails to operate.
v_,
1. Check the sensor.
Refer to "CHEG1NG THE SPEED
SENSOR" on
2. Check the entire signalinps,xstem's
wiring.
Refer to "CIRCUIT
"
NG--t
NG--t
-"!>
SYSTEM

%
'
c.

Properly connect or repair
system's wiring. .sof

Replace the speed

. <?>y,
'<?>
Properly connect or repair the signalirfg,A
system's wiring. ""<1
'
page 8-21.

6"!>

Replace or meter assembly.
Refer to "REI?J.:ACING THE ECU (en-
gine control umtr on page 8-93.

The coolant warning light fails to come on

1. Check the coolant temJ:>}.lrature sen-
sor. -9.,
Refer to "CHECKING
NG--t
ANT TEMPERATURE
on page 8-1 06.
nK-!.
<$),;.:
2. CheCM);le entire signaling system's
wiring.
Refer to DIAGRAM" on NG--t
page 8-21.
Replace the ECU or mv@tllr assembly.
Refer to "REPLACING ECU (en-
gine control unit)'' on page

8-26
... , )!'...?.

Cb

v
.so
'f
'<?
Replace the coolant temperature
'%
"<1
'V'.?
Properly connect the signaling
system's wiring.

-"!>
CbQLING SYSTEM
~ ~
~
EA$27310
CIRCUIT DIAGRAM
,-
::
@ :
8-27
3. Main switch
4. Main fuse
7. Radiator fan fuse
9. Ignition fuse
13. Battery
14.Engi ne ground

18.Joint connector
23.ECU (engine controlil)
35.Coolanttemperature
85.Radiator fan motor relay
86. Radiator fan motor

Cb

.s>
"f

'%

y.?.

EA$27320 co%
TROUBLESHOOTING
TIP
Before troubleshooting, remove the part(s):
1. Rider seat
'
3. Fuel tank cover
-"!>
COOLING
..
%,
4. Fuel tank
5. Air filter case
6
"!> ..
6. Throttle bodies
1. Check the fuses.
(Main, ignition and radiator fanl
Refer to "CHECKING THE FUSe"
" on page 8-93.
Refer to "CHECKING AND
CHARGING THE BATTERY'' on
page 8-94.
6<'!
OKl vh

3. Check the main ...
Refer to "CHECKING
SWITCHES" on page 889.
4. Check the radiator fan motor.
Refer to "CHECKING THE RADIA-
TOR FAN MOTORS" on page
8106.
5. Check the radiatordpn motor relay.
Refer to RE-
LAYS" on page 8-97.
..
6. Check the coolant temperature?s-en-
sor. ..

Refer to "CHECKING THE COOL- '.!>
ANT TEMPERATURE SENSOR" -9.
on page 8106.
OK.!.
Clean the battery terminals.
Recharge or replace the battery.
Replace the radiator fan motor(s).
Replace the coolant temperature sensor.
7. Check the entire cooling system's
wiring.
6
"!> connect or repair cooling sys-
Refer to "CIRCUIT 9JAGRAM" on "fern's wiring.
page 827.

..

OK.!.

Replace the ECU.
Refer to "REPLACING THE ECU
gine control unit)" on page 8-93. .!'
'f
'

'
s!ag

<t>.-
- . . . ~ ?
COOI!iiNG SYSTEM
8-30
v,
'.?

EA$27$31
INJECTION SYSTEM
"!
6
8
8

FUEL
8-31
c
3. Main
4. Main fuse % ..
t
5. Electric throttle v!lhre fuse
""'
9. Ignition fuse <?>
11. Headlight fuse
13.Battery
14.Engi ne ground
(;?.Fuel injection system fuse
1W.{;ltarter relay
18.JbiqJ connector

20. Relay J'riit
21 .Starti ng cut-off relay
22.Fuel pump reThw,
23.ECU (engine cohtr,pl unit)
24.1 gnition coil #1 ""/ <?
. . . >
25.1 gmtlon co11 #2
26.1 gnition coil #3
27.Spark plug
...
Injector # 1 <t>b
29?Jjiiector #2
#3
31.Air system solenoid
32.02
sensor
34.1ntake air temp .rature sensor
"'
35. Coolant temperatU,j;9 sensor
36.1ntake air 1
37.1ntake air pressure seRs.?i, 2
39.Speed sensor
1, 0.Throttle servo motor .. -it.b
41'lf ccelerator position sensor
42.YI'u.ottle position sensor
43. diagnostic tool connector "
44. Yamalfa.&iagnostic tool coupler
45. Meter asS@!):1bly

52.Engine trouble light
58. Gear position
60.Fuel pump . <?>Y.?
61 .Sidestand switch
62.Right handlebar switch
63. Drive mode switch
Start/engine stop switch
switch
84.He3:glight relay "
85. Radicftcy fan motor relay

Cb

.so
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".(?>
y.?

<t> ..
8-32
-"!>
FUEL INJECTION SYSTEM

%,
-
ECU SELF-OIAGNO;lJC FUNCTION
The ECU is equipped witf\$1 self-diagnostic function in order to ensure that the fuel system is
operating normally. If this fllhpion detects a malfunction in the system, it immediately operafes the en-
gine under substitute and illuminates the engine trouble warni ng light to alert rider
that a malfunction has system. Once a malfunction has been detected, a
number is stored in the memory of ECU.
To infonm the rider that the fuel injec'f$n system is not functioning, the engine trouble warning
the "(i)" side of the start1e1f 9We stop switch is being to start the engine.
If a is detected in the system self-diagnostic function, ECU provides an appro- Y-?
00
priate characteristic operation, ancf/alerts the rider of the detected1:!!alfunction by illuminat- "
ing the engin: f t:2uble warning light
After the engine been stopped, the lowest fault code number appears on the display. Once
a fault code has beEf J\displayed, it remains stored in the memory of the ECU until ii1s.,deleted.
Engine trouble warni rf'g Vght indication and fuel injection system operation v
Warning light
f
Fuel injection
f
operation Vehicle operatton
indication

operation

Warning 'i'lLpvided

Flashing when start Operation stopped Cannot be operated
6"!>
.
6"!> engtne
..
.?.;;, Operated with substi-
" tute characteristics in or cannot be oper-
Remains on Malfunction detected accordance with the on the

description of the mal- fault Oq,de

function

The warning light flashes any one of the following conditions is present and side 6f1pe start/en-
gine stop switch is pushed: -9. <> -9. <>
> >

41
: Lean angle sensor
Crankshaft position se (open or short circuit)

Sidestand switch ECU internal malfunction
19: 50:
12:
6
<> J,open circuit in the wire to the (faulty memory)
.., _).._ )!'...?. /', )!'...?.
Leat sensor
30:
detected)
Checking the trouble warning light
The engine trouble w"'&m.ing light comes on for around 2 seconds after the main been set to
"ON" and it comes on side of the start/engine stop switch is being pushed. 9f i he warning
light does not come on unde.y these conditions, the warning light (LED) may be defective. .sof
. <}
b

c

a. "OFP'
b. Main st.f.ilch "ON"
c. Engi ne warning light off
d. Engine troubie,warning l ight on for around 2
seconds

.so
f
.<>>
y.?

<t> ..
y.?.

8-33
c c
ECU detects an aB''\2rmal signal from a sensor

If the ECU detects an l ll Jlormal signal from a sensor while the vehicle is being driven:'\liJ,.e ECU illumi-
nates the engine trouble W!!rning light and provides the engine with alternate operating ins(f\;lctions that
are appropriate for the typeo.bJnalfunction. -9. -<?>
When an abnormal signal is from a sensor, the ECU processes the specified values are
programmed for each sensor in o'a11er to provi de the engine with alternate operating instructions<lgat
enable the engine to continue opera'titl.j:l or stop operating, depending on the conditions.

6"!> 6"!>
? ?
..,h. )!'...?. ..,h. )!'...?.

' '

' '

6"!>

8-34

Cb

f
. -<?>

y.?.

EA$30580 CO...,
METHOD
'!>
The engine oper61t lon Is not normal and the
engine trouble wif11111ng light comes on.
1. Check:
Fault code number
..................
a. Check the fault code numBer displayed on
6
"!> the meter.
b.''1gentify the faulty system with code
"
c. ldent(f the probable cause of the malfunc-
.
t1on. 'b
%

..........
2. Check and repan;, the probable cause of the
malfunction. <>>y

.
Fault code No. ""1W fault code No.

Check and repair.
to "TROUBLE-
repair.

S'I':JOOTING
y.?.
on page

8-38.
Monitor tbg opera-
lion of the g.EU:Jsors
and the
diagnostic modec/.r.
Refer to "TROUB[If-
SHOOTING <>>

DETAILS" on page

8-38 and

"SELF-DIAGNOS-
FUNCTION AND
<t>b

CODE
on page 9-5.
y.?.

"
3. the reinstatement action for the fuel
injection'i;x_stem.
Refer to "CbJ;Jfinnation of service completion"
in the table in "TROUBLE-
SHOOTING DEf--,A.ILS" on page 8-38.
4. Set the main switfu; o "OFF", then to "ON"
again, and then checi<" 1bat no fault code num-
ber is displayed.
TIP
C'tt,another fault code number is repeat
(1) to (4) until no fault code mli:qper is dis-
"
5. malfunction history in the diagnos-
tic mode 1cgde No.62). Refer to "SELF-DIAG-
NOSTIC P('4N.CTION AND DIAGNOSTIC
CODE page 9-5.
''9
'.(?>

-"!>
? ..
FUE(,JNJECTION SYSTE!tt-

TIP--------"1,.---------
Setting the main switch "fa., "OFP' will not erase
the malfunction history. v.so
The engine operation is not fi9J mal, but the
engine trouble warning light ddes not come

on_
1. Check the operation of the
and ae}yators in the diagnostic mode.
to "TRC9\{BLESHOOTING DETAILS"
page 8-38.

"
. ..,
1 : Throttle signal 1
(throttle angle)
13: Throttle position signal 2
(throttle angle) v
14: Accelerator position signal 1
(throttle angle) <>>
15: Accelerator position 2
(throttle angle)
30: Cylinder-#1 ignition coil
31: Cylirt,der-#2 ignition coil
32: ignition coil
36: Injector lbl
37: Injector
38: Injector #3
48: Air induction solenoid

If a malfunction is de?ei;ted in the sensors or
actuators, repair or repla'Cie all faulty parts.
If no malfunction is detecied) n the sensors
and actuators, check and the inner
parts of the engine.

<t>b

y.?.

8-35

<t> ..

"!:>.
"
,.,
.?"0 FUEL

EA.,.,...I1 Cb
-
DIAGNOSTIC MODE
Setting the diagnostic mode v
1. Turn the main switch to "OFF". .s>f
2. Disconnect the wire harness coupler f;8ri;!,the fuel pump.
3. Simultaneously press and hold the button "1" and "RESET" button "2" , turn the main
switch to "ON", and continue to press the for 8 seconds or more.

4. Press the button to select the diagnoSti& mode "diAG".
6
5. Simultaneously pfeJ>s the "SELECT" and "RESET" !rt:Jttons for 2 seconds or more tiYset the diagnos
.
t1c mode.
TIP ' '
The diagnostic code numb;1fl4; appears on the
6. Select the diagnostic code corresponding to the fault code number by pressing
LECT' and "RESET" buttons. %,. ..
TIP v v.s>
The diagnostic code number appears on trn_e display (1-70). .'9 <?>
To decrease the selected diagnostic press the "RESET" button. Press the "RESET"
button for 1 second or longer to automaticatt9' <ttecrease the diagnostic code numbers.
To increase the selected diagnostic code the "SELECT" button. Press the "SELECT"
button for 1 secone,gr longer to automatically the diagnostic code numbe{t.
;, ;,
70 - 1 """'

7. Verify the operation of the sensor or actuator.
Sensor ope 6"!>
The data the operating conditions of appears on the display,.,
Actuator operation

"
Set the start/engine to "()" to operate the actuator.
TIP ' '
If the start/engine stop switch is "()", set it to "15()", and then set it to "()" again.
8. Tum the main switch to "OFP' to Cal'l ,pel the diagnostic mode. "! v.s>

"s, ':16
')J'
.
-"!>
.
SYSTEM\

Information diagnostic code number is organized in this manual as ill,Uows:
If a diagnostic coqe number has a corresponding fault code number, the information is shown in
DETAILS". (Refer to ''TROUBLESHOOTING DETAILS" 838.)
If a diagnostic code nClllJber does not have a corresponding fault code number, the is
shown in TABLE". (Refer to "SELF-DIAGNOSTIC FUNCTION DIAG
NOSTIC CODE TABLE" 95.)

Connect the wire harness to the fuel pump. 6"!>
y

YAMAI:f.A. DIAGNOSTIC TOOL
This the Yamaha diagnostic tool to identify malfunctions.
For informaliGJ.l about using the Yamaha diagnostic tool, refer to the operatl&.r;! manual that is included
with the tool.

v.s- Yamaha diagnost ic tool v.s-
<>> -?' - 9089Q-03215 <>>

Features of the nostic tool
You can use the Yamaha tool to identify malfunctions quicker than with comie.e.tional
wethods. <t>b 6 <t>b
By 1.9onnecting the adapter interta<fel>,which is connected to the US-& port of a computer, to a vehi8'(e<;
ECU<y,sing the communication cable, Y9u can display information thal,)s necessary for identifying
.. and for maintenance to display on the computer. The includes the sen
sor and information recorded in the ECU.
Functions Yamaha diagnostic tool
Fault Fault codes recorded on the ECU are read,\ il)d the contents are
v.s- displayed. v.s-
<> The freeze frame data (FFD) is the operation a mal
function was detected. This data can be used to ide1:l,li _fy when
the malfunction occurred and check the engine and
running conditions when it occurred.

ceynction diagnostic mode: <t>b,&heck the operation of the oeJJ>ut value of each sensor and
'

lnspee).ion mode: DetEl'rmine whether each sensor Ot>4.1ctuator is functioning prop- "

CO mode: Adjust the concentration of CO admissi6At during idling.
Monitoring Displays a graph of sensor output values operating
v.s- conditions. v.s-

. Records and saves the sensor output value in acttfaMri ving con
ditions.
"<1 "<1
Displays the logging data.
<t> <t>
rewrite: the ECU is reW"Figen using ECU rewrite data
.1-! by Yamaha. .1-! .?.
lgn'ffion timing adjustment, etc. cif"U,Jot be changed from the vehi-
cle's original state.

However, tool cannot be used to freely change the basic functions, such as ad
justing the ign'ffit>,g timing.
Connecting the YaQ),i!ha diagnostic tool <! v
Remove the protectJVeAcap "1 ", and then connect the Yamaha diagnostic tool "2" to l'he coupler.

8-37

<t>.. <t> ..
Logging mode:
View log:
"

FUEL

..
. (/ EAS2'14Q
TROUBLESHOOTING DETAILS
Th1s section describes the measures per fault code numbel>Jlisplayed on the meter. Check and service
the items or components that are the probable cause of the 'lBalfunction following the order given.
the check and service of the malfunctioning part have completed, reset the meter display
to the reinstatement method.
No.:
6
"!> 6"!>
Fault co<JO, number displayed on the inster when the engine failed to wor4S normally.
Diagnostit code No.: "
Diagnostic code number to be used

diagnostic mode is operated. Refer to "DIAGNOSTIC
MODE" on page 8-36.

. ...,_
Fault code No. 12

Item
Crankshaft no normal signals are received
from the crankshaft sensor .
.;a,
,Fail-safe system Unable to start engine

uc able to drive vehicle
...
"t>,o, "t>,o,
6,
code No.
"'

;,
...,y.?.
"'
v{; IJ,
Meter display -
Procedure -

Item Probable cause of job Confirmation of service
malfunction and check
oo,.
completion
v
1 Connection of crankshaft Improperly -+ Crank the engine.
position sensor coupler. Connect the coup ej; securely Fault code number is not dis-
Check the locking condition or replace the wire played -+ Service is finished.
>,.. of the coupler.

Fault code number is dis-

Disconnect the coupler and

played -+ Go to item 2.
"t>,o
<to
check the pins (bent or br<f.>"b

6"!>
terminals and locking '.i

r>y

c dition of the pins).
"

-"!>
FUEL SYSTEM

%
' '
c. c.
Fault code No.

12

'&
Crankshaft position sensor: no normal signals are
Item
.s>
'f
. <?_
from the crankshaft position sensor. <?>
""'-
2 Connection of wire harneS'S>"o1 Improperl y connected -t Crank the engine. "%
ECU coupler. .fonnect the coupler securely Fault code number is not

Check the locking condition !:i_; .replace the wire harness. played -t Service is finished.
of>Jhe coupler.

P: 'Jwlt code number is dis-

Dis'ej<lnnect the coupler and
y.?.
-t Go to item 3.
pins (bent or bro

ken and locking

condition pins).

3 Wire harness Open or short circuit -t Crank the

Replace the wire harness. Fault code numo@ri S not dis-
.s>
Between crankshaft position played -t Service is4-if1ished.
'f
'<?> sensor coupler and ECU Fault code number is di.s-
Y,;>
coupler. played -t Go to item 4.
'%

gray- gray
""<1
crankshaft position

6"!>
coupler and joint con-
6"!>
...

,,
blaciJD!J,Je-blacklblue
,,

Betwee'n joint connector and

ECU coupler.

black/blue-black/blue

4 Installed condil1'QP. of crank Improperly installed sensor Crank the engi'n'e.;
shaft position sen'S&>r. -t Reinstall or replace the Fault code numberds not dis
Check for loosenesif.-0r sensor. played -t Service is<lli.nished.
pinching. . <?>y., Refer to "GENERATOR AND Fault code number is df&.>
Check the gap (0.85 mm'% STARTER CLUTCH" on played -t Go to item 5. '%
(0.0335 in)) between the page 5-30.

crankshaft position sensor
i
1 the generator rotor.
6"1>
5 crankshaft position Checf<>4J:Ie crankshaft posi- the engine.
lion seifsor. Fault number is not dis

Refer to "CHECKI NG THE played is finished.

CRANKSHAFT POSITION Fault code is dis-
Cb
SENSOR" on page 81 01. played -t
6.

Replace if defective.
f Replace the ECU.
.s>
'f
'<?>
Refer to "REPLACING THE
'<?>
Y,;>
ECU (engine control unit)" on
Y,;>
'% '%

page 893.

...
.<)
Fault d"QS!e No. 13

6"!>

' '
Item Intake air sensor 1: open or circuit detected.
Fail-safe syste'll1:, Able to start engine

Able to drive vehicle

Diagnostic code No. v
'
03

'
Meter display
. ., <?_
Displays the intake air pressure.
. ., <?
>
8-39
-"!> "<0<

INJECTION SYSTEM

%
' '
c. c.
Fault 13

Item
v
Intake air pressure sensor 1: open or shoYt>_fircuit detected.
.s>
f
'A 'A
Procedure
...
Shift the transmission into gear, extend the then
'% operate the throttle while pushing the "(i)" side of th tarVengine

stop switch. (If the display value changes, the perform is OK.)
.<>.
Item Probable Maintenance Confirmation of seQ(ice
? , malfunction and chiJc;k

completion
}o .;>. .;>.

Connection of intake air pre'S- Improperl y connected -+

Turn the main switch to "Oil!".
sure sensor 1 coupler. Connect the coupler Fault code number is not dis-
the locking condition or replace the wire harness. -+ Service is finished.
ol'1!;!e coupler. FEt:Vt code number is dis-
Dis&.Qnect the coupler and Go to item 2.
check p1ns (bent or bro
v
.s>
ken and locking
f
...
condition o 1b pins).

2 Connection of Improperl y connected -+ Turn the main s\;iqjtch to "ON".
ECU coupler. Connect the coupler securely Fault code numbeh !l not dis-
Check the locking or replace the wire harness. played -+ Service is liqjshed.
of the coupler.

Fault code number is
? ,

Disconnect the coupler arfd.!t played -+ Go to item 3.

check the pins (bent or bro

terminals and locking

6-QDdition of the pins).
'A
0-A
3 Wir99{1arness continuity. Open or short circuit -+ main switch to "ON".

Replace the wire harness. Fault number is not dis-
.s>
f
Between intake air pressure played is finished.
...

sensor 1 coupler and ECU Fault code is dis-
'%
coupler. played -+ Go t'&::item 4.
pink-pink

Between intake air pressure

<t>b
sensor 1 coupler and>,j, oint
<t>b

? ,
?.;>. connector. ?.;>.

blue-blue

black/blue- black/blue

Between joint connector and

ECU coupler.

blue-blue

.. .
4 Installed of intake Improperl y installed sensor Turn the m(!jr switch to "ON".
air pressure 1 . -+ Reinstall or replace the Fault code ni:ioober is not dis-
Check for or sensor. played -+ is finished.
pinching. Fault code dis-
...
played -+ Go to
<t>b
6
. ,. .
8-40
"
INJECTIOt-l-Sy STEM

' '
c. c.
Fault code No.

Item pressure sensor 1: open or short circuit detected.
A
5 Defective intake air pressure the diagnostic Turn the main switch to "ON".
sensor 1. mode. No. 03) Fault code number is not dis-
When engi9,9 is stopped: played Service is finished.
at the Fault code number is dis-
6"!> current weather played G&.!&> item 6.
'.?
conditions is
'.?

At sea level: Appro (/ 101 kPa

(757.6 mmHg, 29.8 inHg)

1 000 m (3300 ft) above sea

Cb
level: Approx. 90 kPa (675.1
Cb

mmHg, 26.6 inHg)

<2Jl00 m (6700 ft) above sea
lev.el: Approx. 80 kPa (600.0
mm"R9., 23.6 inHg)
3000 ft) above sea
level: Ap t_9X. 70 kPa (525.0
mmHg,
6"!>
When engine s,p anking:
6"!>
'.?
Make sure that
'.?

value changes.

The value does not change

when engine is

Cb
Check the intake air pressure
Cb

sensor 1.

'
if defective.
to "CHECKING THE
AIR PRESSURE
on page 81 09.
6 Malfunction in ECU.
Replace
Refer to "R THE
6"!>
ECU (engine t egyol unit)" on
6"!>
'.?
page 8-93. y.?"<>
'.?

TIP ' '
If fault code numbers "13" are both indicated, take the actions specified for fault
"13" first.
Fault code No.
14 '<c:.oS'
f
Item
Intake sensor 1: hose system malfunction
(clogged or hose).
Fail-safe system Able to start
't>
6
Able to drive

"!>'- y
Diagnostic code No.

03

Meter display


Procedure the transmission into gear, extend the sidestand, and the!\o
ope,!;ate the throttle while pushing the "!JJ" side of the
stop"' sw tch. (If the display value changes, the performance is OK.)'
-"!>

'
n
% %
Fault code No. 14
.(.
.s>-9 Item Intake air pressure sens.pr 1: hose system malfunction
<\ (clogged or detached hos4ll J;_

'ftem Probable cause of Maintenance Confirmation of service
malfunction and check completion
1 of intake air pres-
su'fll, sensor 1 hose.
Che&; he intake air pressure
sensor hose condition.
2 Defecti ve intake air pressure
sensor 1.
& logged or detached hose -+
or replace the sensor

0-:o,
Execute the di! JlOStic
mode. (Code No: 0j3)
When engine is
Atmospheric the
current altitude and
the engine and let it idle
5 seconds.
Faulf '(:pde number is not dis-
played -+ Service is finished.
conditions is indicated.
At sea level: Approx. 101 kP<i< <t-
mmHg, 29.8 inHg)
100_P. m (3300 It) above sea
90 kPa (675.1 "
inHg)
2000 m (&:;!00 It) above sea
level: kPa (600.0
mmHg, 23.6 1i'i'W)
3000 m (9800 It)" above sea
level: Approx. 70 kfla (525.0
mmHg, 20.7 inHg)
When engine is
Make sure that the
value changes. <
l[he value does not change
engine is cranking. -+
the intake air pressure

Refer to "CF.l.J;CKING THE
INTAKE
SENSOR" on 8-1 09.
Throttle position sensor: ope'riltqr short circuit detected.
.<>.
Fail-si te system

Diagnostic code No.
_______

to drive vehicle
01, 13

" q

.s>
f
.<?>

'%
8-42

't-.
'
c.
Fault code No. 15

Item Throttle pos.itl<1 sensor: open or short circuit detected.
'A
01 Meter display Throttle position signal 1
11- 21 (fully close osition)
96-106 (fully open p0S)Iion)
Procedure
6"!>
Check with throttle valve<s;JMIIY closed.
6"!>

J< Check with throttle valves f811J& open.
y.?,.
?
'.?
),
13 Meter display position sensor signal 2
(fully closed position)
P.
(fully open position)

Procedure Check vvyh throttle valves fully closed.
Check wit'hqprottle valves fully open.
Item Probable cause of Maintenance job Confirmation of service

complet ion
'%
1 Connection of throttle posi Improperly -+ Turn the main switch to "ON".
lion sensor coupler. Connect the Fault code number is not dis-
.,
Check the locking cofl.gition or replace the wire played -+ Service is
y.?.
of the coupler. '.? J<
y.?.
Fault code number is iS';,

Disconnect the coupler ar'llq.
1


check the pins (bent or bro- 1.
ken terminals and locking

condition of the pins).
Cb

2 Connection of wire harness connected -+ Turn the main switch to "ON".
ECU coupler. Connec tq,e coupler securely Fault code number is not dis-
Check the locking condition or replace th.e wire harness. played -+ Service is finished.
of the coupler.
y.?
'%

check the pins (bent or bro-

ken terminals and <t>b
6"!>

condition of the pins).'!>,

Y, .? Y,
'.?
3 '-tlt Wire harness continuity. Open or short circuit -+ 'tlt Turn the main switch to

Replace the wire harness. Fault code number is not
1.
played -+ Service is finished. P. <eetween throttle position
coupler and ECU Fault code number is dis-
black!BII,:l e- black!blue
white-wfifte
black- blacif>y.?
blue-blue '%

4 Installed condition of throttle Improperly installe'EI-<9.ensor Turn the main switch to "ON".
position sensor. -+ Reinstall or adjusf'<t,ge Fault code number is not dis-
.,
Check for looseness sensor. played -+ Service is lrnished.
y.?.
pinching.
'.?
Refer to "ADJUSTING Fault code number is

THROTTLE POSITION SE - played -+ Go to item 5.

SOR" on page 7-12.

-6
"<0< -"!>

FOEL INJECTION SYS:[EM

%
' '
c. C'
Fault code No. 15

Item Throttle sensor: open or short circuit detected.
A
5 Throttle position sensor Measure throttle position Turn the main switch to "ON".
resistance. sensor res1s ance. Fault code number is not dis-
played Service is finished.
Refer to THE Fault code number is dis-
6"!>

played Go to item 6.
'.?
v,
"b
.?;,

6 Defective throttle

Check throttle position sen Turn the main switch to
sensor. %-o sor signal 1. Fault code number is not dls
5

the diagnostic played Service is finished.'" p,
1fi,gde. (Code No. 01) Fault code number is dis-
the throttle valves are Go to item 7.
fully c Qfed:
A value 01.11-21 is indicated.
When valves are fully
open:
A value of 96- is indi-
6"!>
cated.
6"!>
Check throttle positi&'l;bsen
'.?
sor signal 2.
'.?

Execute the diagnostic "

mode. (Code No. 13)

When the throttle valves are

closed:
p,
A lt.:jlue of 9-23 is indicated.
WhetrJhe throttle valves are
fully ope'"
A value 1 08 is indi-
cated.
An indicated is out of
the specified
6"!>
Replace the throttl.f<Jilg?Sition
6"!>
'.? '.?
vv./

sensor.

7 Malfunction in ECU.
Replace the ECU.
%.0 Refer to "REPLACING THE %.0

;I;CU (engine control unit)" on

p,
P&$Je 893.
"
Fault code No. 19
of

Item
Sidestand switcftiil break or disconnection of the black/red
lead of the ECU
.<>.
Fail-safe system
6"!>
Unable to start engine
e.,,
'.?
Unable to drive vehicle
-?.?.
'.?
"b
Diagnostic code No.

-1..
Meter display switch
"01\t' _,(sidestand retracted)
p,
extended)
Procedure Extend the sidestand (with the transmission in gear).
-"!> "
f
'<}
lead of the ECU Is detected. <>>
>Y.;>.
Y,;>.
Item Probable cause of<:>., Maintenance job Confirmation of
malfunction and completion
1 of sidestand ' ll,mproperl y connected -+ c the main switch to "ON",
)!Yitch coupler. Copnect the coupler securely 9d then extend and retract
the locking condition or the wire harness.
of th <I<OUpler. Fault 1;ode number is not dis
Discon"fh&ct the coupler and played' Service is finished.
check the<pj ns (bent or bra Fault is dis
ken locking played -+ GSl-JE item 2.
condition of
oo ..
v
2 Connection of Improperl y connected -+ Turn the main "ON",
ECU coupler. "Y.? Connect the coupler securely and then extend an r e.t,act
Check the locking or replace the wire harness. the sidestand. <:>
of the coupler. Fault code number is not
Disconnect the coupler and "%
b
played -+ Service is finished\
1
c t heck the pins (bent or bra

code number is dis-
e.Q terminals and locking y.?. -+ Go to item 3.
cofllljJion of the pins).

3 of main switch Improperl y connected -+ Turn thEi>.[lain switch to "ON",
coupler. Connect the coupler securely and then and retract
Check the I&Jsing condi tion or replace the wire harness. the sidestarf%
of the Fault code nuM\!>);r is not dis
Disconnect the and played -+ finished.
check the pins (bentrgr bra Fault code number iS>jJis-
ken terminals and played -+ Go to item
...
4 Connection of relay unit cou% Improperl y connected -+ Turn the main switch to
c g ler. the coupler securely c then extend and retract
Gl)_eck the locking condi tion o the wire harness. sidestand.
of coupler.
"
number is not dis
the coupler and Service is finished.
check t (bent or bra Fault co !l number is dis-
ken and locking played item 5.
condition of lil,j;l pins).

"
5 Wire harness cofitinuity. Open or short circuit -+ Turn the main switlsh to "ON",
f
Replace the wire harness. and then extend '<}>
y.?
Between main switch coupler the sidestand. Y.?-.,
'%
and relay unit coupler. Fault code number is not::'Qis

brown/red-black/red played -+ Service is
'%
main switch coupler Fault code number is dis- -> r..
cfb,.?
i:io.9 ECU coupler. c 'Ji)layed -+ Go to item 6.
blafll5bred-black/red
'.?

Between relay unit coupler

and sidestand switch cou-

pier.

Cb Cb

blue/black-blue/black

"-:b. "-:b ..
o o
8-45
-"!> "
f
.<>
lead of the ECU Is detected. <>>
>Y.;>.
Y,;>.
6 Defective switch. Execute the diagnostic Turn the to "ON'' ,
mode. (Code No. 20) and then exten Wd retract

<t>b
Shift the transmission into the sidestand. ..-it..

gear.
6
"!> Fault code number dis

;,
y.?.
Sidestand retracted: "l )IJ" played Service is

Sidestand extended: Fault code number is dis "

Replace if defective. Go to item 7.
7 Malfunction in ECU. Replace the ECU.

"0

oo ..
oo ..
v v
.s>
page 893.
.s>

> >
Fault code No.
..

20
..

Intake air pressure sensor 1 or intake air 2:
<t>b
when the main switch is turned to "ON", the intake
Item
sure sensor 1 voltage air pressure sensor 2' It- y
..
rsege differ greatly.
system Able to start engine


"0,_ "0,_
No. 03,04
.'!><! v
03 Meter
>
-9
<>>
Shift the transmission into gear, extend the and then

operate the throttle while pushing the"(?)" side of tfie<tart/engine

stop sw1tch. (If the display value changes, the pertornia9.d:e 1s OK.)
04 Meter display Displays the intake air pfesure.
,,

;,
Procedure f$Shift the transmission into ge% extend the sidestand, and the!),

operate the throttle while pushlffQ,the "(?)"side of the start/engine
stop switch. (If the display value the performance is OK.)
Item Probable cause of Maintenance job of service
and check completion
/. /.
8-46
' '
y y
.?"0 FUEL INJECTION SYSTEM

Q Q
%
code No. 20
v.s>f Intake ai r pressure sensor 1 or air pressure sensor 2:
Item <?> when the main switch Is turned to "O!'Jl", the Intake air pres-
sure sensor 1 voltage and intake air sensor 2 volt-
age differ greatly.
1 Defective ui\gke air pressure
sensor 1.
y.?.

a, Defective intake air pressure
sensor 2.
"!
Execute the diagnostic
mode. (Cocfe!f'Jo. 03)
When engine rs;topped:
Atmospheric pre"S$.J.lre at the
current altitude
conditions is indicateO'>.-.c
0 m above sea level: Aptlli9x.
101 kPa (757.6 mmHg, 29?&;
Turn the m<tln switch to "ON".
Fault code namber is not dis-
played -+ Servi&J.s finished.
Fault code numbef'is dis-
inHg) "!
.s>
3000 m (9800 ft) above sea f
level: Approx. 70 kPa (525.0 . <?>Y.?
mmHg, 20.7 inHg)
Displayed value is incorrect
-+ Check the intake air pres-
<t>b
sure sensoll>J .
Replace if .,y.?.
Refer to "CHECR[NG THE
INTAKE AIR PRES$!.)RE
SENSOR" on page
Execute the diagnostic Turn the main switch to "ON".
mode. (Code No. 04) %.. Fault code number is not dis-
When engine is stopped: l:llayed-+ Service is finished.
Atmospheric pressure at the code number is dis-
current altitude and weather Go to item 3.
conditions is indicated.
0 m above sea level: Approx.
101 kPa (757.6 mmHg, 29.8
inHg)
6
"!>
3000 m (9800'ft)_ above sea y.?.
level: Approx. (525.0
mmHg, 20.7 inHg)
Displayed value is inci)l(r,ect
-+ Check the intake air
sure sensor 2.
Replace if defective. "!
.s>
Refer to "CHECKING THE -9
INTAKE AIR PRESSURE <?>y.?
SENSOR" on page 8-109.
Replace the ECU.
Refer to THE <t>b
ECU (enginif<e.entrol unit)" on
page 8-93. \,.. y-?"0
8-47
-"!>
{>

Fault code No.
"0
21
"0

"' "'
Item
voS'
Coolant temperature sensor: open or short circuit de\ ected.

'6.
Fail-safe system

lst,ble to start engine

AB(ll to drive vehicle

Diagns stic code No. 06
"l;>.
, 6,
Meter d15Qiay Displays temperature.
;,
Procedure Compare the actually measured coolant tefl;perature with the

meter display value.

Item Probaffit cause of Maintenance job of service
check
"'
1 Connection of cool a'9t tern Improperly connected Turn the main switc(\,to "ON".
perature sensor coupler. Connect the coupler securely Fault code number is n ot dis-
Check the locking or replace the wire harness. played Service is finfS\_ed.
of the coupler. ""<1 Fault code number is dis-

Disconnect the coupler Go to item 2.
t heck the pins (bent or bro <t>b
6"!>

y.?.

conQi .Jlon of the pins).
.....
2 Connec1ign of wire harness Improperl y connected Turn switch to "ON".
ECU coup1EH. Connect the coupler securely Fault co E1':12, umber is not dis-
Check the condition or replace the wire harness. played is finished.
of the Fault code is dis-
Disconnect the and played Go to ife:"l) 3.
check the pins (ben w r bro '-9
ken terminals and
'.(?>

condition of the pins). "%.,_
...
3 Wire harness continuity. Open or short circuit Turn the main switch to
6"!>
the wire harness. code number is not dis-
coolant tempera pf<)_xed Service is finished.

lure coupler and ECU

coupler. Go to item 4.

green/white-green/white

Between coolant tempera-

Cb Cb
% ture sensor coupler and joint %

oo,. connector. oo,.
v
v
.s> .s>
'-9
'-9
'.(?> '.(?>

ECU coupler.

'% black/blue- black/blue '%

4 Installed condition of coolan( .. mproperl y installed sensor Turn the main switch to
sensor. or replace the J7?ult code number is not dis-
for looseness or sens,s.r. Service is finished.

number is dis-
playe Go to item 5.
-1,_
"'- "'-
8-48

'
c.
Fault code No. 21

,
i(et:p
A
Coolant temperature sensor:. or short circuit detected.
A
5 coolant tempera Execute the diagnostic the main switch to "ON".
tu ' sensor.
mode. (Code No. 06) F tJ..Il code number is not dis-
When engine is cold: Service is finished.

Displayed temperature is Fault caQe number is dis-
<t>b

close ambient temper- played to item 6.
y.?.
ature. '";,
y.?.

The displayEf<:l,!emperature is

not close to thS>ambient tern-
perature Cheek>'l!;le cool-
ant temperature

.s>
COOLANT TEMPERATURB <
f
.<
l>y_, SENSOR" on page 8-106. l>y_,
.. ..
6 in ECU. Replace the ECU. 0"<1

<t>b ECU (e%gine control unit)" on <t>b

page 8- a

Y,
,.,
Y,
..
Fault code No. 22
..
%
Item Intake air temperature open or short circuit detected.
'1'all-safe system Able to start engine

c:-
.s>
f
.<> .<>
code No. 05
y_,

Meter dis"jjl.a_x Displays the air temperature.
.<>.
Procedure
<t>b

Y.>.
Compare thee ctually measured air with the meter
display value. "!>,., L ...
Item Probable' cause of Maintefl.!ilnce job Confirmation of service
,,.
completion
%,_
1 Connection of intake air tern- Improperly Turn the main switch to "ON".
perature sensor coupler. Connect the coupler Fault code number is not dis-

Check the locking condition or replace the wire played Service is finished.
.s>
of the coupler.
.s>
f f
.<
.<
f?.layed Go to item 2.
the pins (bent or bro-

kei?.J_grminals and locking ""<1
of the pins).

.. _
2 wire harness connected Turn the switch to "ON".
ECU coupler,.., Connect securely Fault code nui:ber is not dis-
Check the lod?ing condition or replace th .. harness. Ser rce 1s f1n1shed.
of the coupler.
? ..


'?,
c:- condition of the pins).

.s> .s>
8-49
-"!> "<0<
,.,
SYSTEM-

%
' '
c. c.
Fault cod? N-% 22

Item
v
Intake air temperature sensor: open or shoit'<9rcuit detected.
.s>
f
A A
3 Wire harness Open or short circuit Turn the main to "ON".

Replace the wire harness.
Fault code numb not dis-
Between intake air tempera- played Service i

lure sensor coupler and ECU Fault code number is
cb
<t>b

coupler.
6
"!> played Go to item 4.
,.,
y.?.
y-?0(;

;;;,
Between intake air
lure sensor coupler and joint

connector.

Cb
Cb


ECU coupler.

.s> .s>
f
f

4 Installed of intake Improperly installed sensor Turn the main to "ON".
air temperature Reinstall or replace the Fault code not dis-
Check for loosenesS' -nr sensor. played Service is'fiaished.
cb
pinching.
6"!>
Fault code number is dl%

'.?
y
'.?
y
5 Defecti ve intake air tempera-"' Execute the diagnostic Turn the main switch to "ON"'."
sensor. mode. (Code No. 05) code number is not dis-
When engine is cold: p aJ'ii ed Service is finished.
Cb
Displayed temperature is
Fa number is dis-

close to the ambient temper- playe Go to item 6.

ature.

.s>
The displayed temperature is
.s>
f f

not close to the ambient tem-

y.? y.?
'%
perature. the intake
'%

air temperature sensor.

cb

Refer to "CHECKING

'.? y.?.
INTAKE AIR TEMPERA- '.?
y-?0(;

;;;,
TURE SENSOR" on

8-109.

6 I Millfunction in ECU. Replace the ECU.

Refer to " REPLACING THE


page 8-93.

oS' oS'
Fault code No.
y.?
'%
24
y.?
'%

02 sensor: no normal si gnals are received f rom the
Item

c,
<t
sor.
e.,,
system Aol!b to start engine
'.? -y-?0(;
"\

Able to drive vehicle 1<.
code No.
-

0
Meter dlspl i y-6 -

Procedure
v.s>
f
-
v.s>
f
v, v,
8-50
-"!> "
'-9
'<}
sor. <>>
>Y.;>,
Y,;>,
Item Probab'fe cause of Maintenance job of service
check
1 Installed condition 84.>
2
sen- Improperly installej;J sensor Start the engine, wat[i it up,

-) Remstall or the and then race it, or execute
sor. y.?.
<

sensor. the diagnostic mode.

No. 63)

Fault code number is not dis-
"" l:b

-) Service is finished.

code number is dis-

oo,.
playei -) Go to item 2.
v
2 Connect ign of 0
2
sensor Improperly connected -) Start the warm it up,
>
Connect the coupler securely and then it, or execute
coupler. y"'-.,
Check the condition
or replace the wire harness. the (Code
of the coupler.
No. 63)
Disconnect the and
Fault code not dis-
check the pins (ben bro
6"!> played -) Service i?fiQ!shed.
ken terminals and locl([i:J,%
'"'

\1,.
condition of the pins). "
..
played -) Go to item 3. "
3
Connection of wire harness Improperly connected -) Start the engine, warm it up,
coupler. Connect the coupler securely then race it, or execute
the locking condition or replace the wire harness.
mode. (Code
of tRe&coupler.
Disconn,ect the coupler and Fault ca.9e number is not dis-
check (bent or bro played 4 ervice is finished.
ken locking Fault is dis-
condition of tfi'e,_ins). played -) Go 4.
4 Wire harness conlipuity. Open or short circuit -) Start the engine, it up,

Replace the w1re ti'a,!;ness. and then race it, or

y.?.
Between 0
2
sensor OOJ,!pler the diagnostic mode.
<

and ECU coupler.
No. 63) "
gray/green-gray/green


"" l:b
pink/black-pink/black
played -) Service is finished.

Between 0
2
sensor coupler code number is dis-

and joint connector.
p -) Go to item 5.
oo,.

v
.s> .s>
'-9
red/white-red/white
'-9
'<}> '<}>
Y,;>
Y,;>
'% ECU coupler. '%



<t>b <t>b
fuse box 1.
6
"!>
y.?.
red/white-red/white '"'
y.?.
'lO 'lO
8-51
-"!>
FUEL SYSTEM

%
' '
c. c.
Fault code No.

24

'&
0
2
sensor: no normal signals are received from the&(\) -9! sen-
Item
.s>
'f
'<}

>y
""'-
5 Check fuel pressure. '% Refer to "CHECKING THE Start the engine, warm if'lif!l,

FUEL PRESSURE" on page and then race it, or

the diagnostic mode. (Code
1?,
6"!>

,,
y.?.
Fa'lil.J.! code number is not dis-

Service is finished.
Fault number is dis-

played to item 6.
c
6 Defective 0
2
'%e.,gsor. Check the 0
2
sensor. Start the warm it up,
and then race execute
.s>
Refer to "ENGINE
the diagnostic mo ef (Code
'f
'<}>
REMOVAL" on page 5-3.
No. 63) <>>
Y,;>
'%

played Service is finish
<t>
Fault code number is dis- 1>-
6
J)layed to item 7.
7 I Malfunction in ECU. the ECU.
,,

Refer fo "REPLACING THE


page 8-93.
c c
Fault code No.

25

Item
f
Intake air pressure sensor 2: open or short circuit
<>>
>
Fail-safe system to start engine
v.,, ...
Able4o drive vehicle
...
1?,
Diagn'QtiC code No. 04
>0

6"!>
Meter Displays th'f%;ntake air pressure.

Procedure Sh1ft the transmission into gear, extend the Slq,estand, and then

operate the throttle while push1ng the "<il" side'hbthe starVengine
Cb

stop switch. (If the display value changes, the pei'IC1!f _, mance is OK.)
Item Probable C' a!:!se of Maintenance job Conflrmatlon"-ot service
malfunction anE{fheck
'A 'A
1 Connection of intake Improperl y connected
Turn the main switch
sure sensor 2 coupler. ;:, Connect the coupler securely Fault code number is not
Check the locking or replace the wire harness. played Service is
of the coupler.

1?,
the coupler and

'P.)ilyed Go to item 2.
ch'e.s;k the pins (bent or bro-
y.?.
,,

ken f efJ!linals and locking

the pins).

8-52
"<0< -"!>

FUEL IIVclECTION

'
c.
Fault code No. 25

Item Intake air 2: open or short circuit detected.
A
2 Connection of wire harness Improperl y Turn the main switch to "ON".
'
ECU coupler. Connect the coupler < urely Fault code number is not dis-
Check the locking condition or replace the wire played Service is finished.

of the coupler.
...
"t< <t<

Disconnect the coupler an/4

Go to item 3. 6"!>
v4

y

.?.;;,
k n terminals and locking
"

3 Wire harness continuity. Open O"tO)jlhort circuit Turn the main switch to "ON".
wire harness. Fault code number is not dis-
Between air pressure played Service is finished.
sensor 2 and ECU Fault code number is dis-
coupler. played Go to item 4.

'<\
Between intake air

sensor 2 coupler and

<t<
connector.

!>y
6"!>
blue-blue
!>y
6"!>
'

.?.;;,

.?.;;,
" joint connector and "
EC oupler.

4 Installed condition of intake Improperl y sensor Turn the main switch to "ON".
air pressure sensor 2. Reinstall or 'feglace the Fault code number is not dis-
Check for looseness or
.'<?
played Service is finished. sensor. >y.?
pinching.
'%
'


8-53
Fault code No.
Item
5
6
v.s>'f Intake ai r pressure sensor 2: open or short circuit
"A "A
Defective intake air pressdrt, Execute the diagnostic Turn the main switch to
sensor 2. (Code No. 04) Fault code number is not
'W_!len engine is stopped: played Service is finished.
pressure at the Fault code number is dis
6
"!> altitude and weather Go to item 6.
'.? is indicated. '.? y.?.

At sea lev/31: Approx. 101 kPa

(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea
% level: Approx. 90 kPa (675.1 %
mmHg, 26.6 inHg)
v.s> 2000 m (6700 ft) above sea v.s>
'f level: Approx. 80 kPa (600.0
>y.? mmHg, 23.6 inHg) "Y.?
3000 m (9800 ft) above sea
Approx. 70 kPa (525.0
20.7 inHg)
6"!> Wh!!l)/.engine is cranking: 6"!>
'.? Make uJ.e that the indication '.? .,y.?.

value

The value does not change
when engine is cranking.
Cb% Check the intake air pressure Cb%
sensor 2.
v Replace if defective. v
Malfunction in ECU.
.s>-9 Refer to "CHECKING THE .s>-9

INTAKE AIR PRESSURE

SENSOR" on page 8 109.
the ECU.
Ref&lr to "REPLACING THE
control unit)" on
page
TIP ' '
If fault code "25" and "26" are both indicated, take the actions specified fortaglt code number
"25" first. Cb% o%
If fault code numbers "14" are both indicated, take the actions specified for fault number
"25" f. t v v
IrS . .s> .s>

Fault code No.
'2'
-'y.?

pressure sensor 2: hose system malfunction
p.,
Item
(cloggeit:-Rr detached hose).
6 6
Fail-safe sy:s_!em Able to start"'il@ine
v?.?
),


" "
Diagnostic code i'r' t;,
04

c
Meter display
"0

"0

FUEL
'
c.
'< code No. 26
'<a

':(
':(
':(
'(/
Intake ai r pressure sensor 2: syst em malfunct ion .s>

(clogged or detached hose). <?>
>Y.;>.
Y,;>.

Shift the transmission into gear, extend and then
operate the throttle while pushing the "(i)" s 19, of the starVengine

stop switch. (If display value changes, the fii%rlormance is OK.)
Item of
malfunctiorf'1}nd check
Maln1'W!ance j ob

Conflrmatl'qQ of service
compliJion
1 Condition of intake air pres- Clogged or hose Start the engine and let it idle
sure sensor 2 hose. Repair or replace ttfecsensor for approximately 5 seconds.
Check the intake air pressure hose.
0
':<Q Fault code number is not dis-

sensor hose condition.

played Service is finished.
oo,. oo,.
v v
oS' .s>
'.(?>
. Slayed Go to item 2.
>
2 Del(}&tive intake air pressure Execute the diagnostic

sen
mode. (Code No. 04)

When engine is stopped:

<t>b
pressure at the
<t>b

current altilbde and weather

y.?.
conditions isi b$cated.
y.?.

At sea level: Ap t;px. 101 kPa
(757.6 mmHg, 29:"B>JnHg)
1 000 m (3300 It) abo'7Jl sea
level: Approx. 90 kPa {6..1

mmHg, 26.6 inHg)

2000 m (6700 It) above sea&.s> oS'
'.(?> level: Approx. 80 kPa (600.0 '.(?>
Y.;>
mmHg, 23.6 inHg)
Y.;>
'% '%

3000 m (9800 It) above sea

level: Approx. 70 kPa (525.0

<t>b
mmHg, 29,-7 inHg)
<t>b
When eng1t:1e is cranking:
y.?.
Make sure tffaJ the indication
y.?.

value

The value does
when engine is crarlklng.
Check the intake air

oo,. sensor 2. vo,.
v
Replace if defective. v.s>
oS'
'.(?>
'.(?>
Y.;> INTAKE AIR PRESSURE Y.;>
'% SENSOR" on page 8 109. '%
v'l>, v'l>,

TIP
If fault code num"'5';Js "25" and "26" are both take the actions specified t iS'r>.Jault code number
"25" first '<>y '" '<>y
. h. <,t
If fault code numbers "26" and "37'' are both indicate<f..ot"ke the actions specified for fauifcode number

"26" first.
A
8-55
30

Item Latch .s>f
Fault code No.

Unable to
Unable to drive '\
Fail-safe system
Diagnostic code No.= 08 <t>b

Meter display '<?;, Lean angle sensor outpu'f'\iQitage '<?

0.4-1 .4 (upright) "0

16,_ 3.7-4.4 (overturned)
Procedure the lean angle sensor and incline it more than 65
Item
1
2
3
4

Probable cause of v.s> Maintenance job Confirmation of service v.s>
malfunction and check -9. completion -9.
The vehicle has overturned. Raise upright. Turn the main switch to "ON",
then to "OFF", and then back '\
to "ON".
<t>b Fault code num@er is not dis-
played-+ Servic'i?);> finished.
Fault code number i's_.l is-
played -+ Go to item :!'4 ,._
Turn the main switch to
then to "OFP', and then
Installed condition of Check the installed direction
angle sensor.
and condition of the sensor.

.s>
to "ON".
Fault code number is not dis- v
.s>
f

played -+ Service is finished. f
y<?

Fault code number is dis- .
'\
Defective lean angle sensor. Execute the
mode. (Code N'6' b08)
6
"!> Replace if
Refer to
LEAN ANGLE SENSuR" on
Malfunction in ECU.

.., page 8-101 .

, eplace the ECU.
R' eJer to "REPLACING THE
ECtl<;(engine control unit)" on

Turn the main switch to "ON",
then to "OFP' , <w.d then back
to "ON". "!>,
Fault code numbef r$ not dis-
played -+ Service is fll'liJ>hed.
Fault code number is d1s'; -o

Fault code No. 33
%
<t>b
Item
6
"!> Cylinder-#1 ignition c'au; open or short circuit in t he
'<? primary lead of the ignition coil. '<? ...

Fail-safe system f/'ble to start engine (depending on the number of faulty
A'bjg to drive vehicle (depending on the number of faulty
'2>. "'
Diagnostic code No.
....
'
-"!> "
'-9
'<}
primary lead of the cyllnder-#1 lgnltlon>coll.
>Y.;>.
Y,;>.
Act uat ion

Actuates the cylinder-#1 ignition coil five tim'%\ at one-second

intervals.

Illuminates the engl ne trouble warning light. ..

Procedure
'\b
Check that a spark f"generated five times.
'\b
y.?. y.?.

Connect an

Item Probable cause of Maintenance fop Confirmation of service


complet ion
Cb Cb
Connection of cylinder-#1

Start the engine and let it idle
1>
i.gnition coil coupler. t9r approximately 5 seconds.
Cl:jeck the locking condition or replace the wire harness. code number is not dis-
of coupler. plafe,Q -t Service is finished.
the coupler and Fault number is dis-
check tfie<ins (bent or bro played to item 2.
ken and locking

condition of
<t>
e.,_
2 Connection of Improperly connected -t Start the engine let it idle
ECU coupler. " Connect the for approximately 5 seconds.
Check the locking condition or replace the wire Fault code number is not dis-
of the coupler.

played -t Service is finished.
Cb

check the pins (bent or bro played -t Go to item 3.
v.s>
cona!tion of the pins).
'-9
'<},
3 Wire 'Riirness continuity. Open or short circuit -t Start engine and let it idle

Replace the wire harness. for 5 seconds.

Between cylinder-#1 ignition Fault code"' 'tt!lmber is not dis-

coil coupler <wd ECU cou- played -t Sef!\Oce is finished.

Fault code is dis-
y.?.
played -t Go to 4.

4 Installed condition of cylin- Improperly Start the engine and let it idle

der-#1 ignition coil. coil -t Reinstall or rep 8:f! for approximately 5 seconds.
Cb
Check for looseness or the ignition coil.

pinching. played -t Service is finished.
v.s>
t,fcult code number is dis-
'-9 p -t Go to item 5.
'<}
5 cylinder#l ignition Measure the primary coil engine and let it idle
coil.
resistance of the cylinder-#1 for appr8J9p ately 5 seconds.

ignition coil. Fault code"tlJ.Jmber is not dis-
Replace if ottt of specifica- played -t is finished.

tion. "!> Fault code num'b.er is dis-
y.?.
Refer to THE played -t Go to ite't9 6.

IGNITION COILS..,0-Q page "
8-100.
"' "'
8-57
-"!>
FUEL SYSTEM

' '
c. c.
Fault code No.

33

'(/
Cylinder-#1 ignition coil : open or short circuit in the
Item
.s>
'-9
'<}
primary lead of the cyllnder-#1 Ignition coli . <>>
>y.,
Y,;>.
6 Malfunction in ECU. Execute the diagnostic

mode. (Code No. 30)
">
tf)lo spark Replace the
li.

,,
Refe&to "REPLACING THE
,,

ECU fengine control unit)" on

page 8-93.

" "
Fault code No.

34

v
Cylinder-#2 ignition coil : open or short circuit in the
Item
.s>
'-9
primary lead of the cylinder-#2 ignition coil . -9. <>>y '<}
>y
Fail-safe system to start engine (depending on the number of faulty
Ab'l' E%.!_0 drive vehicle (depending on the number of faulty cylinderS')g
Diagrl'ftStiC code No. 31

6"!>
,, ,,
Actuates tll'E; cylinder-#2 ignition coil at one-second
intervals.
Illuminates the engine trouble warning light.

Procedure

Check that a spark is generated five times.

Connect an ignition checker.

"! "!
Item Probable cad'se of Maintenance job Confirmation of.;;ervice
malfunction and
.;> .;>
1 Connection of Improperl y connected Start the engine and let
1gnit1on co11 coupler. Connect the coupler securely for approximately 5 secon s""'
Check the locking condition ' replace the wire harness. Fault code number is not dis-
li.
the coupler.
is finished.
Of$connect the coupler and
y.?.
F{iuJt code number is dis-
pins (bent or bro-

playe-1 Go to item 2.
ken tefuJ,inals and locking

the pins).

0
2 Connection_ harness Improperl y connected Start the and let it idle
ECU coupler.

v Connect the coupler securely for approximatSlyJ> seconds.
Check the locking tpndition or replace the wire harness. Fault code not dis-
of the coupler. <>> played Service is fiaished.
Disconnect the Fault code number is
check the pins (bent or played Go to item 3.
ken terminals and locking ">

li.
of the pins). 1:-b

3 harness continuity. or short circuit stew the engine and let it idle
Replace the wire harness. for 5 seconds.

Between cylinder-#2 ignition Fault number is not dis-

coil coupler and ECU cou- played ...:P.lil,ervice is finished.
pier. Fault code rugnber is dis-
gray/red-gray/ red played Go fl.titem 4.
"' "'
v v
8-58
-"!>
FUEL INJECTIO"\SYSTEM

' '
c. c.

Fault code No.
%

Item
ignition coil : open or short circuit detected in thi{ ',
prlmar.y, lead of the cyllnder-#2 Ignition coli .
Y,;>.

4 Installed condition of cylin- lmprb(ilerl y installed ignition Start the engine and let it idle
der-#2 ignition coil. coil -)
or replace for approximately 5 seconds.

Check for looseness or the ignitiol\f:oil. Fault code number is not dis-
pinching.
6
"!>

played -) S.rvice is finished.

,,
y<?.
Fault code is dis-

played -) Go t&.iJJ!m 5.
5 Defective Measure the primary coil Start the engine anltJ_et it idle
1
resistance of the cylinder-#2 for approximately 5 si!Q_Qnds. COl . o...,
"0
ignition coiL Fault code number is ndfi;!is-

oo ..
Replace if out of specifica- played -) Service is finishe'Gt v
v

Fault code number is dis- ,

R!ifer to "CHECKING THE played -) Go to item 6.
IGf.lt!ION COILS" on page
81 o&...,.,_
6 Malfunction in ECU. Execute diagnostic
6"!> mode. (Coa&4;!o. 31) 6"!>
,,
No spark -) the
,,

ECU. "


Cb
page 8-93.
Cb

Fault code No. 35 v.s>
v

Item
ignition coil : open or short circuit detected in the
primary I .. of the cyllnder-#3 Ignition coli .
Fail-safe system Able to start eri.i,re (depending on the number faulty cylinders)
6"!>
Able to drive on the numbet ot faulty cylinders)
,,
' .;>
Diagnostic code

32
'tl-

Actuation

Actuates the cylinder-#3 ignition coil five times at

intervals.

!JJJ.uminates the engine trouble warning light.
Procedure that a spark is generated five times.
c'bnJl,ect an ignition checker.
"< v

Item Probable cause of job Confirmation of servic-e
malfunction and check ""<1 completion

1 Connection of cylinder-#3 lmproperl 9'tfonnected -) Start the engine and let it idle
ignition Connect securely for 5 seconds.
Check the lo01Sjng condition or replace the -v.t!f,e harness. Fault code is not dis-
of the coupler.

"
played -) is finished.
Disconnect the and
Fault code dis-
check the pins (ben bro- played -) Go to
ken terminals and
"' "'
v v
"<0< -"!>
'if
FUEL INJECTION SV$J EM

%
' '
c. c.
Fault code No. 35

fl;
Item
coil : open or short circuit detected in the
primary leact:of the cyllnder-#3 Ignition coli .
-?,_
2 Connection of wire harness lmproperi Y"connected -t Start the engine and let it idle
ECU coupler. Connect the ;:>6ller securely for approximately 5 seconds.
Check the locking condition or replace the rg harness. Fault code number is not dis-
b
played -t finished. of the coupler. "!>

Disconnect the col$Jer and
?.?. Fault code numberi S,dis-
check the pins (bent 8rrJ:ro

played -t Go to item

ken terminals and


c
3 Wire harness continuity. or short circuit -t Start the engine and let it idle f!\
the wire harness. for approximately 5 seconds.
cylinder-#3 ignition Fault code number is not dis-
coil and ECU cou played -t Service is finished.
pier. Fault code number is dis-
played -t Go to item 4.
4 Installed condition of cylin- Improperly instaltt!d ignition Start the engine and let it idle
der-#3 ignition cdib coil -t Reinstall for seconds.
'1,
Check for looseness A?r the ignition coil. Fault code number1S;_,not dis-
pinching.
"
played -t Service is

Fault code number is di "%
%.0

5 Defective cylinder-#3 ignition the primary coil Start the engine and let it idle fl;
coil. rEf s_ifrtance of the cylinder-#3 for approximately 5 seconds.
igni le>_Q coil. Fault code number is not dis-
Replace-j f out of specifica- played -t Service is finished.
lion. ?if Fault code number is dis-
Refer to THE played -t Go to item 6.
IGNITION C II;$" on page
6.
8-100. -><t.b,.
6.
6 Malfunction in ECt h h Execute the
v,if

mode. (Code No. 32)

No spark -t Replace the

ECU.
Cb
Cb

(engine control unit)" on
"
S-93.
Fault code No. 39
v>y

" Item Injector: open or sl:lort circuit detected.
.<>,
Fail-safe system
6"!>
Able to start engine (dep$Mlding on the number of cylinders)
'if
Able to dri ve vehicle (depeil'd.[lg on the number of faulty cwinders)
'1,
"
Diagnostic code No.

v ..
36 Actuation ActQ,ates injector #1 five times at one-second intervals.

the engine trouble warning light.
0
fl;
Procedure Check tfi'a1 injector #1 is actuated five times by listening for the
'<l'
operating
-"!>
,,
FUEL

%
' '
c. c.
Fault code No.

Item open or short circuit detected.
. " ir
A
37 Actuation #2 fi ve times at one-second intervals.
Illuminates e engine trouble warning light.
Procedure Check that inj eetp r #2 is actuated five times by listening for the

operating
38 Actuation
'.?
Actuates injector #3 times at one-second

Illuminates the engine trouble warning light.

Procedure

Check that injector #3 is actuated five times by listening

operating sound.
0
Item Probable cause of .. Maintenance job Confirmation of ..
malfunction and check v
'4
complet ion 'c:: l!>
1 Identify the malfunctioning the diagnostic -
injector. mo eb(Code Nos. 36, 37,
38)
Identify that does
6"!>
not operating
6"!>
'.?
sound.
'.?

Perform the folloWing proce

dures for the defective injec

tor.

'b Refer to "CHECKING THE 'b

FUEL INJECTORS" on page

8111.

2 Connection of injector #1 , #2, rr;uproperly connected Execute the diagnostic
and/or injector #3 coupler. C6JJ%ect the coupler securely mode. (Code Nos. 36, 37,
Check the locking condition or re the wire harness. 38)
of the coupler. No operating sound Go to

item 3.
"t>b
check the Pigs (bent or bro

Operating Go to
ken terminal5vWld locking
y.?.
item 7. '.?;,
condition of

3 Defective injector #'1'>.,#2, Measure the injector resis Execute the diagnost!f
and/or injector #3. tance. mode. (Code Nos.

Replace if out of specifica- 38)

lion. No operating sound GoTh c::
to "CHECKING THE item 4. I!>
INJECTORS" on page Operating sound Go to

item 7.
4 Connection of wire harness lmprop"&Jx connected Execute the diagnostic
ECU coupler. Connect securely mode. (Code Nos. 36, 37,
Check the fQS:king condition or replace t harness. 38) 6"!>
of the couplef.?;, y.?. No operating-tound Go to
Disconnect and

item 5.
check the pins or bro Operating sound to
ken terminals and lot:lll.ing item 7.
'b

<t>. <t>.
"
FUEL SYSTEM

'
c.
Fault code No. 39

Item Injector: open or detected.
A
5 Wire harness continuity. Open or short Execute the diagnostic

Replace the wire mode. (Code Nos. 36, 37,
Between injector coupler 38)
ECU coupler. ".it .No operating sound Go to

#1 6. e
y.?.
sound Go to

item' .

bluelblac
Between iniefB!or coupler and
relay unit coup1e:r.!>
red/blue-redlbluef

Refer to "REPLACING

ECU (engine control unit)

6
page 8-93. "-it

e
7 the fault code.
,,
I Sf1 the engine and let it idle
"
for proximately 5 seconds.

Check that the fault code

number is not displayed.

Fault code No. 41

Item Lean angle sensor: or short circuit detected.
>
:fail-safe system Unable to start engine
.. ,

Unable to drive vehicle

code No. 08 e"b
b

Meter dls'pJay Lean arigle sensor output voltage

0.4-1.'111&upright)
"
3.7-4.4

Procedure Remove the sensor and incline it more than 65
degrees.
Item Probable cause of Maintenane, j ob Conf irmation of service

completion

Connection of lean angle Improperly connected Turn the main switch to "ON",
.<)
sensor coupler. Connect the coupler secure! then to "OFP' , and then back
.. .it Check the locking condition or replace the wire harness. -><t .to "ON".
coupler.
?,
'fJ!ult code number is not
the coupler and
Service is finished.
chec the pins (bent or bro-

Faulf code number is dis-



"'0,
-"!> "<0<

INJECTION SYSTEM

%
' '
c. c.
Fault 41

Item
v
Lean angle sensor: open or short circuit
.s>
'f
'A 'A
2 harness Improperl y connected Turn the to "ON",
ECU coupler. Connect the coupler securely then to "OFP' , then back
Check the or replace the wire harness. to "ON".
of the coupler. ".it.. Fault code number dis
Disconnect the 6"!> played Service is fi?rished.
">< check the pins (bent Fault code number is

ken terminals and locking "

played Go to item 3. "

. condition of the pins).
3 Wj re harness continuity. Open or short circuit TillJ.n the main switch to "ON",
"0
Replace the wire harness. "OFF", and then back

Between lean angle sensor to "OI'il''
.s>
coupler and ECU coupler. Fault number is not dis-
'f
yellow/green-yellow/green played S!ilrvice is finished.

Between lean angle sensor Fault code is dis-
'%

coupler and joint connector. played Go tO' d$t,m 4.

blue-blue

Between joint connedgr and

"><
?.?.
ECU coupler.
?.?.

blue-blue

1!>.
1!>.
4 I lean angle sensor. Execute the diagnostic ra,w. the main switch to "ON",

mode. (Code No. 08) and then back
Replace if defective. to "O w
.s>
Refer to "CHECKING THE Fault cocfe number is not dis- 'f

LEAN ANGLE SENSOR" on played is finished.

'%
page 8 101 . Fault code numaer is dis-

Go 5.
5 Malfunction in Replace the ECU. "

Refer to "REPLACif'fu. THE
"><
?.?.
ECU (engine control on
?.?.

page 893.

. .
Fault C'o.Qe No. 42

"0

Speed sensor: no normal signals from the

A
.s>
speed sensor. .s>f
'f

'A
Item

B Neutral switch: open or short circuit is
'%
"
c Clutch switch: open or short circuit is detected.
...

Fail-safe system

Able to start engine
6"!>

"><
to drive vehicle

"
DiifQP.OStiC code No. 07
' '
Meter Vehicle speed pulse Cb
"0
0- 999

8-63

FUEL SYSTEM
'
c.
Fault code No. 42

A
Speed sensor: no signals are received from the
-
speed sensor. <?>

Y,;>.

6 Neutral switch: open or is detected.

c Clutch switch: open or short detected.
<t>,o,.,
6 o,.,
Procedurl!i' Y.?. Check ina_!, the number increases when wheel is rotated.
The numbe'lijs cumulative and does not each time the wheel
is stopped. ..
Item Probable cause of job Confirmation of service

complet ion

1 Locate the malfunction. Execute the Value does not increase
mode. (Code No. 0 )?. Go to item 2.
- Rotate the rear wheel'&t

hand and check that the

cated value increases.

indication Go to "t>,o s xecute the diagnostic

mbf!e. (Code No. 21) in section 6 for the
y.?.
Wh'&i;l the transmission is in

"
When is in
gear with tite clutch lever
released:

When the transmfs.J>ion is in Incorrect Go to
gear with the item 2 in section C for the
- squeezed and the clutch switch.

retracted: "ON"

2
if.onnection of speed sensor
Improperly connected l<:fxecute the diagnostic
the coupler securely (Code No. 07)
Cifegk the locking condition foreplace the wire harness. Ro'tl;le the rear wheel by
of

han<f.a9,d check that the indi

the coupler and cated Value increases.
..
Value increases Go to

item 6 and delete the fault
Cb
condition of the pins). code.

Value does not increase
oo ..
v
Go to item 3.
.s>4
- 3
Connection of wire harness Improperl y Execute the diagnostic

ECU coupler. Connect the coupler mode. (Code No. 07)

Check the locking condition or replace the wire Rotate the rear wheel by

the coupler.
..,.
f.qand and check that the indi
the coupler and
6"!>
value increases.

Va increases Go to
ken tf<91inals and locking item delete the fault

code .
..

c
Go to item 4.

... ,.
8-64
-"!>
FUEL INJECt tQN SYSTEM

%
' '
c. c.
Fault code No.

42

Speed sensor: no normal signals are received from
sensor.
Item
B switch: open or short circuit is detected.
c Clutch open or short circuit is detected.
6 6
4 Wire haPtljlSS continuity. Open or s" grt circuit Execute1l),e diagnostic
Replace the"wire harness. mode. No. 07)

Between speed sensor cou Rotate the wheel by

pier and ECU coupler. hand and the indi

white/yellow-white/yellow cated value

Between speed sensor cou Value increases q. to
pier and joint connector. item 6 and delete the
.so
blue-blue
d .s>
'f
co e. -9
'<?>
black/blue-black/blue Value does not increase <?>
Y,
joint connector and Go to item 5.
'
coupler.

5 Malfuncffb9 in ECU. Replace Go to ite'%6 and delete the

Refer to "RE LACING THE fault code.


page 893.

Cb Cb
6 Delete the fault Turn the main switcff.tg "ON",
and then rotate the rear v
.so
wheel by hand. .sof
'f
'<?>
Start the engine, and input
Y,
'%
the vehicle speed signals by '

operating the vehicle at 20 to

30 km/h (19 mi!h).
6"!>
<t>b
The f<w.lt code can also be

deletedlt>y activating the
'.? y.?.

diagnosti:t:ode and select-

ing diagnos number

"63".

0 0
Fault code No.

42


Item
'
B Neu'trii!l switch: open or short circuit is detected.

6<'!
c Clutch open or short circuit is
"""'- <'!
Fail-safe Able to start
/.?),

Diagnostic code No.

21

Fault code No.
Item
v.s>f A Speed sensor: no normal signals are received from
<

sensor. <?>

s' " : utral switch: open or short circuit Is detected. '%'1$
C switch: open or short circuit is detected.
' h. 6 iJ
-,"
Neutral ""Y.?. -v,.,;, Y.?.
"ON" transmission is in
Meter disPijiY
..
"OFF" (when the transmission is in gear clutch lever
released)
..

Procedure Shift the transmission.
Item
1
2
Probable
malfunction and cll,sck
>
Maintenance job
Locate the malfunction. Execute the diagnostic
"<l mode. (Code No. 07)
6"!>
,.,

..

Cb

.s>
''9
'.(?>
'B_P.tate the rear wheel by
and check that the indi
increases.
.?.
diagnostic
mode. (Code No. 21)
When the transmission is in
neutral: "ON"
gear with the clutch lever
released: "OFF"
'Saueezed and the sidestand
iS'-"r,gtracted: "ON"
.. "
of neutral switch

Check condition
of the couPfeb
Disconnect ttie-4;_oupler and
check the pins or bro-
ken terminals and fo.Gking
condition of the <?
>
yo

'\)
lmprd" J3. WIY connected -7
Conneci'the coupler securely
or replace the wire harness.
Confirmation of Sfl.rvice
completion ''9 <?
>
Go to item 2 in section A
the speed sensor.
<t>i>

6"!>
,., ;,
I -7 Go to
item 2. ..

Cb

.s>
''9
'.(?>
y.?.

Incorrect indication ->
item 2 in section C for the
clutch switch.
<t>i>
ExedtJ!e the diagnostic
mode ... No. 21)
When thEfJJ:ansmission is in
neutral: "OKI'--
When the is in
gear with the lever
released: "OFP' v
Correct indication -7t -o to
't 9
1 em . y.,
Incorrect indication -7 Go t0
0

y.?.

6"!>

8-66
"'1
..

Cb

.s>
''9
'.(?>
yo

<t>.-
'
c.
Fault code No. 42

A
Speed no normal signals are received from the speed
sensor. <?>
Item
Y,;>.
B Neutral switch: op'tn or short circuit Is detected.
.....
c Clutch switch: open or circuit is detected.
'
6 6
'5-..
Connection of wire har'fteJ1S Improperly connected -t""Y.?. Execute the diagnosticr '"' h
"
ECU coupler. Connect the coupler secure'iy mode. (Code No. 21)
Check the locking .. or replace the wire harness. When the transmission is
of the coupler. neutral: "ON"
Cb

check the pins (bent or bro gear with the clutch lever
oo ..
released: "OFP'
v
.s>
Correct indication -t Go to
'-9
'.(?>
item 9.
Y,;>
'%
Incorrect indication -t Go to

item 4.
4 Wire harness continuity. Open or short Execute the diagnostic

6"!>
Replace the wire mode. (Code No. 21 )
6
"!>
y.?.
'"'
Between relay unit When the transmission i s..ln

and gear position sensor " neutral: "ON"
"'
coupler. When the transmission is in
blue-sky blue gear with the clutch lever
Be ween relay unit coupler released: "OFF"
and coupler Correct indication -t Go to
black/yeltgw- black/yellow item 9.
'-9
'.(?>
item 5.
y"'.;,.
5 Defective relay unit. Check the relay '6ii!il. Execute the diagnostic
Refer to THE mode. (Code No. 21)
6"!>
RELAY UNIT (DIODE)o,p n When the transmissiQD is in
page 899. neutral: "ON" "!>,
y.?.
'"' When the transmission

"
..

released: "OFF"

Cb
Correct indication -t Go to

item 9.

oo ..
v
item 6. .s>

6 Defective gear position sen Check the position sen- Execute the diagnostic
sor (neutral circuit). sor. mode. (Code No. 21)
Refer to "CHECKJI),J.G THE When the transmission is in
GEAR POSITION neutral: "ON"

6"!>
onpageB-1 10. .. When the transmissi0(! is in
y.?.
'"'
y.?. gear with the clutch JeJ' eJ. h

released: "OFF" "'

Correct indication -t Go

.. ..

item 9.
Cb

item 7.
v.
"
}i,
FUEL INJECTION

' '

c.
Fault code No. 42

A
Speed no normal signals are received from the speed
sensor. <?>
Item
?.;>_
B Neutral swltch:11"Ren or short circuit Is detected.
.....
c Clutch switch: open circuit is detected.
"
6 6
1.
Faulty shift drum Malfunction Replace'tj;Jl Execute the diagnosil & h
detection area). shift drum. mode. (Code No. 21)

Refer to "TRANSMISSION" When the transmission is

on page 5-76. neutral: "ON" 11-.
<1

oo ..
released: "OFP'
v
.s>
Correct indication Go to
"-9
".(?>
item 9.
?,;>
'%
Incorrect indication Go to

item 8.
8 Malfunction in ECU. Replace the ECU. ""-it.

6"!>
Refer to
6"!>
'.?.
,,
ECU (engine control
,,

page 8-93. "

9 Delete the fault code. Turn the main switch to "ON'fot\ 11-.
<1 and then rotate the rear

wheel by hand.

.s>
the vehicle speed signals by
"-9
".(?>
operating the vehicle at 20 to
?,;>
'%
30 km/h (19 mi/h).

The fault code can also be

delete by activating the diag-
6"!>
<t>b
nostic mode and

..
diagnostic code
. .,_ ?,;>L ?_,,
.. A. ..A.
Fault code No. 42,

A
sensor: no normal signals are received from the speed
sensof';, -6
..
Item
B Neutral open or short circuit is detected.
c Clutch swltch?.qgen or short circuit Is detected.
Fail-safe system Able to start engine
":;:
"
6"!>
6"!>
Dj agnostlc code No.
.,
rt 1

....
" "
Meter display switch
.. (when the clutch lever is squeezed with the transmission 11-.
in and when the sidestand is retracted)
the clutch lever is squeezed with the transmission
in gear when the side stand is extended)
-"!> "
A '-9
'.(?> sensor. <?>
Y,;>.
Item
'%
6 Neutral switch: open or short circuit is

c Clutch switch: open or short circuit Is detected?<t..

6
Procedure ""y.?.

Operate the transmission(vgjutch lever, and sidestand.

i tem Probable cause of Maintenance Confirmation of serv1ce


completion

1 c the malfunction. Execute the diagnostic c
does not increase
mode. (Code No. 07) 11 to item 2 in section A for
oo ..
v Rotate the rear wheel by sensor.
.s>
'-9 hand and check that the indi
'.(?>
cated value increases.
'.(?>

'%
Execute the diagnostic Incorrect to

mode. (Code No. 21) item 2 in secti<Th for the
..
"t>,o When the is in neutral switch. "t>,o

neutral: "ON" "!>,

y.?.
When the transmisshv is in
y.?.

gear with the clutch

released: "OFF"

When the transmission is
indication Go to
"0

squeezed and the sidestand
.s>
retracted: "ON"
.s>

2 Clutch leV' %,adj ustment. Refer to "ADJUSTING THE Execute tfi% diagnostic
CLUTCH LEVER FREE mode. (Code><S.l o. 21)

PLAY" on page 3-11. When the clutcl)dever is

"t>,o
6"!>
released: "OFF" -><t-,o
When the clutch
y.?.

squeezed: "ON"

Correct Go i'o

item 9.

Incorrect indication Go to
c
3.

3 Col1(1ection of clutch switch Improperly connected the diagnostic
couplef. Connect the coupler securely mode-:.' ..(Code No. 21)
Check iill}j ocking condition or replace the wire harness. When ttfu;,clutch lever is
of the coup1fr{; released:
Disconnect t and When the chlfGJ:! Iever is
check the pins (b,ent or bro- squeezed:
ken terminals
6"!>
Correct Go to
condition of the pins

item 9.

Incorrect indication 'B9 to
\1..
"

item 4.
8-69
'
-"!> -u

FUEL INJECTION-?SYSTEM
..

0
c.
code No. 42

'&
Speed sensor: no normal received from the speed
.s>
A 'f
'<?> sensor. <?>

""'-
Item
'%
B Neutral switch: open or short circuit is

.<)
Clutch switch: open or short circuit Is .
..
c
<t>.o,.,
6
4 Connection of"WjJ;e harness Improperl y c'6mJ!ected -t Execute the dta'Jnostic
ECU coupler. Connect the securely mode. (Code
Check the locking condition or replace the When the clutch lever is
of the coupler. released: "OFP'
Cb
When the clutch lever is
-<0


squeezed: "ON"
ken terminals and locking Correct indication-t Go to
of the pins). lsJ)em 9.
'<?>
I rfc::9rrect indication -t Go to

itenif-o
0 '%
6 .
'
5 Wire hafA.ess continuity. Open or short circuit -t diagnostic
";0
Replace the wire harness. mode. (Co'Cl% No. 21)

Between EG!J coupler and When the chl'fcb lever is
y.?.
relay unit released:

When the clutch lever is
Between relay unif c;;pupler squeezed: "ON"
and clutch switch cou'R!er. Correct indication-t Go to
-<0
item 9.

black/red-black/red .. Incorrect indication -t Go to

'G
item 6.
6 .
'
6 oewcti ve relay unit. Check the relay unit. the diagnostic

Refer to "CHECKING THE mo<ie._ (Code No. 21)

RELAY UNIT (DIODE)" on Whenqlile clutch lever is

page 8-99. released':"-%;?FP'

6"!>
When the c'lliljch lever is

squeezed:
y.?.

Correct Go to

item 9 .
..

item 7.

6 .
'

Defective clutch switch. Check the clutch switch. Execute the diagnostic

ls>f
Replace if defective. G (Code No. 21)
Refer to "CHECKING THE the clutch lever is
'<?>
SWITCHES" on page 8-89. re SJ\Sed: "OFF"
'%
Whe'ilt<)he clutch lever is
squeefeg: "ON"

Correct iilaication-t Go to

6"!>
't 9

1 em .
y.?.
Incorrect -t Go to

item 8.
..
6 .
'
Refer to "REPLACINfrcl HE
-<0 ECU (engine control unil)s-.,on

page 8-93.
<! <C
8-70
-"!> "<0<
INJECTION

%
' '
c. c.
Fault No. 42

v
Speed sensor: no normal signals are from the speed .s>
A
f
.<?> sensor. <?>

""'-
Item
'%
6 Neutral switch: open or short circuit is

c Clutch switch: open or short circuit Is detected"?<t..

6
9 Delete the fault code':"'v.?.

Turn the main switch 'te; 'oN",

and then rotate the rear"0

wheel by hand.

c

vehicle speed signals by

op,erating the vehicle at 20 to
30RfP/h (19 mi/h).
.s>
The code can also be f
.<?>
delete the diag

nostic selecting
'%

diagnostic number "63".
... ...
Fault code No.

43
6

"!>?,,

Fuel system voltage: lncorq;Jct voltage supplied to the
I!Jem
Injector and fuel pump.
%.
A
system Able to start engine
c
"0

..

'9.,..
09 Fuel system voltage (battery voltage)

..
Approximately 12.0
'%
...,_.
Procedure Set the start/engine stop switch to "()", and then the
"t>,o
actually measured voltage with the meter displa isj(alue. (If

the actually measured b voltage is low, recharge
y.?.

Actuation Actuates the relay unit five at one-second intervals.
"/
%.0
Illuminates the engine trouble light.

Check that the relay unit is actuatel:l'1j,ve times by listening for the
..
operating sound. ..
Item cause of Maintenance job of service
malfu.l)ction and check <g.omplet ion
1 Connectioif"Q.! relay unit cou- Improperly connected Start the enw e and let it idle
pier.
Connect the coupler securely for approxima'l'eJy 5 seconds.
Check the or replace the wire harness. Fault code numtl'e_f, is not dis-
of the coupler.
6"!>
played Service
Disconnect the coup'fur.?.and

Fault code number isilis-
check the pins (bent or'Bro

played Go to item



8-71
' '
c.
Fault code No. 43

Item
Fuel incorrect voltage supplied to the fuel
Injector and f el pump.

2 Connection of wire harness Improperl y -t Start the engine and let it idle
ECU coupler. Connect the co J'I.W securely for approximately 5 seconds.
Check the locking condition or replace the Fault code number is not dis
of the coupler. 6-'b
b
played -t Service

Disconnect the
y.?.
Fault code number is lis-
"
check the pins (bent or SliQ

played -t Go to item

ken terminals and

c

3 Wire harness continuity. or short circuit -t Start the engine and let it idle
Reptar_. e the wire harness. for approximately 5 seconds.
Betweef:l -9battery and starter Fault code number is not dis-
relay system played -t Service is finished.
fuse). Fault code number is dis-
red- red .. played -t Go to item 4.
Between starter (fuel
6-'b
injection system and
6-'b
relay unit coupler.

'.?
y
'.?

red-red

" Between relay unit couplef

and ECU coupler.

<f;ldlblue-redlblue

bftJ,e/yellow- blue/yellow

4 Defective relay unit. Execute the diagnostic Start the engine and let it idle
mode. No. 50) for approximately 5 seconds.
No sound -t Fault code number is not dis-
Replace the feJay unit. played -t Service is finished.


5 Defective relay Execute the Start the engine anli'<l et it idle

'.?
mode. (Code No. 09) for approximately 5

"
Fuel system voltage is below Fault code number is

3 V -t Replace the relay unit. played -t Service is

Cb

6 Malfunction in ECU. the ECU.
Refer tif..S:REPLACING THE
ECU control unit)" on
page 893.
"
Fault code No. 44

6
<t>b
6
", "

EEPROM fault code numbeT-..,an error Is detected
-w g or writing on EEPROM.

Fail-safe system Ati1El6_l!nable to start engine

to dri ve vehicle
Diagnostic code No. 60

'
. .,
-"!>
? ..
Ft\JEL INJECTION SYS'fEM

%
' '
c. c.
Fault No. 44

v
EEPROM fault code number: an error is while read-
Item
.s>
f
.<}
lng or writing on EEPROM. <>>
>Y.;>,
""'-
Meter display '% EEPROM fault code display

00 (no history)

<t>b
01-03: Cylinder fault code number (history exists) -><t.
If more than one is defective, the display switc1fe.

;;;, every two seconds to the cylinder fault code
" all defective cylinders in a cycle. "

11: Data error for ISC (idle control) learning values (his-

tory exists)

-

Item Pf.o)able cause of Maintenance job Confirmation of service
malfun.; tion and check
1 Locate the ii'iqj!unction. Execute the diagnostic -
'%

mode. (Code No. 60)

2 "1 1"' is indicated in'Cijegnostic Turn the mam sw1tc;R to Turn the main swita:eto "ON".
mode (code No. 60). "OFF". "!>, Fault code number dis-
EEPROM data error
.;>
played -+ Service is tinistwd.

(idle speed control) learniflg Fault code number is dis- "

values. played -+ Repeat item 1 . If
Cb
"-E!
4l:Je same number is indi
go to item 3.

3 Malf6action in ECU. Replace the ECU.
.s>
.s>
f f
.<>>
.<>>
Y,;> Y,;>
'%
page 893.
'%

Fault code No.

46

<t>b,.
6.
<t>b,.
Item
-q
voltage is abnOFIJ!al.
...,y.?.

>
;;;,,
F' at safe system Able to start engine
"'1


code No.
-
..
Meter -
v.s>
f.
Procedure
v>y
.;>"'
-
v>y
.;>"'
Item of Maintenance job service
malfunction check
1 Malfunction in chargll:lg sys- Check the Start the engine anci'les,tt idle

tam. Refer to "CHARGIN l?;, for approximately 5
"
SYSTEM" on page

Fault code number is not is-

Defective played -+ Service is finished.

or AC magneto -+ Replace. "-E! <fault code number is dis-
Cb

Defective connection in the 15J.ayed -+ Repeat the mainte-
charging system circuit -+ job.

Properly connect or replace

.s>
the wire harness.
.s>
f f
.<} .<}
8-73
n n
Faulf'?c;,!?de No. 50
"0

""'
"' voS'
Faulty ECU memory. (When this malfUI'iftion is detected in
f
Item
.<?>
the ECU, the fault code number might on t he

meter display.)

Fail-safe system

Able/Unable to start engine

"t>;o
Able/Unable to drive vehicle

Diagnostic code No.

- 'v'

" "
? display -

Pro:c.edure -

Item Probable cause of mal-
"!&J unction and check
Mai ntenance j ob of service
"! v.s> completion
1 MalfliA"'Gtion in ECU. Replace the ECU. Turn tHe. main switch to "ON".

Refer to "REPLACING THE Check fault code

ECU (engine control unit)" on number is fiqj displayed.
page 8-93.

"t>;o
TIP
"t>;o

Do not perform groce-

y.?. y.?.

dure with the main

?
turned to "ON''.
... "
No.

59

Item
c:-
.s>
f.
Accelerator position sensor: open circuit detected.
Fail-safe Able/Unable to start engine
>

Able/Unable to drive vehicle

Diagnostic code No:'-'t-;o 14, 15
...
..
"t>;o
14 Meter display
""
Accelerator position signal 1
""
y.?. y.?.
12-22 (fully closed posltign)
?
97-107 (fully open

Procedure Check with throttle grip in position.

Check with throttle grip in fully position.
15 1 display Accelerator position sensor signal 2 'c:-
.s>
f
10-24 (fully closed position)
f
.<?>
95-109 (fully open position)
.<?>

Check with throttle grip in fully closed

Check with throttle grip in fully open position.
Item Probable of job

malfunction and'C.!Jeck

..,
8-74
Fault code 59
Item v.s>f Accelerator position sensor: open or short detected.
"A "A
1 Connection of acce1.ii!_rator Improperl y connected Turn the main "ON".
position sensor coupreJ. Connect the coupler securely Fault code number dis
Check the locking condft i9,n or replace the wire harness. played Service is
of the coupler. ..<t,. Fault code number is dis .. <t,.
6
"!> Disconnect the coupler

6
"!> played Go to item 2.
"' t:heck the pins (bent or bro-
terminals and locking "

"
colldj tion of the pins).
Conne6l.i.on of wire harness Improperly connected Turn ttl!t)Tlain switch to "ON".
ECU cotfPte.r. Connect the coupler securely Fault is not dis-
Check the condition or replace the wire harness. played is finished.
of the coupler: .s>f Fault code is dis
Disconnect the and played Go to 1t1;tn 3.
check the pins bro-
ken terminals and "<1
2
3 6"!> Wire harness continuity. Open or short circuit 6"!> Turn the main switch to
'.i 1;) place the wire harness. code number is not dis- j;. Y.?.

Between accelerator posi- Service is finished.
tion sensor coupler and ECU number is dis-
playe<!L. C: -<0 Go to item
4
.
white-white
v black-black v
.s>'9
6
. blue-blue .s>'9
6
.
Installed condition Improperly installed sensor Turn the main "ON".
ator position sensor. Reinstall or adjust the Fault code number is dis
Check for looseness sensor. Service is
6
pinching. ..<t>b Refer to "ADJUSTING Fault code number is dis- .. <t>b
"!>, POSITIO'R/>o, played Go to item 5.
'" on page 7-13.
4
position sensor Measure the accelerator Tu'itl'), the main switch to "ON".
resisl<V'!Ce. position sensor resistance. number is not dis-
black/blue-blue played is finished.
Refer to "CHECKING THE Fault is dis

v ACCELERATOR POSITION played .!P item 6 .
.s>-9 SENSOR" on page 8-107. .s>-9
"6 "6
5
8-75
Fault code No.
Item position sensor: open or short circuit
"A "A
6 Defective accelerator posi- accelerator position Turn the main switch to "ON":
lion sensor. s{ij'g_sor signal 1. Fault code number is not dis-
Exee':l!e the diagnostic played Service is finished.
6"!>
'l?
mode.W"'ode No. 14) Fault code number is dis-
""" ",O
When grip is fully Go to item 7.
closed: 'l? Y,

A value of 12=<22 is indicated.

When the throttle grip is fully
open:
'b
%

oo ..
A value of 97- 107 is indi 'b%
cated.
oo ..
6"!>
'l?

v.sof Check accelerator position
sensor signal 2.
the diagnostic
(Code No. 15)
Wh8'not.he throttle grip is fully
closecf.4,o
A value o't'i].0- 24 is indicated.
When the grip is fully
open:
A value of 95-1 09 is indi
cated.
v
.so
f

'b
%
An indicated value is out of
v the specified range
.sof Replace the accelerator posi-
sensor.

7 Malfunction in ECU. RBglace the ECU.
Ret$r.Jo "REPLACING THE
ECU (e'119ine control unit)" on
6

page 8-9"3:?:- y _ "!>,_,
Item
Fail-safe system
60
YCC-T drive system: malfunction detected.
to start engine
to drive vehicle
Diagnostic code No. -

Meter display -

Procedure

Item Proli'l)!lle cause of
malfuncfigp and check
job
"
Confirri't_j!tion of service

"t>,o

Y,
-"!>
.
SYSTEM'0

%
' '
c. c.
Fault code iiro%. 60

Item
v
YCC-T drive system: malfunction detected. v.s>f .s>
'f
'A 'A
1 Connection of servo Improperl y connected Turn the main to "ON".
motor coupler. Connect the coupler securely Fault code numbe <is not dis-
Check the locking c3' riq(tion or replace the wire harness. Service
of the coupler. "'-it.. Fault code number is dfst,
8"!> Disconnect the coupler 6"!> played Go to item 2.
'"
check the pins (bent or bro- -1
'"
IQ

0

..
!l<en terminals and locking

of the pins).

%,_
2 of wire harness Improperl y connected Turn'U,:)e main switch to "ON".
ECU Connect the coupler securely Fault number is not dis-
Disconnes!Jhe coupler and or replace the wire harness. played is finished.
check the (bent or bro Fault code nfl.plber is dis-
ken terminalsapd locking played Go tGJ;,item 3.
condition of the
..?
"%
3 Check the Abnormality Replace the Turn the main switcff$.tp "ON".
valve fuse. "'-it.. electronic throttle valve fuse. Fault code number is
8"!>

6"!> played Service is finis !!;

'"

'"
Fault code number is dis- .;

0
\ Go to item 4. to
..

4 I harness continuity. Open or short circuit 1Ctr:9. the main switch to "ON".

Replace the wire harness. number is not dis-

Between throttle servo motor Service is finished.

coupler and ECU coupler. Fault coa'e{tumber is dis-

.s> yellow/red- yellow/ red played item 5.
'f
'<?> yellow/white- yellow/white '<?>
.?
Between ECU coupler and
.?
'% '%

fuse box 2 (electronic throttle

.<) valve fuse).
..
red/white- red/white
8.
...
6.
"t>,o, _
5''"
Defective throttle servo
..., . .,
Check the throttle servo v," Turn the main switch to "ON'\

motor .
'
'ffiotor. Fault code number is not dis- IQ ..

Replace the throttle bodies if 'Pited is finished.

defective. F U code number is dis-

Refer to "CHECKING THE Go to item 6.

THROTTLE SERVO

MOTOR" on page 8-108.
.. .
6 Defective throtije bodies. Check the throttle bodies. Turn the to "ON".

Replace if defective. Fault code num&u is not dis-
'%
Refer to "CHECKING THE played Service

.<) THROTTLE SERVO Fault code number
a
"'<t> MOTOR" on page 8-108. played Go to item 7. "'-'t-,o

6
7''"
Malfunction in ECU.
"""
Replace the ECU. "'"
"""

.,

to "REPLACING THE\
to .
..


page 8-93.

8-77
"
INJECTION

89 diagnostic tool)
."i

Fault code No.
Err (mfiJ!j-function meter display)
.s>
Item
Multi-functial2 meter: signals cannot be transmitted between
the ECU and multi-function meter.
"
Fail-safe system Able to start

6"!>
6"!>
Diagnostic code No. 'v' -

'v'
"
Meter display f6-:-

Procedure
...oc

Item Probable cause of

Maintenance job Confirmation of service
oo,.
v
completion
oS'
1 Connection of meter assem- lmprcilfuJ.IY connected -+ Turn the main switch to "ON".
bly coupler. Connecttae coupler securely Fault code number is not dis-
Check the locking condition or wire harness. played -+ Service is finished.
of the coupler.
..

Disconnect the and <t>b played -+ Go toJtem 2.
check the pins ( ent or bro-
..
"!>,
ken terminals and
y.?.
.?;,
condition of the

" "
2 Connection of wire harnessc Improperly connected -+ Turn the main switch to
ECU coupler. Connect the coupler securely Fault code number is not

Check the locking condition replace the wire harness. played -+ Service is finished.
of the coupler.

.s>
f
.<?>
y.?
'%

3 Wire harness CW!tinuity. Open or short -+ Turn the main to "ON".
"!>, Replace the wire it<lrness. Fault code is not dis-
.?;,
Between ECU coupiEi'rv?tnd played -+ Service iS..Jinished.

joint coupler. " Fault code number

light green/blue-light played -+ Go to item 4.

green/blue
c

green/white-light

Befween joint coupler and
coupler.
light
green/blu 'b
light
""
green/white .. -'l,b
""
4 Defective meter Replace the Turn the main to "ON".

Fault code number dis-
"

played -+ Service is fi

Fault code number is dis -o

-"!> " Multi-function meter: signals cannot be4! ansmltted between

the ECU and the multi-function meter.

5 Replace the ECU.

...

<t>b <t>b

ECU (engine coqJrol unit)" on

y.?.
page 893.
y.?.

,.,
8-79
-"!> - . . , . ~
{ ~ ? ..
FUEk INJECTION SYSTEM
~ ~
~
8-80
EA$27550
FUEL PUMP SYSTEM
8-81
3. Main switch
4. Main fuse
9. Ignition fuse
t3.Battery
14.Engi ne ground
15. Fuel injection system fuse
18.Joint connector
20.Relay unit e
22. Fuel pump relay'!>,.?
23. ECU (engine controt'%'it)
60. Fuel pump
62.Right handlebar switch
64.StarVengine stop switch

.s>
"f

y.?
'%

y.?.

-"!>
FUEL

EA$27510 co
TROUBLESHOOTING
If the fuel pump fails to operate. "! v
TIP
Before troubleshooting, remove the fofi' d::Y.ing part(s):
1. Rider seat
2. Air scoop
3. Fuel tank cover
4. Fuel tank
6
"!>
,,

1. Check the fuses.
(Main, ignition and

system) Replace the fuse(s).
Refer to "CHECKING
on page 8-93. v "! v
OK-!. <>_,
r-----------------,


Refer to "CHECKING AND
CHARGING THE BATTERY" on
page 8-94.

Clean the battery terminals.
Recharge or replace the battery.
3. Check the main si!,ch.
Refer to "CHECKIN{j6JHE
SWITCHES" on page

4. Check the start/engine stop swltc;;h.
<t>b
L_ ________
)!'...?. ... ,h;


Replace the right handlebar switch. Refer to "CHECKING THE <>,
SWITCHES" on page 8-89. -

OK-!.

5. Check the relay unit (fuel pump re-
lay).
6
"!>
Refer to "CHEe iS,ING THE RE-
LAYS" on page

6. Check the fuel pump.

Refer to "CHECKING THEf<J,JEL
PUMP OPERATION" on pageq.r3.
7. Check the entire fuel pump sys-
tem's wiring.
page 8-81. e"b
OK-!.
Replace the ECU.
Refer to "REPLACING TF.lE ECU (en-
gine control unit)'' on

<t>b 6
"'-
'<>y Replace the relay unit.

Replace the fuel pump.
Properly connect or repair the fuel pump
system's wiring.

<t>

-"!>

-"!>
y.?. '.? '.?

'
EA$27973
Cb

.s>
f
.<}
>y

3

i 6
6"!>
y.?. '.?

Cb

.s>
7
f.

6"!>
'.?
8

Cb

.s>
f
.<>>
y.?
'%

6"!>
'.?
15

'I

Cb

10
.s>
f
.<>>
y.?
'%
?

I{
6"!>

YY<b4
'.?

"

-=4)
Cb
13

v.s>
.s>
f f
.<>> .<>>
y.? y.?
'% '%

8-85

<t> .. <t> ..
1. Main switch
v 2. Clutch switch
.s> 3. Front brake light switch
"f
<> 4. Battery
5. Fuse box 2
Main fuse
injection system fuse
"' 8. Sl@rter relay
9. ReBtiY,er/regulator
10. Rear i51ake light switch
11. Gear position sensor
12.Sidestand switch
13.0
2
sensor
14.0illevel switch
15.1gnition coil
16. Radiator fan motor
8-86
"<0< -"!>
'.?
ELECTRICAL COMPONENTS

20

19
-"!>
ELECTRICAL CE>JYI PONENTS

%,

12
\

1. Intake air temperature sensor
2. Headlight relay
v.sa. ECU (engine control unit)
;{<?.fuel pump
5. angle sensor
6. Radf@.ter fan motor relay
7. Turn s1gqallhazard relay
8. Relay
9. Speed sens'ii'r,.?.
\ 10.Stator coil
11. Crankshaft position sensor
12.Coolant temperature sensor

14.Accelerator position sensor
c/.s>15. Throttle position sensor
"t'(?,lntake air pressure sensor 1
air pressure sensor 2

19.Air system solenoid
...
20.Fuse boX'tl;

'.?.

8-88
'
'
: 2
'
'
'
'
'
'
:a
'
'
'
'
'
'
'
'
'
:
: 4 gr
: ON
L______________ ------------

I
I '
5 :
: :JaiRI
: :l!@Y)
' '
' ' '
__________ J
---------------------------,
6
'
'
'
'
' '
'---------::.-: :.-.-:.-.- . -
---------------------
'
: 7 I
' IJB
:
: : B :
I I 6 I
i
: I I
: _____ _!
'
'
'
'
'
'
'
'
: Bl '
' '

"!>,
.?;,

f
.<?>
y.?

<t> ..
8-89
-"!>
ELECTRICAL CQMPONENTS

ANI RIB LIW B.

v
RUN
START f
.

:
: .....
:
I I 1:-
,_----
l11 ""h. :----------, Y''-?1'.
I "-?.... :
I 1:Y;.S I
: o$1d
:
: : .... '
'
'
'

Bll Bll f
: I I . <?_,.v

' 12
'- IAI
ON I O +< +ol
OFF I
P I
,y

<t>b

y.?.

c
1. Dimmer
2. Pass switch % ..
3. Turn signal
"-9
4. Horn switch <?>
5. Clutch switch
6. Oil level switch
7. Sidestand switch
e{l. Hazard switch <t>b
"'
9'v Startlengine stop switch .,Y.?.
1 o.B.Jive mode switch
11. light switch
12. Main WlJ,ch
13. Rear bra'R%1ight switch

oo ..
v
.s>
"-9
".(?>
y.?
'%

<t>b

y.?.

-"!> "

c
'<o Check each switch for continuity with the pocket tes'bv-. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the ..
(/ f CAl-1310 . (/
.so-9 NOTICE .so-9
'(> . -
insert the tester probes into the coupler terminal Always insert the probes from
end of the coupler, taking care not to loosen the leads.

1:-b Pocket tester <t>b

6
"!>
Atl.sllog pocket tester
Y0-03112-C "

0 Before checking for continuity, set the pocket teste?' "!i1 "0" and to the "Q x 1" range.
When checking for continuity, switch back and forth the switch positions a few times.
''9
"' oo"' .
;..

'<o
The switches and their terminal connections are illuli{I:Jtted as in the following example of the main
v switch. v
.so'9 <> The switch positions "a" are shown in the far left column switch lead colors "b" are shown in the
"YJOP row.
continuity (i. e., a closed circuit) between switch terminals switch pos1tion IS indicated by

4 .
There '1$ . continuity between red/white, brown/blue, and brown/red between blue/yellow and
the switch is set to 6"!>
There is contiguity between red/white and'bJOWnfred when the switch is "P'' .
" "
b
'

---
Rf'fl llr/1. Br/ AllY UB
ON 0 1-0
OFF <I/.

1:.,
A/IN
Br/1.
Br!RI UB L1Y "'
8-91
b

y,
ELECTRICAL CGMPONENTS

a. Connect the lreJ1itive tester probe to terminal
"1" and the tester probe to terminal
6
"2", and check the OOJ.)tinuity.
"!>,.? b. Connect the positive probe to terminal
"1" and the negative tes'fe; probe to terminal
"3", and check the continuity.

Cb
' If either of the readings indicate no continuity,
the bulb.

c

.so
"f

y.?
'%
.

6"!>
Checking the co"ttdition of the bulbs
The following procedure applies to all of the
.., bulbs.

(
" ,S0-9
"'

iS>_...<>.

y.?.

2
3
-b
1. Remove:
Bulb the condition of the bulb sockets
EWAt 3S20
CfJ; The foubwing procedure applies to all of the bulb
. !"flljl111!1
sockets. -9
the headlight bulb gets extremely hot,
y.?&.
"
8-92

c
1. Check:

Bulb socket (for
(with the pocket testerf.'.s>
No continuity 4 Replace:'-<?>
Pocket tester
90890-03112
'%

Jib
<t>b
6"!>
YU-03112-C

,,
-..,
"'
TIP
Check each socket for continuity in the
same manner in the bulb section;
however, note the IBI\Qwing.
"

a. Install a good bulb into bulb socket.
b. Connect the pocket testeP-f3JObes to the re-
spective leads of the bulb
c. Check the bulb socket for contirf&:i.IX. If any of
the readings indicate no
the socket.
... ,h; yo.?.

CHECKING
The following proced'llt!! applies to all of the Ius-
"
es. v
.s>
'-9
NOTICE . -<?>
To avoid a short circuit, alwaysvset the main
switch to " OFF" when
a fuse.
R

1. emli!\(e:
Rider
Refer to CHASSIS" on page 4-1.
2. Check:
Fuse 'b
%
................
a. Connect the pocket to the fuse and
check the continuity.
TIP >y,
Set the pocket tester selector to\i;Ox 1 ".
& .....
...
, Pocket tester <t>b
t?' - "b 90890-03112
pocket tester

<>,_
b. If the pocket t&$!er indicates "oo", replace the

fuse.
%,.
................ ............ .
'-9
. -<?>
y.?
-"!>
,.,
COMPONENTS

c
3. Replace:

Blown fuse
"'
TTTTTTTTTTTTTTTTTTTTTTT.fr,..,TTTTT'Y
a. Set the main switch to "OFF". -<?>
b. Install a new fuse of the correct
I
. a
ra
c. Set on the switches to veri fy if the electri<213,..
circuit is oper<!\ional.
d. If the fuse blows again, check
the electrical
'"'
Fuses
..

Q'ty

',
Main 5'G,f 1
Headlight 1
Signal 7.5 A '.? 1

Ignition 15 A

Radiator {In 15 A 1
Parking 10 A 1
Fuel injection 10 A 1
"
Auxiliary DC outlet 2A 1
Backup 1
Electric throttle valve 7.5 k o5' 1
Spare fuse 15 A
-c
'
1
'.?
Spare fuse 10 A
,,
Spare fuse 7.5 A 1

Spare fuse.
,.,
2A 1
'
EWA13310
WARNING
Never use a fuse with rating
other than that specified. or us-
ing a fuse with the wrong rating
may cause extensive damage t<fthe electri-
cal system, cause the lighting
systems to malfunction and could
cause a f ire. ..
.
<t>

4. Install : '.? y.?.
Rider seat

Refer to "GENERAL OltJASSIS" on page 4-1.

REPLACING THE ECU unit)
1. Turn the main switch to v
2. Replace the ECU (engine control'\!nit).
3. Clean the throttle bodies and resef.tJ:J,e ISC
'%
8-93

'%

<t> .. <t> ..

(idle speed control) learning value.

to "CHECKING AND CLEANING THE
BODIES" on page 7-8.
4.
Enginlii>JJ!Iing speed
Start the<' e,ngine, warm it up, and then mea-
sure the idling speed.
-"!> ou

COMP.ONENTS

c
Lead Acid) battery should
be according to the appropriate
charging m!!thod. If the battery is over
charged, level will drop con-
siderably. There,tore, take special care
when charging thii\iittery.
TIP "'
'<'

speed
11G0-130qr/min
0
6"!> Since VRLA (Valve Lead Acid) bat-
;,teries are sealed, it is not poss1g[e to check the
state of the battery by '%easuring the
gravity of the electrolyte. Therefore, the
charlfetof the battery has to be checked by mea-
suring at the battery terminals.
CHECKING AND CHARGING THE BATTERY
EWAl 3290
4J:!VIi;UIIdCI __________ _
generate explosive hydrogen gas
and ci>,etain electrolyte which is made of poi-
highly caustic sulfuric acid.
Therefore, <ll/ways follow these preventive
measures:
Wear gear when handling or
6
1.
.so
Rider seat
Refer to ENBf,lAL CHASSIS" on page 4-1.
2. Disconnect:
Battery leads
(from the battery t<>rrTliri'RI"
working near "!>,
Charge batteries area.
Keep batteries away from fire, sparks or disconnect the ne,aa111vE ' I lead
open flames (e.g., welding equipment, "1''1<"'"d then positive battery lead " 2" .
lighted cigarettes).
NOT SMOKE when charging or han-
"
ai!Jig batteries.
KEEP BATTERIES AND ELECTROLYTE
OF CHILDREN.
Avoid bcSgily contact with electrolyte as it
burns or permanent eye
InJury. "t>
FIRST AID IN BODILY CONTACT:
6
"!>
EXTERNAL y-?..
.... " ""l v :21
'<, Skin - Wash with water.
Eyes - Flush with water for 15 minutes and
get immediate medical attention. to "GENERAL CHASSIS" on page 4-1.
4.
'b.'2,nk large quantities of water or milk fol- Battery
with milk of magnesia, beaten egg or "'"'"'"'"'"'"'"'"';;"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'"'
vegetaj?.le oil. Get immediate medical atten- a. Connect a tester to the battery termi-
tion. nals.

NOTICE Positive tester
. . .
6
pos1t1ve battery
Th1s IS a VRLA \ vr11jve Lead Ac1d) Negative tester probe 4
.... " battery. Never remO:y,e the sealing caps be- { negative battery terminal
'<, cause the balance bel ween cells will not be .,__:. "
and battery performance will state of a VRLA (Valve Regulated
' p harging time, charging amperage and Lead h i$)) battery can be checked by measur-
voltage for a VRLA (Valve Regu- ing its o/5' eQ;circuit voltage (i.e., the voltage
Lead Acid) battery are different from when the po&Jlive battery terminal is discon-
thosEP.qf conventional batteries. The VRLA nected). <?>

' M4 '
.
<t>.. <t> ..
c
No charging is necessary when the open-cfl<;, tery overheating and battery plate damage.
l?, cuit voltage equals or exceeds 12.8 V. If it is impossible to regulate the charging
v v
.s>f b. Check the charge of the battery, as shown in .s>f current on the battery charger, be careful
. <?> the charts and the followin exam le. . o_pt to the battery.
g p charging a battery, be sure to remove
Example . it the vehicle. (If charging has to be
J)pen-c1rcu1t voltage = 12.0 V done witp the battery mounted on the vehi-
t1me = 6.5 hours P cle, disc8-.anect the negative battery Jead
of the battery = 2o-30 "l o-b?,, from the terminal.) "!>,.?
""0 To reduce thev_.ehance of sparks, do nof>
A plug in the battery charger until the battery
1
3
0
charger leads are connected to the battery. .o_
' C
12.5 Before removing the battery charger lead
\?.
12
0
_ _ _ _ _ _ _ _ _ clips from the battery terminals, be sure to ..
v.s> v .s> turn off the battery charger.
-9. <?> 11.5 -:Nf,ake sure the battery charger lead clips are
y.? fri1JJII contact with the battery terminal and

10
B are not shorted. A corroded bat-
"<>L 5 6.$
D tery c arger lead clip may generate heat in
the contfic,! area and a weak clip spring may
voltage (V) 6"!> cause spar'f<s.
6
"!>
B. time (hours) '.? If the batteriYI)C,comes hot to the touch '"at)
C. RefRtionship between the open-circ3it,yolt- any time during" the charging process, dis-
age and the charging time at 20 c (6g9" ..f)
.i'l connect the battery charger and let the bat-
D. These values vary with the temperature, l't'b tery cool before reconnectl"ng
1
-t. Hot ..
cond1t1on of the battery plates, and the "
trolyte level. batteries can explode!
A
14
13
-
I
12
,

100 75
I
.._
c
'
1
I
:
I
I
'.?
I
I

'
I
I
50 30 2520 0

"'v As shown in the following illustration, the "!
.s>fopen-circuit voltage of a VRLA (Valve Reg-
. Lead Acid) battery stabilizes about
after charging has been com-
Therefore, wait 30 minutes after
completed before measuring
the open-Clr:s._uit voltage. 6"!>
A C
' -
D
18

A. Open-circuit voltage (V)
17
16
15
B. Charging condition of the battery (%)
C. Ambient temperature 20 c (68 F)
A wARNING
Do not quick charge a battery.

"!v
.s>
14
13
\
f 12
.<>> 1
y.?
1
o 10 20 "' o so oo B
4E

A. Open-Cir&uit voltage (V)
B. Time
C. Charging
D. Ambient temperature 20 c (68 F)
E. Check the open-circuit voltage.

Do not use a high-rate battery charger Charging method using a variable-current
since it forces a high-amperage current charger
into the battery quickly and can cause bat- a?_Measure the open-circuit voltage prior to
8-95
y.?

"!:>.
-u -"!>

ELECTRIGAL

c
charging.
c. Make sure that the current is higher than the

TIP standard charging current written on the bat-
v.s> Voltage should be measured 30 minutes after v.s> tery.
-9. <?> the engine is stopped.
b. Connect a charger and ammeter to the bat- If thi?-By rrent is lower than the standard charging
tery and start charging. on the battery, this type of battery
charger charge the VRLA (Valve Regu-
charging voltage to
1
6-
1
P.,y.
11
the set- lated battery. A variable volt?Je
ling charging will be 11 too charger IS recoli-JI!lended. '.?
htgh, the 'battery wtll be over-charged.

d. Charge the until the battery's

c. Make sure that the current is higher ing voltage is 15 V
" TIP
standard chargtng current wntten on the bat.. -<0,., Set the charging time at 20 hours (maximum).
tery.
v.s> TIP Measure the battery open-circuit voltage after
-9 If the current is lower than the standard charging -9. the battery unused for more than 30
. current written on the battery, set the charging mt,Rutes.
<::>"<1 voltage adjust dial at 2Q-24 V and monitor the r
1
.,
2
=-.7
8
"'zr r- m- o-re- --_-_ C ::-:-h- ar- g"" in_g_i,- s_c_o_m_p-.,. le_t_e_. ----,
for 3-5 minutes to check the battery. 12.7 v ___ Recharging is required.
Under Replace the battery.
6
S'i\t,9dard charging current is nf a_ghed
Battel,y is good. .? h. -y-?._ '.?
"' <>..._
0
Stand .. rd Charging CUrrent iS not re .... &&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&& v
1
,
Replace the battery. 6. Install :
c Bdery
d. Adjust the voltage so that the current is at R
1
r t "GENERAL CHASSIS" n
4
_
1

standard chargtng level. e e o o page
v.s> e. Set the time according to the charging time vJ d
'f suitable for the open-circuit voltage. ._,
4
attery ea s .
. <?>Y.? I If charging requires more than 5 hours it is tt,9 the battery terrmnals)
. '
<::>"<1 advisable to check the charging current after NOTI
lapse of 5 hours. there is any change in First, -th_e_p_o_s-i t i_v_e_b_a_tt _e_r_y-le _a_d_"_1_",
'4e amperage, the to obtatn and then battery lead "2". 6
chargtng current. "!>,.? .:iliy "!>,.?
g. the battery open-circuit after
leaving the battery unused for more tJ\qn 30
minutes.

12.8 V or more --- Charging is complete.

12.7 V or less--- Recharging is required.
v.s> Under 12.0 V --- Replace the battery. v.s>
'f
'<?>
y.?
................................................................................................. ...

Cfij!rging method using a constant voltage 8. Check:

6
"!>, Battery teriT\i.9als
a. the open-circuit to Dirt 4 Clean Wi th a wire brush.
/.
chargtng. Loose connection 4 Connect properly.
TIP 9. Lubricate:
Voltage should be measured 30 minutes Battery terminals
the engine is stopped. Recommended lubricant
b. Connect a charger and ammeter to the bat- c:: -t Dielectric grease
tery and start charging. Lf """ "" >-'---------------'
8-96
y.?

<to ..
10.1nstall:
Rider seat
"' Refer to "GENERAL Cl'te,SSIS" on page 4-1.
'-9
EAS3KWO . (> >
CHECKING THE RELAYS
Check each switch for continuity w'?t'\the pocket
tester. If the continuity reading is inc<5q.ect, re-
place
tester

Anali)g, pocket tester
YU-031:a2-C
"11,_
.
1. D1sconnect the the wire harness.
2. Connect the pocket tes\e\.(Q x 1) and battery
(12 V) to the relay shown.
Check the relay operation.
Starter relay

R
y.?.

0

4 '.(?>
y.?
R
'%

1. Positive battery terminal
2. Negative battery terminal
3. tester probe
4. Negattve tester probe

cor1tihHity
(betwee%" 3" and " 4" )

y.?.

-"!>
'.?

c
Relay unit (starting circuit relay)

1. battery
2. Negative battery terminal
3. tester probe
"' 4. Negative tester probe v.s>
Result
Continuity
(between " 3" and " 4")
'-9
-y.?
'%

Relay unit (fuel Pll!J! P relay)
8-97
)!'..?.

, Cb, 1
II I I
-II I 1n1 >< 
'4
Headlight relay

3
,....,. i>y.?
-
'- "01
6"!>
'.?

F
2

1. Positive battery
2. Negative battery term1i.ijjl

3. Positive tester probe ..
4. Negative tester probe v.s>
'f
.,.
Result
Continuity
(between " 3" and "4")
Radiator tarf'lpotor relay

1

l
/ 3
Cb

2
1. Positive-- .g,attery t erminal
2. terminal
3. Positive
4. Negative teste?p.rgbe
.0
,.....,.,
- 4
'-
...
y.?
'1<:>.,,
....
EAS1RCI801 )!'..,
CHECKING THE TURN
RELAY
1 . Check: ..
Tum relay input voltage
Out of sped il;{ltion --t The wiring circuit from
the main the tum signaVhazard re-
lay coupler is faul\'y,&nd must be repaired.

Turn relay i nput
voltage ..
DC 12 V v.s>
'f. A
-"!>
ELECTRICAL 6QMPONENTS

%,
Cb

a. Connect the pocket tester (DC 2&iy) to the
tum signal/hazard relay terminal as sh'!i)wn.

Pocket tester
v_,.Y
9089()..()3112
'-
YU-03112-C
-"'
"'o
Positive tester
blue/red "1"
Negative tester probe %-o
Ground

UR
"!>, 1
'----l .?;,

b. Turn the main switch to
c. Measure the turn input
voltage.

.s>

2 . Check: "Y.?
Tum signal/hazard relay output voltage
Out of specification --t Replace.
...
Turn signa!Lpazard relay output
voltage '.?;,
DC12 V

a. Connect the pocket tester (DC V) to the
tum signal/hazard relay terminal
Poe ket tester
9089()..()3112 >y.?

y.?.

YU-03112-C

Positive tester probe>,.?
brown/white "1"
Negative tester probe
Ground %-o

y.?.

'

%
Continuity
:-" "! v Positive tester probe "! v
skyblue ''1"
<?> Negative tester probe

black/yellow " 2"
No continuity

f
.<?>
y.?
1 Positive tester probe
<t>b <t>b black/yellow " 2"
6.,_
., '" ' N"gative tester probe
Y'" I', I. v:::
"1"
b. Turn the main switch to "ON". Continuity
c. Measure the turn signal/hazard Positive tester probe
c sky blue "1"
voltage.
'o black/red " 3"
"!&
.s>
11
No continuity
I>Q Positive tester probe
black/red " 3" CHECKING THE RELAY UNIT (DIODE)
sky blue " 1"

1. Check:
Relay unit (diode)
"
"->-

Pocket tester
'.?;,
90890-03112


YU-03112-C

<t>bContinuity
tester probe
SK, blue " 1"
sky blue/white " 4"
No continuity
Positive tester probe
TIP ,. sky blue/white " 4"
The pocket tester or the analog pocket tester v.s> Negative tester probe
readings are shown in the following table. sky blue " 1"
y.? Continuity
blue/black " 5"
" 3"

Posltive tester probe
black/red " 3"
blue/black "5"
"

%

.s>
'-9
'.(?>
............................... .
'%

Oi;j ECKING THE IGNITION COILS
procedure applies of the igni-
tion ci5il.. '.?,

1. ChecK<

Primary coil resistance
Out of specification -+ Replace.

a. Cd"l'\5lect the pocket tester (n x 1 k) to the ig-
as shown.
.<>
tester

Analogcpocket tester
YU-03112-C

Negative tester probe -t
% ..
c:-
.s>
'-9
Primary coil resistance red/black "1"
1.19-1.61 0 tester probe -t

'% a. Remove the ignition coil from the spark plug.
"<>-. Connect the pocket tester (0 x 1) to the igni-
coil as shown.

rufJ Pocket tester
<?' - 90890-03112
YU-03112-C

'6 Positive tester probe -+ -o ..
,apark plug terminal ''2"
v red/black "1" v
.s> oA Measure the secondary coil resistance.
-9 Negative tester probe -+ ., <?
. <?>,.? Cylinder-#1 ignition coil >, "'
'% orange "2"
,_ Cylinder-#2 ignition coil ....,..,.
"2" CHECKINtli(HE IGNITION SPARK GAP
ey!jtlder-#3 ignition coil 6"!> 1. Check: 6"!>
"2" '.?;, Ignition spark' gep '.?;,

'-
_ Out of -+ Perform the ignition

% %

oo ..
c:-
.s>
'-9
'.(?>
'.?
.
'!><!/. , Minimum ignition spark gap
6.0 mm (0.24 in)
>.
'%

<to-
TIP
If the spark gap is within specification,
the ignition circuit is operating normally.
6
c. the primary coil resistcrnpe.
yo.?. 1 h.

2. Check:
Secondary coil resistance
Out of specification -t Replace.
- .
t.>
Ignition checker
9089()-()6754
Oppama pet-4000 spark checker
YM-34487
Cb
%

'-
8-100

v
.s>
'-9
'.(?>

"

ELECTRtCAL COMPONEN 1

'%

<t>b
v
.s>
'-9
'.(?>

6"!>
Y'...?. 1',

2. Ignition coil
c. Tum the main switch to "ON".
d. Measure the ignition spark gap "a".
e. Crank the engine by pushi ng the"(?)" side

v
the start/engine stop switch and gradually in .s>-9....,.,, ,
crease the spark gap until a misfire occurs. GJIECKING THE LEAN ANGLE SENSOR

'%
............................... .

angle sensor
fuel tank bracket)
2. 6
Lean angr@,:>,ensor output voltage
Out of speciffflation -+ Replace.

ll Lean angle sensor output voltage
B1!l Less than 65
0.4-1.4 v '<o,.,
..
THE CRANKSHAFlbPOSITION
SENS_gR
1 . Disc"onnect:
Crankshaft position sensor coupler
(from the wire harness)
'<o
2. Check:
More than 65 v
3.7-4.4 v
Crankshaft position sensor resistance v
Out of specification -+ Replace the crank .s>"i',
shaft position sensor. '"" ..,..------------------'
Crankshaft position sensor resis
tance
228-342 Q (GyB)

a. Connect the pocket tester (Q x 1 to the
crankshaft position sensor coupler as
c .

Pocket tester
-<0-,
90890-03112

YU03112C
< gray "1"
tester probe 6"!>
''2"
;,
..

a. dlg.J:leCt the test harness-lean angle sensor
to the lean angle sensor and wire
shown. 6
b. Connect pocket tester (DC 20 V) t'O>,j he
test angle sensor (6P).

oo,.
c:-
.,

Pocket tester
9089()..()3112
YU03112C
Test harness lean angle sensor

(6P)

9089()..()3209
'%
YU-03209
...
probe
6"!>
yellow/gre'@a-?.(wire harness color)


/.
black/blue (wire harness color)
1
c. Set the main switch to "ON".
CO..., E.A$26150
"0-<& HECKING THE STATOR COIL
1' 1 <Disconnect:
stator coil coupler
(fro'fuJhe wire harness)
2. Checlf. %
Stator cdll<):esistance
Out of --+ Replace the stator coil.
"'
d. T u rn the lean angIe sensor to 65 . "'"'"'"'"' "'"'"'"'"' "'"'"'"' "'"'"'"'"' "'"'"'"' "'"'"'"' "'"'"'"'"'
e. Measure the l ean angle sensor output volt- a. Connect the digital circuit tester to the stator
age. co1l coupler as shown.

"'
.s>
f

GijECKING THE STARTER MOTOR
OPEjATION
...
1. Chesk: e
Start!tP;notor operation "!>,.?
Does n"610operate --+ Perform the
starting system troubleshooting, starting
Np4.
Refer to ''TROUBLESHOOTING" on page
8-11 .

.s>f a. Connect the positive battery terminal "1" and
starter motor lead "2" with a jumper lead "3".

Fti@i;UIIdri ___________ _
A w1W that i s used as a j umper lead must
have the same capacity Oio! he bat-
tery the jumper
burn. "
17 ';,. 90890-03174
88 Multimeter with tachom-
eter
YI:J-A1927
"' <t>
"'-
Positive tester
white "1" "
white "2"
tester probe
Vthite "1"
tester probe

-'1>.
Positive te51li)r probe
white "2" <t>b

Negative
white "3" .?.;;,
"
1 2 3
This check is l ikel y to produce spari(S}-o
theref ore, make sure no f lammabl e gas or
fluid is in the vicinity.

b. Check the starter motor operation.
.s>
.f
.I .
b. Measu. stator co1 res1stance.

"!>
E.AS:28170 )!'...?. ... , h;
CHECKING THE

- 1. Check:
Rectifier/regulator input voltage
Out of specification --+ Correct the stator coil

.. condition.
8-102
'Bei er to "CHECKING THE STATOR COIL"
on ,P_?ge 8-1 02.
y.?
'%

"!:>.
input voltage
r/min
..................................................................
a. Set the engine tachometer to the'tg[lition coil
of cylinder #1.
b. Connect the pocket tester (AC 20 V) 14 the
coupler as shown.
tester %

Analog i)" qs;ket tester

-<0
Posi ti ve tester probe
white "1"
white "2"
Posi ti ve tester probe
white " 1
119
"!>
,.,
Negative tes!.E}r probe
white "3"

Positive tester
white "2" .
Negative tester probe v
white "3"
-'y
1 2
\

;, y.?.

c. Start the engine let it run at approximate-
ly 5000 r/min.
d. Measure the rectifier//gulator input voltage.
'!>

2. Check: ... y
Rectifier/regulator output
Out of specification Replace tl'il v ectifi-
er/regulator.
-
D ll Ri!gulated vol tage (DC)
m
v "

a. Set the engine tachSJ:Q,eter to the ignition coil
of cylinder #1.
b. Connect the pocket testerqpc 20 V) to the
battery as shown.
>
Y.;>
-"!>
ELECTRICAL"' GQMPONENTS

Pocket tester
9089()-()3112
YU-03112-C
positive battery terminal "1"
Negative tester pro9e
negative battery tF>rrn in:.l
c. Start the engine :.nri>IF>t it run at approximate-
ly 5000 r/min.
d. Measure the charging vb11acce
........
CHECKING THE HORN
1. Check:
v.s>
f
...
Hom resistance
Out of specification Replace.

ll Horn
B1!l Coil resis"tance
1.07- 1.11-fu y-? .

"

a. Disconnect the hom leads froG) the horn ter-
minals.
b. Connect the digital circuit tester i& Y,e horn
terminals. .s>f
.,

Digital circui t tester
Y.;>
9089()-()3174

Model 88 Multimeter wi th tachom-
eter
6

'.;>-"
v..,
Horn terminal " 1"
Horn terminal "2"
v.

8-103

"!:>.
2
"t>
6"!>
'
..,h. yo.?.

c. the hom resistance .

.....
2. Check:
Horn souna v.s>
Faulty sound
>y
EA$:2$190
CHECKING THE OIL LEVEL
SWITCH
6
1. Drain:
"'- ""'-
Engine oil ..,

"C!l i,bjevel switch
(fro'hl. the oil pan)
3. ChecR' o
Oil level 'S>u.itch resistance
"'
Oil
resistance (maxi-
mum
..
Oil level switc'fi<J;esistance (mini-
e.,_ mum level positRl!Jl
" 114.o-126.o n
'k

a. Co'flli).ect the pocket tester (n x 1 OO) to the oil
level S'vyj,tch terminal as shown.
P"B' ci$et tester

AnaloQ' RPCket tester
YU-031 f.2qg
Minimum level position
e"b Positive tester probe
>. k Connector (gray) "1" y.?.
'<tJegative tester probe
earth "2"
-"!> "f
Negative tester probe <?>
Body earth "2"
liD
2
1

THE FUEL SENDER
1 . DisconrfEj1:
Fuel pumfi'<lff>Upler
(from the fuel'<ll).Ump)
2. Remove:
Fuel tank
3. Remove: v.s>
Fuel pump '9 <?>
(from the fuel tank)
4. Check:
Fuel sender resistance
Out of specification --t Replace the1tt el pump

Y.
Jiti unit resistance (full)
9.'{b: 11.0 n
Senaer
0
unit resistance (empty)
n
"'
a. Connect the pocket teste'rJO x 1 0/1 00) to the
fuel sender terminals as
-.

Pocket tester

9089()-()3112
'
"!> Analog pocket tester
<t>b

YU-03112-C y.?.
<;,.
Positive probe --t
Fuel sender tgrroinal "1"
Negative tester --t
Fuel sender
;;
8-104
2

6 1
"b ..
?., h. yo.?.

b. fuel sender fl oat to maximum "3"
and "4" level position.
<1
6"!>

%
3
'!><!

""

0
EASZIOCO %
CHECKING FUEL METER/FUEL LEVEL
WARNING LIG.:fv..s>
This model is equipjfe_p with a self-diagnosis de-
vice for the fuel level circuit
1. Check:
Fuel meter/fuel level warffltlJ light "1"
(Tum the main switch to
W:minn light comes on for a 'fe,w seconds,
goes off 4 Warni ng light is 615.
light does not come on 4 Replace
assembly.
W:minriJinl1t flashes eight times, then goes
<ol:\1:.,nti<o in a repeated cycle (mal-
dellecteg in fuel sender) 4 Replace
-"!> ' <U

ELEC 1 F\JCAL COMPONENT&

.AS2g05I) CO...,
CHECKING THE OIL WARNING
LIGHT '\:-
This model is equipped with de-
vice for the oil level detection ctrCj,lit.
1. Check:
Oil level warning light "1"
(Tum the main switch to "ON".)
Warnil'\g light comes on for a few sec%13.9s,
then 4 Warning light is OK.
Warni ng ligntj does not come on 4 Replace"
"
the meter
Warning light flaSiit!!S ten times, then goes off
for 2.5 seconds in cycle (malfunc-
tion detected in oil levelvswitch) -+ Replace
the oil level switch. .s>f

E.AS28:!4t
CHECKING THE SPEED Si;NSOR
1 . Check: -9
>
Speed sensor output voltage
Out of specification -+ Replace.
1
Js(j Output voltage reading
6"!> 0.6 V to 4.8 V to 0.6 V to 4.8
{> -?-

a. Connect the harness S- pressure sensor
(3P) "1" to the sp'%%d sensor coupler and wire
harness as
b. Connect the pocket t!fs.t2r (DC 20 V) to the
test harness S- pressure (3P) .
. -
Pocket tester
>

YU-03112-C -><t.
6
<'ifest harness S- pressure
'-'y.?.
9 o.,

>4>.
c;,
Positive tester
white/yellow (wire color)
Negative tester probe .s>-9
black/blue (wire harness colo;:),

8-105
sensor with

y,

THE ACCELERATOR POSITION
SENSOf!
1. RemoileJ
AcceleratS".OSition sensor
(from the th(GWe bodies)
EWA1FIC1106
-'>.
A WARNING
the throttle position ._ . . .

If the throttle positfOJJ the sensor w1th

replace it. spec1al

Never subJect the accelerlltor pos1t1on sen-
2. Check: sor to strong shocks. If the accelerator po-
Throttle position sensor maximum resistance -o-tition sensor is dropped, replace it.
'<o Out of specification -7 Replace the throttle ---"'7.<.1o. r-------'-----'-----
position sensor. 2.
"' position sensor maximum resis-
. clil. J . Resistance tance .s>-9
1.2D-2.80 kn Ou1 of -7 Replace the accelera-
tor position
.................. .................. ......... ............ ...... ......... ............... r 1 ...
a. Connecf1P.,e pocket tester (n x 1 k) to the ,,fj Resistan&;j!
throttle poSition sensor terminals as showq,
"'>
Pockertester ,.,,,.,.,,,,,.,,,.,.,,,,"",,.,.,,,,.,,,,.,
90890-03112 a. Connect the pocket tester (n x 1 k) to the ac

Cb
'<o
Analog pocket tester celerator position sensor terminals as shown.
c.
YU-03112-C

< .! Positive tester probe -7
-9.!i!lue "1"
tester probe -7
blaCkl .t'!ue "2"
? Pocket tester

pocket tester
Y;.U-03112-C

Positive tester p)pbe -7
blue "1"
Negative tester
black/blue "2"

'.?

b. Measure the position sensor
maximum resistanc'e;.
Cb

3. Install: v
Accelerator position sensor .s>1!
TIP
When installing the accelerator positio ' ensor,
adjust its angle properly. Refer to "ADJU [.!NG
THE ACCELERATOR POSITION
page 7-13.
.? y.?.

EAS1RCI8CC 11Y;.So()
CHECKING THE SERVO MOTOR
1. Remove:
Air filter case
Refer to "GENERAL on page 4-1.
2. Check: .s>f
Throttle valve operation
Throttle valves do not fully close
the throttle bodies.

a. Connect IV!g Csize batteries to the
servo motor "1" as shown. y-? .
ECAIRC\ 802 ""U_/

"
Do not use a 12 V batte-'iY- to operate the throt
tie servo motor.

TIP

Do not use old batteries to oper8,te the throttle
servo motor.
3V
"' A. Check that the valves "2" open.
B. Check that the "2" fully close .

CHECKING THE AIR INDUCTION
SOLENOID . v.s>
f
1 . Check:
Air induction system solenoid resistance
y.?
'%

Solenoid resistance
2D-24 0

'.?'

a. Remove the air induction solenoid
coupler from the air sole
noid.
b. Connect the pocket tester (n x 1) to tht,air in-
duction system solenoid terminal as sh<%vn.

)fb
Pocket tester
-Y'..; i'
9089().()3112
YU-03112-C

,,
Air induction system terminal "1"
Ai r induction system solenoid "2"
.,,.

<t>b

y.?.
;;c
8-108
"

ELECTRICAL COMP'QNENTS

2

c. Measure the air solenoid re-
sistance.
Cb
%

l.fl
CHECKING THE INTAKE AIR PRESSlffi.l;
SENSOR
1. Check:
Intake air pressure sensor output voltage
Out of Replace. Intake air pressure
Intake air p( .. ,.sure sensor output "&<?. Intake air pressure sensor 2 .1-!
v-..._
voltage "'1 c. Sel the main switch to "ON".
3.57-3.71 V@ftJJ-&3 kPa d. Measure the intake air pressure out-
... -,., "=-----....1 put voltage.
......................
a. Connect the test harness s-pres$'08'! sensor \ &
(3P) "1" to the intake air pressure seif&er and .s>f
wire harness as shown. CHECKING THE INTAKE AIR .
A>RCeos TEMPERATURE SENSOR
' '
p -.---h-.--
11
-.-- d-. --.--,- h- 1. Remove:
ay attention tot e tnsta mg trectton o t e .. -it. . Intake air temperature sensor "
test harness S- sensor (3P) cou- .... , ""!>
pier.
b. Connect the digital cirC'1ii! tester (DCV) to the HaKdle the Intake air sensor
test harness s- pressure (3P). with special care.
Never subject the Intake air tempel'!!ture
sensor to strong shocks. If the
temperature sensor is dropped, replace v

.s>
fb
90890-03174 ..
Model 88 Multlmeter with
eter
YU-A 1927
2. Check: <?
>

Test harness S- pressure
Intake air temperature sensor resistance

(3P)
90890-03207
YU-032fit;
'-

Intake air temperature sensor re-
sistance e
0 @0 F)
290-390 0@80 oc

.<)
"

pink (wire harness color) {fQJ.ake air pres-
sure sensor 1)
pink/white (wire harness color)"(Wt ake air
pressure sensor 2) v
Negative tester probe .s>f
black/blue (wire harness color) <?>
y

''f> .
.......................... ...
a. Connect the pocket tester (O x 1 00) to f% in-
take air temperature sensor terminal
h
c:-
sown. .s>
f
.<?>

.<)
"
Pocket"feter
90890-03'1 !2
Analog tester
YU-03112-C <?>

b. Immerse the intake air sensor
"1" in a container filled with
TIP
Make that the intake air
not get wet.
c. Place a "3" in the water.

0%
3
...
f! = 2

d. Slowly the water, then let it cool to
the temperature.
e. Measure the<l!;}take air temperature sensor
resistance.

3. Install: <?>y
Intake air temperature sen'?e,;

EA$1ACHII6 "'",.()
CHECKING THE GEAR
1.
Fuel'f<%J:I k
Refer tJt!Jr UEL TANK" on page 7-1. "
Gear positfe>-9. sensor
Refer to "CRIXt:JKCASE" on page 5-56.
2. Check:
Gear position
Out of specification - l ljleplace the gear posi -
tion sensor. <?>y.?
Jfb
Pocket tester

90890-03112

"'"!>
YU-03112-C

'.? ... y.>.
v
8-110
-"!> -'"'
ELECTRIC)\!,. COMPONENTS

Result
Neutral position v
Continuity .s-f
Positive tester probe <?>y
sky blue " 1"
Sensor terminal " a"
1st ,p_osltlon "-it
Contlouity
Positl\tj! tester probe .?"0
white
Negative t1!%ter probe
Sensor termfr:ml "b"
2nd position .
Continuity ..
Positive tester
pink " 3" <?>
Sensor terminal " c"
3rd position
Co'2]inuity .. "t-
PosiJive tester probe
yelloWt whlte " 4"
Negativi!jtester probe "
Sensor t/ r1J!inal " d"
4th position
Continuity
0
%
Positive tester p'te_pe
white/red " 5" v.s-
Negative tester <?
Sensor terminal " e"
5th position
Continuity
Positive tester probe .
ori_gge " 6"
Negat_L. ve tester probe
" f" "
6th
Continuity
Positive testel'--erobe
gray " 7" ..
Negative tester
Sensor terminal " g" -9
'.(?,

ELECTRICAL C@MPONENTS

EA$1ACHII7
CHECKING THE FUEL INJECTORS
"! v The following procedure applies to all of the fuel
<llj;IJ.?ctors.
1. F,Iemove:
injector
"THROTTLE BODIES" on page 7-5.
2.
Fuel injecf o!Jesistance 6"!>
Out of -+ Replace the fuel
tor. "
I

g
9
!?isconnect the fuel injector coupler from the
injector.
b. Cof.f!;J,ect the pocket tester (n x 1 0) to the fuel
as shown.

. 10
tester 6"!>
y.?.
Analog'-')>ocket tester

YU-03112-C

. Positive tester probe -+
Cb

Injector terminal "1"
v, . Negative tester probe-+
-Gl njector terminal "2"
v.
2
8-111
"!v

f

'%

1bb

y.?.

TFfGJ;! BLESHOOTING

.s>
'-9
TROUBLESHOOTING <f.; 91
GENERAL INFORMATION ...........
STARTING FAILURES ......................
INCORRECT ENGINE IDLING ......................................... 91
POOR MEQJUM-AND-HIGH-SPEED ...........................
FAULTY GE'A&l SHIFTING .................. 'y ... ....... .... ..... ... ..... ....... 9".12.?
SHIFT PEDAL l'il.QES NOT MOVE .................... .. ....... .... ........ ............ . 92
JUMPS OUT ....................................................................... ....... 92
FAULTY CLUTCH ... .ip ......... ..... ... ........ ........ ......... ........ ........ ........ ............. 9-2
OVERHEATING .......... Cb%
OVERCOOLING ..............
POOR BRAKING PERFORiJib.tJCE .. .... ........................... .. ........................ 9-3 v.s>
FAULTY FRONT FORK LEGS ................................ .. .. .. ...... .... .... .......... 9-3
UNSTABLE HANDLI NG ............... .................................... .... ................. 9-3
FAULTY LIGHTING OR SIGNALING
1
\YSTEM ......................................... 9-3

SELF DIAGNO!$liC FUNCTION AND DIAGNCJ&, .J! C CODE TABLE .. .. .. .. ..... 9J

EVENT CODE .... ......................................... ........ ........................... 9-12
' '

.s> oS'

<t>b

y.?.

"<0< -"!>
'.?
TROl?JBLESHOOTING

c
,..,...,
2. Fuse(s)
TROUBLESHOOTING .. Blown, damaged or incorrect fuse
v '4'1mproperly installed fuse
. EA$2$* U" '
GENERALINFORMATION 3. plug(s)
spark plug gap
l\t.,e following guide for troubleshooting does not plug heat range
the possible causes of trouble. It should Fouled plug
be he1p,t!!l, however, as a guide to basi_&: trouble- Worn or dama$Jed electrode
to the relative procedute j n this Worn or damagep insulator
manual adjustments, and 4. Ignition coil(s)
ment of parts. Cracked or broken ignition coil body
Broken or shorted primary or secondary coils
q_-<O ,...,.,. 5. Ignition system
STARTING FAILURES Faulty ECU
v Engine crankshaft position sensor
1. Cylinder(s) and cylinder head(s) irsken generator rotor woodruff key
"Y.? Loose spark plug 6. Swit(;hes and wiring
cylinder head or cylinder switch
't>_emaged cylinder head gasket Faulty stil'J:!I,engine stop switch
or damaged cylinder Broken or wiring
lncori'ect valve clearance
6
"!> Faulty gear po%i.!ion sensor
y y
lmpropet) sealed valve Faulty sidestand s'lY,itch
Incorrect valve-to-valve-seat contact Faulty clutch switcti'

Incorrect valve timing .., Improperly grounded circuit

q_ Faulty valve spring Loose connections
Seized valve Starting system
.. v 2. Piston(s) and piston ring(s) starter motor
Improperl y installed piston ring F{Iulty starter relay
Damaged, worn or fatigued piston ring starting circuit cut-off relay
Seized piston ring clutch
or damaged piston ....,..,.
3. INCORRECT 1-ttGINE IDLING SPEED
lmp'f>012, erly installed air filter
6
"!> Engine
filter element '.? 1. Cylinder(s) and cYI!.pder head(s)
4. Crankcase and crankshaft Incorrect valve clearance
Improperly assembled crankcase Damaged valve train components
q_ Seized crankshaft 2. Air fil ter
Fuel system Clogged air fil ter element
1. Fuel tank
v l,!.el system
.sof Empty fuel tank 1. body (-ies)
Clogged fuel tank cap breather hole or loose throttle body joint
caognetdamf uie nal hteodse fuel synchronized throttle bodies
""-@::' lmprope"f'<\hrottle grip free play
2. pump Flooded th?o!J!e body
Faui\M fuel pump 6"!> Faulty air system
pump relay '.?
3
. Throttle (-ies) Electrical system
u

1. Battery "
Deteriorated or contaminated fuel Discharged battery
q_ Sucked-in air Faulty battery
"0 Electrical system Spark plug(s)
.. v 1. Battery spark plug gap
.sof Discharged battery il:ji:orrect spark plug heat range
Faulty battery Fo1111ed spark plug

9-1

<to.. <to ..
.

'o "
Worn or damaged electrode '<o '-""""

Worn or damaged insulator FAUL TV CLUTCH
)
"! v Clutch slips "! v
3. Ignition coil (s .s> C .s>
'<?, Broken or shorted primary or secondary coils -9
1
lutch 1
-Y.?"" Cracked or broken ignition coil . <?>Y.?; Improperly assembled clutch
_,@properly adjusted clutch cable

4
Ignition system or fatigued clutch spring
Faulty ECU .O<Jl-<>
<t>b Faulty crankshaft position sensor Wori\friction plate
generator rotor woot frJ;l1f key Worn plate
.?.;;, 2. Engine oiF.?
00
, .,...., " Incorrect oil f evel
POOR Incorrect oil viscosity (low)
PERFORMANCE Deteriorated oil
Refer to "STARTING FAILURES" on page Clutch drags
Engine 1. Clutch
.s>f 1. Air filter . . v.s>f Unevenly tensioned clutch springs
<?> Clogged a1r filter element <?> warped pressure plate
Fuel system . clutch plate
1. Throttle body (-1es) friction plate
Faulty throttle body pull rod
Fuel pump 6"!> boss
fuel pump '.? Burnt driven gear bushing

Match marRS' not aligned
FAULTY GEAR SHIFTING 2. Engine oil
Shifting Is difficult Incorrect oil level
Refer to "Clutch drags". '<o Incorrect oil viscosity (high)
Deteriorated oil

.s>-9 SHIFT PEDAL DOES NOT MOVE .s>f ,..,..,.
<?>y Shift shaft <?-QVERHEATING
Improperly adjusted shift rod Eiilgine
Bent shift shaft 1 . Ol@_gged coolant passages
drum and shift forks Cylifiq_er head(s) and piston(s)
object in a shift buildup
shift fork '.?;, 2. Engine oil'.?.
Bent shift fork guide bar

Incorrect oi'l'tevel
Transmission Incorrect oil viscosity
Seized transmission gear Inferior oil quality
Foreign object between transmission Cooling system
Improperly assembled transmission 1 . Coolant

1 EAS2tl:;:c 1
. <?> JUMPS OUT OF GEAR . <?) . Radiator
Shift shaft or leaking radiator
Incorrect shift pedal position radiator cap
Improperly returned stopper lever Be"nt or damaged radiator fin
'Sqift forks 6"!> 3.
YVQI!l shift fork '.?;, faulty water pump
Shitf-tlrum

Thermostai"0
Incorrect axial play Thermostat stays closed
Wom shift drum groove Oil cooler
Transmission Clogged or damaged oil cooler
Worn gear dog Hose(s) and pipe(s)
v .s> Damaged hose
-9. <? Improperly connected hose
>
y.?

9-2

<t>.-
Damaged pipe
Improperly connected pipe ..
Fuel system v.s>
1. Throttle body (-ies) UNSTABLE HANDLING
Damaged or loose throttle body 1. Handlebar
2. Air filter B
Clogged air filter element ent or improperly installed handlebar
Chassis "'-it.. 2. Steering head components
1
. Brake(s)
6
"!> Improperly 1nstalled bracket
Dragging Improperly Installed ,Rracket
Electrical system (Improperly lightened nng
1. Spark pi g(s) Bent steenng stem
spark plug Damaged ball bearing or
Incorrect spark plug heat 3. Front fork.leg(s) %
2. Ignition s stem "! v Uneven Oil levels (both front fork legs} -6"1
Faulty E6'u .s>f Unevenly tens1oned fork spring (both fr.r:mt
<>> fork legs) <>
' '
OVERCOOLING Bent or damaged inner tube
Cooling system or damaged outer tube
1. Thermostat
6
4. Swmgarm
6
<t>b
Thermostat open Worn bearing or
, .,_ Bent or damaged swingarfu
POOR BRAKING 5. Rear shock absorber
Worn brake pad Faulty rear shock absorber spr1i\g
Worn brake disc
Leaking oil or gas

Air in hydraulic brake 6. Tire(s)
Leaking brake fluid v.s> Uneven tire pressures (front and rear) v
'9 oS'
Faulty brake caliper kit <>> Incorrect tire pressure <>
Faulty brake caliper seal Uneven tire wear >y.?
Loose union bolt 7. Wheel(s)
Damaged brake hose Incorrect wheel balance
Oil or grease lijn the brake disc Deformed cast wheel
Oil or grease o1l he brake pad Damaged wheel bearrhg
/.Y_k yo.?. \':)
Incorrect brake Bent or loose wheel axle
Excessive wheel runout
, .,_ 8 ,_
FAULTY FRONT FORK Frame ""-o
Leaking oil Bent frame
Bent, damaged or rusty Damaged steering head pipe ..
Cracked or damaged outer tubev.s> Improperly installed bearing race . v
'9 oS'
Improperly installed oil seal <>> ....,.,,. <>
Damaged oil seal lip FAULTY LIGHTING OR SIGNALING SYSTEM>Y.?
Incorrect oil level (high) Headlight does not come on
Loose damper rod assembly bolt Wrong headlight bulb
Damaged daiJI ,ger rod assembly bolt Too many electrical
washer '.? Hard charging "!>
..1-! yo.?. ... ,
Cracked or cap bolt 0 -ring <S<!- Incorrect connection
Malfunction Improperly grounded circuit
Bent or damaged inneJ\I:J):le Poor contacts (main or light swit'fflt)_
Bent or damaged outer tulJ% Burnt-out headlight bulb
Damaged fork spring Headlight bulb burnt out
Worn or damaged outer tube Wrong headlight bulb v
Bent or damaged damper rod <> Faulty battery .s>f
>
yo&. )!'..,

9-3

Incorrect oil viscosity
Incorrect oil level
-"!>
'.?

c
recti fier/regulator
grounded circuit
Facitty main switch
FaultY.!;Iimmer switch
...
Headligtl\>.:Hulb life expired
TaiVbrake liQ!;Jt does not come on
Too many accessories
Incorrect connec11Qn
&"!>,.? Turn signal does on
Faulty turn signal
Faulty turn signaVhazard relay
Burnt-out turn signal bulb
Incorrect connection
'F).,emaged or faulty wire harness
lmlilf.l?Perly grounded circuit
Faulf1,Battery
Blown, O@Jraged or incorrect fuse
Turn slowly
Faulty turn si!}A)I.Vhazard relay
Faulty main swifeQ,
&"!> Faulty turn signal
'.? Incorrect tum signal 5o!J?
Turn signal remains lit"
%-o Faulty turn signaVhazard relay
Burnt-out turn signal bul b
t1;J.rn signal blinks quickly
li\'tgrrect turn signal bulb
signaVhazard relay
Burnt-6&;-?turn signal bulb
Horn sound
Damaged horn
Faulty main sw&JJ
Faulty horn
Faulty battery y-?
00
Blown, damaged or incorrect fuse
Faulty wire harness

- .

FUNGl:ION AND DIAGNOSTIC CODE TABLE

'
c
EA$1AC191
SELF-DIAGNOSTIC FUNCTION CODE TABLE <o_,
"' Self-diagnostic function table v.s>
Fault
<?_.
Reference

Item

code No.

pages
.
Crankshaft position sensor: no normal signals are from the
8-38
"t>
crankshaft position seq)ior. <t>b
::,_
6
13

Intake air pressure sensor;!: open or short circuit detecte1:b
00
_ 839
14
Intake air pressure sensor 1 :'l:i_o. se system malfunction (clogged or
8-41
detached hose).

15 Throttle position sensor: open or detected. 8-42
19
Sidestand switch: a break or disconnecfrcw of the black/red lead of the
ECU is detected. .s>1! A
8-44

Intake air pressure sensor 1 or intake air sensor 2: when the
main switch is turned to "ON", the intake air pres sensor 1 voltage 8-46
"'
and intake air pressure sensor 2 voltage differ greafty
0
.
21 Coolant temperature open or short ci rcuit 8-48
6"1
22
y.?.
Intake air temperature seti!i9.r: open or short circuit detectea
0
849

"
24 0
2
sensor: no normal signal$,.&16. received from the 0
2
sensor. 8-50
25 Intake air pressure sensor 2: ope/lq;){ short circuit detected. 8-52
26
Intake air pressure sensor 2: hose malfunction (clogged or
detached hose). v.s>
8-54
30 Latch up detected.
'<?
856
>Y.>.

Cylinder-#1 ignition coil: open or short circuit in the primary
8-56
"'
lead of the cylinder-#1 ignition coil.
. ..,b
Cylinder-#2 ignition coi[i open or short circuit detected''ii\J,_Jhe primary
8-58
6-'l
34
lead of the cylinder-#2 i'IO!)tion coil.
y.?.
1-. .?.
35
Cylinder-#3 ignition coil: short circuit detected in the 'Primary
lead of the cylinder-#3
859
39 Inj ector: open or short circuit 860
41 Lean angle sensor: open or short 862
Speed sensor: no normal signals are from the speed sensor. 863

42 Neutral switch: open or short circuit is detecteef.'Q, 8-65

Clutch switch: open or short circuit is detected. 8-68
"' "'
<t>
Fuel system voltage: illOrrect voltage supplied to the fue.l injector and
43
"!> "-<
871 6-'l
":>.
fuel pump.

EEPROM fault code error is detected while readu'lg or
44
writing on EEPROM.
872
46 Charging voltage is abnormal.
c
04,
8-73
50
Faulty ECU memory. (When this malfi1t1,9tion is detected in the ECU,
the fault code number might not appear oQ.Ihe meter display.)
8-74
9-5
-"!> " "<U

FfJNCTION AND CODE TAB['

' '
c. c.
Fault

Reference
Item
code No.

pages
' '
59 position sensor: open or short circuit detected.
...
'"/
'<} 8-74
60 YCC-T malfunction detected. 8-76
70 Engine idling tf)p

"'
...
error with
' '

Fault code No. Item

pages
89 (Yamai]a diagnostic tool) Multi-Junction meter: signals cannot
Err (multi-f&gp ion meter dis- ted between the ECU and the 8-78
play)

meter.

Diagnost ic operation table
Diagnostic

code No.
Meter display
"' "'
01 Throttle
6"!>

signal1

y.?.

Check with throttle

Fully closed positron 11- 21

fully closed.
"-e
with throttle valves
Cb Fully open position 96-106

fu
'
03 IT\!ake air pressure 1 Displays the intake air Shift transmission into
'"/
pressure. gear, the sides-
'<}_,.

land, and operate the
'% throttle while :\f,l'hing the

"<J>" side of the

"t>,o
start/engine stop s\\tilch.

6"!> (If the display value

y.?.

changes, the perfor-

.. ..
mance is OK.) "
04

Intake air pressure 2 Displays the intake air Shift the transmission into

'ear, extend the sides-

pressure.

and then operate the
'
while pushing the
.s>
"<J>" si e_pf the
'"/
'<}_,.
start/engifl.e stop switch.

(If the
'%

changes, the
.. _
mance is OK.)
05 Air Displays the air Compare the

y.?.
lure. measured air

with the meter display "

value.

9-6
- .
' '
SELF-DIAGNOSTIC DIAGNOSTIC CODE TABLE

'
c.
Diagnost ic

code No.
Item Met er Procedure
v
.
'

Coolant temperature When engine is corif.,.gis Compare the actually
>

plays temperature measured coolant temper-
'%
to air temperature. ature with the meter dis-

When engine is hot: Dis- l;l_ij!y value.

g rays current coolant tern-
...
'\
<t>b

'
07 Ve"f\jcle speed pulses speed pulse Check tffat the number
0-99 increases when the rear
wheel is rotated. The num-

ber is cumulative and

does not reset each time
oo,.
the wheel is stopped.
v

Lean angle sensor Lean angle sensor Ol.tJgut Remove the lean angle

voltage sensor and incline it more
'%
Upright
than 65 degrees.

0.4-1.4

Overturned 3.7-4.4

'\
>
6
<t>b
09 system voltage I system voltage Set stop
(battery voltage) Ap 12.0 switch tO'OJo", and then

compare the actually mea-

sured battery voltage with

the meter display value. (If

the actually measured bat-
tery voltage is low,
oS' .s>
recharge the battery.)

Throttle position sensor

'% signal2 '%

Fully closed position 9-23 with throttle valves
'\

6"!>

open position

Check Wgh throttle valves
" fully opeif.

14 Accelerator position sen-
-o,

sor signal 1
Cb

Fully closed position 12- 22

Check with throttle grip
oo,.
v
fully closed position. oS' .s>
'-9 '-9

Fully open position 97- 107

Check with throttle grip

'% ...
'%
fully open position .
15
..
Accelerator position sen-
..

'\
sor signal2
6
<t>b
closed position

throttle grip
"
fully eros d position.

Fully open position Check with throttle grip

fully open position.

9-7
-"!> "<0< -"!> "<0<
'"'
SISLF-DIAGNOSTIC FONCTION AND CODE

Q Q
Item Meter display Procedure
code No.
20
6<'1, 21
'"'

' '
Siifejand switch Extend iih,d retract the sid-
?"' ON estand (witfi;J!!e transmis-
sion in gear). ...
...... -..
Stand OFF
Gear position and 6"!> Operate the transmli' s..jgn.
clutch switch ?"' '"';, clutch lever, and sides- ?"'

Transmission is in neu- ON
tral

c
Transmission is in gear
or the clutch lever
OFF
Cb

60
v.s>released
'f
bfqtch lever is
with the
in gear
and sides
tand is
?
Clutch lever is
squeezed with the
transmission in gear
and when the sides
land is extended
History exists
ON

.s>
'f

?"'
'%

OFF
?.?.

00
No malfunctions
detected (If the
selfdiagnosiSSJBult
code 44 is indica!Jld,
the ECU is

01-Q3 (Cylinder fault
code)
(If more than one cylin-
der is defective, the dis- v
play alternates every .s>f
two seconds to show all
the detected cylinder '%
numbers.
When all cylinder num-
bers are shoW@" the
display repeats fi:IJ.1 ?"'
same process.)

11 (Data error for ISC
speed control) learning
values)
9-8
.
SELF-DIA'(\NOSTIC TABLE

Q Q
Diagnostic
code No.
% %
Meter display Procedul e

' '
61 Malfunction histOI code - <?>
display "Y.?"'" y"'

No history 00
.... ,.()
codes 12-89 <t>b
more than one code
6
"!>
y
nowber is detected, the
display alternates every

.., two seconds to show all ..,

'b the detected code num- 'b
% %

v When all code numbers

v
.s>f are shown, the display .s>f
<?> repeats the same pro- <?>
History exists
cess.)

62 Malfunction history
63
erasure
'
"" No history OO<>y - ""'.? ..,

exists Di!i' plays the total num- To history, set "
ber of malfunctions, the stop
including the current switch to"()".
malfunction, that have
v occurred since the his- v
.s>f tory was last erased. .s>f
<?>y.? (For example, if there <?>yv>.
have been three mal-
functions, "03" is dis-
played.)
v"b Malfunction code rein-
(for fault code
42 only)
v"b

00 code
'b
Malfurl'Gijpn code exists Fault code 24, 42
00
<1 v (If more than one code
.s>-9 number is detected, the
<?> display alternates every
two seconds to show all
the detected code num-
bers.
When all code numbers
shown, the display
the same pro-
cess.)

'b
To reinstate, set>{tle
start/engine stop 'Switch
from "!)(l" to "()". v.s>f
'.(?>
y ....

<t>b

y.?.

- .
'.? ,,
FUNCTION

% %
' '
c. c.

Item Met er display Procedure
cod'etJo.

'
67
'"/
ISC (idle speed control) 00 f <a> erase the ISC (idle
'<?>
'(;
learning condition display I SC (idle speed control) control) learning
(idle speed control) learning data has been data, the starVengine
le R}ng data erasure erased. stop swrfl>);l from "l5<l" to
...
01 "()" 5 seconds .
<t>b
It is not to
y.?.
erase the IS-. (idle speed
y.?.

control) learnfQJl data.

02
It is necessary to eri\se
the ISC (idle speed &.Q-

trol) learning data.
"!
70
,SO

Control number 0-254 (-) lr-

>
Diagnostic c!q,[le: actuator operation table
Diagnost ic

"""'
code No.

Item Actuation
<t>b
6
<t>b
30 Cylindef-11,1 ignition coil Actuates cylinder-#1 Check that a is gen-
ignition coil at erated five
one-second in Connect an ignition

Illuminates the e liJ}..ne checker.

trouble warning
31
"'(6
Cylinder-#2 ignition coil Actuates the cylinder-#2' .; .. Check that a spark is gen-

ignition coil five times at 'G five times.
,SO
'"/
one-second intervals. an ignition
'<?>
Illuminates the engine
>
'(;
%.,_,,

trouble warning light.

32 Cylfrts;!er-#3 ignition coil Actuates the cylinder-#3 Check ttlal>,., a spark is gen-
<t>b
ignition five times at erated five ti'r"Qes.

intervals. Connect
y.?.

Illuminates tf&J;l engine
checker.
trouble

Injector #1 Actuates the injecfe6 #1 Check that injector # 1 is

five times at one-sec'Oad actuated five times by lis-

intervals. .. tening for the operating

Illuminates the engine 'G [s.sound.
,SO
'"/
'"/
'<?> '<?>
37

#2 Actuates the injector #2 injector #2 is

five times at one-second actua eJil five times by lis-

intervals. tening operating
<t>b
lllumina\Sl s the engine sound.

trouble wa"t,ping light.
y"' y"'
38 Injector #3 "-' Actuates the i l)jector #3 Check that injectof #3 is
five times at actuated five times by lis-

intervals. tening for the operating
Illuminates the engirfeo sound.

"! "!
v
9-10
-"!> " "f ir induction system sole Actuates the air induction c iT'e. ck that the air indue-

system solenoid five times lion solenoid is

at one-second intervals. times by lis

Illuminates the engine tening for operating

trouble wa!.ning light.
d ...
<t>b
soun . <t>b
50 Relay unit'-<>?.?. Actuates the'{E!Iay unit five Check that the unit is
times at inter- actuated five times'by lis-

vals. .. tening for the operating
Illuminates the sound.

0%
51
"'<
Radiator fan motor relay Actuates the radiator fan Check that the radiator fan oo,.
v
motor relay five times at R'!,otor relay is actuated
.s>
'"/
five-second intervals. by listening for
'<
Illuminates the engine the sound.
'% trouble warning light.

52 HeadfiQht relay Actuates the headlight Check headlight
<t>b
relay five tiroes at five-sec relay is actua!'eg five times

ond intervaT<) IIuminates by listening for tiifl} operat-
?.?.

the engine trou'QJ: warning ing sound.
4..
light.
9-11

EVENT CODE'ABLE
c

TI P & &
The evei11,o;ode numbers listed below cannot be displayed on the mete'fo<?To display the event code
numbers, Yamaha diagnostic tool.
' '
No.

Symptom Possible causes
Note
""'-.
192 Intake air Brief abnormality as fault code 13 Perform
sure sensor 1 detected in the
'.?
items listed code

air pressure

No. 13. 'l-
sensor 1
'
c<l.-93 Throttle posi- Brief abnormality Same as 15 Perform the inspection
-'1>
tion sensor detected in the
-'1>
items listed for fault code

oo ..
throttle position
oo ..
No. 15.
&
&

sensor
.s>

195 Brief abnormality Same as fault code 19
the inspection
switcft>"<1 detected in the ite , listed for fault code
ECU (black/red
No.

lead) input line
...

"'

196 Coolant templ!rr;, Brief abnormality as fault code 21 Perform the'99spection
ature sensor .?. a in the items listed fo'AI_ault code
coolant tempera-

No. 21 .

ture sensor

Intake air tern- Brief abnormality Same as fault 22 Perform the inspection

perature sensor detected in the


intake air tempera-

No. 22.
.s>
. .(?>
lure sensor

:?>
199 lntal<{l
0
air pres- Brief abnormality Same as fault code 25 the inspection
sure 2 detected in the ite S>sted for fault code

intake air pressure

sensor2

203 Lean angle Brief abnormality Same
1
as fault code 41
Perform the
sor in the lean
..
items listed for ault code
angle sensor

No. 41.

cao7 Accelerator Brief abnormality Same as 59 Perform the inspection
-'1>
position sensor detected in the
-'1>

oo ..
accelerator posi-
oo ..
No. 59.
&
&

tion sensor
.s>

9-1 2

?,
EVENT CODE"0TABLE
'c.
'
c.

Item Symptom Possible Note
240
v
0
2
sensor During 0
2
feed - Open or short
-
If a fault code is
f.
back, the adjust- cuit in the wire > occurring, respond to
(SJuck at the
limit for ment is maintained ness between the ?.?-.,that first.
adjust'f!} : nt) at the upper limit sensor and ECU * Code 240

- Drop in fuel pres
occurs.,even when the
<t>b
6
sure
system

- "e.JP.gged fuel inj ec-
properly.

?.?.

-

- Malfunctil!ln in ECU
- the

fuel injection sw.;

"' tern v.s>
241 During 0
2
feed - Open or short cir ' If a fault code is
at the
back, the adjust- cuit in the wire har ?.?l ccurring, respond to
lower l!j;lit for ment is maintained ness between the first.
..
at the lower limit sensor and ECU * Rarel9:tCode 241

- 6Drop in fuel pres occurs e when the

system is
?.?.
v'l
- Clo'bged fuel inj ec
properly.

tor
'
- Fault in S'e[:!SOr

- ECU

- Malfunction

fuel injection sys!(.s>
tern
> >
242

During idling, the Idling engine speed is - diagnosis
adjustment is main slow
0 67' and check
upper limi\;Aor
tained at the upper - Clogged throttle
the 1\Q maintenance
adjustmen
limit
6Jlody

- ?>e9.rly adjusted
- If a fault c-o,ge is
thr8tt)p cable
occurring, rg-spond to
- Poori"<Wjusted
that first.

cl utch ca'li>Le
Rarely, Code 242

- the occurs even when the

fuel injection SY$ system is functioning

tern &.s> properly.

'f
-
Dirty or worn spark,>
>
?.?
plug
'%

- Malfunction in the

battery
<t>
-
6
jvlalfunction in ECU

/
9-1 3
-"!>
... , 51..

EVENT CODE TABLE

' '
c. c.
No.

Item Symptom Possible causes

Note
243 ISCV<l' During idling, the Idling engine speed is ..: &Jf a fault code is
the adjustment is main- fast <1' cc_vrring, respond to
lower limit>j or tained at the lower - Poorly adj usted

limit throttle cable
* Rarely, 243

Poorly adj usted

-
occurs even 'When the
cl utcl$cable system is funcligning

- in the
properl y.
y.?. y.?.

fuel sys-

tem ..
- Dirty or worn

plug
0
..

battery v
.s>
Malfunction in ECU
.s>
"f
-
"f

244
Poor
Poor starting/inabil- - No gasoline - If a code is
ing/inability ity to start detected - Malfunction in the occurrl?i:g.! respond to
start
f.- b
fuel injection sys- thatfirst.
tem e Rarely, Code

- Dirty o'f spark occurs even
y.?.

plug
system is

- Malfunction
properly.
battery

- Malfunction in
0
flh
245 I ERgi'e stop Engine stop - No gasoline v If a fault code is
.s>
detected
- Poorly adj usted <Ofcurring, respond to
"f

throttle cable ttiat>Jirst.

Poorly adj usted Rare1W<.ode 245
'%
-

clutch cable occurs the
.<)
system is fUI1<SJ.ioning
..

fuel il'li!lction sys-
properly.

"

y.?. tem y.?.

- Dirty or w"&-QJ spark

plug
- Malfunction in fll@.
0

0
battery '<o
- Malfunction in ECU

 1. AC magneto
57. Oil levef"s_witch B Black v
58. Gear posii$1'1 sensor Br Brown .sof
59.Fuel Ch Chocolate <:
'-'y.? 2. Rectifier/regulator
3. Main switch
4. Main fuse
5. Electric throttle valve fuse
Backupfuse
'f.);, Radiator fan fuse
8. lighting fuse
9. Ignition fuse
10. Signal fuse
11 . Headlight fuse
12. Auxiliary DC outlet fuse
t3. Baery
60.Fuel pump Dg Dark green
61.Sidestand switch "01 G Green
62.Right handlebar Gy Gray
6
63. Drive mode "t>b L Blue
6
"!>, 64. Start/engine stop switch Lg Light green "!>,.?
65. Hazard switch Y.?.;;, 0 Orange
Front brake light switch P Pink
brake light switch R Red
6B.'T1.1.rn signal/hazard relay Sb Sky blue
switch v Violet

70. W White ..
71.Horn v Y Yellow v
72. Horn BIL Black/Blue .so'\'<:
73. Turn signal swil%h B/R Black/Red
14. Engine ground
Y <> 15. Fuel injection system fuse
'-'y.? 16. Starter relay
17. Starter motor
18. Joint connector
74.Pass switch B/W
75. Dimmer switch B/Y
19. Joint coupler
76. Rear right turn signal if9!3t Br/L
6 77. Rear left turn signal light Br/R
Relay unit
2\'?.Starting circuit cut-off relay
pump relay
"!>,.? 78. Front right tum signal!positlSI} Br/W
light Br/Y
23. ECU (engine control unit)
24.1gnition coil #1
left turn signal/position G/B
G!W
25.1gnition coil #2
26.1gnition coil #3
BO.i:fee.dlight G/Y
light Gy/G
27. Spark plug
82. light Gy/R
83. Tail!brak61ight LIB
84.Headlight L/R
85.Radiator tan relay LIW
2B.I njector #1
Y <>> 29.1njector #2
86.Radiator tan motoro LIY
87. Auxiliary DC jack Lg!L
Y.? 30.1njector #3
31 .Air i nduction system solenoid
Lg/W
0/G
32.0
2
sensor
33. Crankshaft sensor
Y.?. P/8
P/W
air temperature sensoi!l "b
temperature sensor '.?;,
36.fntake air pressure sensor 1
37. 1ntake air pressure sensor 2
39. Speed sensor
40. Throttle servo motor .
41. Accelerator position sensor .. v
42. Throt11e position sensor .sof
Y <>> 43. Yamaha diagnostic tool con- <>>

44. Yamaha diagnostic tool cou-
pier
.. -it.. 45. Meter assembly
Neutral indicator light 6"!>
47-.Meter light '.? Y.?.;;,
48.'fachometer

49. Multi-function meter
50. Oil level warning light
51. Fuel level indicator light
52. Engine trouble warning light
53. Coolant temperature warning v
light .sof
54. High beam indicator light <>>
y.?

<t> ..
RIB
RIG
AIL
R/W
R/Y
Sb/W
W/B
WIG
W/L
W/R
W/Y
Y/8
Y/G
YIL
Y/R
Y/W
Black/White
Black/Yellow
Brown/Blue
Brown/Red 6
Brown/White"!>,.?
Brown/Yellow
Green/Black
Green/White
Green/Yellow
Gray/Green
Gray/Red ..
Blue/Black v.so
Blue/Red 11 <:
Blue/White
Blue/Yellow
Light green/Blue
Light green/White
Orange/Gre,n
Pink/Black "'.?;,
Pink/White
Red/Black
Red/Green
Red/Blue
0-A
Red/White
Red/Yellow

Sky blue/White .sof
White/Black <:
White/Green
White/Blue
White/Red
White/Yellow

Yellow/Green '.?;,
Yellow/Blue
Yellow/Red

.so
f
"-G
-"!> -"!>
y.?. '.? y.?. '.?

Cb Cb

.s> .s>
f f
.<?> .<?>
y.? y.?
'% '%

<t>b
6"!>
<t>b
6"!>

y.?. '.? y.?. '.?

Cb Cb

.s> .s>
f f
.<?> .<?>
y.? y.?
'% '%

<t>b
6"!>
<t>b
6"!>

y.?. '.? y.?. '.?

Cb Cb

.s> .s>
f f
.<?> .<?>
y.? y.?
'% '%

<t>b
6"!>
<t>b
6"!>

y.?. '.? y.?. '.?

Cb Cb

.s> .s>
f f
.<?> .<?>
y.? y.?
'% '%

<t>b
6"!>
<t>b
6"!>

y.?. '.? y.?. '.?

Cb Cb

.s> .s>
f f
.<?> .<?>
y.? y.?
'% '%

<t> .. <t> ..
-"!> -"!>

'.? y.?. '.? y.?.

Cb Cb

.s> .s>
f f
.<?> .<?>
y.? y.?
'% '%

6"!>
<t>b
6"!>
<t>b

'.? y.?. '.? y.?.

Cb Cb

.s> .s>
f f
.<?> .<?>
y.? y.?
'% '%

6"!>
<t>b
6"!>
<t>b

'.? y.?. '.? y.?.

Cb Cb

.s> .s>
f f
.<?> .<?>
y.? y.?
'% '%

6"!>
<t>b
6"!>
<t>b

'.? y.?. '.? y.?.

Cb Cb

.s> .s>
f f
.<?> .<?>
y.? y.?
'% '%

6"!>
<t>b
6"!>
<t>b

'.? y.?. '.? y.?.

OVAMAHA

Cb Cb

.s> .s>
f f
.<?> .<?>
y.? y.?
'% '%

<t> .. <t> ..
e tl3
.

j,_ ... ._...M_,.

... .:.;.;.:.,.
<ty.?,;,
:.

\=; '

"<!>,
. 'k: . ; ;,

&

-'.?,
.... ' "!>-.,
: '!-
.. '< ,;,.
ti
..
'
'
@'
"
: . ;
@: ........ : :
1- . . :
..

'

\
v,

.. .T .

.: = s
y.?
'%

o
..... ,

6"!
I''
6"!>
...
):/
, .. \, f'\;@

'.?
f?"' "':"'
......
:' --
.... ...; _-,:

7 ,z;_ "' ""'

: .
1!!1: H
<so: A : ;

.
...
' .. :.o,,
' @(fi) ... ... : : , ......

.,
e ..,
. t!. :
@mll
o, @> . ,_. ,,,. ,
h,
-
":':':i=i'
t!!
r.

I "'>y.?.;;, : I: i!i . !

_! : t. ,. ..
-.,,'<, F"b,.?j
.; ' l!i r;: i"' llf'i; c
., ,__ . : If'
.:
' .J :
..

.. . ...
@ .....
I
e

.0,
"
( f'?o,.
'b
:'-' !'-"' . .
@'
J'j

.. ....

---t"'..,
,s>
.....
,s>

'-9 '-9
>

y.?
'.?,;,

y.?
'%

'%

fill IIIIi
,. ,.
I'""""""""
._...M_,.

FZ09 Service Manual OCR

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FZ09 Service Manual OCR

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2014

This indicator comes on when the be-

Push the "SELECT" button to switch the display

set to either :km/L", "U100 km" or "MPG".

36.190 mm (1.4248 in)

250 kPa (2.50 kgf/cm

(1.1 m-kgf, 8.0 ftlbf)

m-kgf, 2.5 ftlbf)

chai n tensioner '<o

pier with the same color. After connecting the

Specified valve clearance =

ARM" on page 4-64.

d. Measure the brake disc runout.

and plastic parts. Therefore, always clean up eke t

Soft or spongy feeling 4 Bleed the brake sys

j. Install the washer and cap bolt, and then fin-

"a" facing up "A".

Connecting arm lower bolt

GENERATOR AND STARTER CLUTCH ....... ...... . ................. ........ 530

INSTALLING THE OIL PAN ......................... ........ ............ %oA ............... 5 55

CHECKING THE PISTON PIN ......................................... o,.. '0 ................ 5-63

adjust bolts (rear) Adapter bolt (left) "5"

12 Nm (1.2 mkgf, 8.7 f11bf)'

Out of specification 4 Replace the piston pin.

1. Measure the compressed Plast1gauge

THERMOSTAT .. .............. ............................. .. ........... .. ............... .. ........... 6-6

TLE BODIES" on page 3-8.

Fuel tank 6"!>

Check the signaling system

and condition of the sensor.

Fault code number is not dis-

or replace for approximately 5 seconds.

13. Throttle servo motor

(idle speed control) learning value.

c. Make sure that the current is higher than the

If the throttle positfOJJ the sensor w1th

Leaking oil or gas

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