Professional Documents
Culture Documents
YZF-R6TC
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-18-45
5SL-28197-12
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YZF-R6T / YZF-R6TC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.
YZF-R6R / YZF-R6SR / YZF-R6RC / YZF-R6SRC SERVICE MANUAL:
LIT-11616-16-45 (5SL-28197-10)
YZF-R6S / YZF-R6SC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-17-46 (5SL-28197-11)
EAS00001
YZF-R6T / YZF-R6TC
SUPPLEMENTARY
SERVICE MANUAL
2004 by Yamaha Motor
Corporation, U.S.A.
First edition, September 2004
All rights reserved. Any reproduction
or unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P / N LIT-11616-18-45
EAS00030
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
Designs and specifications are subject to change without notice.
EAS00040
WARNING
CAUTION:
NOTE:
EAS00007
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols
to
indicate the subject of each
chapter.
General information
Specifications
Periodic checks and adjustments
Chassis
Engine
Cooling system
Fuel injection system
Electrical system
Troubleshooting
Symbols
to
indicate the following.
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols
to
in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Engine oil
Gear oil
Molybdenum-disulfide oil
Wheel-bearing grease
Lithium-soap-based grease
Molybdenum-disulfide grease
Symbols
to
in the exploded diagrams
indicate the following.
Apply locking agent (LOCTITE)
Replace the part
CONTENTS
GENERAL INFORMATION
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
3
4
5
5
5
6
20
22
CHASSIS
FRONT WHEEL AND BRAKE DISCS. . . . . . . . . . . . . . . . . . . . . . . . .
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . .
CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . .
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
25
25
26
29
31
33
33
36
37
38
43
43
COOLING SYSTEM
RADIATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
ELECTRICAL SYSTEM
ELECTRIC STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
47
48
51
51
52
SPECIAL TOOLS
GEN
INFO
EAS00027
GENERAL INFORMATION
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country. When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
For U.S.A. and Canada, use part number starting with YM-, YU-, or ACC-.
For others, use part number starting with 90890-.
Tool No.
90890-01423
YM-01423
90890-01434
YM-01434
90890-01441
YM-01441
90890-01442
YM-01442
Illustration
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Weight
Wet (with oil and a full fuel tank)
Maximum load (except motorcycle)
Standard
5SLR (USA except for CAL)
5SLS (CAL)
Limit
ENGINE SPECIFICATIONS
Item
Throttle bodies
Model (manufacturer) quantity
ID mark
Standard
40EIS (MIKUNI) 4
5SLM 30 (5SLR), 5SLS 40 (5SLS)
Limit
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item
Frame
Caster angle
Trail
Front tire
Size
Model (manufacturer)
Rear tire
Model (manufacturer)
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb)
90 ~ 192 kg (198 ~ 426 lb)
(USA except for CAL)
90 ~ 191 kg (198 ~ 423 lb) (CAL)
High-speed riding
Front brakes
Brake lever free play
Brake discs
Diameter thickness
Min. thickness
Master cylinder inside diameter
Rear brake
Brake pedal freeplay
Standard
Limit
24.5
95 mm (3.74 in)
16 mm (0.63 in)
4.0 mm
(0.16 in)
CHASSIS SPECIFICATIONS /
ELECTRICAL SPECIFICATIONS
Item
Front suspension
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Inner tube outer diameter
Fork oil
Quantity (each front fork leg)
Level (from the top of the outer tube,
with the outer tube fully compressed,
and without the fork spring)
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
Rear suspension
Spring
Free length
Installed length
Spring rate (K1)
Drive chain
Maximum 15-link section
SPEC
Standard
Limit
243.8 mm
(9.60 in)
8
7
0
10
6
1
13
6
1
239.3 mm
(9.42 in)
ELECTRICAL SPECIFICATIONS
Item
Ignition system
CDI unit model (manufacturer)
Fuses (amperage quantity)
Radiator fan motor fuse
Standard
Limit
F8T828 (MITSUBISHI)
15 A 2
SPEC
TIGHTENING TORQUES
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Fastener
Thread
size
Qty
Clutch boss
Nut
M20
Bolt
M6
Item
Tightening torque
Nm
90
mkg
9.0
7.5
0.75
Remarks
ftlb
65 Use a lock
washer
5.4 Yamaha bond No.1215
Item
Handlebar and front fork
Front fender and front fork
Rear brake master cylinder and footrest bracket
Front brake caliper and front fork
Front master cylinder bleed screw
Brake caliper bleed screw
Front wheel axle pinch bolt
M8
M6
M8
M10
M8
M8
M8
Tightening torque
Nm
32
6
13
35
6
5
21
mkg
3.2
0.6
1.3
3.5
0.6
0.5
2.1
Remarks
ftlb
2.3
4.3
9.4
25
4.3
3.6
15 See NOTE
NOTE:
1. Insert the front wheel axle from the right
side and tighten it with the flange bolt from
the left side to 91 Nm (9.1 mkg, 66 ftlb).
2. In the order from the pinch bolt
pinch
bolt
pinch bolt , tighten each bolt to
21 Nm (2.1 mkg, 15 ftlb) without performing temporary tightening.
3. Check that the end face of the axle head
and the end face of the fork side are flushmounted. If they are out of alignment, make
sure to fit them by adding the external force
by hand or with a plastic hammer, etc.
If the end face of the axle is not parallel to
the end face of the fork, align them so that
one point of the axle circumference is positioned on the end face of the fork.
At this stage, it can be accepted if the end
face of the axle becomes partially concave
to the end face of the fork.
4. In the order from the pinch bolt
pinch
bolt
pinch bolt , tighten each bolt to
21 Nm (2.1 mkg, 15 ftlb) without performing temporary tightening.
CABLE ROUTING
SPEC
CABLE ROUTING
Pass the right handlebar switch lead inside the
front brake hoses and over the throttle cables.
Install the throttle cables to the hook so that the
pulling side of the throttle cables is routed downward.
Pass the clutch cable through the guide.
Plastic locking tie shall be positioned at 15 mm
(0.59 in) below from the upper bracket.
Clamp the left handlebar switch lead to the front fork
with the plastic locking tie and cut the tip of the tie.
Clamp it to the protector section.
Clamping position should be 10 mm (0.39 in) or
lower from the top end of the under bracket.
Attach the horn lead to the hook on the steering
cover.
CABLE ROUTING
Clamp it at the position of 50 mm (1.97 in) to 65
mm (2.56 in) from the upper face of the under
bracket with the plastic locking tie. Cut the surplus
part of the clamp tip leaving 2 mm (0.08 in) to 4
mm (0.16 in). Point the tip of the clamp to the outside of vehicle.
Pass the throttle cables inside the front brake
hoses.
Set in the coupler between the headlights hollow
section and the duct.
To the wire harness
To the front turn signal light (right)
Set the sub wire harness in the joint.
Do not catch the sub wire harness when the duct
is assembled.
To the front turn signal light (left)
SPEC
CABLE ROUTING
Throttle stop screw
Coolant reservoir tank hose
Cover 8
Radiator fan motor lead (right)
Pickup coil lead
Rear tail / brake light switch lead
Radiator return hose
Coolant hose
Clutch cable
Coolant hose protector
Hose clamp assembly
Hose clamp
Pass the rear tail / brake light switch lead outside of
rear engine mount bolt.
SPEC
CABLE ROUTING
Route the radiator fan motor lead (right) by the outside of the clutch cable.
Route the radiator fan motor lead (right) and clutch
cable by the inner side of the coolant reservoir
tank hose and radiator return hoses (2 hoses).
The punch mark starting point should be lower
than the clamps top end.
However, the aiming position of the punch mark
starting point should be 5 mm (0.20 in) below the
clamps bottom end.
Pass the clutch cable inside of the radiator hose.
Assemble as shown below when clamping.
Pass the pickup coil lead over the throttle stop
cable.
Tip of the plastic locking tie shall be pointed to the
inner side at the rear part of the vehicle.
SPEC
CABLE ROUTING
SPEC
10
CABLE ROUTING
Pass the fuel tank drain hose, fuel tank breather
hose through the clamp of the coolant reservoir
tank.
Pass the coolant reservoir tank breather hose
through the clamp of under the coolant reservoir
tank.
Projection allowance from the coolant reservoir
tank cover shall be 30 to 50 mm (1.18 ~ 1.97 in).
Pass the oil level switch lead and sidestand switch
lead over the bracket 2.
Pass the oil level switch lead, and sidestand switch
lead through the clamp.
5 ~ 45 mm (0.20 ~ 1.77 in).
Clamp the A.C. magneto lead, oil level switch lead
and sidestand switch lead.
11
SPEC
CABLE ROUTING
Right handlebar switch lead
Radiator fan motor lead (right)
Sub wire harness
Headlight lead
Meter lead
Cover 8
Ignition coil lead
Throttle position sensor coupler
Coolant reservoir tank hose
Throttle stop cable
Speed sensor lead coupler
Crankshaft position sensor lead
coupler
Fuel tank breather hose (except
for CAL)
12
SPEC
CABLE ROUTING
Neutral switch lead coupler (connector 1 pole)
Fuel hose (return side, for CAL)
Canister hose (for CAL)
Fuel hose (feed side, for CAL)
Fuel tank drain hose (for CAL)
To the headlight
Make sure not to drop the headlight sub wire harness beneath the projection of the duct. Check it
when installing the side cowling.
Clamp the plastic locking tie to the cover 8. Place
the coupler at the rear side of the vehicle against
the plastic locking tie. Point the tip of the plastic
locking tie to the downward in the inner side of the
vehicle.
13
SPEC
CABLE ROUTING
Pass the fuel tank breather hose and fuel tank
drain hose over the fuel hose and fuel return hose.
One rotation is possible for a twist of fuel tank
breather hose and fuel tank drain hose before an
engine clamp.
To the rear tail / brake light switch lead.
To the neutral switch
Insert the wire harness wrapping clamp to the
frame hole.
Pass the battery negative lead over the wire harness.
To the engine. Upper or lower position relation
against the heat protector is no object.
There should be no interference between the wire
harness and the tip of the rear frame attaching
bolts.
14
SPEC
CABLE ROUTING
Upper or lower position relation between the left
handlebar switch lead, right handlebar switch lead
and radiator fan motor lead (right) is no object.
Do not catch the coupler when the air filter case is
assembled.
Clamp the wire harness, left handlebar switch
lead, right handlebar switch lead, main switch
lead and radiator fan motor lead (right). Match
the taping positions of three leads except the
wire harness. Point the tip of the clamp to the
front side of the vehicle.
Sealing set of the cover can be either upper or
lower against the frame lower end. However, it
should not be caught.
To the main switch lead coupler
15
SPEC
CABLE ROUTING
The clamp by the side of a hose comes below an
attachment clamp.
Insert until it sets.
Poss the canister hose over fuel return hose and
under the fuel hose.
Route it above the canister hose.
16
SPEC
CABLE ROUTING
SPEC
Push the starter motor lead in the clamping sections (two points) or the battery box assembly and
secure it.
Install to the deepest position of the rib of the battery box assembly.
Fit in the plastic cover of rivet to the main unit after
assembly.
Make sure to clamp the wire harness. (Tighten it
until the clamp latchet stops.)
Insert the turn signal light relay to the back end of
the rib in the battery box assembly.
Hook of the battery box assembly shall hook on
the upper face of the fuse box. (It should not be put
on the side face.)
Set the immobilizer unit couplers (two units) in the
right side space of the tool kit.
17
CABLE ROUTING
Insert it to the back end of the rib in the battery box
assembly.
The 20 mm (0.79 in) knob should be within this
range.
Pass the turn signal lead by the outside of the right
side attaching boss of the tail / brake light.
Connect the turn signal light lead couplers (two
leads).
Pass the turn signal light and license light leads
between the rear side ribs of the battery box
assembly and to the rear part of the vehicle.
Connect the license light leads (two leads).
Route the branching lead to the license light
behind the tail / brake light left side attaching boss.
Route the tail / brake light lead under the projection
part.
18
SPEC
CABLE ROUTING
Connect the negative lead and the wire harness.
Install the starting circuit cut-off relay to the deepest position after placing the tail / brake light lead
and turn signal light lead in the guide.
19
SPEC
CHK
ADJ
EAS00135
WARNING
Bleed the hydraulic brake system whenever:
the system is disassembled.
a brake hose is loosened, disconnected or
replaced.
the brake fluid level is very low.
brake operation is faulty.
NOTE:
Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.
When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this precaution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.
If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
1. Bleed:
hydraulic brake system
a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose
tightly to
the bleed screw .
Front brake master cylinder
Front brake caliper
Rear brake caliper
NOTE:
Bleeding order of the front hydraulic brake system is the following order:
1. front brake master cylinder.
2. front brake calipers.
3. front brake master cylinder.
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
20
CHK
ADJ
f.
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
NOTE:
After bleeding air, the brake fluid may ooze
around the thread section of each bleed screw.
This phenomenon does not show the leakage
but the brake fluid that has been accumulated
in the thread of screw while bleeding air.
Please wipe off to make the parts clean.
21
CHK
ADJ
EAS00155
WARNING
Always adjust both front fork legs evenly.
Uneven adjustment can result in poor handling and loss of stability.
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
CAUTION:
Grooves are provided to indicate the
adjustment position.
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
spring preload
a. Turn the adjusting bolt
.
Direction
Direction
in direction
or
Spring preload is
increased (suspension is
harder).
Spring preload is
decreased (suspension is
softer).
Adjusting positions
Minimum: 8
Standard: 7
Maximum: 0
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
22
CHK
ADJ
1. Adjust:
rebound damping
a. Turn the adjusting screw
or .
Direction
Direction
in direction
Rebound damping is
increased (suspension is
harder).
Rebound damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 10 clicks in direction
*
Standard: 6 clicks in direction
*
Maximum: 1 clicks in direction
*
* with the adjusting screw fully turned-in
direction
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
compression damping
a. Turn the adjusting screw
or .
Direction
Direction
in direction
Compression damping is
increased (suspension is
harder).
Compression damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 13 clicks in direction
*
Standard: 6 clicks in direction
*
Maximum: 1 clicks in direction
*
* with the adjusting screw fully turned-in
direction
23
CHAS
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS
6 Nm (0.6 mkg, 4.3 ftlb)
Order
1
2
3
4
5
6
7
8
9
Job / Part
Removing the front wheel and brake
discs
Qty
2
2
4
1
1
2
2
1
2
Remarks
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
Loosen.
24
CHAS
EAS00577
Order
1
2
3
4
5
6
7
Job / Part
Removing the front brake pads
Qty
Remarks
Remove the parts in the order listed.
NOTE:
The following procedure applies to both of
the front brake calipers.
1
1
2
1
1
2
1
For installation, reverse the removal
procedure.
25
CHAS
EAS00584
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job / Part
Removing the front brake master
cylinder
Brake fluid
Qty
Stopper
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir tank
Brake fluid reservoir hose
Brake lever
Front brake switch connector
Union bolt
Copper washer
Brake hose
Brake master cylinder bracket
1
1
1
1
1
1
1
2
1
2
1
1
26
Remarks
Remove the parts in the order listed.
Drain.
Refer to CHANGING THE BRAKE
FLUID in chapter 3.
Disconnect.
CHAS
Order
13
14
Job / Part
Brake master cylinder
Front brake switch
Qty
1
1
Remarks
27
CHAS
EAS00585
Order
Job / Part
Disassembling the front brake
master cylinder
Brake master cylinder kit
Bleed screw
Brake master cylinder body
Qty
Remarks
Disassemble the parts in the order listed.
1
1
1
For assembly, reverse the disassembly
procedure.
28
CHAS
EAS00613
Order
Job / Part
Removing the front brake calipers
Qty
Brake fluid
1
2
3
4
Remarks
Remove the parts in the order listed.
NOTE:
The following procedure applies to both of
the front brake calipers.
Drain.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM.
Union bolt
Copper washer
Brake hose
Brake caliper
1
2
1
1
For installation, reverse the removal
procedure.
29
CHAS
EAS00615
Order
Job / Part
Disassembling the front brake
calipers
Qty
Remarks
Disassemble the parts in the order listed.
NOTE:
The following procedure applies to both of
the front brake calipers.
2
1
1
2
4
8
1
For assembly, reverse the disassembly
procedure.
30
CHAS
EAS00607
WARNING
Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
Never use solvents on internal brake components.
Recommended brake fluid
DOT 4
1. Install:
brake master cylinder kit
circlip
dust boot
2. Install:
brake master cylinder
13 Nm (1.3 mkg, 9.4 ftlb)
NOTE:
Install the brake master cylinder holder with
the UP mark
facing up.
Align the mating surfaces of the brake master
cylinder holder with the punch mark
on the
right handlebar.
First, tighten the upper bolt, then the lower
bolt. Attach the brake master cylinder to the
vehicles inner side from a punch mark.
3. Install:
copper washers
brake hose
30 Nm (3.0 mkg, 22 ftlb)
union bolt
tail / brake light switch coupler
32 ~ 42
37.6 mm
(1.48 in.)
65.1 mm
(2.56 in.)
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
CABLE ROUTING.
37.2 mm
(1.46 in.)
NOTE:
While holding the brake hose, tighten the
union bolt as shown.
Turn the handlebars to the left and right to
make sure the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
31
CHAS
4. Fill:
brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:
brake system
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM.
6. Check:
brake fluid level
Below the minimum level mark
Add
the recommended brake fluid to the proper
level.
Refer to CHECKING THE BRAKE FLUID
LEVEL in chapter 3.
7. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM.
32
FRONT FORK
CHAS
EAS00647
FRONT FORK
FRONT FORK LEGS
32 Nm (3.2 mkg, 23 ftlb)
26 Nm (2.6 mkg, 19 ftlb)
Order
1
2
3
4
5
6
Job / Part
Removing the front fork legs
Front wheel
Qty
1
1
1
1
2
1
Remarks
Remove the parts in the order listed.
Refer to FRONT WHEEL AND BRAKE
DISCS.
Refer to FRONT AND REAR BRAKES.
Refer to COWLINGS in chapter 3.
Loosen.
Loosen.
Loosen.
Loosen.
For installation, reverse the removal
procedure.
33
FRONT FORK
CHAS
EAS00648
Order
Job / Part
Disassembling the front fork legs
Qty
Cap bolt
O-ring
Damper adjusting rod
Nut
Washer
Spacer
Fork spring
Dust seal
Oil seal clip
Oil seal
1
1
1
1
1
1
1
1
1
1
34
Remarks
Disassemble the parts in the order listed.
NOTE:
The following the procedure applies to
both of the front fork legs.
FRONT FORK
CHAS
Order
Job / Part
Washer
Damper rod assembly bolt
Copper washer
Damper rod assembly
Inner tube
Outer tube
Qty
1
1
1
1
1
1
Remarks
35
FRONT FORK
CHAS
EAS00652
WARNING
The fork spring is compressed.
f.
2. Drain:
fork oil
NOTE:
Stroke the damper rod
draining the fork oil.
3. Remove:
dust seal
oil seal clip
oil seal
washer
(with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
36
FRONT FORK
CHAS
4. Remove:
damper rod assembly bolt
damper rod assembly
NOTE:
While holding the damper rod assembly with
the damper rod holder , loosen the damper
rod assembly bolt.
Damper rod holder
90890-01423, YM-01423
EAS00656
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
spring free length
Out of specification Replace.
Spring free length
248.8 mm (9.80 in)
<Limit> : 243.8 mm (9.60 in)
3. Check:
damper rod
Damage / wear Replace.
Obstruction Blow out all of the oil passages with compressed air.
damper rod adjusting rod
Bends / damage Replace.
37
FRONT FORK
CHAS
CAUTION:
The front fork leg has a built-in damper
adjusting rod and a very sophisticated
internal construction, which are particularly sensitive to foreign material.
When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.
4. Check:
cap bolt O-ring
Damage / wear Replace.
EAS00659
WARNING
Make sure the oil levels in both front fork
legs are equal.
Uneven oil levels can result in poor handling and a loss of stability.
NOTE:
When assembling the front fork leg, be sure
to replace the following parts:
outer tube bushing
oil seal
dust seal
Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
inner tube
damper rod assembly
damper rod assembly bolt
copper washer
38
FRONT FORK
CHAS
WARNING
Always use new copper washer.
CAUTION:
Allow the damper rod assembly to slide
slowly down the inner tube
until it protrudes from the bottom of the inner tube.
Be careful not to damage the inner tube.
2. Lubricate:
inner tubes outer surface
Recommended lubricant
Suspension oil 01 or
equivalent
3. Tighten:
damper rod assembly bolt
23 Nm (2.3 mkg, 17 ftlb)
LOCTITE
NOTE:
While holding the damper rod assembly with
the damper rod holder , tighten the damper
rod assembly bolt.
Damper rod holder
90890-01423, YM-01423
4. Install:
dust seal
oil seal clip
oil seal
washer
39
FRONT FORK
CHAS
CAUTION:
Make sure the numbered side of the oil seal
faces up.
NOTE:
Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
Lubricate the outer surface of the inner tube
with fork oil.
Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
5. Install:
oil seal
(with the fork seal driver
6. Install:
oil seal clip
NOTE:
Adjust the oil seal clip so that it fits into the
outer tubes groove.
7. Install:
dust seal
(with the fork seal driver weight
Fork seal driver
90890-01442, YM-01442
40
FRONT FORK
8. Install:
rod puller
rod puller attachment
(onto the damper rod
CHAS
Rod puller
90890-01437, YM-01437
Rod puller attachment
90890-01436, YM-01436
9. Fill:
front fork leg
(with the specified amount of the recommended fork oil)
Quantity (each front fork leg)
0.475 L (0.418 Imp qt,
0.502 US qt)
Recommended oil
Suspension oil 01 or
equivalent
41
fac-
FRONT FORK
CHAS
to specifica-
Distance
13 mm (0.51 in)
j.
WARNING
The fork spring is compressed.
Always use a new cap bolt O-ring.
42
CHAS
EAS00709
2. Check:
drive chain
Stiffness Clean and lubricate or replace.
3. Clean:
drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
43
CHAS
CAUTION:
This motorcycle has a drive chain with
small rubber O-rings
between the drive
chain side plates. Never use high-pressure
water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to
clean the drive chain. High-pressure methods could force dirt or water into the drive
chains internals, and solvents will deteriorate the O-rings. A coarse brush can also
damage the O-rings. Therefore, use only
kerosine to clean the drive chain.
4. Check:
O-rings
Damage Replace the drive chain.
drive chain rollers
Damage / wear Replace the drive chain.
drive chain side plates
Damage / wear Replace the drive chain.
Cracks Replace the drive chain and
make sure that the battery breather hose is
properly routed away from the drive chain
and below the swingarm.
5. Lubricate:
drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
6. Check:
drive sprocket
rear wheel sprocket
More than 1 / 4 tooth
wear Replace the
drive chain sprockets as a set.
Bent teeth Replace the drive chain
sprockets as a set.
Correct
Drive chain roller
Drive chain sprocket
44
RADIATOR
EAS00454
COOL
COOLING SYSTEM
RADIATOR
Order
1
2
3
4
5
6
7
8
Job / Part
Removing the radiator
Rider seat
Fuel tank
Air filter case
Side cowlings and bottom cowling
Coolant
Qty
1
2
1
1
1
1
1
2
45
Remarks
Remove the parts in the order listed.
Refer to SEATS in chapter 3.
Refer to FUEL TANK in chapter 3.
Refer to AIR FILTER CASE in chapter 3.
Refer to COWLINGS in chapter 3.
Drain
Refer to CHANGING THE COOLANT in
chapter 3.
RADIATOR
Order
9
Job / Part
Radiator cap
Qty
1
COOL
Remarks
For installation, reverse the removal
procedure.
46
ELEC
ELECTRICAL SYSTEM
47
ELEC
EAS00739
EAS00757
TROUBLESHOOTING
2. Battery
Check the condition of the battery.
Refer to CHECKING AND CHARGING
THE BATTERY in chapter 3.
YES
3. Starter motor
Connect the positive battery terminal
and starter motor lead
with a jumper
lead .
Pocket tester
90890-03112, YU-3112
EAS00738
WARNING
NO
Replace the fuse(s).
NO
Repair or replace
the starter motor.
48
ELEC
EAS00759
YES
NO
Replace the starter
relay.
EAS00749
6. Main switch
Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the main switch OK?
YES
NO
YES
NO
Replace the main
switch.
EAS00750
EAS00761
5. Starter relay
Disconnect the starter relay coupler from
the coupler.
Connect the pocket tester ( 1) and battery (12 V) to the starter relay coupler as
shown.
YES
NO
Replace the right
handlebar switch.
EAS00751
8. Neutral switch
NO
Replace the neutral
switch.
49
ELEC
EAS00766
EAS00752
9. Sidestand switch
12. Wiring
YES
NO
YES
Replace the sidestand switch.
EAS00763
NO
Replace the clutch
switch.
EAS00764
NO
Replace the right
handlebar switch.
50
NO
Properly connect or
repair the starting
systems wiring.
COOLING SYSTEM
EAS00807
COOLING SYSTEM
CIRCUIT DIAGRAM
Main switch
Battery
Fuse (main)
Fuse (ignition)
ECU
51
ELEC
COOLING SYSTEM
ELEC
EAS00739
EAS00808
TROUBLESHOOTING
2. Battery
Check the condition of the battery.
Refer to CHECKING AND CHARGING
THE BATTERY in chapter 3.
Check:
1. main, ignition, and radiator fan motor fuses
2. battery
3. main switch
4. radiator fan motor
5. radiator fan motor relay
6. coolant temperature sensor
7. wiring connections
(the entire cooling system)
NOTE:
Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. bottom cowling
4. side cowlings
Troubleshoot with the following special
tool(s).
3. Main switch
Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
Is the main switch OK?
YES
NO
Replace the main
switch.
Pocket tester
90890-03112, YU-3112
EAS00738
NO
NO
Replace the fuse(s).
52
COOLING SYSTEM
ELEC
EAS00809
NO
The radiator fan
motor is faulty and
must be replaced.
Does the radiator fan motor relay have continuity between black
and black ?
YES
NO
Replace the radiator
fan motor relay.
53
COOLING SYSTEM
ELEC
EAS00812
WARNING
Handle the coolant temperature sensor
with special care.
Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace
it.
NO
Replace the coolant
temperature sensor.
EAS00813
7. Wiring
Check the entire cooling systems wiring.
Refer to CIRCUIT DIAGRAM.
Is the cooling systems wiring properly connected and without defects?
YES
This circuit is OK.
54
NO
Properly connect or
repair the cooling
systems wiring.
Horn
Turn signal relay
Rear turn signal light (right)
Rear turn signal light (left)
Front turn signal / position light (right)
Front turn signal / position light (left)
Headlight
License light
Tail / brake light
COLOR CODE
B. . . . . . .
Br . . . . . .
Ch. . . . . .
Dg. . . . . .
Gy. . . . . .
L. . . . . . .
Lg . . . . . .
O ......
P. . . . . . .
R. . . . . . .
Sb. . . . . .
W ......
Y. . . . . . .
B/L . . . . .
B / R. . . . .
B/W . . . .
B / Y. . . . .
Br / L . . . .
Br / R . . . .
Br / W. . . .
Br / Y . . . .
G/B . . . .
G/W . . . .
G/Y . . . .
Gy / G . . .
Gy / R . . .
L/B . . . . .
L/R . . . . .
L/W . . . .
L/Y . . . . .
O/B . . . .
O/G . . . .
P/W . . . .
R / B. . . . .
R/G . . . .
R/L . . . . .
R/W . . . .
R / Y. . . . .
Sb / W . . .
W/B . . . .
W/Y . . . .
Y / B. . . . .
Y/G . . . .
Y/L . . . . .
Y / R. . . . .
Y/W . . . .
Black
Brown
Chocolate
Dark green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black / Blue
Black / Red
Black / White
Black / Yellow
Brown / Blue
Brown / Red
Brown / White
Brown / Yellow
Green / Black
Green / White
Green / Yellow
Gray / Green
Gray / Red
Blue / Black
Blue / Red
Blue / White
Blue / Yellow
Orange / Black
Orange / Green
Pink / White
Red / Black
Red / Green
Red / Blue
Red White
Red / Yellow
Sky blue/White
White / Black
White / Yellow
Yellow / Black
Yellow / Green
Yellow / Blue
Yellow / Red
Yellow / White
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the YZFR6S/YZF-R6SC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.
YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC SERVICE MANUAL:
LIT-11616-16-45 (5SL-28197-10)
EAS00001
YZF-R6S/YZF-R6SC
SUPPLEMENTARY
SERVICE MANUAL
2003 by Yamaha Motor
Corporation, U.S.A.
First edition, September 2003
All rights reserved. Any reproduction
or unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-17-46
EAS00030
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that
you contact a Yamaha dealer for any service information changes that apply to this model. This policy
is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
S This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
S Designs and specifications are subject to change without notice.
EAS00040
WARNING
CAUTION:
NOTE:
EAS00007
3
4
5
8
6
7
EAS00008
GEN
INFO
SYMBOLS
SPEC
CHK
ADJ
CHAS
COOL
ENG
7
FI
ELEC
Symbols 10 to 17 indicate the following.
10
10
11
12
13
14
15
16
17
TRBL
SHTG
11
12
13
14
15
16
17
18
19
20
21
24
22
23
25
Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication
points.
18
19
20
21
22
23
Engine oil
Gear oil
Molybdenum-disulfide oil
Wheel-bearing grease
Lithium-soap- based grease
Molybdenum-disulfide grease
CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
2
3
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
18
19
19
20
25
25
27
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code
Standard
5SLD (USA except for CAL)
5SLE (CAL)
Limit
SSS
ENGINE SPECIFICATIONS
Item
Throttle bodies
ID mark
Throttle valve size
Standard
5SL1 00 (5SLD),
5SL4 10 (5SLE)
#100
Limit
SSS
SSS
CHASSIS SPECIFICATIONS
Item
Front tire
Model (manufacturer)
Rear tire
Model (manufacturer)
Standard
Limit
SSS
SSS
ELECTRICAL SPECIFICATIONS
Item
Standard
Limit
Ignition system
CDI unit model (manufacturer)
F8T816 (MITSUBISHI)
SSS
Ignition coils
Model (manufacturer)
Primary coil resistance
Secondary coil resistance
F6T549 (MITSUBISHI)
0.24 X 0.32 at 20_C (68_F)
5.0 X 6.8 k at 20_C (68_F)
SSS
SSS
SSS
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item
Oil cooler
Cylinder identification sensor
Fastener
Bolt
Bolt
Thread
Qty
Q
ty
size
M20
M6
1
1
Tightening torque
Nm
mSkg
ftSlb
63
6.0
6.3
0.6
46
4.3
Remarks
Yamaha bond
No.1215
CABLE ROUTING
SPEC
CABLE ROUTING
1 Right handlebar switch lead
2 Clutch cable
3 Immobilizer unit lead, main switch lead and left han4
5
6
7
8
9
CABLE ROUTING
F Pass the horn lead by the outside of the throttle
cable and clamp it to the forefront of upper face of
the under bracket. Next, route it under the front
brake hose and clamp it to the pawl of the under
cover.
G Clamp it at the position of 40 (1.57 in.) to 60 mm
(2.36 in.) from the upper face of the under bracket
with the plastic locking tie. Cut the surplus part of the
clamp tip leaving 2 (0.08 in.) to 4 mm (0.16 in.). Point
the tip of the clamp to the outside of vehicle.
H Pass the throttle cables inside the front brake
hoses.
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
SPEC
CABLE ROUTING
L Clamp the clutch cable by routing the upper end of
the clamp along with the bottom end of the hose
clamp assembly.
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
SPEC
CABLE ROUTING
F Pass the coolant reservoir tank breather hose
through the clamp of under the coolant reservoir
tank.
G Projection allowance from the coolant reservoir
tank cover shall be 30 to 50 mm (1.18 X 1.97 in).
H Pass the oil level switch lead and sidestand switch
lead over the bracket 2.
I Pass the oil level switch lead, and sidestand switch
lead through the clamp.
J 5 X 45 mm (0.20 X 1.77 in).
K Clamp the A.C. magneto lead, oil level switch lead
and sidestand switch lead.
L Pass the side stand switch lead, oil level switch lead
and A.C. magneto lead between the engine stay
and the engine.
M
N
O
P
Q
R
S
T
U
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
coupler
Fuel tank breather hose (except
for CAL)
Fuel tank drain hose (except for
CAL)
Fuel hose (return side, except for
CAL)
Fuel pump 2 coupler
Fuel pump 1 coupler
Starter motor lead
SPEC
CAL)
Crankcase breather hose
Air vent hose
Fuse box
Cover 7
Radiator fan motor relay
Radiator fan motor lead
Left handlebar switch lead
Main switch lead
Wire harness
CABLE ROUTING
28 Throttle cables
29 Throttle sub-lead 1 (white 6
(blue 2 poles)
poles)
33 A.C. magneto lead coupler
30 Throttle sub-lead 2 (black 6
(white 3 poles)
poles)
34 Rear brake light switch lead cou31 Oil level switch lead coupler
pler (brown 2 poles)
(white 1 pole)
10
35 Neutral
36
37
38
39
SPEC
CABLE ROUTING
A To the headlight
B Make sure not to drop the headlight sub wire harness beneath the projection of the duct. Check it
when installing the side cowling.
C Clamp the plastic locking tie to the cover 8. Place
the coupler at the rear side of the vehicle against the
plastic locking tie. Point the tip of the plastic locking
tie to the downward in the inner side of the vehicle.
D Route the head light and meter leads under the
frames lower part from the hollow section of the
cover 2.
E Pass the left and right handlebar switch leads outside of the air filter case air vent hose.
SPEC
11
CABLE ROUTING
L To the neutral switch
M Insert the wire harness wrapping clamp to the frame
hole.
N Pass the battery negative lead over the wire harness.
O There should be no interference between the wire
harness and the tip of the rear frame attaching bolts.
P To the coolant reservoir tank
Q To the intake air temperature sensor (air filter case)
R To the oil level switch, sidestand switch and A.C.
magneto
S Install the wire harness wrapping clamp to the stay
of the throttle body.
T Pass the wire harness over the throttle air vent
hose.
SPEC
12
CABLE ROUTING
AA Branching leads to the fuse box and radiator fan
motor relay shall pass through the guide section
of the cover 2 under the wire harness and then to
the outside of the frame.
AB To the fuse box and fan motor relay
AC Pass the throttle cables over the cover 2.
AD Point the tip of the plastic locking tie to the rear
side of the vehicle.
AE To the main switch lead coupler
SPEC
13
CABLE ROUTING
Fuel pump assembly
Fuel tank drain hose
Fuel tank breather hose (except for CAL)
Clamp
Clip
Canister (for CAL)
Blance hose (for CAL)
Canister hose (for CAL)
A Install the O-ring with its lip pointed upward.
B Pass the fuel tank drain hose and fuel tank breather
hose through the clamp.
There needs to be no crookedness in fuel tank drain
hose and fuel tank breather hose between fuel
tanks nipple and clamp.
1
2
3
4
5
6
7
8
SPEC
14
FUEL TANK
CHK
ADJ
EAS00040
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the fuel tank
Rider seat
Fuel hose connector cover
Fuel hose
Fuel return hose
Fuel sender coupler
Fuel pump coupler
Clamp
Fuel tank overflow hose
Fuel tank breather hose
Fuel tank
Fuel pump
Qty
Remarks
Remove the parts in the order listed.
Refer to SEATS.
1
1
1
1
1
1
1
1
1
1
Disconnect.
Disconnect.
15
FUEL TANK
CHK
ADJ
16
A To cylinder #1 and #2
B To cylinder #3 and #4
17
FI
ELECTRICAL COMPONENTS
ELEC
ELECTRICAL
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
18
Speed sensor
Crankshaft position sensor
Cylinder identification sensor
Radiator fan motor relay
Headlight relay (on / off)
Headlight relay (dimmer)
ON
OFF
W W
W W
L/B
L/Y L/B
L/B L/Y
10
Br/L
Br/L
Br/L
W W W
R/W
Br/L
Br/L
48
47
46
R/W
BrG
G/Y
49
BrG
R/Y
Br
L/B
B/L
R/Y
50
B/L
YW
B/Y
52
51
Br Y
L/W
R/W
53
B B
67
- Br/WR/Y
G/Y
Y L/R
Ch L/Y B B/Y Br
Dg Y
Br B R/B
R/B B Br
42
R R
L/WR/W
L/Y
66
43
54
Y Dg
187
55
B B/Y
B/Y H B/Y
B/L C B/L
RUN
OFF
44
Br B/Y B L/Y Ch
R/Y Br/W -
65
ON
57
OFF
L/W
LO
R/Y
HI
56
PUSH
FREE
45
L/W
R/W
Br/L
R/Y A R/Y
L/B
R/Y
B/L
R/W
B/Y
B B/L
59
R/B
B/Y
L/W
B
L/W
B/W
R/W
G/Y
BrG
Br
Y
Y
R/B
187
R/G
Ignition coil
Spark plug
Neutral switch
Crankshaft position sensor
Lean angle cut-off switch
Engine stop switch
Clutch switch
B
Y
Y A Y
YW
B/L
B/Y
YW A YW
L Ch
Ch
64
L
Br
12
60
L/W G/R
35
33
Y/B B/R -
32
31
30
13
37
36
34
B/W B B/W
Y/L B Y/L
Y/L
B/W
Y/B B Y/B
Sb/W A Sb/W
Y/B
Sb/W
B Gy/G O/G
O/G Gy/G B
L
B
B/L
Y L
24
23
L Dg
Dg
63
Dg A Dg
Ch
Ch
Dg
Dg
Dg
40
40
39
39
38
28
B/L
B/L E B/L
L W/B
B/L
B/L
L E L
W/B E W/B
L Y/G B/L
B/L B
B/L
Y/G
B/L
B/L G B/L
- B/R Y/B
B/WR/G Y/L
W L/Y
B/L
G/W B/L
Br/W B/L
B/L
22
21
L W/Y
B/L
B/L
- Sb
G/W
Br/W
Sb -
27
W/B
B/L
Gy
L/Y
B/Y
Y/B
R/L
Lg
L/W
R/W
W/Y
Y/G
Y G Y
19
WIRE HARNESS
Y/B W
- L/W -
L F L
25
B Gy
20
W L/Y
26
B B/L
W/B
P B/L L
P/W B/L L
B/L
Gy B/L
Gy/R O R/B
R/B O Gy/R
P/W
61
G/W
Ch
B/R
W B B/R
R/G
Br
G/W A G/W
R/G B R/G
R/W A Br
29
R/L B
G/W B
L B/L
B/L L
W/B Br/R
Br/R W/B
62
41
R/L
B/Y Sb/W
R/B L/W
L O/B L/B
L/B O/B L
B/L
L/B B
11
- P/W B/L
B B
Br/W
58
Ch A Ch
L/Y
B/Y
G/W Br/W Y
B/L P/W -
Sb/W
L/B
L/B
B
Ch
L/R
Br
B
R/L
B
Sb
Ch
B
L/R
Br/W
Br/W
G/W
B
Dg
Lg
Ch
L
Br
L/R
B
L/Y
B/Y
B
B/L
B
B C B
187
B H B
Dg
Sb
Sb
Sb
14
WIRE HARNESS
G/Y
Y/L
Y/R
Y/R
Br/R
O/B
L/B
F O/B
G/B
Br/R
R/L O/B
O/B
R/L L/B
L/B
R/L G/B
Br/RR/B
Br/R E Br/R
O/B
L/B F L/B
G/B F G/B
G/B
R/L R/B
R/B
R/B F R/B
Gy/G
O/G
B D B
D O/G
Gy/R
Gy/G D Gy/G
O/G
Gy/R D Gy/R
D O
R/B
YW
Gy/G
O/G
Gy/R
17
17
17
17
Br Br/R
16
16
16
16
18
R/L
R/L
R/L
R/L
15
15
15
15
R/B
B Gy/G
B O/G
B Gy/R
B O
- Ch G/W Y R/Y
Sb/W Dg B Y/W Br
R/Y Y G/W Ch -
Y Br/W G/W
B/Y B
B/W
B B/Y
R/L
Dg
B
16
17
20
21
29
47
59
B
Main switch
Battery
Fuse (main)
Fuse (ignition)
Starting circuit cut-off relay
Sidestand switch
ECU
B
Gy
B/L
19
B/L
1
5
6
11
12
13
15
W/Y
187
B A B
IGNITION SYSTEM
ELEC
EAS00735
IGNITION SYSTEM
CIRCUIT DIAGRAM
R/B D R/B
R/L F R/L
IGNITION SYSTEM
EAS00737
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to CHECKING AND CHARGING
THE BATTERY in chapter 3.
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
EAS00741
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. air filter case
4. bottom cowling
5. side cowlings
S Troubleshoot with the following special tool(s).
3. Spark plugs
The following procedure applies to all of the
spark plugs.
S Check the condition of the spark plug.
S Check the spark plug type.
S Measure the spark plug gap.
Refer to CHECKING THE SPARK PLUGS
in chapter 3.
Standard spark plug
CR9EK or CR10EK (NGK)
Spark plug gap
0.6 X 0.7 mm (0.0236 X 0.0276 in)
EAS00738
NO
Re-gap or replace
the spark plug.
NO
Replace the fuse(s).
20
IGNITION SYSTEM
ELEC
EAS00743
1k) to the
YES
NO
EAS00747
21
IGNITION SYSTEM
EAS00748
ELEC
EAS00750
NO
Replace the right
handlebar switch.
EAS00751
9. Neutral switch
S Check the neutral switch for continuity.
Refer to CHECKING THE SWITCHES.
S Is the neutral switch OK?
YES
NO
Replace the neutral
switch.
EAS00752
NO
Replace the
crankshaft position
sensor.
YES
EAS00749
7. Main switch
S Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
S Is the main switch OK?
YES
NO
EAS00763
NO
Replace the main
switch.
YES
NO
Replace the clutch
switch.
22
IGNITION SYSTEM
ELEC
EAS00753
NOTE:
When you switch the positive and negative
tester probes, the readings in the above chart
will be reversed.
Continuity
NO
No
continuity
23
IGNITION SYSTEM
YES
NO
Replace the lean
angle cut-off switch.
EAS00754
14. Wiring
S Check the entire ignition systems wiring.
Refer to CIRCUIT DIAGRAM.
S Is the ignition systems wiring properly connected and without defects?
YES
Replace the ignitor
unit.
NO
Properly connect or
repair the ignition
systems wiring.
24
ELEC
ON
OFF
W W
W W
L/B
Br/L
Br/L
G/Y
BrG
R/W
48
47
10
L/Y L/B
L/B L/Y
Br/L
Br/L
Br/L
46
W W W
49
BrG
R/Y
Br
50
R/W
L/B
B/Y
B/L
B/L
R/Y
YW
R/G
52
51
Br Y
L/W
R/W
53
B B
67
- Br/WR/Y
G/Y
Y L/R
Ch L/Y B B/Y Br
Dg Y
Br B R/B
R/B B Br
42
R R
L/WR/W
R
R
B
L/Y
R/W
G/Y
66
43
54
Y Dg
187
55
B B/Y
B/Y H B/Y
B/L C B/L
RUN
OFF
44
Br B/Y B L/Y Ch
R/Y Br/W -
R/W
B/Y
L/W
65
LO
HI
56
PUSH
FREE
45
R/Y
B B/L
L/W
R/W
R/B
187
ON
OFF
57
59
R/B
B/Y
Br/L
L/W
B
L/W
B/W
L/B
YW
BrG
Br
Y
Y
R/Y A R/Y
R/Y
B/L
B/L
B/Y
YW A YW
B
Y
Y A Y
Br
B
B
L/R
B
L Ch
Ch
64
L
Br
60
L Dg
L/B B
11
Dg
63
Dg A Dg
12
B B
Br/W
58
Ch A Ch
L/Y
L
L/W G/R
Ch
Ch
62
41
R/L
Dg
Dg
61
G/W
Dg
Ch
B/R
W B B/R
R/G
Br
29
G/W A G/W
R/G B R/G
R/W A Br
L O/B L/B
35
33
34
40
40
39
39
38
37
36
L B/L
B/L L
B/W B B/W
Y/L B Y/L
Y/L
B/W
Y/B B Y/B
Sb/W A Sb/W
Y/B
Sb/W
W/B Br/R
Br/R W/B
13
Y/B B/R -
32
31
30
R/L B
G/W B
B/Y Sb/W
R/B L/W
L/B O/B L
B/Y
- P/W B/L
B/L P/W -
Sb/W
L/B
L/B
B
Sb
Ch
B
L/R
Br/W
Br/W
Lg
Ch
L
R/L
B
Dg
R/L
Dg
B
G/W
B
Ch
B
Br
L/R
B
L/Y
B/Y
B
B/L
B
B C B
187
B H B
Dg
B
B Gy/G O/G
O/G Gy/G B
L
B
B/L
Y L
28
B/L
B/L E B/L
L W/B
B/L
L E L
B/L
Y/G
B/L
L F L
25
B Gy
20
B/L
B/L B
-
B/L G B/L
- B/R Y/B
B/WR/G Y/L
W L/Y
B/L
G/W B/L
Br/W B/L
B/L
22
21
L W/Y
B/L
B/L
- Sb
27
W/Y
Y/G
W/B
B/L
Gy
Y G Y
19
L/Y
B/Y
Y/B
R/L
Lg
L/W
R/W
Br/W
Sb -
WIRE HARNESS
Y/B W
W/B E W/B
L Y/G B/L
- L/W -
W/B
P B/L L
P/W B/L L
P/W
B/L
B B/L
W L/Y
26
24
L
B/L
23
Gy B/L
Gy/R O R/B
R/B O Gy/R
Gy
B/L
Sb
Sb
Sb
G/W Br/W Y
14
WIRE HARNESS
G/Y
Y/L
Y/R
Y/R
Br/R
O/B
L/B
F O/B
G/B
Br/R
R/L O/B
O/B
R/L L/B
L/B
R/L G/B
Br/RR/B
Br/R E Br/R
O/B
L/B F L/B
G/B F G/B
G/B
R/L R/B
R/B
R/B F R/B
Gy/G
O/G
B D B
D O/G
Gy/R
Gy/G D Gy/G
O/G
Gy/R D Gy/R
D O
R/B
YW
Gy/G
O/G
Gy/R
17
17
17
17
Br Br/R
16
16
16
16
18
R/L
R/L
R/L
R/L
15
15
15
15
R/B
B Gy/G
B O/G
B Gy/R
B O
- Ch G/W Y R/Y
Sb/W Dg B Y/W Br
R/Y Y G/W Ch -
Y Br/W G/W
B/Y B
B/W
B B/Y
B/L
25
W/Y
187
B A B
LIGHTING SYSTEM
ELEC
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
R/B D R/B
R/L F R/L
LIGHTING SYSTEM
1
5
6
15
40
42
50
54
55
56
60
61
71
72
73
Main switch
Battery
Fuse (main)
ECU
High beam indicator light
Meter light
Fuse (headlight)
Headlight relay (on / off)
Headlight relay (dimmer)
Fuse (park)
Pass switch
Dimmer switch
Headlight
License light
Tail/ brake light
26
ELEC
LIGHTING SYSTEM
ELEC
EAS00788
Headlight
Positive tester probe ! black/yellow 3
Negative tester probe ! black 4
B High beam
NO
Replace the headlight bulb, socket or
both.
2. Voltage
S Connect the pocket tester (DC 20 V) to the
headlight and meter assembly couplers as
shown.
A When the dimmer switch is set to
B When the dimmer switch is set to
Headlight
Positive tester probe ! black/blue 1
Negative tester probe ! black 2
YES
This circuit is OK.
27
NO
The wiring circuit
from the main switch
to the headlight coupler is faulty and
must be repaired.
ELEC
LIGHTING SYSTEM
EAS00789
EAS00790
YES
NO
YES
NO
Replace
the
tail/brake light assembly.
2. Voltage
2. Voltage
YES
This circuit is OK.
NO
YES
28
NO
Wiring circuit from
the main switch to
the tail/brake light
coupler is faulty and
must be repaired.
LIGHTING SYSTEM
EAS00792
NO
Replace the license
light bulb, socket or
both.
2. Voltage
S Connect the pocket tester (DC 20 V) to the
license light coupler (wire harness light side)
as shown.
Positive tester probe ! blue/red 1
Negative tester probe ! black 2
NO
The wiring circuit
from the main switch
to the license light
coupler is faulty and
must be repaired.
29
ELEC
Main switch
A.C. magneto
Rectifier/ regulator
Fuse (backup)
Battery
Fuse (main)
Starter relay
Starter motor
Fuse (fuel injection)
Fuse (ignition)
Starting circuit cut-off relay
Sidestand switch
Fuel pump
ECU
Ignition coil
Spark plug
Fuel injector
Air induction system solenoid
Neutral switch
Crankshaft position sensor
Intake air temperature sensor
Coolant temperature sensor
Throttle position sensor
Intake air pressure sensor
Atmospheric pressure sensor
Cylinder identification sensor
Speed sensor
Lean angle cut-off switch
Meter assembly
Fuel level warning light
Oil level warning light
Neutral indicator light
Tachometer
Shift timing indicator light
Multi-function meter
Engine trouble warning light
Coolant temperature indicator light
High beam indicator light
Turn signal indicator light
Meter light
Oil level switch
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
Fuse (signal)
Fuse (headlight)
Fuse (radiator fan motor)
Radiator fan motor relay
Radiator fan motor
Headlight relay (on / off)
Headlight relay (dimmer)
Rear brake light switch
Left handlebar switch
Clutch switch
Dimmer switch
Horn switch
Turn signal switch
Horn
Turn signal relay
61
62
63
64
65
66
67
COLOR CODE
B .......
Br . . . . . .
Ch . . . . .
Dg . . . . .
G ......
Gy . . . . .
L .......
Lg . . . . . .
O ......
P .......
R.......
Sb . . . . . .
W ......
Y .......
B/ L . . . . .
B/ R . . . .
B/ W . . . .
B/ Y . . . .
Br/ G . . .
Br/ L . . . .
Br/ R . . . .
Br/ W . . .
Br/ Y . . . .
G/B . . . .
G/W . . . .
G/Y . . . .
Gy/ G . . .
Gy/ R . . .
L/B . . . . .
L/R . . . .
L/W . . . .
L/Y . . . . .
O/B . . . .
O/G . . . .
P/ W . . . .
R/ B . . . .
R/ G . . . .
R/ L . . . .
R/ W . . . .
R/ Y . . . .
Sb/ W . . .
W/ B . . . .
W/ Y . . . .
Y/ B . . . .
Y/ G . . . .
Y/ L . . . . .
Y/ W . . . .
Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black/ Blue
Black/ Red
Black/ White
Black/ Yellow
Brown/ Green
Brown/ Blue
Brown/ Red
Brown/ White
Brown/ Yellow
Green / Black
Green / White
Green / Yellow
Gray / Green
Gray / Red
Blue/ Black
Blue/ Red
Blue/ White
Blue/ Yellow
Orange / Black
Orange / Green
Pink/ White
Red/ Black
Red/ Green
Red/ Blue
Red White
Red/ Yellow
Sky blue / White
White/ Black
White/ Yellow
Yellow/ Black
Yellow/ Green
Yellow/ Blue
Yellow/ White
EAS00010
YZF-R6R/YZF-R6SR
YZF-R6RC/YZF-R6SRC
SERVICE MANUAL
2002 by Yamaha Motor
Corporation, U.S.A.
First edition, December 2002
All rights reserved. Any reproduction
or unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-16-45
EAS00030
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that
you contact a Yamaha dealer for any service information changes that apply to this model. This policy
is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
S This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
S Designs and specifications are subject to change without notice.
EAS00040
WARNING
CAUTION:
NOTE:
EAS00007
3
4
5
8
6
7
EAS00008
GEN
INFO
SYMBOLS
SPEC
CHK
ADJ
CHAS
COOL
ENG
7
FI
ELEC
Symbols 10 to 17 indicate the following.
10
10
11
12
13
14
15
16
17
TRBL
SHTG
11
12
13
14
15
16
17
18
19
20
21
24
22
23
25
Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication
points.
18
19
20
21
22
23
Engine oil
Gear oil
Molybdenum-disulfide oil
Wheel-bearing grease
Lithium-soap- based grease
Molybdenum-disulfide grease
EAS00012
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL INJECTION SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG
COOL
FI
ELEC
TRBL
SHTG
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE OF FI SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FI SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-3
1-4
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . .
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS /PLATES AND COTTER PINS . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7
1-7
1-7
1-7
1-8
1-8
1-8
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
GENERAL TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . 2-18
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . 2-24
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
COOLING SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART . . . . . . . . . 3-1
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
3-5
3-5
3-6
3-6
COWLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
AIR FILTER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . .
SYNCHRONIZING THE THROTTLE BODIES . . . . . . . . . . . . . . . . .
ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . .
ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . .
CHECKING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . .
CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . .
ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . .
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE AIR INTAKE SYSTEM SURGE TANKS . . . . . . . .
CHECKING THE THROTTLE BODY JOINTS . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL AND BREATHER HOSES . . . . . . . . . . . . .
CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . .
CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10
3-10
3-16
3-18
3-19
3-21
3-22
3-24
3-25
3-27
3-29
3-30
3-31
3-31
3-32
3-32
3-33
3-33
3-34
3-35
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE PADS . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE HOSES . . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . .
ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . .
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . .
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . .
3-39
3-39
3-40
3-41
3-42
3-43
3-43
3-44
3-45
3-46
3-47
3-48
3-50
3-51
3-53
3-55
3-57
3-58
3-58
3-58
3-58
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . .
CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAMS . . . . . . . . . . . . . . . . . . . . . .
3-59
3-59
3-64
3-66
3-67
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . .
4-1
4-3
4-3
4-5
4-6
4-7
4-9
4-9
4-10
4-12
4-13
4-13
4-13
4-14
4-15
4-16
4-16
4-17
4-18
4-21
4-23
4-26
4-28
4-28
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . .
CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . .
4-45
4-45
4-48
4-49
4-50
4-51
4-56
HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-58
4-59
4-59
4-60
STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE UNDER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . .
4-63
4-63
4-65
4-65
4-66
4-29
4-30
4-32
4-34
4-36
4-38
4-39
4-40
4-41
4-43
4-68
4-71
4-72
4-72
4-73
4-75
4-76
4-76
4-77
4-79
4-70
4-70
4-71
CHAPTER 5
OVERHAULING THE ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEADS AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-2
5-3
5-5
5-6
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . .
INSTALLING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8
5-8
5-9
5-10
5-11
5-13
5-13
5-14
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . .
5-18
5-19
5-19
5-20
5-21
5-23
5-24
5-26
5-28
5-29
5-29
5-31
5-31
5-33
5-34
5-35
5-35
5-36
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT AND STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-38
5-38
5-40
5-40
5-40
5-45
5-45
5-47
5-48
5-48
5-49
5-49
5-50
5-50
5-50
5-51
5-51
5-54
5-57
5-57
5-58
5-58
5-58
5-58
5-59
5-59
5-60
5-60
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . .
CHECKING THE TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-61
5-63
5-64
5-64
5-64
5-64
5-66
5-67
5-68
5-68
5-69
5-70
5-71
5-74
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT JOURNAL BEARINGS . . . . . . . .
INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-78
5-79
5-79
5-82
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT
FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . .
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . .
5-83
5-83
5-89
5-89
5-90
5-90
5-91
CHAPTER 6
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
CHECKING THE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
INSTALLING THE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10
6-12
6-13
6-13
6-15
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECUS SELF-DIAGNOSTIC FUNCTION . . . . . . . . . . . . . . . . . . . . . .
ALTERNATE INSTRUCTIONS OPERATION CONTROL
(FAIL-SAFE ACTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAIL-SAFE ACTIONS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-2
7-3
THROTTLE BODIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PRESSURE REGULATOR . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-27
7-31
7-31
7-32
7-35
7-35
7-35
7-36
7-37
7-4
7-4
7-5
7-6
7-12
7-32
7-33
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
CHECKING THE BULBS AND BULB SOCKETS . . . . . . . . . . . . . . . . .
TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . .
CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . .
CHECKING THE LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5
8-5
8-6
8-7
8-7
8-14
8-14
8-15
8-16
8-26
8-26
8-28
8-30
SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . .
8-33
8-33
8-35
8-35
8-46
8-46
8-47
8-48
8-50
SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-1
9-1
9-1
9-2
9-2
9-2
9-2
9-3
9-3
9-3
9-3
9-4
9-4
9-4
9-4
9-4
9-4
OVERCOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FAULTY FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
LEAKING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9-6
9-6
9-6
9-6
9-6
9-6
9-6
9-6
9-6
9-6
MOTORCYCLE IDENTIFICATION
GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
EAS00018
MODEL LABEL
The model label 1 is affixed to the frame. This
information will be needed to order spare parts.
1-1
FEATURES
GEN
INFO
EAS00896
FEATURES
OUTLINE OF FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature.
In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective chamber.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions
of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it
becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system, in
place of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume
according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions. Furthermore, the air induction system (AI system) has been placed under computer control together with the FI system in order to realize cleaner
exhaust gases.
1 Ignition coil
2 Air filter case
3 Intake
temperature
4
5
6
7
sensor
Fuel delivery hose
Fuel tank
Fuel pump
Fuel return hose
8 Intake
9
10
11
12
13
air pressure
sensor
Throttle position sensor
Fuel injector
Catalytic converter
Crankshaft position
sensor
Coolant temperature
sensor
14 Spark plug
15 Cylinder identification
16
17
18
19
20
1-2
sensor
Pressure regulator
Battery
ECU
Atmospheric pressure
sensor
Fuel injection system
relay
ing light
angle cut-off
switch
23 Air cut-off valve
22 Lean
FEATURES
GEN
INFO
EAS00897
FI SYSTEM
The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel
pressure that is applied to the injector at only 284 kPa (2.84 kg/cm2) higher than the intake manifold
pressure. Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage
remains open. Therefore, the longer the length of time the injector is energized (injection duration), the
greater the volume of fuel that is supplied. Conversely, the shorter the length of time the injector is energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, crankshaft position sensor, intake air pressure sensor, atmospheric pressure
sensor, intake temperature sensor and coolant temperature sensor enable the ECU to determine the
injection duration. The injection timing is determined through the signals from the crankshaft position
sensor and the cylinder identification sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions.
Illustration is for reference only.
1
2
3
4
5
Fuel pump
Pressure regulator
Fuel injector
Throttle body
Intake
temperature
sensor
sor
7 Intake air pressure
sensor
8 ECU
9 Atmospheric pressure
sensor
10 Coolant
temperature
sensor
11 Cylinder identification
sensor
12 Crankshaft
position
sensor
1-3
A Fuel system
B Air system
C Control system
FEATURES
1
2
3
4
GEN
INFO
INSTRUMENT FUNCTION
Multi-function display
The multi-function display is equipped with the
following:
S a speedometer (which shows the riding
speed)
S an odometer (which shows the total distance
traveled)
S two tripmeters (which show the distance
traveled since they were last set to zero)
S a fuel reserve tripmeter (which shows the
distance traveled since the fuel level warning
light came on)
S a clock
S a self-diagnosis device
S a display brightness and engine speed warning light control mode
Multi-function display
SELECT button
RESET button
Engine trouble warning light
NOTE:
S Be sure to turn the key to ON before using the SELECT and RESET buttons.
SFor the U.K. only: To switch the speedometer and odometer/tripmeter display between kilometers
and miles, press the SELECT button and RESET button together for at least two seconds.
Odometer and tripmeter modes
Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP 1 and TRIP 2 in the following order:
ODO ! TRIP 1 ! TRIP 2 ! ODO
If the fuel level warning light comes on, the odometer display will automatically change to the fuel reserve tripmeter mode F-TRIP and start counting the distance traveled from that point. In that case,
pushing the SELECT button switches the display between the various tripmeter and odometer
modes in the following order:
F-TRIP ! TRIP 1 ! TRIP 2 ! ODO ! F-TRIP
To reset a tripmeter, select it by pushing the SELECT button, and then push the RESET button for at
least one second. If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically
and the display will return to the prior mode after refueling and traveling 5 km (3.1 mi).
Clock mode
Turn the key to ON.
To change the display to the clock mode, push the SELECT button for at least one second.
To change the display back to the prior mode, push the SELECT button.
To set the clock:
1. Push the SELECT button and RESET button together for at least two seconds.
2. When the hour digits start flashing, push the RESET button to set the hours.
3. Push the SELECT button, and the minute digits will start flashing.
4. Push the RESET button to set the minutes.
5. Push the SELECT button and then release it to start the clock.
1-4
FEATURES
1
2
3
4.
5.
GEN
INFO
NOTE:
S To make any settings in this mode, you have to cycle through all of its functions. However, if the key is
turned to OFF or engine is started before completing the procedure, only the settings made before
the SELECT button was last pushed will be applied.
S In this mode, the multi-function display shows the current setting for each function (except the shift
timing indicator light activity function).
To adjust the display brightness
1. Turn the key to OFF.
2. Push and hold the SELECT button.
3. Turn the key to ON, and then, after five seconds, release the SELECT button.
4. Push the RESET button to select the desired display brightness level.
5. Push the SELECT button to confirm the selected display brightness level. The control mode
changes to the shift timing indicator light activity function.
To set the shift timing indicator light activity function
1. Push the RESET button to select one of the following indicator light activity settings:
a. The indicator light will stay on when activated. (This setting is selected when the indicator light stays
on.)
b. The indicator light will flash when activated. (This setting is selected when the indicator light flashes
four times per second.)
c. The indicator light is deactivated; in other words, it will not come on or flash. (This setting is selected
when the indicator light flashes once every two seconds.)
2. Push the SELECT button to confirm the selected indicator light activity. The control mode changes
to the shift timing indicator light activation function.
1-5
FEATURES
GEN
INFO
1-6
IMPORTANT INFORMATION
GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the SPECIAL TOOLS.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
mated through normal wear. Mated parts
must always be reused or replaced as an assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS00022
lip
lip
spring
oil
grease
1-7
IMPORTANT INFORMATION
GEN
INFO
EAS00023
EAS00024
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
1 Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Always replace piston pin clips after one use.
When installing a circlip 1 , make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
4 Shaft
1-8
GEN
INFO
EAS00026
5. Check:
S continuity
(with the pocket tester)
Pocket tester
90890-03112, YU-3112
NOTE:
S If there is no continuity, clean the terminals.
S When checking the wire harness, perform
steps (1) to (3).
S As a quick remedy, use a contact revitalizer
available at most part stores.
1-9
GEN
INFO
SPECIAL TOOLS
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
S For U.S.A. and Canada, use part number starting with YM-, YU-, or ACC-.
S For others, use part number starting with 90890-.
Tool No.
Flywheel puller
90890-01362
YU-33270-B
Adapter
90890-04089
YM-33282
Tool name/Function
Flywheel puller
Adapter
This tool is used to remove the generator rotor.
Sheave holder
90890-01701
YS-01880-A
90890-01304
YU-01304
This tool is used to remove the piston pins.
Radiator cap
tester
90890-01325
YU-24460-01
Adapter
90890-01352
YU-33984
90890-01403
YU-33975
This tool is used to loosen or tighten the steering stem ring nuts.
Damper rod holder
90890-01473
This tool is used to hold the damper rod assembly when loosening or tightening the
damper rod assembly bolt.
Pivot shaft
wrench
90890-01471
YM-01471
Pivot shaft wrench
adapter
90890-01476
1-10
Illustration
SPECIAL TOOLS
Tool No.
90890-01426
YU-38411
Rod puller
90890-01437
YM-01437
Rod puller
attachment
90890-01436
Fork seal driver
90890-01367
YM-33963
Fork seal driver
attachment
90890-01374
YM-8020-A
Vacuum gauge
90890-03094
YU-08030
Compression
gauge
90890-03081
YU-33223
Adapter
90890-04136
90890-03112
YU-3112
Oil pressure
gauge
90890-03153
YU-03153
Adapter
90890-03139
Tool name/Function
Oil filter wrench
90890-03174
This tool is used to check the electrical system.
Fuel pressure adapter
90890-03176
YM-03176
This tool is needed to measure fuel pressure.
Pressure gauge
90890-03153
YU-03153
This tool used is to measure fuel pressure.
1-11
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
90890-04044
YM-04044
Tool name/Function
Piston ring compressor
90890-03158
Valve spring
compressor
90890-04019
YM-04019
Attachment
90890-04108
YM-01253
Middle driven shaft
bearing driver
90890-04058
YM-4058
Mechanical seal
installer
90890-04078
YM-33221
90890-04086
YM-91042
90890-04101
This tool is needed to remove and install
the valve lifter.
Valve guide remover (4)
90890-04111
This tool is used to remove or install the valve
guides.
Valve guide installer (4)
90890-04112
This tool is used to install the valve guides.
Valve guide reamer (4)
90890-04113
YM-04113
90890-06754
YM-34487
1-12
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
90890-06756
YB-35956
90890-85505
ACC-1100105-01
Tool name/Function
Vacuum/pressure pump gauge set
1-13
GEN
INFO
Illustration
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Weight
Wet (with oil and a full fuel tank)
Maximum load (except motorcycle)
Standard
Limit
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
2-1
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item
Engine
Engine type
Displacement
Cylinder arrangement
Bore
stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Engine oil
Lubrication system
Recommended oil
Standard
Liquid-cooled, 4-stroke, DOHC
600 cm3 (36.61 cu.in)
Forward-inclined parallel 4-cylinder
65.5
44.5 mm (2.58
1.75 in)
12.4 : 1
1,250 X 1,350 r/min
24 kPa (180 mmHg, 7.0872inHg)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Wet sump
SSS
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure
Limit
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
2-2
SSS
SSS
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Oil filter
Oil filter type
Bypass valve opening pressure
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip
clearance
Outer-rotor-to-oil-pump-housing
clearance
Cooling system
Radiator capacity
Radiator cap opening pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity
Water pump
Water pump type
Reduction ratio
Max. impeller shaft tilt
Limit
Formed
80 X 120 kPa (0.8 X 1.2 kg/cm2,
0.8 X 1.2 bar, 11.6 X 17.4 psi)
SSS
SSS
Trochoid
0.03 X 0.09 mm
(0.0012 X 0.0035 in)
0.03 X 0.08 mm
(0.0012 X 0.0031 in)
SSS
0.15 mm
(0.0059 in)
0.15 mm
(0.0059 in)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
0.15 mm
(0.006 in)
Electric starter
INP-250/4
NIPPON INJECTOR
SSS
SSS
SSS
SSS
SSS
0.05 mm
(0.002 in)
Spark plugs
Model (manufacturer)
Spark plug gap
Cylinder head
Volume
Max. warpage
quantity
2-3
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Limit
SSS
SSS
SSS
0.08 mm
(0.0031 in)
Measurement A
Measurement B
33.40 mm
(1.315 in)
25.07 mm
(0.987 in)
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaftcap clearance
Intake camshaft lobe dimensions
Measurement A
Measurement B
SSS
2-4
32.50 mm
(1.280 in)
25.02 mm
(0.985 in)
0.06 mm
(0.0024 in)
ENGINE SPECIFICATIONS
Item
Standard
Timing chain
Model/number of links
Tensioning system
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Head Diameter
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Limit
RH2015 /120
Automatic
SSS
SSS
SSS
SSS
Face Width
Exhaust
SPEC
Seat Width
Margin Thickness
SSS
SSS
SSS
SSS
3.95 mm
(0.1555 in)
3.935 mm
(0.1549 in)
SSS
2-5
4.042 mm
(0.1591 in)
4.042 mm
(0.1591 in)
0.08 mm
(0.0031 in)
0.10 mm
(0.0039 in)
0.04 mm
(0.0016 in)
ENGINE SPECIFICATIONS
Item
Valve springs
Free length
Intake (inner)
Intake (outer)
Exhaust
Installed length (valve closed)
Intake (inner)
Intake (outer)
Exhaust
Compressed spring force
(installed)
Intake (inner)
SPEC
Standard
Limit
30 mm (1.18 in)
32.5 mm (1.28 in)
36.1 mm (1.42 in)
SSS
SSS
SSS
SSS
Intake (inner)
SSS
Intake (outer)
SSS
Exhaust
SSS
2.5_/1.6 mm
(0.06 in)
2.5_/1.8 mm
(0.07 in)
2.5_/1.8 mm
(0.07 in)
(outer)
Exhaust
SSS
SSS
Spring tilt
Cylinders
Cylinder arrangement
Bore
stroke
Compression ratio
Bore
Max. out-of-round
Counter clockwise
Clockwise
Clockwise
SSS
SSS
SSS
SSS
SSS
SSS
SSS
0.05 mm
(0.002 in)
2-6
ENGINE SPECIFICATIONS
Item
Piston
Piston-to-cylinder clearance
SPEC
Standard
0.010 X 0.035 mm (0.0004 X 0.0014 in)
Limit
Diameter D
0.055 mm
(0.0022 in)
SSS
Height H
Piston pin bore (in the piston)
Diameter
4 mm (0.16 in)
SSS
16.002 X 16.013 mm
(0.6300 X 0.6304 in)
0.5 mm (0.0197 in)
Intake side
16.043 mm
(0.6316 in)
SSS
SSS
15.991 X 16.000 mm
(0.6296 X 0.6299 in)
0.002 X 0.022 mm (0.0001 X 0.0009 in)
15.971 mm
(0.6288 in)
0.072 mm
(0.0028 in)
Ring type
Dimensions (B
T)
End gap (installed)
Barrel
0.90
2.45 mm (0.04
0.10 in)
0.25 X 0.35 mm (0.0098 X 0.0138 in)
SSS
SSS
0.60 mm
(0.0236 in)
0.115 mm
(0.0045 in)
Offset
Offset direction
Piston pins
Outside diameter
Piston-pin-to-piston-pin-bore
clearance
Piston rings
Top ring
2nd ring
Ring type
Dimensions (B
T)
End gap (installed)
Taper
0.8
2.5 mm (0.03
0.10 in)
0.7 X 0.8 mm (0.0276 X 0.0315 in)
SSS
SSS
1.15 mm
(0.0453 in)
0.125 mm
(0.0049 in)
Oil ring
Dimensions (B
T)
End gap (installed)
1.5
2.0 mm (0.06
0.08 in)
0.10 X 0.35 mm (0.0039 X 0.0138 in)
2-7
SSS
SSS
ENGINE SPECIFICATIONS
Item
Connecting rods
Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code
SPEC
Standard
Limit
0.09 mm
(0.0035 in)
1 = Blue 2 = Black 3 = Brown 4 = Green SSS
Crankshaft
Width A
Width B
Max. runout C
Clutch
Clutch type
Clutch release method
Clutch release method operation
Operation
Clutch cable free play (at the end
of the clutch lever)
Friction plates
Color code
Thickness
Plate quantity
Color code
Thickness
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
SSS
SSS
0.03 mm
(0.0012 in)
SSS
SSS
SSS
0.10 mm
(0.0039 in)
SSS
SSS
SSS
SSS
SSS
SSS
Brown
2.9 X 3.1 mm (0.114 X 0.122 in)
SSS
2.8 mm
(0.110 in)
SSS
SSS
2.8 mm
(0.110 in)
SSS
6
Purple
2.9 X 3.1 mm (0.114 X 0.112 in)
2
1.9 X 2.1 mm (0.07 X 0.08 in)
7
SSS
2.2 X 2.4 mm (0.086 X 0.095 in)
1
SSS
50 mm (1.97 in)
6
2-8
SSS
SSS
0.1 mm
(0.0039 in)
SSS
SSS
0.1 mm
(0.0039 in)
49 mm
(1.93 in)
SSS
ENGINE SPECIFICATIONS
Item
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4nd gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
SPEC
Standard
Limit
SSS
SSS
SSS
SSS
SSS
SSS
37/13 (2.846)
37/19 (1.947)
28/18 (1.556)
32/24 (1.333)
25/21 (1.190)
26/24 (1.083)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
0.02 mm
(0.0008 in)
0.02 mm
(0.0008 in)
SSS
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
SSS
0.05 mm
(0.002 in)
Wet element
SSS
Fuel pump
Pump type
Model (manufacturer)
Output pressure
Electrical
SSS
5PW (DENSO)
SSS
294 kPa (2.94 kg/cm2, 2.94 bar, 42.6 psi) SSS
2-9
ENGINE SPECIFICATIONS
Item
Throttle position sensor
Resistance
Output voltage (at idle)
Throttle bodies
Model (manufacturer)
quantity
Intake vacuum pressure
Throttle cable free play
lay (at the flange
of the throttle grip)
ID mark
Throttle valve size
Standard
SPEC
Limit
SSS
38EIS (MIKUNI)
4
24 kPa (180 mmHg, 7.0872 inHg)
6 X 8 mm (0
(0.24
24 X 0
0.31
31 in)
SSS
SSS
SSS
2-10
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item
Frame
Frame type
Caster angle
Trail
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Rear wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Max. radial wheel runout
Max. lateral wheel runout
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 X 90 kg (0 X 198 lb)
90 X 193 kg (198 X 426 lb)
(USA except for CAL)
90 X 192 kg (198 X 423 lb)
(CAL)
High-speed riding
Min. tire tread depth
Standard
Limit
Diamond
24_
86 mm (3.39 in)
SSS
SSS
SSS
Cast wheel
SSS
17 M/C
MT3.50
Aluminum
120 mm (4.72 in)
SSS
SSS
SSS
SSS
SSS
1 mm (0.04 in)
0.5 mm (0.02 in)
Cast wheel
SSS
17 M/C
MT5.50
Aluminum
120 mm (4.72 in)
SSS
SSS
SSS
SSS
SSS
1 mm (0.04 in)
0.5 mm (0.02 in)
Tubeless
120/60 ZR17 M/C (55W)
Pilot SPORT N (MICHELIN)
D208FL (DUNLOP)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
1.6 mm
(0.06 in)
2-11
CHASSIS SPECIFICATIONS
Item
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 X 90 kg (0 X 198 lb)
90 X 193 kg (198 X 426 lb)
(USA except for CAL)
90 X 192 kg (198 X 423 lb) (CAL)
High-speed riding
Min. tire tread depth
Front brakes
Brake type
Operation
Recommended fluid
Brake lever free play
Brake discs
Diameter
thickness
Min. thickness
Standard
SSS
SSS
SSS
SSS
SSS
SSS
SSS
1.6 mm
(0.06 in)
SSS
SSS
SSS
SSS
298
SSS
SSS
4.5 mm
(0.18 in)
0.1 mm
(0.004 in)
0.5 mm
(0.02 in)
5 mm (11.73
SSS
Rear brake
Brake type
Operation
Brake pedal position (below the
bottom of the footrest bracket)
Recommended fluid
Brake pedal freeplay
Brake discs
Diameter
thickness
Min. thickness
Limit
Tubeless
180/55 ZR17 M/C (73W)
Pilot SPORT B (MICHELIN)
D208L (DUNLOP)
Max. deflection
SPEC
0.20 in)
SSS
14 mm (0.55 in)
30.2 mm and 27 mm (1.19 in and 1.06 in) SSS
Single disc brake
Right foot operation
7 X 11 mm (0.28 X 0.43 in)
SSS
SSS
SSS
DOT 4
4.3 X 9.3 mm (0.17 X 0.37 in)
SSS
SSS
220
SSS
SSS
4.5 mm
(0.18 in)
0.15 mm
(0.006 in)
1.0 mm
(0.04 in)
5 mm (8.66
Max. deflection
SSS
2-12
0.20 in)
SSS
SSS
CHASSIS SPECIFICATIONS
Item
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
Spacer length
Installed length
Spring rate (K1)
Spring stroke (K1)
Inner tube outer diameter
Inner tube bending limit
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the inner
tube, with the inner tube fully
compressed, and without the
fork spring)
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
SPEC
Standard
Limit
Telescopic fork
Coil spring/oil damper
120 mm (4.72 in)
SSS
SSS
SSS
No
244.3 mm
(9.62 in)
SSS
SSS
SSS
SSS
SSS
0.2 mm
(0.01 in)
SSS
Suspension oil 01
0.49 L (0.43 Imp qt, 0.52 US qt)
106 mm (4.17 in)
SSS
SSS
SSS
8
7
1
SSS
SSS
SSS
10
9
1
SSS
SSS
SSS
9
7
1
SSS
SSS
SSS
2-13
CHASSIS SPECIFICATIONS
Item
Steering
Steering bearing type
Rear suspension
Suspension type
Rear shock absorber assembly
type
Rear shock absorber assembly
travel
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Standard spring preload gas/air
pressure
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
Swingarm
Free play (at the end of the
swingarm)
Radial
Axial
Drive chain
Model (manufacturer)
Link quantity
Drive chain slack
Maximum ten-link section
SPEC
Standard
Limit
Angular bearing
SSS
SSS
SSS
60 mm (2.36 in)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
1
4
9
SSS
SSS
SSS
20
10
5
SSS
SSS
SSS
20
10
1
SSS
SSS
SSS
SSS
1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
SSS
2-14
SSS
SSS
SSS
150.1 mm
(5.91 in)
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
Standard
Limit
12 V
SSS
DC. CDI
10_ BTDC at 1,300 r/min
(USA except for CAL)
5_ BTDC at 1,300 r/min (CAL)
248 X 372 at 20_C (68_F)/Gy-B
SSS
SSS
F8T926 (MITSUBISHI)
SSS
Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
J0454 (DENSO)
6 mm (0.24 in)
0.17 X 0.23 at 20_C (68_F)
4.8 X 7.2 k at 20_C (68_F)
SSS
SSS
SSS
SSS
Charging system
System type
Model (manufacturer)
Normal output
Stator coil resistance/color
A.C. magneto
LLZ68 (DENSO)
14 V/300 W at 5,000 r/min
0.18 X 0.26 at 20_C (68_F)/W-W
SSS
SSS
SSS
SSS
Rectifier/regulator
Regulator type
Model ((manufacture))
No-load regulated voltage
Rectifier capacity
Withstand voltage
SSS
SSS
SSS
SSS
SSS
Battery
Battery type
Battery voltage/capacity
Specific gravity
Manufacturer
Ten hour rate amperage
GT9B-4
12 V/8 Ah
1.320
GS
0.8A
SSS
SSS
SSS
SSS
SSS
Headlight type
Halogen bulb
Bulbs (voltage/wattage
quantity)
Headlight
Tail/brake light
Front turn signal/position light
Rear turn signal light
Licence light
Meter light
12 V 55 W
2
LED
1
12 V 21 W/5W
12 V 21 W
2
12 V 5 W
1
LED
1
System voltage
Ignition system
Ignition system type
Ignition timing
2-15
SSS
SSS
SSS
SSS
SSS
SSS
SSS
ELECTRICAL SPECIFICATIONS
Item
SPEC
Standard
Indicator light
(voltage /wattage
quantity)
Neutral indicator light
High beam indicator light
Oil level indicator light
Turn signal indicator light
Fuel level warning light
Coolant temparture indicator light
Engine trouble warning light
Shift timing indicator light
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
LED
LED
LED
LED
LED
LED
LED
LED
1
1
1
2
1
1
1
1
Limit
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Constant mesh
SSS
SM-14 (MITSUBA)
0.6 kW
SSS
SSS
10 mm (0.39 in)
3.5 mm
(0.14 in)
SSS
Mica undercut
SSS
27 mm
(1.06 in)
SSS
Starter relay
Model (manufacturer)
Amperage
Coil resistance
2768088-A (JIDECO)
180 A
4.18 X 4.62 at 20_C (68_F)
SSS
SSS
SSS
Horn
Horn type
Model (manufacturer)
Max. amperage
Performance
Coil resistance
Plain
YF-12 (NIKKO)
1
3A
105 X 113 db/2 m
1.15 X 1.25 at 20_C (68_F)
SSS
SSS
SSS
SSS
SSS
Full transistor
FE246BH (DENSO)
No
75 X 95 cycles/min.
21 W
2 + 3.4 W
SSS
SSS
SSS
SSS
SSS
SSS
Spring force
quantity
2-16
ELECTRICAL SPECIFICATIONS
Item
SPEC
Standard
Limit
Fuses (amperage
quantity)
Main fuse
Fuel injection system fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan motor fuse
Backup fuse (odometer and clock)
Reserve fuse
40 A
1
15 A
1
20 A
1
15 A
1
15 A
1
15 A
1
10 A
1
40 A, 20 A, 15 A, 10 A
5PW (DENSO)
750 X 1,100
SSS
SSS
G8R-30Y-R (OMRON)
162 X 198
SSS
SSS
ACA12115 (MATSUSHITA)
72 X 88
SSS
SSS
G8R-30Y-R (OMRON)
162 X 198
SSS
SSS
K003T20191 (MITSUBISHI)
0.2898 X 0.3542 at 80_C (176_F)
SSS
SSS
2-17
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS
SPEC
EAS00028
EAS00030
CONVERSION TABLE
MULTIPLIER
** mm
0.03937
** in
2 mm
0.03937
0.08 in
This chart specifies tightening torques for standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special components or assemblies are provided
for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a
crisscross pattern and progressive stages until
the specified tightening torque is reached. Unless otherwise specified, tightening torque
specifications require clean, dry threads. Components should be at room temperature.
IMPERIAL
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
Multiplier
Imperial unit
Tightening
torque
mSkg
mSkg
cmSkg
cmSkg
7.233
86.794
0.0723
0.8679
ftSlb
inSlb
ftSlb
inSlb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km / hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume /
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cuSin
qt (IMP liq.)
gal (IMP liq.)
Misc.
kg / mm
kg / cm2
Centigrade
(_C)
55.997
14.2234
9 / 5+32
lb / in
psi (lb / in2)
Fahrenheit
(_F)
2-18
A
(nut)
B
(bolt)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm
6 mm
8 mm
10 mm
12 mm
14 mm
16 mm
General tightening
torques
Nm
6
15
30
55
85
130
mSkg
0.6
1.5
3.0
5.5
8.5
13.0
ftSlb
4.3
11
22
40
61
94
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item
Spark plugs
Cylinder head
Camshaft caps
Cylinder head cover
Camshaft cap oil check bolt
Reed valve cover
Air-cut valve stay
Camshaft sprockets
Connecting rod caps
Generator rotor
Timing chain tensioner
Timing chain tensioner cap bolt
Thermostat cover
Coolant hose joint
Water pump cover
Water pump
Radiator and frame
Radiator stay and crankcase
Oil pump cover
Oil pump
Oil pan
Oil pan (center)
Oil cooler
Engine oil drain bolt
Oil filter union bolt
Oil filter
Oil pump chain guide
Oil pipe
Throttle body joint
Air filter case cover
Air filter case and frame
Throttle body and throttle body
joint
Throttle body and air filter case
Exhaust pipe and cylinder head
Exhaust pipe and exhaust pipe
stay
Exhaust pipe and muffler
Exhaust pipe stay and frame
Crankcase (main journal)
Crankcase
Crankcase
Crankcase
Fastener
Thread
Qty
Q
ty
size
Nut
M10
M10
4
10
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Screw
Bolt
Clamp
M6
M6
M6
M8
M6
M6
M7
M7
M12
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M20
M14
M20
M20
M6
M6
M6
M5
M6
M4
2
20
6
1
4
1
4
8
1
2
1
2
2
2
2
2
1
3
3
12
1
1
1
1
1
2
2
8
6
1
4
Clamp
Nut
Bolt
M5
M8
M8
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
M8
M8
M8
M6
M6
M8
2-19
Tightening torque
Nm
mSkg
ftSlb
13
1st 19
2nd 50
12
10
12
20
10
10
24
1.3
1.9
5.0
1.2
1.0
1.2
2.0
1.0
1.0
2.4
9.4
14
36
8.7
7.2
8.7
15
7.2
7.2
17
Remarks
Yamaha bond
No.1215
75
12
7.0
12
10
10
12
7.0
10
12
12
12
12
63
43
70
17
12
12
10
3.0
10
3.0
7.5
1.2
0.7
1.2
1.0
1.0
1.2
0.7
1.0
1.2
1.2
1.2
1.2
6.3
4.3
7.0
1.7
1.2
1.2
1.0
0.3
1.0
0.3
54
8.7
5.1
8.7
7.2
7.2
8.7
5.1
7.2
8.7
8.7
8.7
8.7
46
31
51
12
8.7
8.7
7.2
2.2
7.2
2.2
4
8
1
3.0
20
20
0.3
2.0
2.0
2.2
15
15
1
1
10
2
13
2
20
34
2.0
3.4
See NOTE 2
14
1.4
12
1.2
24
2.4
15
25
1.0
8.7
17
See NOTE 1
TIGHTENING TORQUES
Item
Generator rotor cover
Clutch cover
Clutch cover
Pickup coil rotor cover
Clutch cable holder
Pickup coil rotor cover
Shift shaft cover
Breather plate
Stator coil
Pickup rotor cover and
clamp
Drive sprocket cover
Oil gallery bolt
Generator rotor cover and
stator coil lead clamp
Breather hose cover
Oil pipe
Crankshaft position sensor
Starter clutch
Clutch pressure plate
Clutch boss
Drive sprocket
Transmission bearing housing
Shift drum retainer
Shift shaft spring stopper
Shift rod
Shift rod
Shift rod joint
Shift arm
Pickup coil rotor
Starter motor
Neutral switch
Oil level switch
Speed sensor
Cylinder identification sensor
Fastener
Thread
Qty
Q
ty
size
SPEC
Tightening torque
Nm
mSkg
ftSlb
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Screw
Screw
Screw
M6
M6
M6
M6
M6
M8
M6
M6
M6
M6
9
9
1
5
2
1
6
3
3
1
12
12
12
12
12
15
12
12
10
7.0
1.2
1.2
1.2
1.2
1.2
1.5
1.2
1.2
1.0
0.7
8.7
8.7
8.7
8.7
8.7
11
8.7
8.7
7.2
5.1
Bolt
Screw
M6
M16
M6
3
2
1
10
8
10
1.0
0.8
1.0
7.2
5.8
7.2
Bolt
Bolt
Bolt
Screw
Bolt
Nut
M6
M6
M6
M8
M6
M20
4
2
2
3
6
1
12
12
10
32
8.0
70
1.2
1.2
1.0
3.2
0.8
7.0
8.7
8.7
7.2
23
5.8
51
Nut
M18
90
9.0
65
Screw
Bolt
Screw
Nut
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
M6
M6
M8
M8
M6
M6
M6
M8
M6
M10
M6
M6
M6
3
2
1
1
1
1
1
1
2
1
2
1
1
12
10
22
10
6.5
10
10
35
10
20
10
10
10
1.2
1.0
2.2
1.0
0.65
1.0
1.0
3.5
1.0
2.0
1.0
1.0
1.0
8.7
7.2
16
7.2
4.7
7.2
7.2
25
7.2
14
7.2
7.2
7.2
Remarks
Yamaha bond
No.1215
Use a lock
washer
Use a lock
washer
Left thread
Yamaha bond
No.1215
NOTE 1:
Retighten the bolt at 1000 km (600 ml).
NOTE 2:
1. First, tighten the bolts to approximately 12 Nm (1.2 mSkg, 8.7 ftSlb) with a torque wrench.
2. Retighten the bolts 25 Nm (2.5 mSkg, 18 ftSlb) with a torque wrench.
3. Loosen the all bolts one by one following the tightening order and then tighten them to 27 Nm (2.7
mSkg, 20 ftSlb) again.
2-20
TIGHTENING TORQUES
Cylinder head tightening sequence:
2-21
SPEC
SPEC
TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES
Tightening
Item
Thread
size
Nm
mSkg
ftSlb
M8
M28
M8
M6
M30
M8
M8
M4
M10
M6
M5
M5
M5
M5
M8
M5
M5
M4
M5
M6
M5
M6
M10
M10
M10
M16
M10
M5
M8
M6
M18
M10
M10
M10
M10
M10
M14
M5
M6
M6
M6
M6
M6
M8
M8
M8
M8
26
113
33
13
14
23
23
1.2
30
13
0.4
1.7
2.5
1.3
23
1.3
1.3
1.2
1.2
7
1.5
4.5
45
45
45
7
47
3.8
7
4.5
95
44
44
44
44
44
52
4
7
7
7
7
6.5
28
28
23
18
2.6
11.3
3.3
1.3
1.4
2.3
2.3
0.12
3.0
1.3
0.04
0.17
0.25
0.13
2.3
0.13
0.13
0.12
0.12
0.7
0.15
0.45
4.5
4.5
4.5
0.7
4.7
0.38
0.7
0.45
9.5
4.4
4.4
4.4
4.4
4.4
5.2
0.4
0.7
0.7
0.7
0.7
0.65
2.8
2.8
2.3
1.8
19
82
24
9.4
10
17
17
0.9
22
9.4
0.3
1.23
1.81
0.94
17
0.94
0.94
0.87
0.87
5.1
1.1
3.3
33
33
33
5.1
34
2.7
5.1
3.3
69
32
32
32
32
32
38
2.9
5.1
5.1
5.1
5.1
4.7
20
20
17
13
2-22
Remarks
See NOTE 1
TIGHTENING TORQUES
Item
Rear brake hose union bolt
Sidestand bracket and frame
Front wheel axle shaft and bolt
Rear wheel axle nut
Front brake caliper and front fork
Front brake disc and front wheel
Rear brake disc and rear wheel
Rear wheel sprocket and rear wheel drive hub
Brake caliper bleed screw
Pinch bolt (front wheel axle)
SPEC
Tightening
Thread
size
Nm
mSkg
ftSlb
M10
M10
M14
M24
M10
M6
M8
M10
M8
M8
30
61
91
110
40
18
30
100
6
18
3.0
6.1
9.1
11.0
4.0
1.8
3.0
10.0
0.6
1.8
22
44
66
80
29
13
22
72
4.3
13
Remarks
See NOTE 2
NOTE 1:
1. First, tighten the ring nut to approximately 52 Nm (5.2 mSkg, 38 ftSlb) with a torque wrench, then
loosen the ring nut completely.
2. Retighten the lower ring nut to specification.
NOTE 2:
S Tighten wheel axle pinch bolts 2 and 1 to
specified torque.
S Retighten pinch bolt 2 to specified torque.
S Tap the outer side of the left fork leg with a rubber mallet to align it with the end of the wheel
axle.
S Tighten wheel axle pinch bolts 4 and 3 to
specified torque.
S Retighten pinch bolt 4 to specified torque.
2-23
SPEC
EAS00031
Lubricant
Yamaha bond
No.1215
Yamaha bond
No.1215
Yamaha bond
No.1215
Yamaha bond
No.1215
2-24
SPEC
EAS00032
CHASSIS
Lubrication point
Lubricant
2-25
2-26
SPEC
2-27
SPEC
2-28
SPEC
2-29
SPEC
2-30
SPEC
LUBRICATION DIAGRAMS
LUBRICATION DIAGRAMS
1 Oil level switch
2 Oil cooler
3 Relief valve
2-31
SPEC
LUBRICATION DIAGRAMS
1
2
3
4
Oil pump
Exhaust camshaft
Intake camshaft
Oil strainer
2-32
SPEC
LUBRICATION DIAGRAMS
1 Oil cooler
2 Oil strainer
3 Oil level switch
4 Oil pump
2-33
SPEC
LUBRICATION DIAGRAMS
1 Main axle
2 Oil pump
3 Relief valve
2-34
SPEC
LUBRICATION DIAGRAMS
1
2
3
4
Cylinder head
Intake camshaft
Exhaust camshaft
Crankshaft
2-35
SPEC
LUBRICATION DIAGRAMS
1 Main axle
2 Drive axle
2-36
SPEC
CABLE ROUTING
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
2-37
CABLE ROUTING
F Pass the horn lead by the outside of the throttle
cables and clamp it to the forefront of upper face of
the under bracket. And then route it under the front
brake hose and clamp it to the pawl of the under
cover.
G Clamp it at the position of 40 X 60 mm (1.57 X 2.36
in) from the upper face of the under bracket with the
plastic locking tie. Cut the surplus part of the clamp
tip leaving 2 X 4 mm (0.08 X 0.16 in). Point the tip
of the clamp to the outside of vehicle.
H Pass the throttle cables inside the front brake
hoses.
I Set in the coupler between the head lights hollow
section and the duct.
SPEC
2-38
CABLE ROUTING
1
2
3
4
5
6
7
8
9
SPEC
2-39
CABLE ROUTING
K Put and apply the hose clamp to it.
L Pass the crankshaft position sensor lead over the
throttle stop screw.
2-40
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
SPEC
2-41
CABLE ROUTING
F Pass the fuel tank drain hose and fuel tank breather
hose through the clamp of the coolant reservoir
tank.
G Projection allowance from the coolant reservoir
tank cover shall be 30 X 50 mm (1.18 X 1.97 in).
H 10 X 50 mm (0.39 X 1.97 in).
I Fasten the sidestand switch lead and oil level switch
lead with a clamp.
J Pass the coolant reservoir tank breather hose, oil
level switch lead and sidestand switch lead through
the clamp.
K Pass the sidestand switch lead, oil level switch lead
and A.C. magneto lead between the engine stay
and the engine.
L To the radiator fan motor relay and fuse box
SPEC
2-42
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
2-43
SPEC
poles)
30 Oil level switch lead coupler
(white 1 pole)
31 Sidestand switch lead coupler
(blue 2 poles)
magneto lead coupler
(white 3 poles)
33 Rear brake light switch lead coupler (brown 2 poles)
34 Neutral switch lead coupler
(connector 1 pole)
32 A.C.
CABLE ROUTING
A To the headlight
B Make sure not to drop the headlight sub wire harness beneath the projection of the duct. Check it
when installing the side cowling.
C Clamp the plastic locking tie to the cover 8. Place
the coupler at the rear side of the vehicle against the
plastic locking tie. Point the tip of the plastic locking
tie to the downward in the inner side of the vehicle.
D Route the head light and meter leads under the
frames lower part from the hollow section of the
cover 2.
E Pass the left and right handlebar switch leads outside of the air filter case air vent hose.
F Connect the couplers (4 units) at the frame side
hole. Do not catch each lead and wire harness when
the cover 8 is attached.
SPEC
2-44
CABLE ROUTING
P To the coolant reservoir tank
Q To the intake air temperature sensor (air filter case)
R To the oil level switch, sidestand switch and A.C.
magneto
S Install the wire harness wrapping clamp to the stay
of the throttle body.
T Pass the wire harness over the throttle air vent
hose.
U Pass the wire harness between frame and coolant
hose.
V Pass it through the frame hole.
W Do not catch the coupler when the air filter case is
assembled.
SPEC
2-45
CABLE ROUTING
AB To the fuse box and fan motor relay
AC Pass the throttle cables over the cover 2.
AD Point the tip of the plastic locking tie to the rear
side of the vehicle.
AE To the main switch lead coupler
AF Tip of the plastic locking tie should point to the
downward outside of the vehicle.
AG Use the plastic locking tie to clamp the starter motor lead at the protector section.
AH Branching harness from the wire harness.
2-46
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
Battery
Battery positive lead
Starter relay
Turn signal relay
Pressure sensor
Tail/ brake light
Tool kit
Starting circuit cut-off relay
Battery box
ECU
Wire harness
Battery negative lead
Battery band
SPEC
2-47
CABLE ROUTING
H The knob section should be positioned in this area.
I Pass the turn signal lead by the outside of the right
side attaching boss of the tail / brake light.
J Pass the turn signal light and license light leads between the rear side ribs of the battery box assembly
and to the rear part of the vehicle.
K Connect the turn signal lead couplers.
L Connect the license light leads.
M Route the branching lead to the license light behind
the tail / brake light left side attaching boss.
N Route the tail / brake light lead under the projection
part.
O Route the tail / brake light lead above the projection
part.
P There should be no significant difference between
right and left side of the tension rate on the band.
SPEC
2-48
CABLE ROUTING
SPEC
For California
1
2
3
4
5
6
A Install the roll over valve until it contacts with the fuel
tanks nipple.
B Install the O-ring with its lip pointed upward.
C Install the clip with its tab pointed in the upward
direction.
D Install the breather hose without projecting canister
nipple out of the breather hose.
E Install the clip with its tab pointed in the downward
direction.
2-49
CHK
ADJ
EAS00036
ITEM
600 mi
(1,000 km)
or
1 month
REMARKS
ODOMETER READINGS
4,000mi
(7,000 km)
or
6 months
8,000 mi
(13,000 km)
or
12 months
12,000 mi
(19,000 km)
or
18 months
16,000 mi
(25,000 km)
or
24 months
20,000 mi
(31,000 km)
or
30 months
Valve clearance
(See page 3-10)
Spark plugs
(See page 3-21)
S Check condition.
S Adjust gap and clean.
S Replace at 8,000 mi (13,000 km) or 12
months.
Replace.
Replace.
Crankcase ventilation
system
(See page 3-32)
Fuel line
(See page 3-32)
Exhaust system
(See page 3-33)
Evaporative emission
control system**
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the
service.
** California only
ITEM
REMARKS
ODOMETER READINGS
600 mi
(1,000 km)
or
1 month
4,000mi
(7,000 km)
or
6 months
8,000 mi
(13,000 km)
or
12 months
12,000 mi
(19,000 km)
or
18 months
16,000 mi
(25,000 km)
or
24 months
20,000 mi
(31,000 km)
or
30 months
Engine oil
(See page 3-24, 25)
Cooling system
(See page 3-34, 35)
Replace.
Brake system
(See page 3-39, 40, 41,
43)
Clutch
(See page 3-29)
S Check operation.
S Adjust or replace cable.
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the
service.
3-1
CHK
ADJ
ITEM
REMARKS
ODOMETER READINGS
600 mi
(1,000 km)
or
1 month
4,000mi
(7,000 km)
or
6 months
8,000 mi
(13,000 km)
or
12 months
12,000 mi
(19,000 km)
or
18 months
16,000 mi
(25,000 km)
or
24 months
20,000 mi
(31,000 km)
or
30 months
Control cables
(See page 3-58)
Swingarm pivot
bearing
(See page 4-75)
Repack.
S Check operation.
S Correct if necessary.
10
Shock absorber
assembly
(See page 4-71)
11
Front fork
(See page 3-50)
12
Steering bearings
(See page 3-48)
Repack.
13
14
15
Drive chain
(See page 3-46)
Wheel bearings
(See page 4-3)
Sidestand pivot
(See page 3-58)
16
17
18
Sidestand switch
(See page 8-4)
19
Chassis fasteners
(See page 2-22)
20
Brake hoses
(See page 3-43)
21
Wheels
(See page 4-3)
22
Tires
(See page 3-55)
S
S
S
S
S Replace.
Every 4 years
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the
service.
NOTE:
From 24,000 mi (37,000 km) 36 months, repeat the maintenance intervals starting from 4,000 mi
(7,000 km) or 6 months.
NOTE:
D The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
D Hydraulic brake service
S After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
S Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
S Replace the brake hoses every four years and if cracked or damaged.
3-2
SEATS
CHK
ADJ
EAS00039
SEATS
Order
1
2
Job/Part
Qty
Remarks
Remove the parts in the order listed.
1
1
For installation, reverse the removal
procedure.
3-3
FUEL TANK
CHK
ADJ
EAS00040
FUEL TANK
Order
1
2
3
4
5
6
7
8
9
Job/Part
Qty
Remarks
Remove the parts in the order listed.
Refer to SEATS.
1
1
1
1
1
1
1
1
1
Disconnect.
Disconnect.
3-4
FUEL TANK
CHK
ADJ
CAUTION:
S Be sure to disconnect the fuel hose by
hand. Do not forcefully disconnect the
hose with tools.
S Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hoses, since there may be fuel remaining in it.
NOTE:
Before removing the hoses, place a few rags in
the area under where it will be removed.
3. Remove:
S fuel tank
NOTE:
Do not set the fuel tank down so that the installation surface of the fuel pump is directly under the
tank. Be sure to lean the fuel tank in an upright
position.
CAUTION:
S Do not drop the fuel pump or give it a
strong shock.
S Do not touch the base section of the fuel
sender.
3-5
FUEL TANK
CHK
ADJ
CAUTION:
When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose holders are in the correct position,
otherwise the fuel hose will not be properly
installed.
NOTE:
Install the fuel hose connector securely onto the
fuel tank until a distinct click is heard, and then
make sure that it does not come loose.
After installing the fuel hose connector cover 1 ,
make sure that the holders a , b , and c on the
cover are installed scurely.
2. Install:
S fuel sender coupler
S fuel pump coupler
S fuel tank breather hose
S fuel tank overflow hose
3-6
COWLINGS
CHK
ADJ
COWLINGS
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Qty
Remarks
Remove the parts in the order listed.
Refer to SEATS.
2
2
2
2
Disconnect.
2
1
1
2
1
1
2
For installation, reverse the removal
procedure.
3-7
COWLINGS
CHK
ADJ
REMOVAL
1. Remove:
S rear cowling
S side cowlings
NOTE:
To remove the quick fastener, push its center
with a screwdriver, then pull the fastener out.
INSTALLATION
1. Install:
S side cowlings
S rear cowling
NOTE:
To install the quick fastener, push its pin so that it
protrudes from the fastener head, then insert
the fastener into the cowling and push the pin a
in with a screwdriver. Make sure that the pin is
flush with the fasteners head.
3-8
CHK
ADJ
Order
1
2
3
4
5
6
7
Job/Part
Qty
Remarks
Remove the parts in the order listed.
Refer to SEATS.
Refer to FUEL TANK.
2
1
2
1
4
1
1
3-9
Disconnect.
Disconnect.
Disconnect.
Loosen.
Disconnect.
For installation, reverse the removal
procedure.
CHK
ADJ
EAS00045
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
S Valve clearance adjustment should be made
on a cold engine, at room temperature.
S When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove
S rider seat
Refer to SEATS.
S fuel tank
Refer to FUEL TANK.
S air filter case
Refer to AIR FILTER CASE.
S bottom cowling
S side cowlings
Refer to COWLINGS.
S throttle body assembly
Refer to THROTTLE BODIES in chapter 7.
S air cut-off valve
Refer to AIR INDUCTION SYSTEM in
chapter 7.
S radiator
S radiator fan motor
Refer to RADIATOR in chapter 6.
2. Remove
S ignition coils
S spark plugs
S cylinder head cover
S cylinder head cover gasket
Refer to CAMSHAFT in chapter 5.
3. Remove
S pickup rotor cover 1
3-10
CHK
ADJ
4. Measure:
S valve clearance
Out of specification ! Adjust.
Valve clearance (cold)
Intake valve
0.13 X 0.20 mm
(0.0051 X 0.0079 in)
Exhaust valve
0.23 X 0.30 mm
(0.0091 X 0.0118 in)
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the
pickup rotor with the crankcase mating surface b .
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
c. Measure the valve clearance with a thickness gauge 1 .
NOTE:
S If the valve clearance is incorrect, record the
measured reading.
S Measure the valve clearance in the following
sequence.
Valve clearance measuring sequence
Cylinder #1 ! #2 ! #4 ! #3
A Front
d. To measure the valve clearances of the other
cylinders, starting with cylinder #1 at TDC,
turn the crankshaft counterclockwise as specified in the following table.
B Degrees that the crankshaft is turned counterclockwise
C Cylinder
D Combustion cycle
3-11
Cylinder #2
180_
Cylinder #4
360_
Cylinder #3
540_
CHK
ADJ
NOTE:
S Refer to DISASSEMBLING THE ENGINE
CAMSHAFT AND CYLINDER HEAD in chapter 5.
S When removing the timing chain and camshafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase.
6. Adjust:
S valve clearance
a. Remove the valve lifter 1 and the valve pad
2 with a valve lapper 3 .
Valve lapper
90890-04101
NOTE:
S Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
S Make a note of the position of each valve lifter
1 and valve pad 2 so that they can be
installed in the correct place.
b. Select the proper valve pad from the following table.
Valve pad
thickness range
Nos.
120 X
240
1.20
(0.0472) X
2.40 mm
(0.0945 in)
Available valve
pads
25 thicknesses in
0.05 mm (0.002 in)
increments
NOTE:
S The thickness a of each valve pad is marked
in hundredths of millimeters on the side that
touches the valve lifter.
S Since valve pads of various sizes are originally
installed, the valve pad number must be
rounded in order to reach the closest equivalent to the original.
3-12
CHK
ADJ
c. Round off the original valve pad number according to the following table.
Last digit
Rounded value
0 or 2
10
EXAMPLE:
Original valve pad number
= 148 (thickness =1.48 mm (0.058 in))
Rounded value = 150
d. Locate the rounded number of the original
valve pad and the measured valve clearance
in the valve pad selection table. The point
where the column and row intersect is the
new valve pad number.
NOTE:
The new valve pad number is only an approximation. The valve clearance must be measured
again and the above steps should be repeated if
the measurement is still incorrect.
e. Install the new valve pad 1 and the valve lifter 2 .
NOTE:
S Lubricate the valve pad with molybdenum disulfide grease.
S Lubricate the valve lifter with molybdenum disulfide oil.
S The valve lifter must turn smoothly when rotated by hand.
S Install the valve lifter and the valve pad in the
correct place.
f. Install the exhaust and intake camshafts,
timing chain and camshaft caps.
Camshaft cap bolt
10 Nm (1.0 mSkg, 7.2 ftSlb)
3-13
CHK
ADJ
NOTE:
S Refer to ASSEMBLING AND ADJUSTING
THE ENGINE CYLINDER HEAD AND CAMSHAFT in chapter 5.
S Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.
S First, install the exhaust camshaft.
S Align the camshaft marks with the camshaft
cap marks.
S Turn the crankshaft counterclockwise several
full turns to seat the parts.
g. Measure the valve clearance again.
h. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is
obtained.
3-14
CHK
ADJ
INTAKE
INSTALLED PAD NUMBER
MEASURED
CLEARANCE
0.00 X 0.02
0.03 X 0.07
0.08 X 0.12
0.13 X 0.20
0.21 X 0.25
0.26 X 0.30
0.31 X 0.35
0.36 X 0.40
0.41 X 0.45
0.46 X 0.50
0.51 X 0.55
0.56 X 0.60
0.61 X 0.65
0.66 X 0.70
0.71 X 0.75
0.76 X 0.80
0.81 X 0.85
0.86 X 0.90
0.91 X 0.95
0.96 X 1.00
1.01 X 1.05
1.06 X 1.10
1.11 X 1.15
1.16 X 1.20
1.21 X 1.25
1.26 X 1.30
1.31 X 1.35
1.36 X 1.40
140
125
130
135
145
130
135
140
150
135
140
145
155
140
145
150
160
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
125
130
135
140
145
155
130
135
140
145
150
160
135
140
145
150
155
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165 170 175 180 185 190 195 200 205 210 215
150 155 160 165 170 175 180 185 190 195 200
155 160 165 170 175 180 185 190 195 200 205
160 165 170 175 180 185 190 195 200 205 210
STANDARD CLEARANCE
170 175 180 185 190 195 200 205 210 215 220
175 180 185 190 195 200 205 210 215 220 225
180 185 190 195 200 205 210 215 220 225 230
185 190 195 200 205 210 215 220 225 230 235
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
235 240
VALVE CLEARANCE (cold):
240
220
205
210
215
225
210
215
220
230
215
220
225
235 240
220 225
225 230
230 235
EXHAUST
INSTALLED PAD NUMBER
MEASURED
CLEARANCE
0.00 X 0.02
0.03 X 0.07
0.08 X 0.12
0.13 X 0.17
0.18 X 0.22
0.23 X 0.30
0.31 X 0.35
0.36 X 0.40
0.41 X 0.45
0.46 X 0.50
0.51 X 0.55
0.56 X 0.60
0.61 X 0.65
0.66 X 0.70
0.71 X 0.75
0.76 X 0.80
0.81 X 0.85
0.86 X 0.90
0.91 X 0.95
0.96 X 1.00
1.01 X 1.05
1.06 X 1.10
1.11 X 1.15
1.16 X 1.20
1.21 X 1.25
1.26 X 1.30
1.31 X 1.35
1.36 X 1.40
1.41 X 1.45
1.46 X 1.50
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
165 170 175 180 185 190 195 200 205 210 215
140 145 150 155 160 165 170 175 180 185 190
145 150 155 160 165 170 175 180 185 190 195
150 155 160 165 170 175 180 185 190 195 200
155 160 165 170 175 180 185 190 195 200 205
160 165 170 175 180 185 190 195 200 205 210
STANDARD CLEARANCE
170 175 180 185 190 195 200 205 210 215 220
175 180 185 190 195 200 205 210 215 220 225
180 185 190 195 200 205 210 215 220 225 230
185 190 195 200 205 210 215 220 225 230 235
190 195 200 205 210 215 220 225 230 235 240
195 200 205 210 215 220 225 230 235 240
200 205 210 215 220 225 230 235 240
205 210 215 220 225 230 235 240
210 215 220 225 230 235 240
215 220 225 230 235 240
220 225 230 235 240
225 230 235 240
230 235 240
235 240
VALVE CLEARANCE (cold):
240
220
195
200
205
210
215
225
200
205
210
215
220
230
205
210
215
220
225
235 240
210 215
215 220
220 225
225 230
230 235
3-15
CHK
ADJ
7. Install:
S all removed parts
NOTE:
For installation, reverse the removal procedure.
3. Remove:
S synchronizing hose 1
4. Install:
S vacuum gauge 1
(onto the synchronizing hose)
S digital tachometer
(near the spark plug)
Vacuum gauge
90890-03094, YU-08030
3-16
CHK
ADJ
5. Install:
S air filter case
Refer to AIR FILTER CASE.
S fuel tank
Refer to FUEL TANK.
6. Start the engine and let it warm up for several
minutes.
7. Measure:
S engine idling speed
Out of specification ! Adjust.
Refer to ADJUSTING THE ENGINE IDLING
SPEED.
Engine idling speed
1,250 X 1,350 r/min
8. Adjust:
S throttle body synchronization
a. With throttle body #3 as standard, adjust
throttle bodies #1, #2, and #4 using the air
screws 1 .
NOTE:
S After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
S If the air screw is removed, turn the screw 3/4
turn in and be sure to synchronize the throttle
body.
CAUTION:
Do not use the throttle valve adjusting
screws to adjust the throttle body synchronization.
Carburetor angle driver
90890-03158
Vacuum pressure at engine
idling speed
24 kPa
(180 mmHg, 7.0872 inHg)
NOTE:
The difference in vacuum pressure between
two throttle bodies should not exceed 1.33 kPa
(10 mmHg, 0.39 inHg).
3-17
CHK
ADJ
9. Measure:
S engine idling speed
Out of specification ! Adjust.
Make sure that the vacuum pressure is within
specification.
10. Stop the engine and remove the measuring
equipment.
11. Adjust:
S throttle cable free play
Refer to ADJUSTING THE THROTTLE
CABLE FREE PLAY.
Throttle cable free play
(at the flange of the throttle grip)
6 X 8 mm (0.24 X 0.31 in)
12. Remove:
S digital tachometer
S vacuum gauge
13. Install:
S air filter case
Refer to AIR FILTER CASE.
S fuel tank
Refer to FUEL TANK.
S rider seat
Refer to SEATS.
EAS00052
3-18
CHK
ADJ
4. Adjust:
S engine idling speed
a. Turn the throttle stop screw 1 in direction a
or b until the specified engine idling speed is
obtained.
Direction a
Direction b
5. Adjust:
S throttle cable free play
Refer to ADJUSTING THE THROTTLE
CABLE FREE PLAY.
Throttle cable free play (at the
flange of the throttle grip)
6 X 8 mm (0.24 X 0.31 in)
EAS00056
1. Check:
S throttle cable free play a
Out of specification ! Adjust.
Throttle cable free play (at the
flange of the throttle grip)
6 X 8 mm (0.24 X 0.31 in)
2. Remove:
S rider seat
Refer to SEATS.
S fuel tank
Refer to FUEL TANK.
S air filter case
Refer to AIR FILTER CASE.
S left frame side cover
Refer to COWLINGS.
3-19
CHK
ADJ
3. Adjust:
S throttle cable free play
NOTE:
When the throttle is opened, the accelerator
cable 1 is pulled.
Throttle body side
a. Loosen the locknut 2 on the decelerator
cable.
b. Turn the adjusting nut 3 in direction a or b
to take up any slack on the decelerator cable.
Direction a
Direction b
Handlebar side
a. Loosen the locknut 1 .
b. Turn the adjusting nut 2 in direction a or b
until the specified throttle cable free play is
obtained.
Direction a
Direction b
WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
3-20
CHK
ADJ
4. Install:
S left frame side cover
Refer to COWLINGS.
S air filter case
Refer to AIR FILTER CASE.
S fuel tank
Refer to FUEL TANK.
S rider seat
Refer to SEATS.
EAS00059
CAUTION:
Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
with compressed air to prevent it from falling into the cylinders.
3. Check:
S spark plug type
Incorrect ! Change.
Spark plug type (manufacturer)
CR9EK or CR10EK (NGK)
4. Check:
S electrode 1
Damage/wear ! Replace the spark plug.
S insulator 2
Abnormal color ! Replace the spark plug.
Normal color is medium-to-light tan.
5. Clean:
S spark plug
(with a spark plug cleaner or wire brush)
3-21
CHK
ADJ
6. Measure:
S spark plug gap a
(with a wire Thickness gauge)
Out of specification ! Regap.
Spark plug gap
0.6 X 0.7 mm
(0.0236 X 0.0276 in)
7. Install:
S spark plug
NOTE:
Before installing the spark plug, clean the spark
plug and gasket surface.
8. Install:
S air filter case
Refer to AIR FILTER CASE.
S fuel tank
Refer to FUEL TANK.
S rider seat
Refer to SEATS.
EAS00065
3-22
CHK
ADJ
CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it
from falling into the cylinders.
5. Install:
S compression gauge 1
S adapter
Compression gauge
90890-03081, YU-33223
Adapter
90890-04136
6. Measure:
S compression pressure
Out of specification ! Refer to steps (c) and
(d).
Compression pressure
(at sea level)
Minimum
1,350 kPa (13.50 kg/cm2,
13.50 bar, 191.87 psi)
Standard
1,550 kPa (15.50 kg/cm2,
15.50 bar, 220.46 psi)
Maximum
1,736 kPa (17.36 kg/cm2,
17.36 bar, 246.92 psi)
a. Turn the main switch to ON.
b. With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilizes.
WARNING
To prevent sparking, ground all spark plug
leads before cranking the engine.
NOTE:
The difference in compression pressure between cylinders should not exceed 100 kPa (1
kg/cm2, 1 bar, 14.22 psi).
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits ! Eliminate.
3-23
CHK
ADJ
Diagnosis
Higher than
without oil
Same as without
oil
Piston, valves,
cylinder head
gasket or piston
possibly defective
! Repair.
7. Install:
S spark plug
13 Nm (1.3 mSkg, 9.4 ftSlb)
8. Install:
S ignition coils
9. Install:
S heat protector plate
S air filter case
Refer to AIR FILTER CASE.
S fuel tank
Refer to FUEL TANK.
S rider seat
Refer to SEATS.
EAS00069
3-24
CHK
ADJ
Recommended oil
At 5_C (40_F) or higher A
Yamalube 4 (20W40) or
SAE 20W40 type SE motor
oil
At 15_C (60_F) or lower B
Yamalube 4 (10W30) or
SAE 10W30 type SE motor
oil
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few
minutes until the oil has settled.
EAS00074
3-25
CHK
ADJ
CAUTION:
Make sure the O-ring 3 is positioned correctly in the groove of the oil filter cartridge.
c. Tighten the new oil filter cartridge to specification with an oil filter wrench.
Oil filter cartridge
17 Nm (1.7 mSkg, 12 ftSlb)
7. Replace:
S engine oil drain bolt gasket New
8. Install:
S engine oil drain bolt
(along with the new gasket)
43 Nm (4.3 mSkg, 31 ftSlb)
9. Fill:
S crankcase
(with the specified amount of the recommended engine oil)
Quantity
Total amount
3.4 L (2.99 Imp qt, 3.59 US qt)
Without oil filter cartridge
replacement
2.4 L (2.11 Imp qt, 2.54 US qt)
With oil filter cartridge
replacement
2.6 L (2.29 Imp qt, 2.75 US qt)
3-26
CHK
ADJ
10. Install:
S engine oil filler cap
S coolant reservoir tank
Refer to CHANGING THE COOLANT.
S bottom cowling
Refer to COWLINGS.
11. Start the engine, warm it up for several minutes, and then turn it off.
EAS00077
CAUTION:
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.
3. Remove:
S bottom cowling
Refer to COWLINGS.
4. Remove:
S oil gallery bolt 1
WARNING
The engine, muffler and engine oil are extremely hot.
5. Install:
S oil pressure gauge 1
S adapter 2
Pressure gauge
90890-03153, YU-03153
Oil pressure adapter
90890-03139
3-27
CHK
ADJ
6. Measure:
S engine oil pressure
(at the following conditions)
Engine oil pressure
240 kPa
(2.4 kg/cm2, 2.4 bar, 34.1 psi)
Engine speed
Approx. 6,600 r/min
Engine oil temperature
96_C (205_F)
NOTE:
Regarding the oil pressure as its own data may
fluctuate depending on the oil temperature and
viscosity, the oil pressure may fluctuate when
measuring. The following data should be used
only as a reference when measuring the engine
oil pressure.
Engine oil pressure
Below
specification
ifi i
Possible causes
Faulty oil pump
Clogged oil filter
Leaking oil
passage
Broken or
damaged oil seal
Above
specification
Leaking oil
passage
Faulty oil filter
Oil viscosity too
high
7. Install:
S oil gallery bolt 1
8 Nm (0.8 mSkg, 5.8 ftSlb)
8. Install:
S bottom cowling
Refer to COWLINGS.
3-28
CHK
ADJ
EAS00078
Direction c
NOTE:
If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable, use
the adjusting nut on the engine side.
Engine side
a. Remove the bottom cowling. Refer to
COWLINGS.
b. Loosen the locknuts 1 .
c. Turn the adjusting nut 2 in direction a or b
until the specified clutch cable free play is obtained.
Direction a
Direction b
3-29
CHK
ADJ
EAS00086
CAUTION:
Never operate the engine without the air filter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the throttle bodies tuning, leading to poor
engine performance and possible overheating.
NOTE:
When installing the air filter element into the air
filter case cover, make sure their sealing surfaces are aligned to prevent any air leaks.
7. Install:
S fuel tank
Refer to FUEL TANK.
S rider seat
Refer to SEATS.
3-30
CHK
ADJ
EAS00092
2. Remove:
S air intake system surge tank 1
3. Clean:
S air intake system surge tank
a. Thoroughly flush out the air intake system
surge tank with clean water.
b. Hold the air intake system surge tank upside
down to allow the water to drain out.
c. Repeat the flushing steps until the excess
water is clear and free of debris.
d. Place the air intake system surge tank in an
upright position to allow any remaining water
to drain out of the lower drain tube.
e. Keep the air intake system surge tank upright
to allow it to dry sufficiently.
4. Install:
S air intake system surge tank
5. front cowling
Refer to COWLINGS.
EAS00095
2. Check:
S throttle body joints 1
Cracks/damage ! Replace.
3. Install:
S throttle bodies
Refer to THROTTLE BODIES in chapter 7.
3-31
CHK
ADJ
EAS00096
EAS00098
CAUTION:
Make sure the crankcase breather hose is
routed correctly.
3. Install:
S fuel tank
Refer to FUEL TANK.
S rider seat
Refer to SEATS.
3-32
CHK
ADJ
EAS00099
2. Check:
S exhaust pipe 1
S muffler 2
Cracks/damage ! Replace.
S gasket 3
Exhaust gas leaks ! Replace.
3. Check:
S tightening torque
Exhaust pipe nut 4
20 Nm (2.0 mSkg, 15 ftSlb)
Exhaust pipe and muffler bolt 5
20 Nm (2.0 mSkg, 15 ftSlb)
Muffler and rear footrest nut 6
23 Nm (2.3 mSkg, 17 ftSlb)
Exhaust pipe and exhaust pipe
stay 7
20 Nm (2.0 mSkg, 15 ftSlb)
4. Install:
S radiator
Refer to RADIATOR in chapter 6.
S bottom cowling
Refer to COWLINGS.
EAS00102
3-33
CHK
ADJ
2. Check:
S coolant level
The coolant level should be between the
maximum level mark a and minimum level
mark b .
Below the minimum level mark ! Add the
recommended coolant to the proper level.
CAUTION:
S Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant.
S Use only distilled water. However, if distilled water is not available, soft water may
be used.
3. Start the engine, warm it up for several minutes, and then turn it off.
4. Check:
S coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
EAS00104
3-34
CHK
ADJ
2. Check:
S radiator 1
S radiator inlet hose 2
S radiator outlet hose 3
S oil cooler 4
S oil cooler inlet hose 5
S oil cooler outlet hose 6
S water jacket outlet joint 7
S water jacket hose 8
S water pump outlet pipe 9
S water pump outlet hose 10
Cracks/damage ! Replace.
Refer to COOLING SYSTEM in chapter 6.
3. Install:
S side cowlings
S bottom cowling
Refer to COWLINGS.
EAS00105
3-35
CHK
ADJ
3. Disconnect:
S coolant reservoir cap 1
4. Drain:
S coolant
(from the coolant reservoir tank)
5. Remove:
S radiator cap 1
CAUTION:
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious injury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counterclockwise toward the detent to allow any
residual pressure to escape. When the hissing sound has stopped, press down on the
radiator cap and turn it counterclockwise to
remove.
7. Drain:
S coolant
(from the engine and radiator)
8. Check:
S copper washer 1 New
(coolant drain bolt-water pump 2 )
9. Install:
S coolant drain bolt (water pump)
(with copper washer)
10 Nm (1.0 mSkg, 7.2 ftSlb)
3-36
CHK
ADJ
10. Install:
S coolant reservoir tank
11. Connect:
S coolant reservoir hose
12. Fill:
S cooling system
(with the specified amount of the recommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
2.15 L (1.89 Imp qt,
2.27 US qt)
Coolant reservoir capacity
0.44 L (0.39 Imp qt,
0.47 US qt)
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
S If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.
S If coolant splashes on your clothes, quickly wash it away with water and then with
soap and water.
S If coolant is swallowed, induce vomiting
and get immediate medical attention.
CAUTION:
S Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant.
3-37
CHK
ADJ
S Use only distilled water. However, if distilled water is not available, soft water may
be used.
S If coolant comes into contact with painted
surfaces, immediately wash them with water.
S Do not mix different types of antifreeze.
13. Install:
S radiator cap
14. Fill:
S coolant reservoir tank
(with the recommended coolant to the maximum level mark a )
15. Install:
S coolant reservoir cap
16. Start the engine, warm it up for several minutes, and then stop it.
17. Check:
S coolant level
Refer to CHECKING THE COOLANT LEVEL.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
18. Install:
S coolant reservoir tank cover
S bottom cowling
S left side cowling
Refer to COWLINGS.
3-38
CHK
ADJ
EAS00107
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
S brake lever position
(distance a from the throttle grip to the brake
lever)
NOTE:
S While pushing the brake lever forward, turn the
adjusting dial 1 until the brake lever is in the
desired position.
S Be sure to align the setting on the adjusting dial
with the arrow mark 2 on the brake lever holder.
Position #1
Position #5
Distance a is the
largest.
Distance a is the
smallest.
WARNING
S After adjusting the brake lever position,
make sure the pin on the brake lever holder
is firmly inserted in the hole in the adjusting dial.
S A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce in loss of control and possibly an accident. Therefore, check and if
necessary, bleed the brake system.
CAUTION:
After adjusting the brake lever position,
make sure there is no brake drag.
3-39
CHK
ADJ
EAS00110
Direction b
WARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt c is
visible through the hole d .
c. Tighten the locknut 1 to specification.
Locknut
16 Nm (1.6 mSkg, 12 ftSlb)
WARNING
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if necessary, bleed the brake system.
CAUTION:
After adjusting the brake pedal position,
make sure there is no brake drag.
3-40
CHK
ADJ
3. Adjust:
S rear brake light switch
Refer to ADJUSTING THE REAR BRAKE
LIGHT SWITCH.
EAS00115
2. Check:
S brake fluid level
Below the minimum level mark a ! Add the
recommended brake fluid to the proper level.
WARNING
3-41
CHK
ADJ
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake fluid
reservoir is horizontal.
EAS00128
3-42
Direction a
Direction b
CHK
ADJ
EAS00122
2. Check:
S front brake pad
S rear brake pad
Brake pad wear limit a , b
Wear limit reached ! Replace the brake
pads as a set.
Refer to FRONT AND REAR BRAKES in
chapter 7.
A Front brake
B Rear brake
EAS00131
3-43
CHK
ADJ
EAS00135
WARNING
Bleed the hydraulic brake system whenever:
S the system is disassembled.
S a brake hose is loosened, disconnected or
replaced.
S the brake fluid level is very low.
S brake operation is faulty.
NOTE:
S Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.
S When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this precaution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.
S If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
1. Bleed:
S hydraulic brake system
a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2 .
A Front
B Rear
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down
the brake pedal and hold it in position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the pressure and cause the brake lever to contact the
throttle grip or the brake pedal to fully extend.
3-44
CHK
ADJ
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
EAS00136
3-45
CHK
ADJ
EAS00140
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swingarm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Spin the rear wheel several times and find
the tightest position of drive chain.
3. Check:
S drive chain slack a
Out of specification ! Adjust.
Drive chain slack
35 X 45 mm (1.38 X 1.77 in)
4. Adjust:
S drive chain slack
a. Loosen the wheel axle nut 1 .
b. Loosen both locknuts 2 .
c. Turn both adjusting bolts 3 in direction a or
b until the specified drive chain slack is obtained.
3-46
CHK
ADJ
Direction a
Direction b
NOTE:
To maintain the proper wheel alignment, adjust
both sides evenly.
d. Tighten both locknuts to specification.
Locknut
16 Nm (1.6 mSkg, 12 ftSlb)
e. Tighten the wheel axle nut to specification.
Wheel axle nut
110 Nm (11 mSkg, 80 ftSlb)
EAS00142
3-47
CHK
ADJ
EAS00146
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Check:
S steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness ! Adjust the steering
head.
3. Remove:
S upper bracket
Refer to HANDLEBAR and STEERING
HEAD in chapter 4.
4. Adjust:
S steering head
a. Remove the lock washer 1 , the upper ring
nut 2 , and the rubber washer 3 .
b. Loosen the lower ring nut 4 and then tighten
it to specification with a steering nut wrench
5.
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
Steering nut wrench
90890-01403, YU-33975
Lower ring nut (initial tightening
torque)
52 Nm (5.2 mSkg, 38 ftSlb)
3-48
CHK
ADJ
WARNING
Do not overtighten the lower ring nut.
Lower ring nut (final tightening
torque)
14 Nm (1.4 mSkg, 10 ftSlb)
d. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the under bracket and check the upper and
lower bearings.
Refer to STEERING HEAD in chapter 4.
e. Install the rubber washer 3 .
f. Install the upper ring nut 2 .
g. Finger tighten the upper ring nut 2 , then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
h. Install the lock washer 1 .
NOTE:
Make sure the lock washer tabs a sit correctly
in the ring nut slots b .
5. Install:
S upper bracket
Refer to HANDLEBAR and STEERING
HEAD in chapter 4.
6. Measure:
S steering head tension
NOTE:
Make sure all of the cables and wires are properly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie 1 loosely around
the end of the handlebar as shown.
c. Hook a spring gauge 2 onto the plastic locking tie.
d. Hold the spring gauge at a 90_ angle from the
handlebar, pull the spring gauge, and then
record the measurement when the handlebar starts to run.
3-49
CHK
ADJ
EAS00150
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Check:
S inner tube 1
Damage/scratches ! Replace.
S oil seal 2
Oil leakage ! Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
S front fork operation
Push down hard on the handlebars several
times and check if the front fork rebounds
smoothly.
Rough movement ! Repair.
Refer to FRONT FORK in chapter 4.
3-50
CHK
ADJ
EAS00155
WARNING
S Always adjust both front fork legs evenly.
Uneven adjustment can result in poor handling and loss of stability.
S Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
CAUTION:
S Grooves are provided to indicate the adjustment position.
S Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
S spring preload
a. Turn the adjusting bolt 1 in direction a or
b.
Direction a
Spring preload is
increased (suspension is
harder).
Direction b
Spring preload is
decreased (suspension
is softer).
Adjusting positions
Minimum: 8
Standard: 7
Maximum: 1
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
3-51
CHK
ADJ
1. Adjust:
S rebound damping
a. Turn the adjusting screw 1 in direction a or
b.
Direction a
Rebound damping is
increased (suspension is
harder).
Direction b
Rebound damping is
decreased (suspension
is softer).
Adjusting positions
Minimum: 10 clicks in direction b *
Standard: 9 clicks in direction b *
Maximum: 1 clicks in direction b *
* with the adjusting screw fully
turned-in direction a
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
S compression damping
a. Turn the adjusting screw 1 in direction a or
b.
Direction a
Compression damping is
increased (suspension is
harder).
Direction b
Compression damping is
decreased (suspension
is softer).
Adjusting positions
Minimum: 9 clicks in direction b *
Standard: 7 clicks in direction b *
Maximum: 1 clicks in direction b *
* with the adjusting screw fully
turned-in direction a
3-52
CHK
ADJ
EAS00158
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
S spring preload
a. Adjust the spring preload with the special
wrench and extension bar included in the
owners tool kit.
b. Turn the adjusting ring 1 in direction a or
b.
c. Align the desired position on the adjusting
ring with the stopper 2 .
Direction a
Spring preload is
increased (suspension is
harder).
Direction b
Spring preload is
decreased (suspension
is softer).
Adjusting positions
Minimum: 1
Standard: 4
Maximum: 9
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
3-53
CHK
ADJ
1. Adjust:
S rebound damping
a. Turn the adjusting screw 1 in direction a or
b.
Direction a
Rebound damping is
increased (suspension is
harder).
Direction b
Rebound damping is
decreased (suspension
is softer).
Adjusting positions
Minimum: 20 clicks in direction b *
Standard: 10 clicks in direction b *
Maximum: 5 clicks in direction b *
*: with the adjusting knob fully
turned-in direction a
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
S compression damping
a. Turn the adjusting screw 1 in direction a or
b.
Direction a
Compression damping is
increased (suspension is
harder).
Direction b
Compression damping is
decreased (suspension
is softer).
Adjusting positions
Minimum: 20 clicks in direction b *
Standard: 10 clicks in direction b *
Maximum: 1 clicks in direction b *
* with the adjusting screw fully
turned-in direction a
3-54
CHK
ADJ
EAS00162
WARNING
S The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
S The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and accessories) and the anticipated riding
speed.
S Operation of an overloaded motorcycle
could cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic
weight
(with oil
and a full
fuel tank)
Maximum
load*
Cold tire
pressure
Front
Rear
Up to
90 kg
load*
250 kPa
250 kPa
(2.5 kgf/cm2, (2.5 kgf/cm2,
2.5 bar,
2.5 bar,
35.6 psi)
35.6 psi)
90 kg X
maximum
load*
2.5 kPa
(2.5 kgf/cm2,
2.5 bar,
35.6 psi)
Highspeed
riding
2.5 kPa
2.5 kPa
(2.5 kgf/cm2, (2.5 kgf/cm2,
2.5 bar,
2.5 bar,
35.6 psi)
35.6 psi)
290 kPa
(29 kgf/cm2,
2.9 bar,
41.3 psi)
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
3-55
CHK
ADJ
2. Check:
S tire surfaces
Damage/wear ! Replace the tire.
Minimum tire tread depth
1.6 mm (0.06 in)
WARNING
S Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation.
S When using a tube tire, be sure to install the
correct tube.
S Always replace a new tube tire and a new
tube as a set.
S To avoid pinching the tube, make sure the
wheel rim band and tube are centered in the
wheel groove.
S Patching a punctured tube is not recommended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality replacement.
A Tire
B Wheel
Tube wheel
T beless wheel
Tubeless
Tube or tubeless
tire
WARNING
S After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer and of the same design. No guarantee
concerning handling characteristics can
be given if a tire combination other than
one approved by Yamaha is used on this
motorcycle.
3-56
CHK
ADJ
Front tire
Manufacturer
Size
Model
DUNLOP
120/60ZR 17
M/C (55W)
D208FL
MICHELIN
120/60ZR 17
M/C (55W)
Pilot
SPORTS N
Manufacturer
Size
Model
DUNLOP
180/55ZR 17
M/C (73W)
D208L
MICHELIN
180/55ZR 17
M/C (73W)
Pilot
SPORTS B
Rear tire
WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
NOTE:
For tires with a direction of rotation mark 1 :
S Install the tire with the mark pointing in the
direction of wheel rotation.
S Align the mark 2 with the valve installation
point.
EAS00168
WARNING
Never attempt to make any repairs to the
wheel.
NOTE:
After a tire or wheel has been changed or replaced, always balance the wheel.
3-57
CHK
ADJ
EAS00170
WARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Replace damaged outer cable and inner cables
as soon as possible.
1. Check:
S outer cable
Damage ! Replace.
2. Check:
S cable operation
Rough movement ! Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
NOTE:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suitable lubricating device.
EAS00171
3-58
CHK
ADJ
EAS00178
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
S Wear protective eye gear when handling or
working near batteries.
S Charge batteries in a well-ventilated area.
S Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
S DO NOT SMOKE when charging or handling batteries.
S KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
S Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
S Skin Wash with water.
S Eyes Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
S Drink large quantities of water or milk followed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical attention.
CAUTION:
S This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery performance will deteriorate.
S Charging time, charging amperage and
charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged as
explained in the charging method illustrations. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
3-59
CHK
ADJ
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by measuring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:
S rider seat
Refer to SEATS.
2. Disconnect:
S battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative battery lead
1 , and then the positive battery lead 2 .
3. Remove:
S battery
4. Check:
S battery charge
a. Connect a pocket tester to the battery terminals.
NOTE:
S The charge state of an MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive battery terminal is disconnected).
S No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
12.5
12.0
11.5
5 6.5
10
Charging time (hours)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level.
Ambient
temperature
20_C
3-60
CHK
ADJ
5. Charge:
S battery
(refer to the appropriate charging method illustration)
Charging
Open-circuit voltage (V)
WARNING
Do not quick charge a battery.
Time (minutes)
Check the open-circuit
voltage.
CAUTION:
S Never remove the MF battery sealing caps.
S Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause battery overheating and battery plate damage.
S If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
S When charging a battery, be sure to remove
it from the motorcycle. (If charging has to
be done with the battery mounted on the
motorcycle, disconnect the negative battery lead from the battery terminal.)
S To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
S Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
S Make sure the battery charger lead clips
are in full contact with the battery terminal
and that they are not shorted. A corroded
battery charger lead clip may generate heat
in the contact area and a weak clip spring
may cause sparks.
S If the battery becomes hot to the touch at
any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode!
S As shown in the following illustration, the
open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has
been completed. Therefore, wait 30 minutes after charging is completed before
measuring the open-circuit voltage.
3-61
CHK
ADJ
YES
NOTE:
Voltage should be measured 30
minutes after the machine is stopped.
NOTE:
Set the charging voltage at 16 X 17 V.
(If the setting is lower, charging will be
insufficient. If too high, the battery will
be over-charged.)
NO
YES
3-62
CHK
ADJ
NOTE:
Voltage should be measured 30
minutes after the machine is stopped.
YES
NO
NOTE:
Set the charging time at 20 hours
(maximum).
3-63
CHK
ADJ
6. Install:
S battery
7. Connect:
S battery leads
(to the battery terminals)
CAUTION:
First, connect the positive battery lead 1 ,
and then the negative battery lead 2 .
8. Check:
S battery terminals
Dirt ! Clean with a wire brush.
Loose connection ! Connect properly.
9. Lubricate:
S battery terminals
Recommended lubricant
Dielectric grease
10. Install:
S rider seat
Refer to SEATS.
EAS00181
CAUTION:
To avoid a short circuit, always set the main
switch to OFF when checking or replacing
a fuse.
1. Remove:
S front cowling inner panel (left)
Refer to COWLINGS.
S rider seat
Refer to SEATS.
2. Check:
S fuse
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to
3-64
1.
CHK
ADJ
Pocket tester
90890-03112, YU-3112
b. If the pocket tester indicates , replace the
fuse.
3. Replace:
S blown fuse
a. Set the main switch to OFF.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Fuses
Amperage
rating
Qty
Main
40 A
Fuel injection
system
15 A
Headlight
20 A
Signaling
system
15 A
Ignition
15 A
Backup fuse
(odometer
and clock)
10 A
Radiator
fan motor
15 A
Reserve
40 A, 20 A,
15 A, 10 A
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or using a fuse with the wrong amperage rating
may cause extensive damage to the electrical system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
4. Install:
S front cowling inner panel (left)
Refer to COWLINGS.
S rider seat
Refer to SEATS.
3-65
CHK
ADJ
EAS00183
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
5. Install:
S headlight bulb New
Secure the new headlight bulb with the headlight bulb holder.
CAUTION:
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
6. Install:
S headlight bulb holder
7. Install:
S headlight bulb cover
8. Connect:
S headlight coupler
9. Install:
S front cowling inner panels
Refer to COWLINGS.
3-66
CHK
ADJ
EAS00185
Direction b
Headlight beam is
lowered.
3. Adjust:
S headlight beam (horizontally)
a. Turn the adjusting screw 2 in direction a or
b.
Direction a
Direction b
4. Install:
S front cowling inner panels
Refer to COWLINGS.
3-67
CHAS
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS
7 Nm (0.7 mSkg, 5.1 ftSlb)
7 Nm (0.7 mSkg, 5.1 ftSlb)
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
9
2
2
4
1
1
2
2
2
2
Remarks
Loosen.
4-1
CHAS
EAS00518
Order
1
2
3
Job/Part
Qty
Remarks
Remove the parts in the order listed.
2
2
1
For assembly, reverse the disassembly
procedure.
4-2
CHAS
EAS00521
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Remove:
S left brake caliper
S right brake caliper
Refer to FRONT BRAKE CALIPERS.
NOTE:
Do not apply the brake lever when removing the
brake calipers.
3. Elevate:
S front wheel
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
4. Remove:
S front wheel axle
S front wheel axle bolt
S front wheel
EAS00525
WARNING
Do not attempt to straighten a bent wheel
axle.
2. Check:
S tire
S front wheel
Damage/wear ! Replace.
Refer to CHECKING THE TIRES and
CHECKING THE WHEELS in chapter 3.
4-3
CHAS
3. Measure:
S radial wheel runout 1
S lateral wheel runout 2
Over the specified limits ! Replace.
Radial wheel runout limit
1 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4. Check:
S wheel bearings
Front wheel turns roughly or is loose ! Replace the wheel bearings.
S oil seals
Damage/wear ! Replace.
5. Replace:
S wheel bearings New
S oil seals New
a. Clean the outside of the front wheel hub.
b. Remove the oil seals 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel surface.
c. Remove the wheel bearings 3 with a general bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing inner race
1 or balls 2 . Contact should be made only
with the outer race 3 .
NOTE:
Use a socket 4 that matches the diameter of
the wheel bearing outer race and oil seal.
4-4
CHAS
EAS00533
2. Measure:
S brake disc deflection
Out of specification ! Correct the brake disc
deflection or replace the brake disc.
Brake disc deflection limit
(maximum)
Front: 0.1 mm (0.004 in)
Rear: 0.15 mm (0.006 in)
a. Place the motorcycle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc deflection, turn the handlebars to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 2 X 3 mm (0.08 X
0.12 in) below the edge of the brake disc.
3. Measure:
S brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification ! Replace.
Brake disc thickness limit
(minimum)
Front: 4.5 mm (0.18 in)
Rear: 4.5 mm (0.18 in)
4. Adjust:
S brake disc deflection
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
4-5
CHAS
4-6
CHAS
4-7
CHAS
3. Adjust:
S front wheel static balance
a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot X.
NOTE:
Start with the lightest weight.
b. Turn the front wheel 90_ so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that position, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.
4. Check:
S front wheel static balance
a. Turn the front wheel and make sure it stays at
each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
4-8
CHAS
EAS00551
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
9
10
Remarks
1
2
2
1
1
1
1
1
1
1
Loosen.
Loosen.
4-9
CHAS
EAS00556
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
9
Remarks
Remove the parts in the order listed.
1
1
1
1
2
1
6
1
1
For installation, reverse the removal
procedure.
4-10
CHAS
EAS00560
Order
1
2
3
4
5
6
Job/Part
Disassembling the rear wheel
Collar
Bearing
Spacer
Oil seal
Circlip
Bearing
Qty
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
For installation, reverse the disassembly
procedure.
4-11
CHAS
EAS00561
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
S brake caliper 1
NOTE:
Do not depress the brake pedal when removing
the brake caliper.
3. Loosen:
S locknuts 1 (left and right)
S adjusting bolts 2 (left and right)
4. Remove:
S wheel axle nut 3
S wheel axle 4
S rear wheel
NOTE:
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
5. Remove:
S left collar 1
S rear wheel drive hub 2
S rear wheel drive hub damper
S right collar
4-12
CHAS
EAS00565
EAS00567
EAS00568
4-13
CHAS
EAS00572
(rear)
23 Nm (2.3 mSkg, 17 ftSlb)
4-14
CHAS
EAS00575
4-15
CHAS
EAS00577
Order
Job/Part
Qty
1
2
3
4
5
6
Remarks
1
2
1
1
2
1
For installation, reverse the removal
procedure.
4-16
CHAS
Order
1
2
3
4
5
6
Job/Part
Removing the rear brake pads
Screw plug
Brake pad pin
Rear brake caliper
Brake pad shim
Brake pad
Bleed screw
Qty
Remarks
Remove the parts in the order listed.
1
2
1
4
2
1
For installation, reverse the removal
procedure.
4-17
CHAS
EAS00579
CAUTION:
Disc brake components rarely require disassembly.
Therefore, always follow these preventive
measures:
WARNING
S Never disassemble brake components unless absolutely necessary.
S If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reassembly.
S Never use solvents on internal brake components.
S Use only clean or new brake fluid for cleaning brake components.
S Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
S Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
S Flush with water for 15 minutes and get immediate medical attention.
EAS00582
1. Remove:
S brake hose holder 1
S brake caliper 2
4-18
CHAS
2. Remove:
S brake pad clips 1
S brake pad pin 2
S brake pad spring 3
3. Remove:
S brake pads 1
4. Measure:
S brake pad wear limit a
Out of specification ! Replace the brake
pads as a set.
Brake pad wear limit
0.5 mm (0.02 in)
5. Install:
S brake pads
S brake pad spring
NOTE:
Always install new brake pads, and a brake pad
spring as a set.
4-19
CHAS
6. Install:
S brake pad pins
S brake pad clips
S brake caliper
7. Check:
S brake fluid level
Below the minimum level mark a ! Add the
recommended brake fluid to the proper level.
Refer to CHECKING THE BRAKE FLUID
LEVEL in chapter 3.
8. Check:
S brake lever operation
Soft or spongy feeling ! Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
4-20
CHAS
EAS00583
1. Remove:
S screw plug 1
S brake pad pin
S brake caliper 2
2. Remove:
S brake pad spring
3. Remove:
S brake pads 1
(along with the brake pad shims 2 )
4. Measure:
S brake pad wear limit a
Out of specification ! Replace the brake
pads as a set.
Brake pad wear limit
1.0 mm (0.04 in)
5. Install:
S brake pad shims
(onto the brake pads)
S brake pads
S brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
4-21
CHAS
4-22
CHAS
EAS00584
Order
Job/Part
Qty
Remarks
Stopper
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir tank
Brake fluid reservoir hose
Dust cover
Circlip
Hose joint
Brake lever
Front brake switch connector
Union bolt
Copper washer
Brake hose
1
1
1
1
1
1
1
1
1
1
2
1
3
2
4-23
Disconnect.
CHAS
Order
15
16
17
Job/Part
Brake master cylinder bracket
Brake master cylinder
Front brake switch
Qty
Remarks
1
1
1
For installation, reverse the removal
procedure.
4-24
CHAS
EAS00585
Order
1
2
3
4
Job/Part
Disassembling the front brake
master cylinder
Dust boot
Circlip
Brake master cylinder kit
Brake master cylinder body
Qty
Remarks
Disassemble the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-25
CHAS
EAS00586
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
9
10
Remarks
Drain.
Refer to CHANGING THE BRAKE
FLUID in chapter 3.
1
1
1
1
1
1
1
2
1
1
For installation, reverse the removal
procedure.
4-26
CHAS
EAS00587
Order
Job/Part
Qty
1
2
Remarks
Disassemble the parts in the order listed.
1
1
For assembly, reverse the disassembly
procedure.
4-27
CHAS
EAS00588
1. Disconnect:
brake light switch connector 1
(from the brake light switch)
2. Remove:
S union bolt 2
S copper washers 3
S brake hoses 4
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
3. Remove:
S brake master cylinder bracket
S brake master cylinder assembly
4. Remove:
S dust boot
S circlip
EAS00589
4-28
CHAS
EAS00593
2. Check:
S brake master cylinder kit
Damage/scratches/wear ! Replace.
A Front
B Rear
3. Check:
S brake fluid reservoir 1
Cracks/damage ! Replace.
S brake fluid reservoir diaphragm 2
Cracks/damage ! Replace.
4. Check:
S brake hoses
Cracks/damage/wear ! Replace.
4-29
CHAS
EAS00607
WARNING
S Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
S Never use solvents on internal brake components.
Recommended brake fluid
DOT 4
1. Install:
S brake master cylinder kit
S circlip New
S dust boot
2. Install:
S brake master cylinder 1
13 Nm (1.3 mSkg, 9.4 ftSlb)
NOTE:
S Install the brake master cylinder holder with
the UP mark a facing up.
S Align the mating surfaces of the brake master
cylinder holder with the punch mark b on the
right handlebar.
S First, tighten the upper bolt, then the lower bolt.
There should be 8.2 mm (0.32 in.) for clearance between the right handlebar switch and
the brake master cylinder holder.
3. Install:
S copper washers New
S brake hose
S union bolt
30 Nm (3.0 mSkg, 22 ftSlb)
S brake light switch coupler
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
CABLE ROUTING.
4-30
CHAS
NOTE:
S While holding the brake hose, tighten the
union bolt as shown.
S Turn the handlebars to the left and right to
make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads).
Correct if necessary.
4. Fill:
S brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
S Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
S Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
S When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:
S brake system
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
4-31
CHAS
6. Check:
S brake fluid level
Below the minimum level mark a ! Add the
recommended brake fluid to the proper level.
Refer to CHECKING THE BRAKE FLUID
LEVEL in chapter 3.
7. Check:
S brake lever operation
Soft or spongy feeling ! Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
EAS00610
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure that the
brake pipe touches the projection a on the
brake master cylinder.
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
CABLE ROUTING.
3. Fill:
S brake fluid reservoir
(to the maximum level mark)
Recommended brake fluid
DOT 4
4-32
CHAS
WARNING
S Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
S Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
S When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
S brake system
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
5. Check:
S brake fluid level
Below the minimum level mark a ! Add the
recommended brake fluid to the proper level.
Refer to CHECKING THE BRAKE FLUID
LEVEL in chapter 3.
6. Adjust:
S brake pedal position a
Refer to ADJUSTING THE REAR BRAKE
in chapter 3.
Brake pedal position
Brake pedal position (below the
bottom of the footrest bracket)
7 X 11 mm (0.28 X 0.43 in)
7. Adjust:
S rear brake light operation timing
Refer to ADJUSTING THE REAR BRAKE
LIGHT SWITCH in chapter 3.
4-33
CHAS
EAS00613
Order
Job/Part
Qty
1
2
3
4
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper
Remarks
Drain.
1
2
1
1
For installation, reverse the removal
procedure.
4-34
CHAS
EAS00615
Order
Job/Part
Qty
1
2
3
4
5
6
7
Remarks
2
1
1
2
4
8
1
For assembly, reverse the disassembly
procedure.
4-35
CHAS
EAS00616
Order
1
2
3
4
Job/Part
Removing the rear brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper
Qty
Remarks
Remove the parts in the order listed.
Drain.
1
2
1
1
For installation, reverse the removal
procedure.
4-36
CHAS
EAS00617
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
1
1
2
4
1
1
2
1
Remarks
Disassemble the parts in the order listed.
4-37
CHAS
EAS00625
1. Remove:
S union bolt 1
S copper washers 2
S brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
S brake caliper pistons 1
S brake caliper piston seals 2
WARNING
S Never try to pry out the brake caliper pistons.
S Do not loosen the bolts 3 .
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
4-38
CHAS
EAS00627
1. Remove:
S union bolt 1
S copper washers 2
S brake hose 3
S brake caliper 4
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
S brake caliper piston 1
S brake caliper piston seals 2
a. Blow compressed air into the brake hose
joint opening a to force out the pistons from
the brake caliper.
WARNING
S Cover the brake caliper piston with a rag.
Be careful not to get injured when the pistons are expelled from the brake caliper.
S Never try to pry out the brake caliper pistons.
b. Remove the brake caliper piston seals.
4-39
CHAS
EAS00633
If necessary
Piston seals
Brake hoses
Brake fluid
1. Check:
S brake caliper pistons 1
Rust/scratches/wear ! Replace the brake
caliper pistons.
S brake caliper cylinders 2
Scratches/wear ! Replace the brake caliper assembly.
S brake caliper body 3
Cracks/damage ! Replace the brake caliper assembly.
S brake fluid delivery passages
(brake caliper body)
Obstruction ! Blow out with compressed air.
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
A Front
B Rear
2. Check:
S rear brake caliper bracket 1
Cracks/damage ! Replace.
4-40
CHAS
EAS00640
WARNING
S Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
S Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
S Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install:
S brake pads
S brake pad spring
S brake pad pin
2. Install:
S brake caliper 1
40 Nm (4.0 mSkg, 29 ftSlb)
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
CABLE ROUTING.
CAUTION:
When installing the brake hose onto the
brake caliper, make sure the brake pipe a
touches the projection b on the brake caliper.
4-41
CHAS
3. Fill:
S brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
S Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
S Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
S When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
S brake system
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
5. Check:
S brake fluid level
Below the minimum level mark a ! Add the
recommended brake fluid to the proper level.
Refer to CHECKING THE BRAKE FLUID
LEVEL in chapter 3.
6. Check:
S brake lever operation
Soft or spongy feeling ! Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
4-42
CHAS
WARNING
S Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
S Never use solvents on internal brake components as they will cause the piston seals
to swell and distort.
S Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install:
S brake caliper 1
(front)
28 Nm (2.8 mSkg, 20 ftSlb)
(rear)
23 Nm (2.3 mSkg, 17 ftSlb)
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
CABLE ROUTING.
CAUTION:
When installing the brake hose onto the
brake caliper, make sure that the brake pipe
a touches the projection b on the brake
caliper.
2. Fill:
S brake fluid reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
4-43
CHAS
WARNING
S Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
S Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake performance.
S When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
3. Bleed:
S brake system
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
4. Check:
S brake fluid level
Below the minimum level mark a ! Add the
recommended brake fluid to the proper level.
Refer to CHECKING THE BRAKE FLUID
LEVEL in chapter 3.
5. Check:
S brake pedal operation
Soft or spongy feeling ! Bleed the brake
system.
Refer to BLEEDING THE HYDRAULIC
BRAKE SYSTEM in chapter 3.
4-44
FRONT FORK
CHAS
EAS00647
FRONT FORK
FRONT FORK LEGS
Order
1
2
3
4
5
6
Job/Part
Removing the front fork legs
Front wheel
Front brake calipers
Front cowling inner panels
Front fender
Cap bolt
Handlebar pinch bolt
Upper bracket pinch bolt
Under bracket pinch bolt
Front fork leg
Qty
Remarks
Remove the parts in the order listed.
Refer to FRONT AND REAR BRAKES.
Refer to COWLINGS in chapter 3.
1
1
1
1
2
1
Loosen.
Loosen.
Loosen.
Loosen.
For installation, reverse the removal
procedure.
4-45
FRONT FORK
CHAS
EAS00648
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
9
10
11
12
Cap bolt
O-ring
Damper adjusting rod
Nut
Washer
Spacer
Washer
Fork spring
Dust seal
Oil seal clip
Damper rod assembly bolt
Copper washer
Remarks
1
1
1
1
1
1
1
1
1
1
1
1
4-46
FRONT FORK
CHAS
Order
13
14
15
16
17
18
19
Job/Part
Damper rod assembly
Inner tube
Oil seal
Washer
Outer tube bushing
Inner tube bushing
Oil lock piece
Qty
Remarks
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-47
FRONT FORK
CHAS
EAS00649
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Remove
S front wheel
S front brake caliper
Refer to FRONT WHEEL AND BRAKE
DISCS.
3. Remove:
S front cowling inner panels
Refer to COWLINGS in chapter 3.
S handlebar
4. Loosen:
S handlebar pinch bolt 1
S upper bracket pinch bolt 2
S cap bolt 3
S under bracket pinch bolt 4
WARNING
Before loosening the upper and under
bracket pinch bolts, support the front fork
leg.
5. Remove:
S front fork leg
4-48
FRONT FORK
CHAS
EAS00655
3. Remove:
S damper adjusting rod 1
S washer 2
S spacer 3
S fork spring
4. Drain:
S fork oil
NOTE:
Stroke the damper rod 1 several times while
draining the fork oil.
5. Remove:
S dust seal
S oil seal clip 1 (with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
6. Remove:
S damper rod assembly bolt
S copper washer
NOTE:
While holding the damper rod with the damper
rod holder 1 , loosen the damper rod assembly
bolt.
4-49
FRONT FORK
CHAS
8. Remove:
S inner tube
S oil seal
S inner tube bushing
a. Hold the front fork leg horizontally.
b. Slowly push A the inner tube into the outer
tube and just before it bottoms out, pull B the
inner tube back quickly.
c. Repeat this step until the inner tube separates from the outer tube.
EAS00657
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
S spring free length a
Out of specification ! Replace.
Spring free length
249.3 mm (9.81 in)
<Limit> :
244.3 mm (9.62 in)
3. Check:
S damper rod 1
Damage/wear ! Replace.
Obstruction ! Blow out all of the oil passages with compressed air.
S oil lock piece 2
S damper rod adjusting rod 3
Bends/damage ! Replace.
4-50
FRONT FORK
CHAS
CAUTION:
S The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly
sensitive to foreign material.
S When disassembling and assembling the
front fork leg, do not allow any foreign material to enter the front fork.
4. Check:
S cap bolt O-ring
Damage/wear ! Replace.
EAS00661
WARNING
S Make sure the oil levels in both front fork
legs are equal.
S Uneven oil levels can result in poor handling and a loss of stability.
NOTE:
S When assembling the front fork leg, be sure to
replace the following parts:
inner tube bushing
outer tube bushing
oil seal
dust seal
S Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
S inner tube bushing
S oil lock piece
S inner tube 1
S damper rod assembly 2
S damper rod assembly bolt
S copper washer New
4-51
FRONT FORK
CHAS
WARNING
Always use new copper washers.
CAUTION:
Allow the damper rod assembly to slide
slowly down the inner tube 1 until it protrudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
2. Lubricate:
S inner tubes outer surface
Recommended lubricant
Suspension oil 01 or
equivalent
3. Tighten:
S damper rod assembly bolt 1
40 Nm (4.0 mSkg, 29 ftSlb)
LOCTITE
NOTE:
While holding the damper rod assembly with the
damper rod holder 2 , tighten the damper rod
assembly bolt.
4. Install:
S outer tube bushing 1
(with the fork seal driver weight 2 and fork
seal driver attachment 3 )
Fork seal driver weight
90890-01367, YM-33963
Fork seal driver attachment
90890-01374, YM-8020-A
4-52
FRONT FORK
CHAS
5. Install:
S washer
S oil seal 1
(with the fork seal driver weight and fork seal
driver attachment)
CAUTION:
Make sure the numbered side of the oil seal
faces up.
NOTE:
S Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
S Lubricate the outer surface of the inner tube
with fork oil.
S Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 2 to protect
the oil seal during installation.
6. Install:
S oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the outer
tubes groove.
7. Install:
S dust seal 1
(with the fork seal driver weight)
8. Install:
S rod puller 1
S adapter 2
(onto the damper rod 3 )
Rod puller
90890-01437, YM-01437
Rod puller attachment
90890-01436
4-53
FRONT FORK
CHAS
CAUTION:
S Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
S When disassembling and assembling the
front fork leg, do not allow any foreign material to enter the front fork.
11. After filling the front fork leg, slowly stroke
the damper rod 1 up and down (at least ten
times) to distribute the fork oil.
NOTE:
Be sure to stroke the damper rod slowly because the fork oil may spurt out.
4-54
FRONT FORK
CHAS
14. Measure:
S front fork leg oil level a
Out of specification ! Correct.
Front fork leg oil level (from the
top of the inner tube, with the inner
tube fully compressed, and without
the spring)
106 mm (4.17 in)
15. Install:
S nut 1
S fork spring 2
S washer 3
S spacer 4
S washer 5
S damper adjusting rod 6
S cap bolt 7
4-55
FRONT FORK
CHAS
WARNING
S Before installing the cap bolt, apply grease
onto the O-ring.
S Always use a new cap bolt O-ring.
f. Hold the cap bolt and tighten the nut to specification.
Nut
15 Nm (1.5 mSkg, 11 ftSlb)
EAS00662
4. Tighten:
S under bracket pinch bolt
23 Nm (2.3 mSkg, 17 ftSlb)
4-56
CHAS
FRONT FORK
5. Install:
S handlebar
S handlebar pinch bolt 1
S handlebar bolt 2
13 Nm (1.3 mSkg, 9.4 ftSlb)
WARNING
Make sure the brake hoses are routed properly.
6. Adjust:
S spring preload
S rebound damping
S compression damping
Refer to ADJUSTING THE FRONT FORK
LEGS in chapter 3.
4-57
HANDLEBARS
CHAS
EAS00665
HANDLEBARS
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Job/Part
Removing the handlebars
Grip end
Handlebar grip
Clutch switch connector
Left handlebar switch
Clutch cable
Clutch lever
Right handlebar switch
Throttle grip
Throttle cables
Front brake light switch connector
Front brake master cylinder holder
Front brake master cylinder
Reservoir tank bracket
Handlebar
Qty
Remarks
Remove the parts in the order listed.
2
1
1
1
1
1
1
1
2
2
1
1
1
2
Disconnect.
Disconnect.
4-58
HANDLEBARS
CHAS
EAS00667
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
S grip end
S handlebar grip
NOTE:
Blow compressed air between the left handlebar and the handlebar grip, and gradually push
the grip off the handlebar.
3. Remove:
S left handlebar switch 1
S clutch lever holder 2
4. Remove:
S grip end
S right handlebar switch 1
S throttle grip 2
S front brake master cylinder 3
EAS00669
WARNING
Do not attempt to straighten bent handlebars as this may dangerously weaken them.
4-59
CHAS
HANDLEBARS
EAS00674
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Install:
S throttle cables
S throttle grip 1
S right handlebar switch 2
NOTE:
Align the projection a on the right handlebar
switch with the hole b in the right handlebar.
3. Install:
S right handlebar 1
S right handlebar pinch bolt 2
33 Nm (3.3 mSkg, 24 ftSlb)
4. Install:
S front brake master cylinder 1
S master cylinder holder 2
13 Nm (1.3 mSkg, 9.4 ftSlb)
CAUTION:
S Install the brake master cylinder holder
with the UP mark facing up.
S First, tighten the upper bolt, and then the
lower bolt.
NOTE:
S Align the mating surfaces of the brake master
cylinder holder with the punch mark a on the
right handlebar.
S There should be 8.2 mm (0.32 in) of clearance
between the right handlebar switch and the
brake master cylinder holder.
4-60
CHAS
HANDLEBARS
5. Install:
S clutch lever holder 1
NOTE:
Align the slit on the clutch lever holder with the
punch mark a on the left handlebar.
6. Install:
S left handlebar
S left handlebar pinch bolt 1
33 Nm (3.3 mSkg, 24 ftSlb)
7. Install:
S left handlebar switch 1
NOTE:
Align the projection a on the left handlebar
switch with the hole b on the left handlebar.
8. Install:
S handlebar grip
a. Apply a thin coat of rubber adhesive onto the
end of the left handlebar.
b. Slide the handlebar grip over the end of the
left handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
9. Install:
S grip ends
4-61
HANDLEBARS
CHAS
10. Adjust:
S clutch cable free play
Refer to ADJUSTING THE CLUTCH
CABLE FREE PLAY in chapter 3.
Clutch cable free play
(at the end of the clutch lever)
10 X 15 mm (0.39 X 0.59 in)
11. Adjust:
S throttle cable free play
Refer to ADJUSTING THE THROTTLE
CABLE FREE PLAY in chapter 3.
Throttle cable free play
(at the flange of the throttle grip)
6 X 8 mm (0.24 X 0.31 in)
4-62
STEERING HEAD
CHAS
EAS00676
STEERING HEAD
UNDER BRACKET
26 Nm (2.6 mSkg, 19 ftSlb)
113 Nm (11.3 mSkg, 82 ftSlb)
23 Nm (2.3 mSkg, 17 ftSlb)
Order
Job/Part
Qty
Remarks
2
1
1
1
1
1
1
4-63
Refer to HANDLEBARS.
Refer to FUEL TANK in chapter 3.
Refer to AIR FILTER CASE in chapter
3.
Disconnect
STEERING HEAD
CHAS
Order
8
9
10
11
12
13
14
15
16
Job/Part
Rubber washer
Lower ring nut
Under bracket
Bearing cover
Bearing inner race
Upper bearing
Lower bearing
Dust seal
Bearing outer race
Qty
Remarks
1
1
1
1
2
1
1
1
2
For installation, reverse the removal
procedure.
4-64
STEERING HEAD
CHAS
EAS00679
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
S steering stem nut
S washer
S upper bracket
S lock washer
S rubber washer
S ring nut 1
(with the steering nut wrench 2 )
NOTE:
Hold the lower ring nut with the exhaust and
steering nut wrench, and then remove the upper
ring nut with the ring nut wrench.
Steering nut wrench
90890-01403, YU-33975
WARNING
Securely support the under bracket so that
there is no danger of it falling over.
EAS00681
2. Check:
S bearings 1
S bearing races 2
Damage/pitting ! Replace.
4-65
STEERING HEAD
CHAS
3. Replace:
S bearings
S bearing races
a. Remove the bearing races 1 from the steering head pipe with a long rod 2 and hammer.
b. Remove the bearing race 3 from the under
bracket with a floor chisel 4 and hammer.
c. Install a new rubber seal and new bearing
races.
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
S Always replace the bearings and bearing
races as a set.
S Whenever the steering head is disassembled,
replace the rubber seal.
4. Check:
S upper bracket
S under bracket
(along with the steering stem)
Bends/cracks/damage ! Replace.
EAS00683
2. Install:
S lower ring nut 1
S rubber washer 2
S upper ring nut 3
S lock washer 4
Refer to CHECKING THE STEERING
HEAD in chapter 3.
4-66
STEERING HEAD
3. Install:
S upper bracket
S washer
S steering stem nut
CHAS
NOTE:
Temporarily tighten the steering stem nut.
4. Install:
S front fork legs
Refer to INSTALLING THE FRONT FORK
LEGS.
NOTE:
Temporarily tighten the upper and under bracket pinch bolts.
5. Install:
S front wheel
Refer to FRONT WHEEL AND BRAKE
DISCS.
4-67
CHAS
EAS00685
Order
Job/Part
Qty
Self-locking nut/bolt
(Relay arm rear shock absorber)
Self-locking nut/bolt
(Rear shock absorber upper)
Rear shock absorber
Self-locking nut/bolt
(Relay arm swingarm)
Self-locking nut/bolt
(Relay arm connecting rod)
Relay arm
Self-locking nut/nut
(Connecting rod frame)
Connecting rod
Remarks
4-68
CHAS
Order
9
10
11
Job/Part
Oil seal/bearing/collar
Oil seal/bearing/collar
Bracket
Qty
Remarks
6/3/3
2/1/1
1
For installation, reverse the removal
procedure.
4-69
CHAS
EAS00687
WARNING
This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, read and make sure you understand the following information. The
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.
S Do not tamper or attempt to open the rear
shock absorber or gas cylinder.
S Do not subject the rear shock absorber or
gas cylinder to an open flame or any other
source of high heat. High heat can cause an
explosion due to excessive gas pressure.
S Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.
EAS00689
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
4-70
CHAS
EAS00694
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
S rear wheel
Refer to REAR WHEEL AND BRAKE
DISC.
3. Remove:
S rear shock absorber assembly lower bolt 1
NOTE:
While removing the rear shock absorber assembly lower bolt, hold the swingarm so that it
does not drop down.
4. Remove:
S rear shock absorber assembly upper bolt 1
S rear shock absorber assembly
EAS00696
4-71
CHAS
S spring
Damage/wear ! Replace the rear shock absorber assembly.
S gas cylinder
Damage/gas leaks ! Replace.
S bushings
Damage/wear ! Replace.
S dust seals
Damage/wear ! Replace.
S bolts
Bends/damage/wear ! Replace.
CHECKING THE CONNECTING ROD AND
RELAY ARMS
1. Check:
S connecting rod 1
S relay arms 2
Damage/wear ! Replace.
2. Check:
S bearings 3
S oil seals 4
Damage/pitting ! Replace.
3. Check:
S collars 5
Damage/scratches ! Replace.
EAS00698
4-72
CHAS
EAS00700
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
9
Remarks
2
2
1
1/1
1
1
1
1
2
4-73
CHAS
Order
10
11
12
13
Job/Part
Bearing
Spacer
Pivot shaft adjust bolt
Drive chain case
Qty
Remarks
2
1
1
1
For installation, reverse the removal
procedure.
4-74
CHAS
EAS00703
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
S rear wheel
Refer to REAR WHEEL AND BRAKE
DISC.
S rear shock absorber assembly, relay arm
and connecting rod
Refer to REAR SHOCK ABSORBER ASSEMBLY.
3. Measure:
S swingarm side play
S swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut
95 Nm (9.5 mSkg, 69 ftSlb)
b. Measure the swingarm side play A by moving the swingarm from side to side.
c. If the swingarm side play is out of specification, check the spacers, bearings, washers,
and dust covers.
Swingarm side play
(at the end of the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical movement B
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers,
bearings, washers, and dust covers.
4-75
CHAS
EAS00704
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
S drive chain (with the drive chain cutter)
EAS00707
2. Check:
S pivot shaft
Roll the pivot shaft on a flat surface.
Bends ! Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash:
S pivot shaft
S dust covers
S spacer
S washers
S bearings
Recommended cleaning solvent
Kerosene
4-76
CHAS
4. Check:
S dust covers 1
S spacer 2
Damage/wear ! Replace.
S bearings
Damage/pitting ! Replace.
EAS00709
2. Check:
S drive chain
Stiffness ! Clean and lubricate or replace.
3. Clean:
S drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
4-77
CHAS
CAUTION:
This motorcycle has a drive chain with small
rubber O-rings 1 between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean the
drive chain. High-pressure methods could
force dirt or water into the drive chains internals, and solvents will deteriorate the Orings. A coarse brush can also damage the
O-rings. Therefore, use only kerosene to
clean the drive chain. Dont soak drive chain
in kerosine more then ten minutes. O-ring is
damage by kerosine.
4. Check:
S O-rings 1
Damage ! Replace the drive chain.
S drive chain rollers 2
Damage/wear ! Replace the drive chain.
S drive chain side plates 3
Damage/wear ! Replace the drive chain.
Cracks ! Replace the drive chain and make
sure the battery breather hose is properly
routed away from the drive chain and below
the swingarm.
5. Lubricate:
S drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
6. Check:
S drive sprocket
S rear wheel sprocket
More than 1/4 tooth a wear ! Replace the
drive chain sprockets as a set.
Bent teeth ! Replace the drive chain sprockets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket
4-78
CHAS
S swingarm
S pivot shaft
NOTE:
Use the pivot shaft wrench 2 and adapter 3 to
tighten the pivot adjust bolt to specification
torque.
Pivot shaft wrench:
90890-01471, YM-01471
Pivot shaft wrench adapter
90890-01476
3. Install:
S relay arms 1
S connecting rod 2
NOTE:
Install the connecting rod front bolt 3 from the
left.
4. Install:
S rear shock absorber assembly
S rear wheel
Refer to INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY and INSTALLING THE REAR WHEEL.
5. Adjust:
S drive chain slack
Refer to ADJUSTING THE DRIVE CHAIN
SLACK in chapter 3.
Drive chain slack
35 X 45 mm (1.38 X 1.77 in)
4-79
ENGINE
ENG
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
Remarks
2
1
1
1
1
1
1
1
Lock nut
Shift rod
Shift arm
Drive sprocket cover
Nut
Lock washer
Chain guide
Drive sprocket
Loosen.
Refer to ADJUSTING THE DRIVE
CHAIN in chapter 3.
Loosen.
5-1
ENGINE
ENG
EAS00189
EXHAUST PIPE
Order
1
2
3
Job/Part
Qty
Remarks
Remove the parts in the order listed.
5-2
ENGINE
ENG
EAS00188
Order
Job/Part
Qty
Engine oil
Oil filter cartridge
Oil cooler
Air cut-off valve
Starter motor
1
2
Remarks
1
1
CAUTION:
First, disconnect the negative battery
lead, and then the positive battery lead.
For connecting, reverse the disconnection procedure.
5-3
ENGINE
ENG
Order
3
4
5
6
7
8
9
10
Job/Part
Qty
1
1
1
1
1
1
1
1
Clutch cable
Ground lead
Stator coil assembly coupler
Crankshaft position sensor coupler
Oil level switch connector
Neutral switch connector
Speed sensor coupler
Cylinder identification sensor coupler
5-4
Remarks
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For connecting reverse the disconnection
procedure.
ENGINE
ENG
EAS00191
ENGINE
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
9
Remarks
1
2
2
2
2
2
1
2
1
NOTE:
Use the pivot shaft wrench and adapter to
loosen the engine mounting adjust bolts.
For installation, reverse the removal
procedure.
5-5
ENGINE
ENG
EAS00192
2. Install:
S rear engine mounting bolts 1
NOTE:
S Lubricate the rear engine mounting bolt
threads with lithium-soap-based grease.
3. Install:
S right front engine mounting bolts 1
(temporary tighten)
S left front engine mounting bolts 2
45 Nm (4.5 mSkg, 33 ftSlb)
NOTE:
First tighten the rear side engine mounting bolt.
4. Tighten:
S engine mounting adjust bolts
7 Nm (0.7 mSkg, 5.1 ftSlb)
NOTE:
S First tighten the lower engine mounting adjust
bolt.
S Use the pivot shaft wrench 1 and pivot shaft
wrench adapter 2 to tighten the engine
mounting adjust bolts.
5-6
ENGINE
ENG
5. Tighten:
S nuts 1 (rear engine mounting bolts)
45 Nm (4.5 mSkg, 33 ftSlb)
NOTE:
First tighten the lower self-locking nut.
6. Tighten:
S right front engine mounting bolts 1
45 Nm (4.5 mSkg, 33 ftSlb)
NOTE:
First tighten the rear side engine mounting bolt.
7. Install:
S shift arm 1
NOTE:
S Align the punch mark a in the shift shaft with
the slot in the shift arm.
S Align the bottom edge of the shift pedal with the
mark on the frame-to-swingarm bracket.
8. Install:
S drive chain guide 1
7 Nm (0.7 mSkg, 5.1 ftSlb)
5-7
CAMSHAFTS
ENG
EAS00194
CAMSHAFTS
CYLINDER HEAD COVER
Order
Job/Part
Qty
Remarks
4
4
1
1
1
1
Ignition coil
Spark plug
Cylinder head cover
Cylinder head cover gasket
Timing chain guide (top side)
Cylinder identification sensor
5-8
CAMSHAFTS
ENG
EAS00196
CAMSHAFTS
Order
Job/Part
Qty
4
1
1
1
3
6
3
6
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to CRANKSHAFT POSITION
SENSOR AND PICKUP ROTOR.
Loosen.
NOTE:
During removal, the dowel pins may still
be connected to the camshaft caps.
5-9
CAMSHAFTS
ENG
EAS00198
3. Loosen:
S camshaft sprocket bolts 1
4. Loosen:
S cap bolt 1
5. Remove:
S timing chain tensioner 2
S gasket
6. Remove:
S timing chain guide (exhaust side)
S camshaft caps 1
S dowel pins
CAUTION:
To prevent damage to the cylinder head,
camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a crisscross pattern, working from the outside in.
5-10
CAMSHAFTS
ENG
7. Remove:
S intake camshaft 1
S exhaust camshaft 2
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire a .
8. Remove:
S camshaft sprockets
EAS00204
2. Measure:
S camshaft lobe dimensions a and b
Out of specification ! Replace the camshaft.
Camshaft lobe dimension limit
Intake camshaft
a 33.45 X 33.55 mm
(1.317 X 1.321 in)
<Limit>: 33.40 mm (1.315 in)
b 25.12 X 25.22 mm
(0.989 X 0.993 in)
<Limit>: 25.07 mm (0.987 in)
Exhaust camshaft
a 32.55 X 32.65 mm
(1.282 X 1.285 in)
<Limit>: 32.50 mm (1.280 in)
b 25.07 X 25.17 mm
(0.987 X 0.991 in)
<Limit>: 25.02 mm (0.985 in)
5-11
CAMSHAFTS
ENG
3. Measure:
S camshaft runout
Out of specification ! Replace.
Camshaft runout limit
0.06 mm (0.0024 in)
4. Measure:
S camshaft-journal-to-camshaft-cap
clearance
Out of specification ! Measure the camshaft
journal diameter.
Camshaft-journal-to-camshaftcap clearance
0.028 X 0.062 mm
(0.0011 X 0.0024 in)
<Limit>: 0.08 mm (0.0031 in)
5-12
CAMSHAFTS
ENG
EAS00208
2. Check:
S camshaft sprocket
More than 1/4 tooth wear a ! Replace the
camshaft sprockets and the timing chain as a
set.
a 1 / 4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
3. Check:
S timing chain guide (exhaust side) 1
S timing chain guide (intake side) 2
S timing chain guide (top side) 3
Damage/wear ! Replace the defective
part(s).
EAS00210
5-13
CAMSHAFTS
ENG
EAS00215
5-14
ENG
CAMSHAFTS
3. Install:
S dowel pins
S exhaust camshaft caps
S intake cmashaft caps
NOTE:
S Make sure each camshaft cap is installed in its
original place.
S Make sure the arrow mark a on each camshaft cap points towards the right side of the
engine.
4. Install:
S camshaft cap bolts
10 Nm (1.0 mSkg, 7.2 ftSlb)
NOTE:
Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.
I1, 12: Intake side camshaft cap mark
E1, E2: Exhaust side camshaft cap mark
CAUTION:
S Lubricate the camshaft cap bolts with the
engine oil.
S The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
S Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
5. Install:
S timing chain guide (exhaust side)
NOTE:
When installing the timing chain guide, be sure
to keep the timing chain as tight as possible on
the exhaust side.
5-15
ENG
CAMSHAFTS
6. Install:
S timing chain tensioner
a. While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1 .
b. With the timing chain tensioner rod turned all
the way into the timing chain tensioner housing (with the thin screwdriver still installed),
install the gasket and the timing chain tensioner 2 onto the cylinder block.
WARNING
Always use a new gasket.
c. Tighten the timing chain tensioner bolts 3 to
the specified torque.
Timing chain tensioner bolt
12 Nm (1.2 mSkg, 8.7 ftSlb)
d. Remove the screwdriver, make sure that the
timing chain tensioner rod releases, and then
tighten the cap bolt to the specified torque.
Cap bolt
7 Nm (0.7 mSkg, 5.1 ftSlb)
7. Turn:
S crankshaft
(several full turns clockwise)
8. Check:
S T mark a
Make sure the T mark on the pickup rotor is
aligned with the crankcase mating sure face
b.
S camshaft sprocket match mark c
Make sure the match marks on the camshaft
sprockets are aligned with the crankcase
mating surface d .
Out of alignment ! Adjust.
Refer to the installation steps above.
9. Tighten:
S camshaft sprocket bolts 1
24 Nm (2.4 mSkg, 17 ftSlb)
CAUTION:
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
5-16
CAMSHAFTS
ENG
10. Measure:
S valve clearance
Out of specification ! Adjust.
Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3.
5-17
CYLINDER HEAD
ENG
EAS00221
CYLINDER HEAD
Order
1
2
3
Job/Part
Removing the cylinder head
Intake and exhaust camshaft
Engine bracket
Cylinder head
Cylinder head gasket
Dowel pin
Qty
Remarks
Remove the parts in the order listed.
Refer to CAMSHAFTS.
Refer to ENGINE.
1
1
2
For installation, reverse the removal
procedure.
5-18
CYLINDER HEAD
ENG
EAS00222
5-19
CYLINDER HEAD
ENG
EAS00233
1 X 10
19 Nm (1.9 mSkg, 14 ftSlb)
50 Nm (5.0 mSkg, 36 ftSlb)
11 , 12
12 Nm (1.2 mSkg, 8.7 ftSlb)
NOTE:
S First, tighten the bolts 1 X 10 to approximately 19 Nm (1.9 mSkg, 14 ftSlb) with a torque
wrench and then tighten the 50 Nm (5.0 mSkg,
36 ftSlb).
S Lubricate the cylinder head bolts with engine
oil.
S Tighten the cylinder head bolts in the proper
tightening sequence as shown and torque
them in two stages.
4. Install:
S exhaust camshaft
S intake camshaft
Refer to INSTALLING THE CAMSHAFTS.
5-20
ENG
EAS00236
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
Remarks
Remove the parts in the order listed.
Refer to CYLINDER HEAD.
8
8
16
8
8
8
8
8
8
8
8
8
16
5-21
Refer to REMOVING/INSTALLING
THE VALVES.
Order
14
15
16
17
18
19
Job/Part
Exhaust valve upper spring seat
Exhaust valve spring
Exhaust valve oil seal
Exhaust valve lower spring seat
Exhaust valve
Exhaust valve guide
Qty
8
8
8
8
8
8
ENG
Remarks
Refer to REMOVING/INSTALLING
THE VALVES.
5-22
ENG
EAS00238
1. Remove:
S valve lifter 1
S valve pad 2
NOTE:
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:
S valve sealing
Leakage at the valve seat ! Check the valve
face, valve seat, and valve seat width.
Refer to CHECKING THE VALVE SEATS.
a. Pour a clean solvent a into the intake and
exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat 1 .
3. Remove:
S valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve springs with the valve spring compressor
2 and the valve spring compressor attachment
3.
5-23
ENG
4. Remove:
S upper spring seat 1
S valve spring outer 2
S valve spring inner (intake only) 3
S valve 4
S oil seal 5
S lower spring seat 6
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
EAS00239
5-24
ENG
2. Replace:
S valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100_C (212_F) in an oven.
3. Eliminate:
S carbon deposits
(from the valve face and valve seat)
4. Check:
S valve face
Pitting/wear ! Grind the valve face.
S valve stem end
Mushroom shape or diameter larger than the
body of the valve stem ! Replace the valve.
5-25
ENG
5. Measure:
S valve margin thickness a
Out of specification ! Replace the valve.
Valve margin thickness
0.6 X 0.8 mm
(0.0236 X 0.0315 in)
<Limit>: 0.5 mm (0.02 in)
6. Measure:
S valve stem runout
Out of specification ! Replace the valve.
NOTE:
S When installing a new valve, always replace
the valve guide.
S If the valve is removed or replaced, always replace the oil seal.
Valve stem runout
<Limit>: 0.04 mm (0.0016 in)
EAS00240
5-26
ENG
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been removed.
4. Lap:
S valve face
S valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth between your hands.
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanics blueing dye (Dykem) b
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
5-27
ENG
EAS00241
2. Measure:
S compressed valve spring force a
Out of specification ! Replace the valve
spring.
b Installed length
Compressed valve spring force
(installed)
Intake valve spring (inner)
61.5 X 70.7 N
(6.27 X 7.21 kg,
13.83 X 15.89 lb)
Intake valve spring (outer)
139.1 X 160.1 N
(14.18 X 16.33 kg,
31.27 X 35.99 lb)
Exhaust valve spring
160 X 184 N
(16.32 X 18.76 kg,
35.97 X 41.36 lb)
5-28
ENG
3. Measure:
S valve spring tilt a
Out of specification ! Replace the valve
spring.
Spring tilt limit
Intake valve spring (inner)
2.5_/1.6 mm (0.06 in)
(outer)
2.5_/1.8 mm (0.07 in)
Exhaust valve spring
2.5_/1.8 mm (0.07 in)
EAS00242
2. Lubricate:
S valve stem 1
S valve stem seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3. Install:
S valve 1
S lower spring seat 2
S valve stem seal 3
S valve spring inner (intake only) 4
S valve spring outer 5
S upper spring seat 6
(into the cylinder head)
5-29
ENG
NOTE:
S Make sure that each valve is installed in its
original place.
S Install the valve springs with the larger pitch a
facing up.
b Smaller pitch
4. Install:
S valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve springs with the valve spring compressor
2 and the valve spring compressor attachment
3.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
6. Install:
S valve pad 1
S valve lifter 2
NOTE:
S Lubricate the valve lifter and valve pad with
molybdenum disulfide oil.
S The valve lifter must move smoothly when rotated with a finger.
S Each valve lifter and valve pad must be reinstalled in its original position.
5-30
ENG
EAS00341
Order
Job/Part
Qty
Engine oil
1
2
3
4
5
Remarks
1
1
1
2
1
5-31
Drain.
Refer to CHANGING THE COOLANT in
chapter 3.
Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3.
Disconnect.
ENG
Order
6
7
8
9
10
11
12
13
Job/Part
Stator coil assembly
Generator rotor bolt
Washer
Generator rotor
Starter clutch assembly
Idler gear shaft
Idler gear
Starter clutch drive gear
Qty
1
1
1
1
1
1
1
1
Remarks
Refer to REMOVING/INSTALLING
THE GENERATOR.
5-32
ENG
EAS00347
2. Drain:
S coolant
Refer to CHANGING THE COOLANT in
chapter 3.
S engine oil
Refer to CHANGING THE ENGINE OIL in
chapter 3.
3. Remove:
S generator rotor cover
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
4. Remove:
S generator rotor bolt 1
S washer
NOTE:
S While holding the generator rotor 2 with the
sheave holder 3 , loosen the generator rotor
bolt.
S Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701, YS-01880-A
5-33
ENG
5. Remove:
S generator rotor 1
(with the flywheel puller 2 and flywheel puller attachment)
S woodruff key
CAUTION:
To protect the end of the crankshaft, place
an appropriate sized socket between the flywheel puller sets center bolt and the crankshaft.
NOTE:
Make sure the flywheel puller is centered over
the generator rotor.
Flywheel puller
90890-01362, YU-33270
Flywheel puller attachment
90890-04089, YM-33282
5-34
ENG
EAS00351
2. Check:
S starter clutch idle gear 1
S starter clutch drive gear 2
Burrs/chips/roughness/wear ! Replace
the defective part(s).
3. Check:
S starter clutch gears contacting surfaces a
Damage/pitting/wear ! Replace the starter
clutch gear.
4. Check:
S starter clutch operation
a. Install the starter clutch drive gear 1 onto
the starter clutch 2 and hold the starter
clutch.
b. When turning the starter clutch drive gear
clockwise A , the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and must be
replaced.
c. When turning the starter clutch drive gear
counterclockwise B , it should turn freely,
otherwise the starter clutch is faulty and must
be replaced.
EAS00355
LOCTITIER
NOTE:
S While holding the generator rotor 1 with the
sheave holder 2 , tighten the starter clutch
bolt.
5-35
ENG
EAS00354
NOTE:
S While holding the generator rotor 2 with the
sheave holder 3 , tighten the generator rotor
bolt.
S Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701, YS-01880-A
3. Apply:
S sealant
(onto the stator coil assembly lead grommet)
Yamaha bond No.1215
90890-85505, ACC-11001-05-01
4. Install:
S stator coil
5. Install:
S generator rotor cover
12 Nm (1.2 mSkg, 8.7 ftSlb)
5-36
ENG
NOTE:
Tighten the generator rotor cover bolts in stages
and in a crisscross pattern.
6. Fill:
S engine oil
Refer to CHANGING THE ENGINE OIL in
chapter 3.
S coolant
Refer to CHANGING THE COOLANT in
chapter 3.
7. Install:
S left side cowling
S buttom cowling
Refer to COWLINGS in chapter 3.
S rider seat and fuel tank
Refer to SEATS and FUEL TANK in chapter 3.
5-37
SHIFT SHAFT
ENG
EAS00327
SHIFT SHAFT
SHIFT SHAFT AND STOPPER LEVER
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
9
10
Remarks
Drain.
Refer to CHANGING THE COOLANT
in chapter 3.
Refer to ENGINE.
1
1
1
1
1
1
1
1
1
1
5-38
SHIFT SHAFT
ENG
Order
11
12
13
14
Job/Part
Stopper lever
Collar
Washer
Shift shaft spring stopper
Qty
Remarks
1
1
1
1
For installation, reverse the removal
procedure.
5-39
SHIFT SHAFT
ENG
EAS00328
EAS00330
EAS00332
S washers
S shift shaft 2
NOTE:
S Apply LOCTITE to the threads of the shift
shaft spring stopper.
S Hook the ends 3 of the stopper lever spring
onto the stopper lever 4 and the crankcase
boss.
S Mesh the stopper lever with the shift drum segment assembly.
2. Install:
S shift shaft cover
NOTE:
Lubricate the oil seal lips with lithium-soapbased grease.
5-40
ENG
Order
Job/Part
Qty
Generator cover
1
2
3
4
5
Remarks
Clutch cable
Crankshaft position sensor lead coupler
Pickup rotor cover
Pickup rotor cover gasket
Dowel pin
1
1
1
1
2
5-41
Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3.
Refer to STARTER CLUTCH AND
GENERATOR.
Disconnect.
Disconnect.
ENG
Order
6
7
8
Job/Part
Crankshaft position sensor
Pickup rotor
Plug screw
Qty
Remarks
1
1
1
For installation, reverse the removal
procedure.
5-42
ENG
2. Remove:
S pickup rotor bolt 1
S washer 2
S pickup rotor 3
NOTE:
While holding the generator rotor 4 with the rotor holding tool 5 , loosen the pickup rotor bolt.
Sheave holder
90890-01701, YS-01880-A
5-43
ENG
2. Tighten:
S pickup rotor bolt 1
35 Nm (3.5 mSkg, 25 ftSlb)
NOTE:
While holding the generator rotor 2 with the
sheave holder 3 , tighten the pickup rotor bolt.
Sheave holder
90890-01701, YS-01880-A
3. Apply:
S sealant
(onto the crankshaft position sensor lead
grommet)
Yamaha bond No.1215
90890-85505, ACC-11001-5-01
4. Install:
S pickup rotor cover
S clutch cable holder
NOTE:
S When installing the pickup rotor cover, align
the timing chain guide (intake side) pin 1 of
the with the hole 2 in the pickup rotor cover.
S Tighten the pickup rotor cover bolts in stages
and in a crisscross pattern.
5-44
CLUTCH
ENG
EAS00273
CLUTCH
CLUTCH COVER
Order
Job/Part
Qty
Coolant
1
2
3
4
5
Coolant hose
Clutch cable
Clutch cover
Clutch cover gasket
Dowel pin
Remarks
1
1
1
1
2
Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3.
Drain.
Refer to CHANGING THE COOLANT in
chapter 3.
Disconnect.
Disconnect.
5-45
CLUTCH
Order
1
2
3
4
5
6
Job/Part
Disassembling the clutch cover
Circlip
Washer
Pull lever
Pull lever spring
Oil seal
Bearing
Qty
ENG
Remarks
Disassemble the parts in the order listed.
2
2
1
1
1
2
For assembly, reverse the disassembly
procedure.
5-46
CLUTCH
ENG
EAS00274
CLUTCH
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Removing the clutch
Compression spring
Pressure plate
Pull rod
Bearing
Friction plate (Brown)
Clutch plate (t=2.0 mm, 0.08 in)
Friction plate (Purple)
Clutch plate (t=2.3 mm, 0.09 in)
Clutch boss nut
Lock plate
Clutch boss
Thrust plate
Qty
Remarks
Remove the parts in the order listed.
6
1
1
1
6
7
2
1
1
1
1
1
For installation, reverse the removal
procedure.
5-47
CLUTCH
ENG
EAS00276
EAS00280
5-48
CLUTCH
ENG
2. Measure:
S friction plate thickness
Out of specification ! Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
Friction plate thickness
2.9 X 3.1 mm (0.114 X 0.122 in)
<Limit>: 2.8 mm (0.110 in)
EAS00281
EAS00282
5-49
CLUTCH
ENG
2. Measure:
S clutch spring free length a
Out of specification ! Replace the clutch
springs as a set.
Clutch spring free length
50 mm (1.97 in)
<Limit>: 49 mm (1.93 in)
EAS00284
EAS00285
5-50
CLUTCH
ENG
EAS00287
EAS00299
NOTE:
While holding the clutch boss 2 with the clutch
holding tool 5 , tighten the clutch boss nut.
Universal clutch holder
90890-04089, YM-91042
3. Bend the lock washer tab along a flat side of
the nut.
4. Lubricate:
S friction plates
S clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
5-51
CLUTCH
ENG
5. Install:
S friction plates
S clutch plates
NOTE:
First, install a clutch plate and then alternate between a friction plate and a friction plate.
a. Install the clutch plate and friction plate at following the illustrated.
Clutch plate 1 : t=2.3 mm (0.09 in)
Clutch plate 2 : t=2.0 mm (0.08 in)
Friction plate 3 : Color code/Purple
Friction plate 4 : Color code/Brown
6. Install:
S pressure plate 1
NOTE:
Align the punch mark b in the pressure plate
with the punch mark a in the clutch boss.
7. Install:
S bearing 1
S pull rod 2
S pressure plate 3
S clutch springs
S clutch spring bolts
8 Nm (0.8 mSkg, 5.8 ftSlb)
NOTE:
Tighten the clutch spring bolts in stages and in a
crisscross pattern.
8. Install:
S pull lever
NOTE:
In stall the pull lever with the UP mark facing
toward lower side.
5-52
CLUTCH
ENG
9. Install:
S clutch cover
S gasket New
NOTE:
S Install the pull rod so that the teeth a face towards the rear of the motorcycle. Then, install
the clutch cover.
S Apply oil onto the bearing.
S Apply molybdenum disulfide grease onto the
pull rod.
S When installing the clutch cover, push the pull
lever and check that the punch mark a on the
pull lever aligns with the mark b on the clutch
cover. Make sure that the pull rod teeth and
pull lever shaft pinion gear are engaged.
S Tighten the clutch cover bolts in stages and in
a crisscross pattern.
10. Adjust:
S clutch cable free play
Refer to ADJUSTING THE CLUTCH
CABLE FREE PLAY in chapter 3.
5-53
ENG
EAS00356
Order
Job/Part
Qty
Coolant
1
2
3
4
5
6
7
8
1
1
1
1
1
2
1
1
5-54
Remarks
Remove the parts in the order listed.
Drain.
Refer to CHANGING THE ENGINE OIL
in chapter 3.
Refer to CHANGING THE COOLANT in
chapter 3.
Refer to ENGINE.
Refer to WATER PUMP in chapter 6.
Disconnect.
ENG
Order
9
10
11
12
13
Job/Part
Oil pipe
Oil delivery pipe
Oil pump assembly
Dowel pin
Relief valve assembly
Qty
Remarks
1
1
1
2
1
For installation, reverse the removal
procedure.
5-55
ENG
Order
1
2
3
4
5
6
7
8
Job/Part
Disassembling the oil pump
assembly
Oil pump cover
Pin
Oil pump inner rotor
Oil pump outer rotor
Pin
Washer
Oil pump rotor housing
Oil pump driver sprocket
Qty
Remarks
Disassemble the parts in the order listed.
1
2
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
5-56
ENG
EAS00362
EAS00364
2. Measure:
S inner-rotor-to-outer-rotor-tip clearance a
S outer-rotor-to-oil-pump-housing clearance
b
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.03 X 0.09 mm
(0.0012 X 0.0035 in)
<Limit>: 0.15 mm (0.0059 in)
Outer-rotor-to-oil-pump-housing
clearance
0.03 X 0.08 mm
(0.0012 X 0.0031 in)
<Limit>: 0.15 mm (0.0059 in)
5-57
ENG
3. Check:
S oil pump operation
Rough movement ! Repeat steps (1) and
(2) or replace the defective part(s).
EAS00365
EAS00367
EAS00368
EAS00373
5-58
ENG
EAS00374
NOTE:
When installing the inner rotor, align the pin 4 in
the oil pump shaft with the groove in the inner rotor 5 .
3. Check:
S oil pump operation
Refer to CHECKING THE OIL PUMP.
EAS00376
CAUTION:
After tightening the bolts, make sure the oil
pump turns smoothly.
5-59
ENG
EAS00378
EAS00380
WARNING
Always use new copper washers.
NOTE:
S Tighten the oil pan bolts in stages and in a
crisscross pattern.
S Lubricate the oil level switch O-ring with engine oil.
5-60
CRANKCASE
ENG
CRANKCASE
Order
Job/Part
Qty
1
2
3
4
5
Shift shaft
Crankshaft position sensor and pickup
rotor
Clutch
Water pump assembly
Oil pan and oil pump
Timing chain
Oil pump drive chain
Oil pump drive chain guide
Lower crankcase
Dowel pin
Remarks
1
1
1
1
3
5-61
CRANKCASE
ENG
Order
6
7
8
Job/Part
Thrust plate
Washer
Plate
Qty
Remarks
1
1
1
For installation, reverse the removal
procedure.
5-62
CRANKCASE
ENG
EAS00384
CAUTION:
Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves separate evenly.
4. Remove:
S dowel pins
5. Remove:
S crankshaft journal lower bearing
(from the lower crankcase)
NOTE:
Identify the position of each crankshaft journal
lower bearing so that it can be reinstalled in its
original place.
5-63
CRANKCASE
ENG
EAS00399
2. Apply:
S sealant
Yamaha bond No. 1215
90890-85505, ACC-1109-05-01
5-64
CRANKCASE
ENG
NOTE:
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 X 3 mm of
the crankshaft journal bearings.
3. Install:
S dowel pin
4. Set the shift drum assembly and transmission gears in the neutral position.
5. Install:
S lower crankcase 1
(onto the upper crankcase 2 )
CAUTION:
Before tightening the crankcase bolts, make
sure that the transmission gears shift correctly when the shift drum assembly is
turned by hand.
6. Install:
S crankcase bolts
NOTE:
S Lubricate the bolt threads with engine oil.
S Install a washer on bolts 1 X 10 .
S Seal bolt 18
S Tighten the bolts in the tightening sequence
cast on the crankcase.
M8
M8
M8
M6
M6
M6
M6
M6
M6
* Loosen the all bolts following the tightening order and then tighten to specification torque.
5-65
ENG
EAS00252
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
9
10
Remarks
Remove the parts in the order listed.
Refer to CRANKCASE.
4
4
4
8
4
4
4
4
4
4
For installation, reverse the removal
procedure.
5-66
ENG
EAS00393
2. Remove:
S piston pin clips 1
S piston pin 2
S piston 3
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
S For reference during installation, put identification marks on the piston crown.
S Before removing the piston pin, deburr the piston pin clip groove and the piston pin bore
area. If both areas are debarred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set 4 .
Piston pin puller set
90890-01304, YU-01304
3. Remove:
S top ring
S 2nd ring
S oil ring
NOTE:
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
5-67
ENG
EAS00387
EAS00261
2. Measure:
S piston-to-cylinder clearance
a. Measure cylinder bore C with the cylinder
bore gauge.
NOTE:
Measure cylinder bore C by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements.
5-68
ENG
65.50 X 65.51 mm
(2.5787 X 2.5791 in)
Wear limit
65.56 mm
(2.5811 in)
Taper limit T
Out of round R
C = maximum of D1 X D6
T = maximum of D1 or D2 maximum
of D5 or D6
R = maximum of D1 D3 or D5
minimum of D2 D4 or D6
b. If out of specification, replace the cylinder,
and the pistons and piston rings as a set.
c. Measure piston skirt diameter P with the
micrometer.
a 4 mm (0.16 in) from the bottom edge of the piston
Piston size P
65.475 X 65.490 mm
(2.5778 X 2.5783 in)
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore C
Piston skirt diameter P
Piston-to-cylinder clearance
0.010 X 0.035 mm
(0.0004 X 0.0014 in)
<Limit>: 0.055 mm (0.0022 in)
f. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
EAS00263
5-69
ENG
NOTE:
The oil ring expander spacers end gap cannot
be measured. If the oil ring rails gap is excessive, replace all three piston rings.
Piston ring end gap
Top ring
0.25 X 0.35 mm
(0.0098 X 0.0138 in)
<Limit>: 0.60 mm (0.0236 in)
2nd ring
0.7 X 0.8 mm
(0.0276 X 0.0315 in)
<Limit>: 1.15 mm (0.0453 in)
Oil ring
0.10 X 0.35 mm
(0.0039 X 0.0138 in)
5-70
ENG
2. Measure:
S piston pin outside diameter a
Out of specification ! Replace the piston
pin.
Piston pin outside diameter
15.991 X 16.000 mm
(0.6296 X 0.6299 in)
<Limit>: 15.971 mm (0.6288 in)
3. Measure:
S piston pin bore inside diameter b
Out of specification ! Replace the piston.
Piston pin bore inside diameter
16.002 X 16.013 mm
(0.6300 X 0.6304 in)
<Limit>: 16.043 mm (0.6316 in)
4. Calculate:
S piston-pin-to-piston clearance
Out of specification ! Replace the piston pin
and piston as a set.
Piston-pin-to-piston clearance =
Piston pin bore size
Piston pin outside diameter
Piston-pin-to-piston clearance
0.002 X 0.022 mm
(0.0001 X 0.0009 in)
<Limit>: 0.072 mm (0.0028 in)
CHECKING THE BIG END BEARINGS
1. Measure:
S crankshaft-pin-to-big-end-bearing
clearance
Out of specification ! Replace the big end
bearings.
Crankshaft-pin-to-big-end-bearing
clearance
0.028 X 0.052 mm
(0.0011 X 0.0020 in)
The following procedure applies to all of the
connecting rods.
5-71
ENG
CAUTION:
Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing
clearance and prevent engine damage, the big
end bearings must be installed in their original positions.
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rods halves.
b. Install the big end upper bearing into the connecting rod and the big end lower bearing
into the connecting rod cap.
NOTE:
Align the projections a on the big end bearings
with the notches b in the connecting rod and
connecting rod cap.
5-72
ENG
CAUTION:
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
Always install new bolts and nuts.
g. Clean the connecting rod bolts and nuts.
h. Tighten the connecting rod nuts.
i. Put a mark 1 on the corner of the connecting
rod nut 2 and the connecting rod 3 .
WARNING
When the nut is tightened more than the specified angle, do not loosen the nut and then
retighten it.
Replace the bolt with a new one and perform
the procedure again.
CAUTION:
S Do not use a torque wrench to tighten the
nut to the specified angle.
S Tighten the nut until it is at the specified
angles.
NOTE:
When using a hexagonal nut, note that the
angle from one corner to another is 60_
k. Remove the connecting rod and big end
bearings.
Refer to REMOVING THE CONNECTING
RODS.
l. Measure the compressed Plastigauge
width on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select replacement big end bearings.
5-73
ENG
2. Select:
S big end bearings (P1 X P4)
NOTE:
S The numbers A stamped into the crankshaft
web and the numbers 1 on the connecting
rods are used to determine the replacement
big end bearing sizes.
S P1 X P4 refer to the bearings shown in the
crankshaft illustration.
For example, if the connecting rod P1 and the
crankshaft web P1 numbers are 5 and 2 respectively, then the bearing size for P1 is:
P1 (connecting rod) P1
(crankshaft) =
5 2 = 3 (brown)
BIG END BEARING COLOR CODE
1
Blue
Black
Brown
Green
5-74
ENG
2. Install:
S piston 1
(onto the respective connecting rod 2 )
S piston pin 3
S piston pin clip New 4
NOTE:
S Apply engine oil onto the piston pin.
S Make sure that the Y mark a on the connecting rod faces left when the arrow mark b on
the piston is pointing up. Refer to the illustration.
S Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#4).
3. Lubricate:
S piston
S piston rings
S cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
4. Offset:
S piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
e Oil ring expander
5. Lubricate:
S crankshaft pins
S big end bearings
S connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
5-75
ENG
6. Install:
S big end bearings
S connecting rod assembly
(into the cylinder and onto the crankshaft pin)
S connecting rod cap
(onto the connecting rod)
NOTE:
S Align the projections on the big end bearings
with the notches in the connecting rods and
connecting rod caps.
S Be sure to reinstall each big end bearing in its
original place.
S While compressing the piston rings with one
hand, install the connecting rod assembly into
the cylinder with the other hand.
S Make sure that the Y marks a on the connecting rods face towards the left side of the
crankshaft.
S Make sure that the characters b on both the
connecting rod and connecting rod cap are
aligned.
7. Align:
S bolt heads
(with the connecting rod caps)
8. Tighten:
S connecting rod nuts
15 Nm (1.5 mSkg, 11 ftSlb) + 150_
CAUTION:
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
Always install new bolts and nuts.
5-76
ENG
WARNING
When the nut is tightened more than the specified angle, do not loosen the nut and then
retighten it.
Replace the bolt with a new one and perform
the procedure again.
CAUTION:
S Do not use a torque wrench to tighten the
nut to the specified angle.
S Tighten the nut until it is at the specified
angles.
NOTE:
When using a hexagonal nut, note that the
angle from one corner to another is 60_.
5-77
CRANKSHAFT
ENG
EAS00381
CRANKSHAFT
Order
Job/Part
Qty
Crankshaft
Crankshaft journal lower bearing
Crankshaft journal upper bearing
Remarks
1
5
5
For installation, reverse the removal
procedure.
5-78
CRANKSHAFT
ENG
EAS00395
CAUTION:
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing clearance and prevent engine damage, the crankshaft journal bearings must be installed in
their original positions.
5-79
CRANKSHAFT
ENG
5-80
CRANKSHAFT
ENG
g. Remove the lower crankcase and the crankshaft journal lower bearings.
h. Measure the compressed Plastigauge
width c on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-journal-bearing clearance is out of specification,
select replacement crankshaft journal bearings.
2. Select:
S crankshaft journal bearings (J1 X J5)
NOTE:
S The numbers A stamped into the crankshaft
web and the numbers 1 stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes.
S J1 X J5 refer to the bearings shown in the
crankshaft illustration.
S If J1 X J5 are the same, use the same size
for all of the bearings.
S If the size is the same for all J1 to J5 one digit
for that size is indicated. (Crankcase side only)
For example, if the crankcase J1 and crankshaft web J1 numbers are 6 and 2 respectively, then the bearing size for J1 is:
J1 (crankcase) J1
(crankshaft web) 1 =
6 2 1 = 3 (brown)
CRANKSHAFT JOURNAL BEARING
COLOR CODE
5-81
White
Blue
Black
Brown
Green
CRANKSHAFT
ENG
EAS00407
5-82
TRANSMISSION
ENG
EAS00419
TRANSMISSION
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS
Order
Job/Part
Qty
Remarks
Remove the part in the order listed.
Separate.
Refer to CRANKCASE.
1
1
1
1
1
2
4
1
1
1
1
5-83
TRANSMISSION
ENG
Order
12
13
14
15
16
Job/Part
Main axle assembly
Oil pipe
Oil baffle plate
Thrust plate
Washer
Qty
Remarks
1
1
1
1
1
For installation, reverse the removal
procedure.
5-84
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Job/Part
Disassembling the main axle
assembly
Bearing
2nd pinion gear
Toothed lock washer
Toothed lock washer retainer
6th pinion gear
Collar
Washer
Circlip
3rd pinion gear
Circlip
Washer
5th pinion gear
Collar
Main axle
Qty
ENG
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5-85
TRANSMISSION
Order
15
16
Job/Part
Bearing housing
Bearing
Qty
ENG
Remarks
1
1
For installation, reverse the removal
procedure.
5-86
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Job/Part
Disassembling the drive axle
assembly
Washer
1st wheel gear
Collar
5th wheel gear
Circlip
Washer
Collar
3rd wheel gear
Toothed lock washer
Toothed lock washer retainer
4th wheel gear
Collar
Washer
Circlip
Qty
ENG
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5-87
TRANSMISSION
Order
15
16
17
18
19
20
21
22
23
24
Job/Part
6th wheel gear
Circlip
Washer
2nd wheel gear
Collar
Collar
Oil seal
Bearing
Circlip
Drive axle
Qty
ENG
Remarks
1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
5-88
TRANSMISSION
ENG
EAS00420
EAS00421
2. Check:
S shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends ! Replace.
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
3. Check:
S shift fork movement
(along the shift fork guide bar)
Rough movement ! Replace the shift forks
and shift fork guide bar as a set.
5-89
TRANSMISSION
ENG
EAS00422
EAS00425
3. Check:
S transmission gears
Blue discoloration/pitting/wear ! Replace
the defective gear(s).
S transmission gear dogs
Cracks/damage/rounded edges ! Replace
the defective gear(s).
5-90
TRANSMISSION
ENG
4. Check:
S transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect ! Reassemble the transmission
axle assemblies.
5. Check:
S transmission gear movement
Rough movement ! Replace the defective
part(s).
6. Check:
S circlips
Bends/damage/looseness ! Replace.
EAS00430
5-91
TRANSMISSION
ENG
3. Install:
S shift fork R 1 and L 2
S drive axle 3
S shift fork guide bar
S shift drum retainer
10 Nm (1.0 mSkg, 7.2 ftSlb)
NOTE:
S Install shift fork L into the groove in the 6th
wheel gear and shift fork R into the groove in
the 5th wheel gear on the drive axle.
S Make sure that the drive axle bearing circlip a
is inserted into the grooves in the upper crankcase.
9. Check:
S transmission
Rough movement ! Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.
5-92
RADIATOR
COOL
EAS00454
COOLING SYSTEM
RADIATOR
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
Remarks
1
2
1
1
1
1
1
1
6-1
RADIATOR
COOL
Order
9
Job/Part
Qty
Radiator cap
Remarks
1
For installation, reverse the removal
procedure.
6-2
RADIATOR
COOL
EAS00455
3. Measure:
S radiator cap opening pressure
Below the specified pressure ! Replace the
radiator cap.
Radiator cap opening pressure
110 X 140 kPa
(1.1 X 1.4 kg/cm2, 1.1 X 1.4 bar,
16.0 X 20.3 psi)
a. Install the radiator cap tester 1 and radiator
cap tester adapter 2 to the radiator cap 3 .
Radiator cap tester
90890-01325, YU-24460-01
Radiator cap tester adapter
90890-01352, YU-33984
b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
4. Check:
S radiator fan
Damage ! Replace.
Malfunction ! Check and repair.
Refer to COOLING SYSTEM in chapter 8.
6-3
RADIATOR
COOL
EAS00456
6-4
OIL COOLER
COOL
EAS00457
OIL COOLER
Order
Job/Part
Qty
1
2
3
4
5
6
7
8
9
10
11
Remarks
1
1
1
1
1
1
1
1
1
1
2
6-5
OIL COOLER
COOL
EAS00458
EAS00459
6-6
THERMOSTAT
COOL
EAS00461
THERMOSTAT
Order
Job/Part
Qty
1
2
3
Remarks
1
1
1
For installation, reverse the removal
procedure.
6-7
THERMOSTAT
COOL
EAS00462
Thermostat
Thermometer
Water
Container
Fully closed
Fully open
NOTE:
If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious
overheating or overcooling.
2. Check:
S thermostat housing cover
Cracks/damage ! Replace.
NOTE:
Before installing the thermostat cover to the cylinder head, lubricate the O-ring with a thin coat
of lithium soap based grease.
6-8
THERMOSTAT
COOL
3. Fill:
S cooling system
(with the specified amount of the recommended coolant)
Refer to CHANGING THE COOLANT in
chapter 3.
4. Check:
S cooling system
Leaks ! Repair or replace any faulty part.
5. Measure:
S radiator cap opening pressure
Below the specified pressure ! Replace the
radiator cap.
Refer to CHECKING THE RADIATOR.
6-9
WATER PUMP
COOL
EAS00408
WATER PUMP
Order
Job/Part
Qty
1
2
3
4
5
Remarks
Remove the parts in the order listed.
Refer to COWLINGS in chapter 3.
Drain.
Refer to CHANGING THE COOLANT in
chapter 3.
1
1
1
1/1
1
NOTE:
It is not necessary to remove the water
pump unless the coolant level is extremely
low or the coolant contains engine oil.
For installation, reverse the removal
procedure.
6-10
WATER PUMP
COOL
Order
1
2
3
4
5
6
7
8
Job/Part
Disassembling the water pump
Water pump cover
O-ring
Impeller shaft
Circlip
Water pump seal
Oil seal
Bearing
Water pump housing
Qty
Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
6-11
WATER PUMP
COOL
EAS00471
2. Remove:
S water pump seal 1
NOTE:
Remove the water pump seal from the outside
of the water pump housing.
2 Water pump housing
3. Remove:
S oil seal 1
(with a thin, flat-head screwdriver)
NOTE:
Remove the oil seal from the outside of the water pump housing.
4. Remove:
S bearing 1
NOTE:
Remove the bearing from inside of the water
pump housing.
5. Remove:
S rubber damper holder 1
S rubber damper 2
(from the impeller, with a thin, flat-head
screwdriver)
NOTE:
Do not scratch the impeller shaft.
6-12
WATER PUMP
COOL
EAS00473
EAS00475
CAUTION:
Never lubricate the water pump seal surface
with oil or grease.
NOTE:
S Install the water pump seal with the special
tools.
S Before installing the water pump seal, apply
Yamaha bond No.1215 or Quick Gasket 2 to
the water pump housing 3 .
6-13
WATER PUMP
COOL
3. Install:
S rubber damper New 1
S rubber damper holder New 2
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
4. Measure:
S impeller shaft tilt
Out of specification ! Repeat steps (3) and
(4).
CAUTION:
Make sure the rubber damper and rubber
damper holder are flush with the impeller.
Impeller shaft tilt limit
0.15 mm (0.006 in)
1 Straightedge
2 Impeller
6-14
WATER PUMP
COOL
NOTE:
Align the projection a at the oil pump shaft and
water pump shaft groove b .
2. Install:
S water pump outlet hose 1
S water pump inlet hose 2
NOTE:
S Install the inlet hose with yellow a mark positioned outside.
S Install the hose clamp with its screw head
pointed to the inner side not to contact with the
cowling.
3. Fill:
S coolant
Refer to CHANGING THE COOLANT in
chapter 3.
6-15
FI
sensor
Fuel delivery hose
Fuel tank
Fuel pump
Fuel return hose
8 Intake
13 Coolant
19 Atmospheric pressure
14
15
10
11
12
air pressure
sensor
Throttle position sensor
Fuel injector
Catalytic converter
Crankshaft
position
sensor
16
17
18
7-1
temperature
sensor
Spark plug
Cylinder identification
sensor
Pressure regulator
Battery
ECU
sensor
relay
21 Engine trouble warning
light
22 Lean
switch
angle
cut-off
FI
WIRING DIAGRAM
1 Main switch
5 Battery
6 Fuse (main)
9 Fuse (fuel injection)
10 Fuse (ignition)
11 Starting circuit cut-off relay
12 Sidestand switch
13 Fuel pump
14 ECU
15 Ignition coil
16 Spark plug
17 Fuel injector
19 Neutral switch
20 Crankshaft position sensor
21 Intake air temperature sensor
22 Coolant temperature sensor
23 Throttle position sensor
24 Intake air pressure sensor
25 Atmospheric pressure sensor
26 Cylinder identification sensor
27 Speed sensor
28 Lean angle cut-off switch
35 Multi-function meter
44 Engine stop switch
7-2
FI
ECUs operation
FI operation
Vehicle operation
Flashing*
Warning provided
when unable to start
engine
Operation stopped
Remains ON
Malfunction detected
Operated with
substitute
characteristics
in accordance with the
description of the
malfunction.
* The warning light flashes when any one of the conditions listed below is present and the start switch is
pushed.
11:
30:
12:
41:
19:
Sidestand switch
(open circuit in wire to ECU)
50:
EAS00901
7-3
FI
EAS00902
Symptom
Fail-safe action
Engine
startability
Vehicle
drivability
Cylinder identification
sensor
Unable
Able
Crankshaft position
sensor
Unable
Unable
Able
Able
Able
Able
-- (No start)
19
Unable
Unable
20
Able
Able
21
Coolant temperature
sensor
Able
Able
22
Intake temperature
sensor
Able
Able
23
Atmospheric pressure
sensor
Able
Able
Faulty ignition
Able
(depending
on the number of faulty
cylinders)
Able
(depending
on the number of faulty
cylinders)
Unable
Unable
Able
Depending
on the malfunction
case.
Depending
on the malfunction
case.
--
44
Able
Able
46
--
Unable
Able
50
ECU internal
malfunction (memory
check error)
Unable
Unable
Unable
11
12
13
14
15
16
Item
33
34
35
36
30
41
42
43
7-4
FI
TROUBLESHOOTING CHART
Engine operation is not normal or the engine trouble warning light is on.
* Engine trouble warning light may not come on even if the engine operation is not normal.
The engine trouble warning light does not come
on.
Check the operation of following sensors and actuators in the Diagnostic mode (Refer to Diagnostic mode table in chapter 7.)
01: Throttle position sensor (throttle angle)
30: Ignition coil #1
31: Ignition coil #2
32: Ignition coil #3
33: Ignition coil #4
36: Injector #1
37: Injector #2
38: Injector #3
39: Injector #4
48: Al system solenoid
OK
NG
Malfunction of engine
Defective sensor
or actuator
OK
NG
OK
Fault code
number displayed
OK
7-5
FI
EAS00905
DIAGNOSTIC MODE
Setting the diagnostic mode
1. Turn the main switch to OFF and set the engine stop switch to ON.
2. Disconnect the wire harness coupler from
the fuel pump.
3. Simultaneously press and hold the SELECT and RESET buttons, turn the main
switch to ON, and continue to press the buttons for 8 seconds or more.
NOTE:
S All displays on the meter disappear except the
clock and tripmeter displays.
S dIAG appears on the clock LCD.
4. Press the SELECT button to select the CO
adjustment mode CO or the diagnostic
mode dIAG.
5. After selecting dIAG, simultaneously press
the SELECT and RESET buttons for 2 seconds or more to execute the selection.
6. Set the engine stop switch to OFF.
7. Select the diagnostic code number that applies to the item that was verified with the
fault code number by pressing the SELECT
and RESET buttons.
NOTE:
S The diagnostic code number appears on the
clock LCD (01-70).
S To decrease the selected diagnostic code
number, press the RESET button. Press the
RESET button for 1 second or longer to automatically decrease the diagnostic code numbers.
S To increase the selected diagnostic code number, press the SELECT button. Press the
SELECT button for 1 second or longer to automatically increase the diagnostic code numbers.
8. Verify the operation of the sensor or actuator.
S Sensor operation
The data representing the operating conditions of the sensor appears on the trip LCD.
S Actuator operation
Set the engine stop switch to ON to operate
the actuator.
* If the engine stop switch is set to ON, set it
to OFF, and then set it to ON again.
9. Turn the main switch to OFF to cancel the
the diagnostic mode.
7-6
FI
Symptom
11
S
S
S
S
S
S
S
S
S
S
S
S
S
S
03
S
S
S
S
S
12
13
14
15
Diagnostic
code
03
01
16
19
03
02
S
S
S
S
06
S
S
S
S
05
S
S
S
S
02
S Overturned.
S Malfunction in ECU.
20
21
22
23
30
7-7
01
20
08
Symptom
FI
Diagnostic
code
S
S
S
S
30
S
S
S
S
31
S
S
S
S
32
S
S
S
S
33
08
S
S
S
S
S
S
07
21
43
09
44
60
46
50
33
34
35
36
41
42
Er-1
Er-2
Er-3
Er-4
7-8
FI
EAS00907
Item
Description of action
Throttle angle
0 X 125 degrees
S Fully closed position (15 X 17)
S Fully open position (97 X 100)
Atmospheric
pressure
Pressure difference
(atmospheric
pressure-intake air
pressure)
10 X 200 mmHg
Intake temperature
Coolant temperature
08
09
0 X 18.7 V
Normally, approximately 12.0 V
Sidestand switch
Stand retracted: ON
Stand extended: OFF
Neutral switch
Neutral: ON
In gear: OFF
Ignition coil #1
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates ignition
coil #1 for five times every second and illuminates the
engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Ignition coils #2
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates ignition
coil #2 for five times every second and illuminates the
engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
01
02
03
05
06
07
20
21
30
31
7-9
Item
Ignition coil #3
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates ignition
coil #3 for five times every second and illuminates the
engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Ignition coil #4
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates ignition
coil #4 for five times every second and illuminates the
engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Injector #1
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the
injector five times every second and illuminates the engine
trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Injector #2
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the
injector five times every second and illuminates the engine
trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Injector #3
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the
injector five times every second and illuminates the engine
trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Injector #4
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the
injector five times every second and illuminates the engine
trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
AI system solenoid
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the AI
system solenoid five times every second and illuminates the
engine trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the fuel
injection system relay five times every second and
illuminates the engine trouble warning light (the light is OFF
when the relay is ON, and the light is ON when the relay is
OFF).
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the
radiator fan motor relay five times every 5 seconds and
illuminates the engine trouble warning light. (ON 2 seconds,
OFF 3 seconds)
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
32
33
36
37
38
39
48
50
51
Description of action
FI
7-10
FI
Item
Headlight relay 1
After 1 second has elapsed from the time the engine stop
switch has been turned from OFF to ON, it actuates the
headlight relay five times every 5 seconds and illuminates
the engine trouble warning light. (ON 2 seconds, OFF 3
seconds)
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.
Malfunction history
code display
11 X 50
(00) Displays when there is no
malfunction.
Malfunction history
code erasure
00 X 21
(00) Displays when there is no
malfunction.
Control number
00 X 255
52
60
61
62
70
Description of action
7-11
FI
EAS00908
TROUBLESHOOTING DETAILS
This section describes the countermeasures per fault code number displayed on the meter. Check and
service the items or components that are the probable cause of the malfunction following the order in
the TROUBLESHOOTING CHART.
After the check and service of the malfunctioned part has been completed, reset the meter display according to the Reinstatement method.
Fault code No.:
Fault code number displayed on the meter when the engine failed to work normally. (Refer to the
Fault code table.)
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. (Refer to DIAGNOSTIC
MODE.)
Fault code No.
11
Symptom
No normal signals are received from the cylinder identification sensor when the
engine is started or while the motorcycle travels.
Reinstatement
method
Replace if defective.
1. Connect the pocket tester (DC 20 V) to the
cylinder identification sensor coupler terminal
as shown.
Reinstated by
starting the engine
and operating it at
idle.
7-12
Reinstated by
starting the engine
and operating it at
idle.
FI
12
Symptom
Reinstatement
method
Replace if defective.
1. Disconnect the crankshaft position sensor coupler from the wire harness.
2. Connect the pocket tester (
100) to the
crankshaft position sensor coupler as shown.
Reinstated by
cranking the
engine.
7-13
13
Symptom
FI
Reinstatement
method
Replace if defective.
1. Connect the pocket tester (DC 20 V) to the
intake air pressure sensor coupler terminal as
shown.
Reinstated by
turning the main
switch ON.
7-14
14
Symptom
FI
Intake air pressure sensor - hose system malfunction (clogged or detached hose).
Reinstatement
method
Reinstated by
starting the engine
and operating it at
idle.
Replace if defective.
Refer to Fault code No. 13.
15
Symptom
Reinstatement
method
Replace if defective.
Refer to THROTTLE BODIES section.
Reinstated by
turning the main
switch ON.
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Black / Blue - Black / Blue
Yellow - Yellow
Blue - Blue
Installed condition of throttle position sensor.
16
Symptom
Reinstatement
method
Replace if defective.
Refer to THROTTLE BODIES section.
Reinstated by
starting the engine,
operating it at idle,
and then racing it.
7-15
19
Symptom
FI
Open circuit is detected in the input line from the sidestand switch to the ECU.
Reinstatement
method
Replace if defective.
Refer to CHECKING THE SWITCHES in
chapter 8.
If the transmission
is in gear, it is
reinstated by
retracting the
sidestand.
If the transmission
is in neutral, it is
reinstated by
reconnecting the
wiring.
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between the starting circuit cut-off relay coupler
and main switch coupler
Blue / Yellow Blue / Yellow
Between the main switch coupler and ECU coupler
Blue / Black Blue / Black
Fault code No.
20
Symptom
Reinstatement
method
Reinstated by
turning the main
switch ON.
Replace if defective.
Refer to Fault code No.13 or No.23.
21
Symptom
Reinstatement
method
Replace if defective.
Refer to COOLING SYSTEM in chapter 8.
Reinstated by
turning the main
switch ON.
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Black / Blue - Black / Blue
Green / White - Green / White
Connected condition of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
7-16
FI
7-17
Reinstatement
method
Reinstated by
turning the main
switch ON.
23
Symptom
FI
Reinstatement
method
Replace if defective.
1. Connect the pocket tester (DC 20 V) to the
atmospheric pressure sensor coupler terminal
as shown.
Reinstated by
turning the main
switch ON.
7-18
30
Symptom
FI
Reinstatement
method
Replace if defective.
1. Remove the lean angle cut-off switch from the
motorcycle.
2. Connect the lean angle cut-off switch coupler
to the wireharness.
3. Connect the pocket tester (DC 20 V) to the
lean angle cut-off switch coupler as shown.
Reinstated by
turning the main
switch ON
(however, the
engine cannot be
restarted unless
the main switch is
first turned OFF).
7-19
33
Symptom
FI
Reinstatement
method
Replace if defective.
Refer to IGNITION SYSTEM in chapter 8.
Reinstated by
starting the engine
and
d operating
ti it att
idle.
In case of multiple
cylinder open or
short circuit in
lead, make sure to
turn ON and OFF
the main switch
after each time of
cranking.
34
Symptom
Reinstatement
method
Replace if defective.
Refer to IGNITION SYSTEM in chapter 8.
Reinstated by
starting the engine
and operating it at
idle.
In case of multiple
cylinder open or
short circuit in
lead, make sure to
turn ON and OFF
the main switch
after each time of
cranking.
35
Symptom
Reinstatement
method
Replace if defective.
Refer to IGNITION SYSTEM in chapter 8.
Reinstated by
starting the engine
and operating it at
idle.
In case of multiple
cylinder open or
short circuit in
lead, make sure to
turn ON and OFF
the main switch
after each time of
cranking.
7-20
36
Symptom
FI
Reinstatement
method
Replace if defective.
Refer to IGNITION SYSTEM in chapter 8.
Reinstated by
starting the engine
and operating it at
idle.
In case of multiple
cylinder open or
short circuit in
lead, make sure to
turn ON and OFF
the main switch
after each time of
cranking.
41
Symptom
Reinstatement
method
Replace if defective.
Refer to Fault code No. 30.
Reinstated by
turning the main
switch ON.
7-21
42
FI
Symptom
Replace if defective.
Refer to CHECKING THE SWITCHES in
chapter 8.
Replace if defective.
Refer to TRANSMISSION in chapter 5.
Repair or replace if there is an open or short
circuit.
Between switch connector and ECU coupler
Sky blue - Black / Yellow
If there is a malfunction, repair it and connect it
securely.
Neutral switch connector
Main wiring harness ECU coupler
7-22
Reinstatement
method
Reinstated by
starting the
engine, and
inputting the
vehicle speed
signals by
operating the
motorcycle at a
low speed of 20 to
30 km / h.
43
Symptom
FI
Reinstatement
method
Malfunction in ECU
Reinstated by
starting the engine
and operating it at
idle.
Replace if defective.
1. Disconnect the starting circuit cut-off relay
from the wire harness.
2. Connect the pocket tester (
1) and battery
(12 V) to the starting circuit cut-off relay terminals as shown.
Battery positive terminal ! red / black 1
Battery positive terminal ! light green 2
Tester positive probe ! red 3
Tester negative probe ! red / blue 4
3. Does the starting circuit cut-off relay have continuity between red and red / blue?
Connected condition of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
7-23
44
Symptom
FI
Reinstatement
method
Malfunction in ECU
Reinstated by
turning the main
switch ON.
46
Symptom
Faulty battery
Reinstated by
Replace or change the battery
Refer to CHECKING AND CHARGING THE BAT- starting the engine
and operating it at
TERY in chapter 3.
idle.
Repair or replace if there is an open or short cir-
Reinstatement
method
cuit.
S Between battery and main switch
Red Red
S Between main switch and Fuse (ignition)
Brown/blue Brown/blue
S Between Fuse (ignition) and ECU
Red/white Red/white
Connected condition of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
Fault code No.
50
Symptom
Faulty ECU memory. (When this malfunction is detected in the ECU, the fault
code number might not appear on the meter.)
Reinstatement
method
Malfunction in ECU
Reinstated by
turning the main
switch ON.
7-24
Er-1
Symptom
FI
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Yellow / Blue - Yellow / Blue
Black / White - Black / White
Connected condition of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
Malfunction in meter
Malfunction in ECU
Er-2
Symptom
Reinstatement
method
Reinstated by
turning the main
switch ON.
No signal are received from the ECU within the specified duration.
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Yellow / Blue - Yellow / Blue
Black / White - Black / White
Connected condition of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
Malfunction in meter
Malfunction in ECU
Er-3
Symptom
Reinstatement
method
Reinstated by
turning the main
switch ON.
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Yellow / Blue - Yellow / Blue
Black / White - Black / White
Connected condition of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
Malfunction in meter
Malfunction in ECU
7-25
Reinstatement
method
Reinstated by
turning the main
switch ON.
Er-4
Symptom
FI
Open or short circuit in wiring harness and / or Repair or replace if there is an open or short
sub lead.
circuit.
Between sensor coupler and ECU coupler
Yellow / Blue - Yellow / Blue
Black / White - Black / White
Connected condition of connector
Inspect the coupler for any pins that may
have pulled out.
Check the locking condition of the coupler.
Malfunction in meter
Malfunction in ECU
7-26
Reinstatement
method
Reinstated by
turning the main
switch ON.
THROTTLE BODIES
FI
THROTTLE BODIES
Order
Job/Part
Qty
1
2
3
4
5
2
1
1
4
1
7-27
Remarks
Remove the parts in the order listed.
Refer to SEATS and FUEL TANK in
chapter 3.
Refer to AIR FILTER CASE in chapter 3.
Drain.
Refer to CHANGING THE COOLANT in
chapter 3.
Disconnect.
Loosen.
THROTTLE BODIES
Order
6
7
8
9
Job/Part
Throttle cable
Plunger control unit hose
Throttle body joint
Heat protector
Qty
2
2
4
1
FI
Remarks
Disconnect.
Disconnect.
7-28
THROTTLE BODIES
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the injector
Throttle position sensor coupler
Intake air pressure sensor
Cylinder #1-injector coupler
Cylinder #2-injector coupler
Cylinder #3-injector coupler
Cylinder #4-injector coupler
Sub wire harness 2
Negative pressure hose
Pressure regulator
Qty
1
1
1
1
1
1
1
1
1
7-29
FI
Remarks
Remove the parts in the order listed.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
THROTTLE BODIES
Order
10
11
12
13
14
Job/Part
Intake air pressure sensor
Fuel distributor
Injector
Throttle position sensor
Throttle body assembly
Qty
FI
Remarks
1
1
4
1
1
For installation, reverse the removal
procedure.
7-30
THROTTLE BODIES
FI
EAS00911
CAUTION:
The throttle bodies should not be disassembled.
EAS00912
EAS00913
2. Check:
S fuel passages
Obstruction ! Clean.
a. Wash the throttle body in a petroleumbased
solvent.
Do not use any caustic carburetor cleaning
solution.
b. Blow out all of passages with compressed
air.
7-31
THROTTLE BODIES
FI
7-32
THROTTLE BODIES
FI
EAS00916
CHECKING
AND
ADJUSTING
THROTTLE POSITION SENSOR
THE
NOTE:
Before adjusting the throttle position sensor, the
engine idling speed should be properly adjusted.
1. Check:
S throttle position sensor
a. Disconnect the throttle position sensor coupler.
b. Remove the throttle position sensor from the
throttle body.
c. Connect the pocket tester (
1k) to the
throttle position sensor.
Positive tester probe ! blue terminal 1
Negative tester probe ! black terminal 2
d. Measure the maximum throttle position sensor resistance.
Out of specification ! Replace the throttle
position sensor.
Maximum throttle position
sensor resistance
3.5 X 6.5 k at 20_C (68_F)
(blue - black)
e. Connect the pocket tester (
throttle position sensor.
1k) to the
7-33
THROTTLE BODIES
FI
2. Adjust:
S throttle position sensor angle
a. Connect the throttle position sensor coupler
to the wire harness.
b. Connect the digital circuit tester to the throttle
position sensor.
Tester positive probe !
yellow terminal 1
Tester negative probe !
black terminal 2
7-34
FI
EAS00507
EAS0097
7-35
A To cylinder #1 and #2
B To cylinder #3 and #4
7-36
FI
FI
EAS00510
2. Check:
S reed valve 1
S reed valve stopper
S reed valve seat
Cracks/damage ! Replace the reed valve.
3. Measure:
S reed valve bending limit a
Out of specification ! Replace the reed
valve.
Reed valve bending limit
0.4 mm (0.016 in)
1 Surface plate
4. Check:
S air cut-off valve
Cracks/damage ! Replace.
7-37
FI
5. Check
S air induction system solenoid
a. Remove the air induction system solenoid
coupler from the wire harness.
b. Connect the pocket tester (
1) to the air
induction system solenoid terminal as
shown.
Tester positive probe ! orange 1
Tester negative probe ! green 2
c. Measure the air induction system solenoid
resistance.
Air induction system solenoid
resistance
18 X 22 at 20_C (68_F)
d. Out of specification ! Replace.
7-38
ELECTRICAL COMPONENTS
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
8
Main switch
Front brake light switch
Clutch switch
Battery
Starter relay
Fuse (main)
Neutral switch
Rear brake light switch
9
10
11
12
13
14
8-1
Sidestand switch
Oil level switch
Radiator fan motor
Horn
Ignition coil
Fuse box
ELEC
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
ELEC
Speed sensor
Crankshaft position sensor
Cylinder identification sensor
Radiator fan motor relay
Headlight relay (on / off)
Headlight relay (dimmer)
8-2
ELEC
EAS00730
CAUTION:
Never insert the tester probes into the coupler terminal slots. Always insert the probes
from the opposite end of the coupler 1 taking care not to loosen or damage the leads.
Pocket tester
90890-03112, YU-3112
NOTE:
S Before checking for continuity, set the pocket
tester to 0 and to the
1 range.
S When checking for continuity, switch back and
forth between the switch positions a few times.
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions a are shown in the far left
column and the switch lead colors b are shown
in the top row in the switch illustration.
NOTE:
8-3
ELEC
EAS00731
1
2
3
4
5
Main switch
Horn switch
Dimmer switch
Turn signal switch
Clutch switch
6
7
8
9
10
Sidestand switch
Engine stop switch
Front brake light switch
Start switch
Oil level switch
8-4
11 Neutral switch
12 Rear brake light switch
13 Fuse box
ELEC
EAS00732
8-5
ELEC
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
CAUTION:
S Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in
the coupler.
S Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb, and the luminous flux will be adversely affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Check:
S bulb (for continuity)
(with the pocket tester)
No continuity ! Replace.
Pocket tester
90890-03112, YU-3112
NOTE:
Before checking for continuity, set the pocket
tester to 0 and to the
1 range.
8-6
ELEC
WARNING
S A wire that is used as a jumper lead must
have at least the same capacity of the battery lead, otherwise the jumper lead may
burn.
S This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.
c. When the jumper leads are connected to the
terminals the respective LED should illuminate.
Does not light ! Replace the meter assembly.
8-7
IGNITION SYSTEM
ELEC
EAS00735
IGNITION SYSTEM
CIRCUIT DIAGRAM
1
5
6
10
11
12
14
15
16
19
20
28
44
55
8-8
Main switch
Battery
Fuse (main)
Fuse (ignition)
Starting circuit cut-off relay
Sidestand switch
ECU
Ignition coil
Spark plug
Neutral switch
Crankshaft position sensor
Lean angle cut-off switch
Engine stop switch
Clutch switch
IGNITION SYSTEM
EAS00737
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to CHECKING AND CHARGING
THE BATTERY in chapter 3.
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
EAS00741
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. air filter case
4. bottom cowling
5. side cowlings
S Troubleshoot with the following special tool(s).
3. Spark plugs
The following procedure applies to all of the
spark plugs.
S Check the condition of the spark plug.
S Check the spark plug type.
S Measure the spark plug gap.
Refer to CHECKING THE SPARK PLUGS
in chapter 3.
Standard spark plug
CR9EK or CR10EK (NGK)
Spark plug gap
0.6 X 0.7 mm (0.0236 X 0.0276 in)
EAS00738
NO
Re-gap or replace
the spark plug.
NO
Replace the fuse(s).
8-9
ELEC
IGNITION SYSTEM
EAS00743
EAS00747
1k) to the
YES
The ignition system
is OK.
NO
Replace the ignition
coil.
8-10
IGNITION SYSTEM
EAS00748
ELEC
EAS00750
NO
Replace the right
handlebar switch.
EAS00751
9. Neutral switch
S Check the neutral switch for continuity.
Refer to CHECKING THE SWITCHES.
S Is the neutral switch OK?
YES
NO
Replace the neutral
switch.
EAS00752
NO
Replace the
crankshaft position
sensor.
YES
EAS00749
7. Main switch
S Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
S Is the main switch OK?
YES
NO
EAS00763
NO
Replace the main
switch.
YES
NO
Replace the clutch
switch.
8-11
IGNITION SYSTEM
ELEC
EAS00753
NOTE:
When you switch the positive and negative
tester probes, the readings in the above chart
will be reversed.
Continuity
NO
No
continuity
8-12
IGNITION SYSTEM
YES
NO
Replace the lean
angle cut-off switch.
EAS00754
14. Wiring
S Check the entire ignition systems wiring.
Refer to CIRCUIT DIAGRAM.
S Is the ignition systems wiring properly connected and without defects?
YES
Replace the ignitor
unit.
NO
Properly connect or
repair the ignition
systems wiring.
8-13
ELEC
ELEC
EAS00755
8-14
Main switch
Battery
Fuse (main)
Starter relay
Starter motor
Fuse (ignition)
Starting circuit cut-off relay
Sidestand switch
Neutral switch
Engine stop switch
Start switch
Clutch switch
ELEC
EAS00756
8-15
Battery
Main fuse
Main switch
Ignition fuse
Engine stop switch
Starting circuit cut-off relay
Diode
Clutch switch
Sidestand switch
Neutral switch
Start switch
Starter relay
Starter motor
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to CHECKING AND CHARGING
THE BATTERY in chapter 3.
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
EAS00758
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. left side cowling
S Troubleshoot with the following special tool(s).
3. Starter motor
S Connect the positive battery terminal 1 and
starter motor lead 2 with a jumper lead 3 .
Pocket tester
90890-03112, YU-3112
EAS00738
WARNING
S A wire that is used as a jumper lead
must have at least the same capacity or
more as that of the battery lead, otherwise the jumper lead may burn.
S This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
NO
Replace the fuse(s).
NO
Repair or replace the
starter motor.
8-16
ELEC
EAS00759
S Does the starter relay have continuity between red and black?
YES
NO
Replace the starter
relay.
EAS00749
6. Main switch
S Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
S Is the main switch OK?
YES
NO
NO
Replace the main
switch.
EAS00750
EAS00761
5. Starter relay
S Disconnect the starter relay coupler from the
coupler.
S Connect the pocket tester ( 1) and battery
(12 V) to the starter relay coupler as shown.
YES
NO
Replace the right
handlebar switch.
EAS00751
8. Neutral switch
S Check the neutral switch for continuity.
Refer to CHECKING THE SWITCHES.
S Is the neutral switch OK?
YES
NO
Replace the neutral
switch.
8-17
ELEC
EAS00766
9. Sidestand switch
12. Wiring
YES
NO
YES
Replace the sidestand switch.
EAS00763
NO
Replace the clutch
switch.
EAS00764
NO
Replace the right
handlebar switch.
8-18
NO
Properly connect or
repair the starting
systems wiring.
STARTER MOTOR
ELEC
EAS00767
STARTER MOTOR
Order
1
2
Job/Part
Removing the starter motor
Rider seat
Fuel tank
Left side cowling
Starter motor lead
Starter motor
Qty
Remarks
Remove the parts in the order listed.
Refer to SEATS in chapter 3.
Refer to FUEL TANK in chapter 3.
Refer to COWLINGS in chapter 3.
1
1
For installation, reverse the removal
procedure.
8-19
STARTER MOTOR
ELEC
EAS00768
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job/Part
Disassembling the starter motor
O-ring
Front cover
Lock washer
Oil seal
Bearing
Washer set
Rear cover
Washer set
O-ring
Brush holder
Armature assembly
Starter motor yoke
Qty
Remarks
Disassembly the parts in the order listed.
1
1
1
1
1
1
1
1
2
1
1
1
For assembly, reverse the disassembly
procedure.
8-20
STARTER MOTOR
ELEC
EAS00770
4. Measure:
S armature assembly resistances (commutator and insulation)
Out of specification ! Replace the starter
motor.
a. Measure the armature assembly resistances
with the pocket tester.
Pocket tester
90890-03112, YU-3112
Armature coil
Commutator resistance 1
0.0012 X 0.0022
at 20_C (68_F)
Insulation resistance 2
Above 1 M at 20_C (68_F)
b. If any resistance is out of specification, replace the starter motor.
8-21
STARTER MOTOR
ELEC
5. Measure:
S brush length a .
Out of specification ! Replace the brushes
as a set.
Brush length wear limit
3.5 mm (0.14 in)
6. Measure:
S brush spring force
Out of specification ! Replace the brush
springs as a set.
Brush spring force
7.16 X 9.52 N
(730 X 971 gf, 25.77 X 34.27 oz)
7. Check:
S gear teeth
Damage/wear ! Replace the gear.
8. Check:
S bearing
S oil seal
Damage/wear ! Replace the defective
part(s).
EAS00772
2. Install:
S starter motor yoke 1
S O-ring 2 New
S front cover 3
Srear cover 4
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the front and
starter motor rear covers.
8-22
ELEC
CHARGING SYSTEM
EAS00773
CHARGING SYSTEM
CIRCUIT DIAGRAM
2
3
5
6
8-23
A.C. magneto
Rectifier/ regulator
Battery
Fuse (main)
CHARGING SYSTEM
ELEC
EAS00774
TROUBLESHOOTING
The battery is not being charged.
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil resistance 1
5. stator coil resistance 2
6. wiring connections
(of the entire charging system)
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
EAS00775
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. bottom cowling
S Troubleshoot with the following special tool(s).
3. Charging voltage
S Set the engine tachometer to the ignition coil
of cylinder #1.
S Connect the pocket tester (DC 20 V) to the
battery as shown.
Positive tester probe !
positive battery terminal
Negative tester probe !
negative battery terminal
Pocket tester
90890-03112, YU-3112
EAS00738
1. Main fuse
S Check the main fuse for continuity.
Refer to CHECKING THE FUSES in chapter 3.
S Are the main fuse OK?
YES
NO
S Start the engine and let it run at approximately 5,000 r/min.
S Measure the charging voltage.
Charging voltage
14 V at 5,000 r/min
EAS00739
2. Battery
S Check the condition of the battery.
Refer to CHECKING AND CHARGING
THE BATTERY in chapter 3.
NOTE:
Make sure the battery is fully charged.
S Is the charging voltage within specification?
NO
YES
The charging circuit
is OK.
8-24
ELEC
CHARGING SYSTEM
EAS00776
NO
Replace the stator
coil assembly.
NO
EAS00779
6. Wiring
8-25
NO
Properly connect or
repair the charging
systems wiring.
LIGHTING SYSTEM
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
8-26
ELEC
LIGHTING SYSTEM
1
5
6
10
14
38
40
47
51
52
56
63
64
65
66
67
Main switch
Battery
Fuse (main)
Fuse (ignition)
ECU
High beam indicator light
Meter light
Fuse (headlight)
Headlight relay (on / off)
Headlight relay (dimmer)
Dimmer switch
Front turn signal/position light (right)
Front turn signal/position light (left)
Headlight
License light
Tail/ brake light
8-27
ELEC
LIGHTING SYSTEM
ELEC
EAS00781
TROUBLESHOOTING
Any of the following fail to light: headlight,
high beam indicator light, taillight, licence
light or meter light.
Check:
1. main, ignition and headlight fuses
2. battery
3. main switch
4. dimmer switch
5. headlight relay (on/off)
6. headlight relay (dimmer)
7. wiring connections
(of the entire lighting system)
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
EAS00749
3. Main switch
S Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
S Is the main switch OK?
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. side cowlings
4. rear cowling
S Troubleshoot with the following special tool(s).
YES
NO
Replace the main
switch.
EAS00784
Pocket tester
90890-03112, YU-3112
4. Dimmer switch
S Check the dimmer switch for continuity.
Refer to CHECKING THE SWITCHES.
S Is the dimmer switch OK?
EAS00738
YES
NO
The dimmer switch is
faulty. Replace the
left
handlebar
switch.
NO
Replace the fuse(s).
EAS00739
2. Battery
S Check the condition of the battery.
Refer to CHECKING AND CHARGING
THE BATTERY in chapter 3.
8-28
LIGHTING SYSTEM
ELEC
YES
NO
Replace the headlight relay (dimmer).
EAS00787
7. Wiring
S Check the entire lighting systems wiring.
Refer to CIRCUIT DIAGRAM.
S Is the lighting systems wiring properly connected and without defects?
S Does the headlight relay (on/off) have continuity between red/yellow and black/blue?
YES
NO
YES
8-29
NO
Properly connect or
repair the lighting
systems wiring.
LIGHTING SYSTEM
ELEC
EAS00788
Headlight
Positive tester probe ! black/yellow 3
Negative tester probe ! black 4
B High beam
NO
Replace the headlight bulb, socket or
both.
2. Voltage
S Connect the pocket tester (DC 20 V) to the
headlight and meter assembly couplers as
shown.
A When the dimmer switch is set to
B When the dimmer switch is set to
Headlight
Positive tester probe ! black/blue 1
Negative tester probe ! black 2
YES
This circuit is OK.
8-30
NO
The wiring circuit
from the main switch
to the headlight coupler is faulty and
must be repaired.
ELEC
LIGHTING SYSTEM
EAS00789
EAS00790
YES
NO
YES
NO
Replace
the
tail/brake light assembly.
2. Voltage
2. Voltage
YES
This circuit is OK.
NO
YES
8-31
NO
Wiring circuit from
the main switch to
the tail/brake light
coupler is faulty and
must be repaired.
LIGHTING SYSTEM
ELEC
EAS00792
NO
YES
Replace the license
light bulb, socket or
both.
NO
Replace the turn signal/position light bulb,
socket or both.
2. Voltage
2. Voltage
YES
NO
8-32
NO
The wiring circuit
from the main switch
to the turn signal/
position light connectors is faulty and
must be repaired.
SIGNALING SYSTEM
EAS00793
SIGNALING SYSTEM
CIRCUIT DIAGRAM
8-33
ELEC
SIGNALING SYSTEM
1
5
6
10
11
13
14
19
27
30
31
32
33
34
35
37
39
41
43
46
53
57
58
59
60
61
62
63
64
67
Main switch
Battery
Fuse (main)
Fuse (ignition)
Starting circuit cut-off relay
Fuel pump
ECU
Neutral switch
Speed sensor
Fuel level warning light
Oil level warning light
Neutral indicator light
Tachometer
Shift timing indicator light
Multi-function meter
Coolant temperature indicator light
Turn signal indicator light
Oil level switch
Front brake light switch
Fuse (signal)
Rear brake light switch
Horn switch
Turn signal switch
Horn
Turn signal relay
Rear turn signal light (right)
Rear turn signal light (left)
Front turn signal / position light (right)
Front turn signal / position light (left)
Tail/ brake light
8-34
ELEC
SIGNALING SYSTEM
ELEC
EAS00794
TROUBLESHOOTING
YES
S Any of the following fail to light: turn signal light, brake light or an indicator light.
S The horn fails to sound.
Check:
1. main, ignition and signaling fuses
2. battery
3. main switch
4. wiring connections
(of the entire signaling system)
EAS00749
3. Main switch
S Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
S Is the main switch OK?
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. bottom cowling
4. side cowlings
5. rear cowling
S Troubleshoot with the following special tool(s).
YES
NO
Replace the main
switch.
4. Wiring
Pocket tester
90890-03112, YU-3112
EAS00738
NO
YES
Check the condition
of each of the signaling systems circuits.
Refer to CHECKING THE LIGHTING
SYSTEM.
NO
NO
Properly connect or
repair the signaling
systems wiring.
EAS00739
2. Battery
S Check the condition of the battery.
Refer to CHECKING AND CHARGING
THE BATTERY in chapter 3.
1. Horn switch
S Check the horn switch for continuity.
Refer to CHECKING THE SWITCHES.
S Is the horn switch OK?
YES
NO
Replace the left handlebar switch.
8-35
ELEC
SIGNALING SYSTEM
EAS00797
2. Voltage
YES
NO
Replace
the
tail/brake light assembly.
NO
NO
Replace the brake
light switch.
3. Voltage
S Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
3. Horn
NO
Replace the horn.
8-36
SIGNALING SYSTEM
YES
This circuit is OK.
NO
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
YES
NO
The wiring circuit
from the main switch
to the turn signal
relay coupler is faulty
and must be repaired.
EAS00799
ELEC
4. Voltage
S Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
NO
NO
Replace the left handlebar switch.
YES
NO
3. Voltage
S Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
5. Voltage
S Connect the pocket tester (DC 20 V) to the
turn signal/position light connector or meter
assembly coupler (wire harness side) as
shown.
A Front turn signal/position light
B Rear turn signal light
C Turn signal indicator light
8-37
SIGNALING SYSTEM
ELEC
YES
NO
Replace the meter
assembly.
2. Neutral switch
S Check the neutral switch for continuity.
Refer to CHECKING THE SWITCHES.
S Is the neutral switch OK?
YES
NO
Replace the neutral
switch.
3. Voltage
S Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
Positive tester probe ! brown 1
Negative tester probe ! ground
S Turn the main switch to ON.
S Set the turn signal switch to
or
.
S Measure the voltage (DC 12 V) of the chocolate 1 or dark green 2 at the turn signal light
connector (wire harness side).
S Is the voltage within specification?
YES
This circuit is OK.
NO
S Turn the main switch to ON.
S Measure the voltage (DC 12 V) of brown at
the meter assembly coupler (wire harness
side).
S Is the voltage within specification?
YES
NO
EAS00801
8-38
SIGNALING SYSTEM
ELEC
EAS00802
3. Voltage
NO
Replace the meter
assembly.
YES
This circuit is OK.
NO
The wiring circuit
from the main switch
to the meter assembly is faulty and must
be repaired.
EAS00803
YES
NO
NO
Replace the meter
assembly.
8-39
SIGNALING SYSTEM
ELEC
2. Fuel sender
3. Voltage
NO
YES
Replace the fuel
pump assembly.
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be repaired.
EAS00806
NO
Replace the meter
assembly.
8-40
SIGNALING SYSTEM
ELEC
2. Speed sensor
3. Voltage
YES
YES
NO
This circuit is OK.
Replace the speed
sensor.
8-41
COOLING SYSTEM
EAS00807
COOLING SYSTEM
CIRCUIT DIAGRAM
1
5
6
10
14
Main switch
Battery
Fuse (main)
Fuse (ignition)
ECU
22
48
49
50
8-42
ELEC
COOLING SYSTEM
EAS00808
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to CHECKING AND CHARGING
THE BATTERY in chapter 3.
Check:
1. main, ignition, and radiator fan motor fuses
2. battery
3. main switch
4. radiator fan motor
5. radiator fan motor relay
6. coolant temperature sensor
7. wiring connections
(the entire cooling system)
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. bottom cowling
4. side cowlings
S Troubleshoot with the following special tool(s).
EAS00749
3. Main switch
S Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
S Is the main switch OK?
YES
Pocket tester
90890-03112, YU-3112
NO
Replace the main
switch.
EAS00738
NO
Replace the fuse(s).
8-43
COOLING SYSTEM
ELEC
EAS00809
NO
The radiator fan motor is faulty and must
be replaced.
S Does the radiator fan motor relay have continuity between brown/green and blue?
YES
NO
Replace the radiator
fan motor relay.
8-44
COOLING SYSTEM
ELEC
EAS00812
WARNING
S Handle the coolant temperature sensor
with special care.
S Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace
it.
NO
Replace the coolant
temperature sensor.
EAS00813
7. Wiring
S Check the entire cooling systems wiring.
Refer to CIRCUIT DIAGRAM.
S Is the cooling systems wiring properly connected and without defects?
YES
This circuit is OK.
8-45
NO
Properly connect or
repair the cooling
systems wiring.
ELEC
EAS00814
1
5
6
9
10
11
13
14
44
8-46
Main switch
Battery
Fuse (main)
Fuse (fuel injection)
Fuse (ignition)
Starting circuit cut-off relay
Fuel pump
ECU
Engine stop switch
ELEC
EAS00815
1 Battery
2 Fuse (main)
3 Main switch
4 Fuse (ignition)
5 Engine stop switch
6 ECU
7 Fuse (fuel injection)
8 Starting circuit cut-off relay
9
8-47
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
Check:
1. Main, ignition and fuel injection fuses
2. Battery
3. Main switch
4. Engine stop switch
5. Starting circuit cut-off relay
(the fuel pump injection system relay)
6. Fuel pump
7. Wiring connections
(the entire fuel system)
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
NOTE:
S Before troubleshooting, remove the following
part(s):
1. Seat
2. Fuel tank
Troubleshoot with the following special tool(s).
EAS00749
3. Main switch
S Check the main switch for continuity.
Refer to CHECKING THE SWITCHES.
Pocket tester
90890-03112, YU-3112
EAS00738
YES
NO
NO
YES
NO
Replace the right
handlebar switch.
8-48
ELEC
EAS00817
NO
NO
Replace
pump.
the
fuel
EAS00818
7. Wiring
S Check the entire fuel pump systems wiring.
Refer to CIRCUIT DIAGRAM.
S Is the fuel systems wiring properly connected and without defects?
YES
Replace the ECU.
8-49
NO
Properly connect or
repair the fuel systems wiring.
ELEC
EAS00819
WARNING
Gasoline is extremely flammable and under
certain circumstances there can be a danger
of an explosion or fire. Be extremely careful
and note the following points:
S Stop the engine before refueling.
S Do not smoke, and keep away from open
flames, sparks, or any other source of fire.
S If you do accidentally spill gasoline, wipe it
up immediately with dry rags.
S If gasoline touches the engine when it is
hot, a fire may occur. Therefore, make sure
the engine is completely cool before performing the following test.
1. Check:
S Fuel pump operation
a. Insert the plug 1 to fuel return hose end.
b. Fill the fuel tank.
c. Put the end of the fuel hose into an open container.
d. Connect the battery (DC 12 V) to the fuel
pump coupler as shown.
Positive battery lead ! red/blue 2
Negative battery lead ! black 3
e. If fuel flows out of the fuel hose, the fuel pump
is OK. If fuel does not flow, replace the fuel
pump.
8-50
SELF-DIAGNOSIS
ELEC
SELF-DIAGNOSIS
The YZF-R6 features a self-diagnosing system for the following circuit(-s):
S Fuel sender
S Oil level switch
If any of these circuits are defective, their respective condition codes will be displayed on the warning
light when the main switch is turn to ON (irrespective of whether the engine is running or not)
Circuit
Defect(-s)
System response
Condition code
Fuel sender
S Open-circuit
S Short-circuit
Refer to *1
S Open-circuit
S Short-circuit
Refer to *2
*1 Condition code
Fuel warning light
*2 Condition code
Oil level warning light
8-51
SELF-DIAGNOSIS
TROUBLESHOOTING
ELEC
1. Wire harness
Check:
1. Fuel sender
2. Oil level switch
YES
NOTE:
S Before troubleshooting, remove the following
part(-s):
1) Seats
2) Fuel tank
3) Lower cowling
S Troubleshoot with the following special
tool(-s).
NO
Repair or replace the
wire harness.
2. Fuel sender
S Check the fuel sender for continuity.
Refer to The fuel level indicator light fails to
come on.
S Is the fuel sender OK?
Pocket tester
90890-03112, YU-3112
YES
1. Fuel sender
CIRCUIT DIAGRAM
13 Fuel pump
35 Multi-function meter
8-52
NO
Replace
pump.
the
fuel
SELF-DIAGNOSIS
2. Oil level switch
CIRCUIT DIAGRAM
35 Multi-function meter
41 Oil level switch
1. Wire harness
S Check the wire harness for continuity.
Refer to CIRCUIT DIAGRAM.
S Is the wire harness OK?
YES
ELEC
NO
Repair or replace the
wire harness.
8-53
NO
Replace the oil level
switch.
STARTING FAILURES
TRBL
SHTG
EAS00844
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for
checks, adjustments, and replacement of parts.
STARTING FAILURES
ENGINE
Cylinder(s) and cylinder head(s)
S Loose spark plug
S Loose cylinder head or cylinder
S Damaged cylinder head gasket
S Worn or damaged cylinder
S Incorrect valve clearance
S Improperly sealed valve
S Incorrect valve-to-valve-seat contact
S Incorrect valve timing
S Faulty valve spring
S Seized valve
Piston(s) and piston ring(s)
S Improperly installed piston ring
S Damaged, worn or fatigued piston ring
S Seized piston ring
S Seized or damaged piston
Air filter
S Improperly installed air filter
S Clogged air filter element
Crankcase and crankshaft
S Improperly assembled crankcase
S Seized crankshaft
FUEL SYSTEM
Fuel tank
S Empty fuel tank
S Clogged fuel filter
S Clogged fuel tank drain hose
S Clogged rollover valve
S Clogged rollover valve hose
S Deteriorated or contaminated fuel
Fuel pump
S Faulty fuel pump
S Faulty fuel pump relay
Throttle body (-ies)
S Deteriorated or contaminated fuel
S Sucked-in air
ELECTRICAL SYSTEMS
Battery
S Discharged battery
S Faulty battery
Fuse(s)
S Blown, damaged or incorrect fuse
S Improperly installed fuse
Spark plug(s)
S Incorrect spark plug gap
S Incorrect spark plug heat range
S Fouled spark plug
S Worn or damaged electrode
S Worn or damaged insulator
Ignition coil(s)
S Cracked or broken ignition coil body
S Broken or shorted primary or secondary
coils
Ignition system
S Faulty ECU
S Faulty crankshaft position sensor
S Faulty cylinder identification sensor
9
9-1
TRBL
SHTG
Starting system
S Faulty starter motor
S Faulty starter relay
S Faulty starting circuit cut-off relay
S Faulty starter clutch
EAS00846
ELECTRICAL SYSTEMS
Battery
S Discharged battery
S Faulty battery
Spark plug(s)
S Incorrect spark plug gap
S Incorrect spark plug heat range
S Fouled spark plug
S Worn or damaged electrode
S Worn or damaged insulator
Ignition coil(s)
S Broken or shorted primary or secondary
coils
S Cracked or broken ignition coil
Ignition system
S Faulty ECU
S Faulty crankshaft position sensor
S Faulty cylinder identification sensor
EAS00848
9-2
TRBL
SHTG
EAS00850
EAS00851
FAULTY CLUTCH
CLUTCH DRAGS
Clutch
S Unevenly tensioned clutch springs
S Warped pressure plate
S Bent clutch plate
S Swollen friction plate
S Bent clutch push rod
S Broken clutch boss
S Burnt primary driven gear bushing
S Match marks not aligned
Engine oil
S Incorrect oil level
S Incorrect oil viscosity (high)
S Deteriorated oil
CLUTCH SLIPS
Clutch
S Improperly assembled clutch
S Improperly adjusted clutch cable
S Loose or fatigued clutch spring
S Worn friction plate
S Worn clutch plate
Engine oil
S Incorrect oil level
S Incorrect oil viscosity (low)
S Deteriorated oil
9-3
OVERHEATING/OVERCOOLING/
POOR BRAKING PERFORMANCE
TRBL
SHTG
EAS00855
OVERHEATING
ENGINE
Cylinder head(s) and piston(s)
S Heavy carbon buildup
Engine oil
S Incorrect oil level
S Incorrect oil viscosity
S Inferior oil quality
COOLING SYSTEM
Coolant
S Low coolant level
Radiator
S Damaged or leaking radiator
S Faulty radiator cap
S Bent or damaged radiator fin
Water pump
S Damaged or faulty water pump
S Thermostat
S Thermostat stays closed
S Oil cooler
S Clogged or damaged oil cooler
S Hose(s) and pipe(s)
S Damaged hose
S Improperly connected hose
S Damaged pipe
S Improperly connected pipe
FUEL SYSTEM
Throttle body (-ies)
S Damaged or loose throttle body joint
Air filter
S Clogged air filter element
CHASSIS
Brake(s)
S Dragging brake
ELECTRICAL SYSTEMS
Spark plug(s)
S Incorrect spark plug gap
S Incorrect spark plug heat range
Ignition system
S Faulty ignitor unit
Cooling system
S Faulty radiator fan motor relay
S Faulty coolant temperature sensor
S Faulty ECU
EAS00856
OVERCOOLING
COOLING SYSTEM
Thermostat
S Thermostat stays open
EAS00857
9-4
TRBL
SHTG
EAS00861
MALFUNCTION
S Bent or damaged inner tube
S Bent or damaged outer tube
S Damaged fork spring
S Worn or damaged outer tube bushing
S Bent or damaged damper rod
S Incorrect oil viscosity
S Incorrect oil level
EAS00863
UNSTABLE HANDLING
Handlebars
S Bent or improperly installed right handlebar
S Bent or improperly installed left handlebar
Steering head components
S Improperly installed upper bracket
S Improperly installed lower bracket
(improperly tightened ring nut)
S Bent steering stem
S Damaged ball bearing or bearing race
Front fork leg(s)
S Uneven oil levels (both front fork legs)
S Unevenly tensioned fork spring (both front
fork legs)
S Broken fork spring
S Bent or damaged inner tube
S Bent or damaged outer tube
Swingarm
S Worn bearing or bushing
S Bent or damaged swingarm
9-5
TRBL
SHTG
EAS00866
9-6
Main switch
A.C. magneto
Rectifier/ regulator
Fuse (backup)
Battery
Fuse (main)
Starter relay
Starter motor
Fuse (fuel injection)
Fuse (ignition)
Starting circuit cut-off relay
Sidestand switch
Fuel pump
ECU
Ignition coil
Spark plug
Fuel injector
Air induction system solenoid
Neutral switch
Crankshaft position sensor
Intake air temperature sensor
Coolant temperature sensor
Throttle position sensor
Intake air pressure sensor
Atmospheric pressure sensor
Cylinder identification sensor
Speed sensor
Lean angle cut-off switch
Meter assembly
Fuel level warning light
Oil level warning light
Neutral indicator light
Tachometer
Shift timing indicator light
Multi-function meter
Engine trouble warning light
Coolant temperature indicator light
High beam indicator light
Turn signal indicator light
Meter light
Oil level switch
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
Fuse (signal)
Fuse (headlight)
Fuse (radiator fan motor)
Radiator fan motor relay
Radiator fan motor
Headlight relay (on / off)
Headlight relay (dimmer)
Rear brake light switch
Left handlebar switch
Clutch switch
Dimmer switch
Horn switch
Turn signal switch
Horn
Turn signal relay
61
62
63
64
65
66
67
COLOR CODE
B .......
Br . . . . . .
Ch . . . . .
Dg . . . . .
G ......
Gy . . . . .
L .......
Lg . . . . . .
O ......
P .......
R.......
Sb . . . . . .
W ......
Y .......
B/ L . . . . .
B/ R . . . .
B/ W . . . .
B/ Y . . . .
Br/ G . . .
Br/ L . . . .
Br/ R . . . .
Br/ W . . .
Br/ Y . . . .
G/B . . . .
G/W . . . .
G/Y . . . .
Gy/ G . . .
Gy/ R . . .
L/B . . . . .
L/R . . . .
L/W . . . .
L/Y . . . . .
O/B . . . .
O/G . . . .
P/ W . . . .
R/ B . . . .
R/ G . . . .
R/ L . . . .
R/ W . . . .
R/ Y . . . .
Sb/ W . . .
W/ B . . . .
W/ Y . . . .
Y/ B . . . .
Y/ G . . . .
Y/ L . . . . .
Y/ W . . . .
Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black/ Blue
Black/ Red
Black/ White
Black/ Yellow
Brown/ Green
Brown/ Blue
Brown/ Red
Brown/ White
Brown/ Yellow
Green / Black
Green / White
Green / Yellow
Gray / Green
Gray / Red
Blue/ Black
Blue/ Red
Blue/ White
Blue/ Yellow
Orange / Black
Orange / Green
Pink/ White
Red/ Black
Red/ Green
Red/ Blue
Red White
Red/ Yellow
Sky blue / White
White/ Black
White/ Yellow
Yellow/ Black
Yellow/ Green
Yellow/ Blue
Yellow/ White
Main switch
A.C. magneto
Rectifier/ regulator
Fuse (backup)
Battery
Fuse (main)
Starter relay
Starter motor
Fuse (fuel injection)
Fuse (ignition)
Starting circuit cut-off relay
Sidestand switch
Fuel pump
ECU
Ignition coil
Spark plug
Fuel injector
Air induction system solenoid
Neutral switch
Crankshaft position sensor
Intake air temperature sensor
Coolant temperature sensor
Throttle position sensor
Intake air pressure sensor
Atmospheric pressure sensor
Cylinder identification sensor
Speed sensor
Lean angle cut-off switch
Meter assembly
Fuel level warning light
Oil level warning light
Neutral indicator light
Tachometer
Shift timing indicator light
Multi-function meter
Engine trouble warning light
Coolant temperature indicator light
High beam indicator light
Turn signal indicator light
Meter light
Oil level switch
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
Fuse (signal)
Fuse (headlight)
Fuse (radiator fan motor)
Radiator fan motor relay
Radiator fan motor
Headlight relay (on / off)
Headlight relay (dimmer)
Rear brake light switch
Left handlebar switch
Clutch switch
Dimmer switch
Horn switch
Turn signal switch
Horn
Turn signal relay
61
62
63
64
65
66
67
PRINTED IN U.S.A.