XVS13AW(C) XVS13CTW(C)

SERVICE MANUAL

LIT-11616-20-42

3D8-28197-10

EAS20050

XVS13AW(C)/XVS13CTW(C) SERVICE MANUAL 2006 by Yamaha Motor Corporation, U.S.A. First edition, August 2006 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-11616-20-42

EAS20070

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.
EAS20080

IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator, a bystander or a person checking or repairing the vehicle. A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle. A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION: NOTE:

EAS20090

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. The manual is divided into chapters and each chapter is divided into sections. The current section title 1 is shown at the top of each page. Sub-section titles 2 appear in smaller print than the section title. To help identify parts and clarify procedure steps, there are exploded diagrams 3 at the start of each removal and disassembly section. Numbers 4 are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step. Symbols 5 indicate parts to be lubricated or replaced. Refer to SYMBOLS. A job instruction chart 6 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. Jobs 7 requiring more information (such as special tools and technical data) are described sequentially.

4 5 6

7 2

EAS20100

SYMBOLS
The following symbols are used in this manual for easier understanding.
NOTE:

The following symbols are not relevant to every vehicle.

1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6. Wear limit, clearance 7. Engine speed 8. Electrical data 9. Engine oil 10. Gear oil 11. Molybdenum-disulfide oil 12. Wheel-bearing grease 13. Lithium-soap-based grease 14. Molybdenum-disulfide grease 15. Apply locking agent (LOCTITE) 16. Replace the part

T.

9
E

10
G

11
M

12
B

13
LS

14
M

15

16

LT

New

EAS20110

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

1 2 3 4 5 6 7 8 9

GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER..................................................... 1-1 MODEL LABEL ......................................................................................... 1-1 FEATURES ..................................................................................................... 1-2 OUTLINE OF THE FI SYSTEM................................................................. 1-2 FI SYSTEM ............................................................................................... 1-3 INSTRUMENT FUNCTIONS..................................................................... 1-4 IMPORTANT INFORMATION ......................................................................... 1-6 PREPARATION FOR REMOVAL AND DISASSEMBLY .......................... 1-6 REPLACEMENT PARTS .......................................................................... 1-6 GASKETS, OIL SEALS AND O-RINGS .................................................... 1-6 LOCK WASHERS/PLATES AND COTTER PINS..................................... 1-6 BEARINGS AND OIL SEALS.................................................................... 1-7 CIRCLIPS.................................................................................................. 1-7 CHECKING THE CONNECTIONS .................................................................. 1-8 SPECIAL TOOLS ............................................................................................ 1-9

IDENTIFICATION
EAS20130

IDENTIFICATION
EAS20140

VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe.

EAS20150

MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.

1-1

FEATURES
EAS20170

FEATURES
EAS3D81037

OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor. Despite the same volume of intake air, the fuel volume requirement varies by the engine operating 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 airfuel 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.

6 7 8 9 10 11 12 13 14

19

18

17 16 15
15. Rear cylinder injector 16. ISC (idle speed control) unit 17. Crankshaft position sensor 18. Front cylinder injector 19. Coolant temperature sensor

1. Air temperature sensor 2. Engine trouble warning light 3. Front cylinder intake air pressure sensor 4. Rear cylinder intake air pressure sensor 5. Rear cylinder ignition coil 6. Front cylinder ignition coil 7. Throttle position sensor 8. Spark plug 9. Speed sensor 10. Lean angle sensor 11. Relay unit (fuel pump relay) 12. Fuel pump 13. ECU (engine control unit) 14. O2 sensor

1-2

FEATURES
EAS3D81038

FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm, 46.1 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser the volume of fuel that is supplied. The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position sensor, crankshaft position sensor, intake air pressure sensor, air temperature sensor, coolant temperature sensor, lean angle sensor, speed sensor and O2 sensor enable the ECU to determine the injection duration. The injection timing is determined through the signals from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions.
Illustration is for reference only.

5 6 1 C A
Rear Front

7 8 4 10 11 B 14 13 12

2 3 15

1. Fuel pump 2. Fuel injector 3. Ignition coil 4. ECU (engine control unit) 5. Air temperature sensor 6. Lean angle sensor 7. ISC (idle speed control) unit 8. Throttle position sensor 9. O2 sensor 10. Coolant temperature sensor 11. Catalytic converter 12. Crankshaft position sensor 13. Intake air pressure sensor

14. Throttle body 15. Air filter case A. Fuel system B. Air system C. Control system

1-3

FEATURES
EAS3D81033

INSTRUMENT FUNCTIONS Multi-function meter unit

EWA3D81011

Speedometer

WARNING

Be sure to stop the vehicle before making any setting changes to the multi-function meter unit.

1. Speedometer

The speedometer shows the riding speed. When the key is turned to ON, the speedometer needle will sweep once across the speed range and then return to zero in order to test the electrical circuit. Odometer, tripmeter, and fuel reserve tripmeter modes

1. Speedometer 2. Odometer/tripmeter/fuel reserve tripmeter/clock

The multi-function meter unit is equipped with the following: a speedometer (which shows the riding speed) an odometer (which shows the total distance traveled) two tripmeters (which show the distance traveled since they were last set to zero) a fuel reserve tripmeter (which shows the distance traveled on the fuel reserve) a clock a self-diagnosis device a brightness control mode
NOTE:

1. Odometer/tripmeter/fuel reserve tripmeter/clock

Be sure to turn the key to ON before using the SELECT switch / and RESET switch, except for setting the brightness control mode.

Push the side of the SELECT switch to switch the display between the odometer mode ODO, the tripmeter modes TRIP 1 and TRIP 2 and the clock mode in the following order: ODO TRIP 1 TRIP 2 Clock ODO
NOTE:

Push the side of the SELECT switch to switch the display in the reverse order.

1
SELECT

RESET

1. SELECT switch 2. RESET switch

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, push the side of the SELECT switch to switch the display between the various tripmeter, odometer, and clock modes in the following order: F-TRIP TRIP 1 TRIP 2 Clock ODO F-TRIP

1-4

FEATURES
NOTE:

Push the side of the SELECT switch to switch the display in the reverse order. To reset a tripmeter, select it by pushing the or side of the SELECT switch, and then push the RESET switch for at least one second. If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically, and the display will return to the prior mode after refueling and traveling 5 km (3 mi). Clock mode

If the odometer/tripmeter/clock display indicates any error codes, note the code number, and then check the vehicle. Refer to FUEL INJECTION SYSTEM on page 8-31.
ECA3D81016

CAUTION:

If the display indicates an error code, the vehicle should be checked as soon as possible in order to avoid engine damage. Brightness control mode

1 1 2

1. Clock

1. Speedometer panel 2. Brightness level

Push the RESET switch for less than one second to display the clock for five seconds, regardless of the currently selected display mode. To set the clock: 1. Push the or side of the SELECT switch to change the display to the clock mode. 2. Push the side of the SELECT switch and the RESET switch together for at least two seconds. 3. When the hour digits start flashing, push the or side of the SELECT switch to set the hours. 4. Push the RESET switch, and the minute digits will start flashing. 5. Push the or side of the SELECT switch to set the minutes. 6. Push the RESET switch and then release it to start the clock. Self-diagnosis device This model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the engine trouble warning light will come on, and then the odometer/tripmeter/clock display will indicate a two-digit error code (e.g., 12, 13, 14).

This function allows you to adjust the brightness of the speedometer panel to suit the outside lighting conditions. To set the brightness: 1. Turn the key to OFF. 2. Push and hold the side of the SELECT switch. 3. Turn the key to ON, and then release the SELECT switch after five seconds or more. 4. Push the or side of the SELECT switch to select the desired brightness level. 5. Push the RESET switch to confirm the selected brightness level. The display will return to the odometer, tripmeter or clock mode.

1-5

IMPORTANT INFORMATION
EAS20180

IMPORTANT INFORMATION
EAS20190

PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material.

EAS20210

2. Use only the proper tools and cleaning equipment. Refer to SPECIAL TOOLS on page 1-9. 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.

GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.

1. 2. 3. 4.

Oil Lip Spring Grease

EAS20220

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.
EAS20200

LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.

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.

1-6

IMPORTANT INFORMATION
EAS20230

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

ECA13300

CAUTION:

Do not spin the bearing with compressed air because this will damage the bearing surfaces.

EAS20240

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.

1-7

CHECKING THE CONNECTIONS

EAS20250

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: Lead Coupler Connector 2. Check: Lead Coupler Connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times.

Pocket tester 90890-03112 Analog pocket tester YU-03112-C

NOTE:

If there is no continuity, clean the terminals. When checking the wire harness, perform steps (1) to (3). As a quick remedy, use a contact revitalizer available at most part stores.

3. Check: All connections Loose connection Connect properly.

NOTE:

If the pin 1 on the terminal is flattened, bend it up.

4. Connect: Lead Coupler Connector

NOTE:

Make sure all connections are tight. 5. Check: Continuity (with the pocket tester)

1-8

SPECIAL TOOLS
EAS20260

SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of 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 numbers starting with YM-, YU-, or ACC-. For others, use part numbers starting with 90890-. Tool name/Tool No. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Illustration Reference pages 1-8, 5-64, 8-73, 8-74, 8-75, 8-79, 8-80, 8-81, 8-82, 8-83, 8-84, 8-85, 8-86, 8-87, 8-88, 8-89, 8-90 3-5, 3-6

Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 Tappet adjusting tool 90890-04154 YM-04154

3-6
3

Vacuum gauge 90890-03094 Carburetor synchronizer YU-44456

3-7

YU-44456

Timing light 90890-03141 Inductive clamp timing light YU-03141

3-10

1-9

SPECIAL TOOLS
Tool name/Tool No. Compression gauge 90890-03081 Engine compression tester YU-33223 Oil filter wrench 90890-01469 YM-01469
66.8

Illustration

Reference pages 3-11

3-12

Belt tension gauge 90890-03170 Rear drive belt tension gauge YM-03170 Steering nut wrench 90890-01403 Spanner wrench YU-33975 Damper rod holder 90890-01460

3-25

3-26, 4-61

4-54, 4-56

T-handle 90890-01326 T-handle 3/8" drive 60 cm long YM-01326 Fork seal driver 90890-01442 Adjustable fork seal driver (3646 mm) YM-01442 Rotor holding tool 90890-01235 Universal magneto & rotor holder YU-01235 Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm YU-01083-1

4-54, 4-56

4-56, 4-57

5-15, 5-21, 5-22

5-16

1-10

SPECIAL TOOLS
Tool name/Tool No. Weight 90890-01084 YU-01083-3 Illustration Reference pages 5-16

YU-01083-3

Valve spring compressor 90890-04019 YM-04019

5-28, 5-33

Valve spring compressor attachment 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1 Valve guide remover (6) 90890-04064 Valve guide remover (6.0 mm) YM-04064-A Valve guide installer (6) 90890-04065 Valve guide installer (6.0 mm) YM-04065-A Valve guide reamer (6) 90890-04066 Valve guide reamer (6.0 mm) YM-04066

5-28, 5-33

5-29

5-29

5-29

1-11

SPECIAL TOOLS
Tool name/Tool No. Piston pin puller set 90890-01304 Piston pin puller YU-01304 Illustration Reference pages 5-35

YU-01304

Sheave holder 90890-01701 Primary clutch holder YS-01880-A Flywheel puller 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 90890-85505 (Three Bond No.1215)

5-43, 5-44, 5-51, 5-54

5-43

5-45, 5-71, 6-10

Universal clutch holder 90890-04086 YM-91042

5-51, 5-55

1-12

SPECIAL TOOLS
Tool name/Tool No. Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 Illustration Reference pages 6-3

YU-24460-01

Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984

6-3

YU-33984

Mechanical seal installer 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 90890-04058 Bearing driver 40 mm YM-04058 Pressure gauge 90890-03153 YU-03153

6-10

6-10

7-11

Fuel pressure adapter 90890-03176 YM-03176

7-11

1-13

SPECIAL TOOLS
Tool name/Tool No. Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Ignition checker 90890-06754 Opama pet-4000 spark checker YM-34487 Illustration Reference pages 7-11

8-83

1-14

SPECIAL TOOLS

1-15

SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1 ENGINE SPECIFICATIONS ............................................................................ 2-2 CHASSIS SPECIFICATIONS.......................................................................... 2-9 ELECTRICAL SPECIFICATIONS ................................................................. 2-12 TIGHTENING TORQUES .............................................................................. 2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-15 ENGINE TIGHTENING TORQUES......................................................... 2-16 CHASSIS TIGHTENING TORQUES....................................................... 2-20 LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-24 ENGINE .................................................................................................. 2-24 CHASSIS ................................................................................................ 2-25 LUBRICATION SYSTEM CHART AND DIAGRAMS ................................... 2-27 ENGINE OIL LUBRICATION CHART ..................................................... 2-27 LUBRICATION DIAGRAMS .................................................................... 2-29 COOLING SYSTEM DIAGRAMS .................................................................. 2-37 CABLE ROUTING ......................................................................................... 2-43

GENERAL SPECIFICATIONS
EAS20280

GENERAL SPECIFICATIONS
Model Model XVS13AW 3D81 (USA) XVS13AWC 3D82 (California) XVS13AW 3D83 (CDN) XVS13CTW 5S61 (USA) XVS13CTWC 5S62 (California) XVS13CTW 5S63 (CDN)

Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Weight With oil and fuel Maximum load

2490 mm (98.0 in) 980 mm (38.6 in) XVS13AW(C) 1115 mm (43.9 in) XVS13CTW(C) 1520 mm (59.8 in) 715 mm (28.1 in) 1690 mm (66.5 in) 145 mm (5.71 in) 3500 mm (137.8 in)

XVS13AW(C) 303.0 kg (668 lb) XVS13CTW(C) 323.0 kg (712 lb) XVS13AW(C) 210 kg (463 lb) XVS13CTW(C) 190 kg (419 lb)

2-1

ENGINE SPECIFICATIONS
EAS20290

ENGINE SPECIFICATIONS
Engine Engine type Displacement Cylinder arrangement Bore stroke Compression ratio Standard compression pressure (at sea level) Minimummaximum Starting system Fuel Recommended fuel Liquid cooled 4-stroke, SOHC 1304.0 cm V-type 2-cylinder 100.0 83.0 mm (3.94 3.27 in) 9.50 :1 1450 kPa/400 r/min (206.2 psi/400 r/min) (14.5 kgf/cm/400 r/min) 12001500 kPa (170.7213.3 psi) (12.015.0 kgf/cm) Electric starter

Fuel tank capacity Fuel reserve amount Engine oil Lubrication system Type Recommended engine oil grade Engine oil quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil filter Oil filter type Oil pump Oil pump type Inner-rotor-to-outer-rotor-tip clearance Limit Outer-rotor-to-oil-pump-housing clearance Limit Oil-pump-housing-to-inner-and-outer-rotor clearance Limit Bypass valve opening pressure Relief valve operating pressure

XVS13AW(C) Unleaded gasoline only (USA/California) XVS13AW Regular unleaded gasoline only (CDN) XVS13CTW(C) Unleaded gasoline only (USA/California) XVS13CTW Regular unleaded gasoline only (CDN) 18.5 L (4.89 US gal) (4.07 Imp.gal) 3.7 L (0.98 US gal) (0.81 Imp.gal)

Wet sump YAMALUBE 4 (20W40) or SAE20W40 API service SG type or higher, JASO standard MA 3.70 L (3.91 US qt) (3.26 Imp.qt) 3.20 L (3.38 US qt) (2.82 Imp.qt) 3.40 L (3.59 US qt) (2.99 Imp.qt)

Cartridge (paper)

Trochoid Less than 0.12 mm (0.0047 in) 0.20 mm (0.0079 in) 0.090.19 mm (0.00350.0075 in) 0.26 mm (0.0102 in) 0.060.13 mm (0.00240.0051 in) 0.20 mm (0.0079 in) 80.0120.0 kPa (11.617.4 psi) (0.801.20 kgf/cm) 391.0489.0 kPa (56.770.9 psi) (3.914.89 kgf/cm)

2-2

ENGINE SPECIFICATIONS

Cooling system Radiator capacity (including all routes) 2.10 L (2.22 US qt) (1.85 Imp.qt) Radiator capacity 0.55 L (0.58 US qt) (0.48 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.45 L (0.48 US qt) (0.40 Imp.qt) Radiator cap opening pressure 93.3122.7 kPa (13.517.8 psi) (0.931.23 kgf/cm) Valve relief pressure 4.9 kPa (0.7 psi) (0.05 kgf/cm) Thermostat Model/manufacturer 1AE/YAMAHA Valve opening temperature 80.583.5 C (176.9182.3 F) Valve full open temperature 95.0 C (203.0 F) Valve lift (full open) 8.0 mm (0.31 in) Radiator core Width 197.0 mm (7.76 in) Height 320.0 mm (12.60 in) Depth 22.0 mm (0.87 in) Water pump Water pump type Single suction centrifugal pump Reduction ratio 70/45 17/26 (1.017) Impeller shaft tilt limit 0.15 mm (0.006 in) Spark plug (s) Manufacturer/model Spark plug gap Cylinder head Volume Warpage limit

NGK/LMAR7A-9 0.80.9 mm (0.0310.035 in)

44.2046.40 cm (2.702.83 cu.in) 0.03 mm (0.0012 in)

Camshaft Drive system Camshaft journal diameter Camshaft lobe dimensions Intake A Limit Intake B Limit Exhaust A Limit Exhaust B

Chain drive (left and right) 20.95920.980 mm (0.82520.8260 in) 42.98843.088 mm (1.69241.6964 in) 42.888 mm (1.6885 in) 37.04537.145 mm (1.45851.4624 in) 36.945 mm (1.4545 in) 43.15643.256 mm (1.69911.7030 in) 43.056 mm (1.6951 in) 37.11837.218 mm (1.46131.4653 in)

2-3

ENGINE SPECIFICATIONS
Limit 37.018 mm (1.4574 in)

B
Timing chain Model/number of links Tensioning system Rocker arm/rocker arm shaft Rocker arm inside diameter Rocker arm shaft outside diameter Rocker-arm-to-rocker-arm-shaft clearance Limit Valve, valve seat, valve guide Valve clearance (cold) Intake Exhaust Valve dimensions Valve head diameter A (intake) Valve head diameter A (exhaust)

98XRH2010132M/132 Automatic

12.00012.018 mm (0.47240.4731 in) 11.97611.991 mm (0.47150.4721 in) 0.0090.042 mm (0.00040.0017 in) 0.095 mm (0.0037 in)

0.090.13 mm (0.00350.0051 in) 0.140.18 mm (0.00550.0071 in) 35.9036.10 mm (1.41341.4213 in) 31.9032.10 mm (1.25591.2638 in)

A
Valve seat width C (intake) Valve seat width C (exhaust) 1.001.20 mm (0.03940.0472 in) 1.001.20 mm (0.03940.0472 in)

C
Valve margin thickness D (intake) Valve margin thickness D (exhaust) 1.151.45 mm (0.04530.0571 in) 1.151.45 mm (0.04530.0571 in)

D
Valve stem diameter (intake) Limit Valve stem diameter (exhaust) Limit Valve guide inside diameter (intake) Limit Valve guide inside diameter (exhaust) 5.9755.990 mm (0.23520.2358 in) 5.945 mm (0.2341 in) 5.9605.975 mm (0.23460.2352 in) 5.930 mm (0.2335 in) 6.0006.012 mm (0.23620.2367 in) 6.050 mm (0.2382 in) 6.0006.012 mm (0.23620.2367 in)

2-4

ENGINE SPECIFICATIONS
Limit Valve-stem-to-valve-guide clearance (intake) Limit Valve-stem-to-valve-guide clearance (exhaust) Limit Valve stem runout 6.050 mm (0.2382 in) 0.0100.037 mm (0.00040.0015 in) 0.080 mm (0.0032 in) 0.0250.052 mm (0.00100.0020 in) 0.100 mm (0.0039 in) 0.010 mm (0.0004 in)

Cylinder head valve seat width (intake) Limit Cylinder head valve seat width (exhaust) Limit Valve spring Free length (intake) Limit Free length (exhaust) Limit Installed length (intake) Installed length (exhaust) Spring rate K1 (intake) Spring rate K2 (intake) Spring rate K1 (exhaust) Spring rate K2 (exhaust) Installed compression spring force (intake) Installed compression spring force (exhaust) Spring tilt (intake) Spring tilt (exhaust)

1.001.20 mm (0.03940.0472 in) 1.6 mm (0.06 in) 1.001.20 mm (0.03940.0472 in) 1.6 mm (0.06 in)

42.43 mm (1.67 in) 40.31 mm (1.59 in) 42.43 mm (1.67 in) 40.31 mm (1.59 in) 35.00 mm (1.38 in) 35.00 mm (1.38 in) 24.75 N/mm (141.32 lb/in) (2.52 kgf/mm) 34.93 N/mm (199.45 lb/in) (3.56 kgf/mm) 24.75 N/mm (141.32 lb/in) (2.52 kgf/mm) 34.93 N/mm (199.45 lb/in) (3.56 kgf/mm) 171197 N (38.4444.29 lbf) (17.4420.09 kgf) 171197 N (38.4444.29 lbf) (17.4420.09 kgf) 2.5/1.9 mm 2.5/1.9 mm

Winding direction (intake) Winding direction (exhaust) Cylinder Bore Taper limit Out of round limit Piston Piston-to-cylinder clearance Limit Diameter D

Clockwise Clockwise

100.000100.010 mm (3.93703.9374 in) 0.050 mm (0.0020 in) 0.050 mm (0.0020 in)

0.0300.055 mm (0.00120.0022 in) 0.15 mm (0.0059 in) 99.95599.970 mm (3.93523.9358 in)

2-5

ENGINE SPECIFICATIONS
Height H 8.0 mm (0.31 in)

H D
Offset Piston pin bore inside diameter Limit Piston pin outside diameter Limit Piston-pin-to-piston-pin-bore clearance Limit Piston ring Top ring Ring type Dimensions (B T) 0.50 mm (0.0197 in) 23.00423.015 mm (0.90570.9061 in) 23.045 mm (0.9073 in) 22.99123.000 mm (0.90520.9055 in) 22.971 mm (0.9044 in) 0.0040.024 mm (0.000160.00094 in) 0.074 mm (0.00291 in)

Barrel 1.20 3.80 mm (0.05 0.15 in)

B T
End gap (installed) Limit Ring side clearance Limit 2nd ring Ring type Dimensions (B T) 0.200.35 mm (0.00790.0138 in) 0.60 mm (0.0236 in) 0.0300.080 mm (0.00120.0032 in) 0.130 mm (0.0051 in) Taper 1.20 4.00 mm (0.05 0.16 in)

B T
End gap (installed) Limit Ring side clearance Limit Oil ring Dimensions (B T) 0.450.60 mm (0.01770.0236 in) 0.95 mm (0.0374 in) 0.0300.070 mm (0.00120.0028 in) 0.130 mm (0.0051 in) 2.50 3.40 mm (0.10 0.13 in)

B T
End gap (installed) Connecting rod Oil clearance (using plastigauge) Bearing color code 0.200.70 mm (0.00790.0276 in)

0.0300.054 mm (0.00120.0021 in) 1.Blue 2.Black 3.Brown 4.Green 5.Yellow

2-6

ENGINE SPECIFICATIONS
Small end inside diameter Crankshaft Width A Runout limit C Big end side clearance D Big end radial clearance E Limit 23.01523.028 mm (0.90610.9066 in)

97.9598.00 mm (3.8563.858 in) 0.020 mm (0.0008 in) 0.3200.474 mm (0.01260.0187 in) 0.0220.046 mm (0.00090.0018 in) 0.09 mm (0.0035 in)

Balancer Balancer drive method Clutch Clutch type Clutch release method Operation Clutch lever free play Friction plate 1, 3 thickness Wear limit Plate quantity Friction plate 2 thickness Wear limit Plate quantity Clutch plate thickness Plate quantity Warpage limit Clutch spring height Minimum height Spring quantity Clutch housing thrust clearance Clutch housing radial clearance Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratio 1st 2nd 3rd 4th

Gear

Wet, multiple-disc Outer push, screw push Left hand operation 5.010.0 mm (0.200.39 in) 2.903.10 mm (0.1140.122 in) 2.80 mm (0.1102 in) 2 pcs 2.923.08 mm (0.1150.121 in) 2.82 mm (0.1110 in) 7 pcs 1.902.10 mm (0.0750.083 in) 8 pcs 0.20 mm (0.0079 in) 6.70 mm (0.26 in) 6.37 mm (0.25 in) 1 pc 0.0500.450 mm (0.00200.0177 in) 0.0100.046 mm (0.00040.0018 in)

Constant mesh 5-speed Spur gear 70/45 (1.556) Belt drive 70/30 (2.333) Left foot operation 36/13 (2.769) 32/18 (1.778) 29/21 (1.381) 29/26 (1.115)

2-7

ENGINE SPECIFICATIONS
5th Main axle runout limit Drive axle runout limit Shifting mechanism Shift mechanism type Shift fork guide bar bending limit Shift fork thickness Air filter Air filter element Fuel pump Pump type Model/manufacturer Maximum consumption amperage Output pressure Fuel injector Model/quantity Manufacturer Throttle body Type/quantity Manufacturer ID mark Throttle valve size Throttle position sensor Resistance Output voltage (at idle) Fuel injection sensor Crankshaft position sensor resistance Intake air pressure sensor output voltage Coolant temperature sensor resistance Idling condition Engine idling speed Intake vacuum Water temperature Oil temperature Throttle cable free play 24/25 (0.960) 0.08 mm (0.0032 in) 0.08 mm (0.0032 in)

Guide bar 0.025 mm (0.0010 in) 6.266.39 mm (0.24650.2516 in)

Oil-coated paper element

Electrical 2920200100/DENSO 4.6 A 392.0 kPa (56.8 psi) (3.92 kgf/cm)

INP-284/2 NIKK

ACW40/2 MIKUNI 3D81 00 (USA/CDN) 3D82 10 (California) #40 4.06.0 k 0.630.73 V 248372 3.754.25 V 290354 at 80 C (176 F) 9501050 r/min 32.037.3 kPa (9.411.0 inHg) (240280 mmHg) 90.0100.0 C (194.00212.00 F) 70.080.0 C (158.00176.00 F) 4.06.0 mm (0.160.24 in)

2-8

CHASSIS SPECIFICATIONS
EAS20300

CHASSIS SPECIFICATIONS
Chassis Frame type Caster angle Trail Front wheel Wheel type Rim size Rim material Wheel travel Radial wheel runout limit Lateral wheel runout limit Rear wheel Wheel type Rim size Rim material Wheel travel Radial wheel runout limit Lateral wheel runout limit Front tire Type Size Manufacturer/model Manufacturer/model Wear limit (front) Rear tire Type Size Manufacturer/model Manufacturer/model Wear limit (rear) Tire air pressure (measured on cold tires) Loading condition Front Rear Loading condition Front Rear Front brake Type Operation Front brake lever free play Front disc brake Disc outside diameter thickness Double cradle 32.70 145.0 mm (5.71 in)

Cast wheel 16M/C MT3.00 Aluminum 135.0 mm (5.31 in) 1.0 mm (0.04 in) 0.5 mm (0.02 in)

Cast wheel 16M/C MT4.50 Aluminum 110.0 mm (4.33 in) 1.0 mm (0.04 in) 0.5 mm (0.02 in)

Tubeless 130/9016M/C 67H DUNLOP/D404F X BRIDGESTONE/EXEDRA G721 1.0 mm (0.04 in)

Tubeless 170/70B 16M/C 75H DUNLOP/K555 BRIDGESTONE/EXEDRA G722 G 1.0 mm (0.04 in)

090 kg (0198 lb) 250 kPa (36 psi) (2.50 kgf/cm) 280 kPa (41 psi) (2.80 kgf/cm) XVS13AW(C) 90210 kg (198463 lb) XVS13CTW(C) 90190 kg (198419 lb) 250 kPa (36 psi) (2.50 kgf/cm) 280 kPa (41 psi) (2.80 kgf/cm)

Dual disc brake Right hand operation 2.05.0 mm (0.080.20 in) 298.0 5.0 mm (11.73 0.20 in)

2-9

CHASSIS SPECIFICATIONS
Brake disc thickness limit Brake disc deflection limit Brake pad lining thickness (inner) Limit Brake pad lining thickness (outer) Limit Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Rear brake Type Operation Rear disc brake Disc outside diameter thickness Brake disc thickness limit Brake disc deflection limit Brake pad lining thickness (inner) Limit Brake pad lining thickness (outer) Limit Master cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Steering Steering bearing type Lock to lock angle (left) Lock to lock angle (right) Front suspension Type Spring/shock absorber type Front fork travel Fork spring free length Limit Collar length Installed length Spring rate K1 Spring stroke K1 Inner tube outer diameter Optional spring available Recommended oil Quantity Level Rear suspension Type Spring/shock absorber type Rear shock absorber assembly travel Spring free length Installed length 4.5 mm (0.18 in) 0.12 mm (0.0047 in) 6.0 mm (0.24 in) 0.8 mm (0.03 in) 6.0 mm (0.24 in) 0.8 mm (0.03 in) 14.00 mm (0.55 in) 25.40 mm (1.00 in) 30.16 mm (1.19 in) DOT 4

Single disc brake Right foot operation 298.0 6.0 mm (11.73 0.24 in) 5.5 mm (0.22 in) 0.15 mm (0.0059 in) 5.8 mm (0.23 in) 0.8 mm (0.03 in) 5.8 mm (0.23 in) 0.8 mm (0.03 in) 12.7 mm (0.50 in) 41.30 mm (1.63 in) DOT 4

Angular bearing 35.0 35.0

Telescopic fork Coil spring/oil damper 135.0 mm (5.31 in) 345.5 mm (13.60 in) 339.4 mm (13.36 in) 183.0 mm (7.20 in) 339.4 mm (13.36 in) 7.35 N/mm (41.97 lb/in) (0.75 kgf/mm) 0.0135.0 mm (0.005.31 in) 41.0 mm (1.61 in) No Yamaha fork oil 10WT 490.0 cm (16.57 US oz) (17.28 Imp.oz) 105.0 mm (4.13 in)

Swingarm (link suspension) Coil spring/gas-oil damper 48.0 mm (1.89 in) 182.0 mm (7.17 in) 166.0 mm (6.54 in)

2-10

CHASSIS SPECIFICATIONS
Spring rate K1 Spring stroke K1 Optional spring available Enclosed gas/air pressure (STD) Spring preload adjusting positions Minimum Standard Maximum Swingarm Swingarm end free play limit (radial) Swingarm end free play limit (axial) Drive belt Model/manufacturer Drive belt slack (on the sidestand) Drive belt slack (on a suitable stand) 160.00 N/mm (913.60 lb/in) (16.32 kgf/mm) 0.048.0 mm (0.001.89 in) No 1200 kPa (170.7 psi) (12.0 kgf/cm) 1 4 9

1.0 mm (0.04 in) 1.0 mm (0.04 in)

UBD-0734/GATES CORPORATION 5.07.0 mm (0.200.28 in) 4.06.0 mm (0.160.24 in)

2-11

ELECTRICAL SPECIFICATIONS
EAS20310

ELECTRICAL SPECIFICATIONS
Voltage System voltage Ignition system Ignition system Advancer type Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer Ignition coil Model/manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance Spark plug cap Material Resistance AC magneto Model/manufacturer Standard output Standard output Stator coil resistance Rectifier/regulator Regulator type Model/manufacturer Regulated voltage (DC) Rectifier capacity (DC) Withstand voltage Battery Model Voltage, capacity Manufacturer Ten hour rate amperage Headlight Bulb type Bulb voltage, wattage quantity Headlight Tail/brake light Front turn signal light Rear turn signal light License plate light Meter lighting 12 V

Transistorized coil ignition (digital) Electric 5.0/1000 r/min

FUA0013/MITSUBISHI

2JN/MORIC 6.0 mm (0.24 in) 2.162.64 8.6412.96 k. Resin 10.0 k. F3D8/MORIC 14.0 V 32.9 A 5000 r/min 14.0 V 460 W 5000 r/min 0.1120.168 Semiconductor, short circuit FH012AA/SHINDENGEN 14.214.8 V 50.0 A 40.0 V

YTX20L-BS 12 V, 18.0 Ah GS YUASA 1.80 A

Halogen bulb 12 V, 60 W/55.0 W 1 12 V, 5.0 W/21.0 W 1 12 V, 21.0 W/5.0 W 2 12 V, 21.0 W 2 12 V, 5.0 W 1 LED

2-12

ELECTRICAL SPECIFICATIONS

Indicator light Neutral indicator light Turn signal indicator light Oil level warning light High beam indicator light Fuel level warning light Coolant temperature warning light Engine trouble warning light Electric starting system System type Starter motor Model/manufacturer Power output Armature coil resistance Brush overall length Limit Brush spring force Commutator diameter Limit Mica undercut (depth) Starter relay Model/manufacturer Amperage Coil resistance Horn Horn type Quantity Model/manufacturer Maximum amperage Coil resistance Performance Turn signal relay Relay type Model/manufacturer Built-in, self-canceling device Turn signal blinking frequency Wattage Oil level switch Model/manufacturer Starting circuit cut-off relay Model/manufacturer Coil resistance Headlight relay Model/manufacturer

LED LED LED LED LED LED LED

Constant mesh

SM13/MITSUBA 0.90 kW 0.01000.0200 12.5 mm (0.49 in) 5.00 mm (0.20 in) 7.6510.01 N (27.5436.03 oz) (7801021 gf) 28.0 mm (1.10 in) 27.0 mm (1.06 in) 0.70 mm (0.03 in)

2768115-A/JIDECO 180.0 A 4.184.62 Plane 1 pc HF-12/NIKKO 3.0 A 1.011.11 108116 dB/2 m

Semi transistor FB246H/DENSO Yes 75.095.0 cycles/min 21(23) W 2 + LED 3D8/YAMATO

G8R-30Y-U3/OMRON 162.0198.0 ACM33211 M05/MATSUSHITA

2-13

ELECTRICAL SPECIFICATIONS
Coil resistance Fuel pump relay Model/manufacturer Coil resistance Fan motor relay Model/manufacturer Coil resistance Fuses Main fuse Headlight fuse Taillight fuse Signaling system fuse Ignition fuse Radiator fan fuse Fuel injection system fuse Backup fuse Reserve fuse Reserve fuse Reserve fuse 86.40105.60 G8R-30Y-U3/OMRON 162.0198.0 ACM33211 M05/MATSUSHITA 86.40105.60 50.0 A 20.0 A 10.0 A 10.0 A 15.0 A 20.0 A 10.0 A 10.0 A 20.0 A 15.0 A 10.0 A

2-14

TIGHTENING TORQUES
EAS20320

TIGHTENING TORQUES
EAS20330

GENERAL TIGHTENING TORQUE SPECIFICATIONS 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.

A. Distance between flats B. Outside thread diameter

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 mkg 0.6 1.5 3.0 5.5 8.5 13.0 ftlb 4.3 11 22 40 61 94

2-15

TIGHTENING TORQUES
EAS20340

ENGINE TIGHTENING TORQUES Item Cylinder head stud bolt (exhaust pipe) Oil check bolt Cylinder head nut Cylinder head bolt Front cylinder head cover bolt Front cylinder head cover bolt Front cylinder head cover bolt Rear cylinder head cover bolt Rear cylinder head cover bolt Rear cylinder head cover bolt Cylinder head blind plug Spark plug Tappet cover bolt Timing chain tensioner housing bolt Timing chain tensioner bolt Connecting rod bolt (1st) Thread Qty size M8 M8 M12 M8 M6 M6 M6 M6 M6 M6 M14 M10 M6 M6 M6 M8 4 2 8 4 2 3 2 2 7 2 2 2 8 2 4 4 Tightening torque 15 Nm (1.5 mkg, 11 ftlb) 15 Nm (1.5 mkg, 11 ftlb) 65 Nm (6.5 mkg, 47 ftlb) 13 Nm (1.3 mkg, 9.4 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 6 Nm (0.6 mkg, 4.3 ftlb) 13 Nm (1.3 mkg, 9.4 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 15 Nm (1.5 mkg, 11 ftlb) See NOTE.
M
E E

Remarks

l = 30 mm (1.18 in) l = 45 mm (1.77 in) l = 55 mm (2.17 in) l = 30 mm (1.18 in) l = 45 mm (1.77 in) l = 55 mm (2.17 in)

Connecting rod bolt (final) Generator rotor bolt Right balancer assembly bolt Left balancer assembly bolt Camshaft assembly bolt Locknut (rocker arm adjusting screw) Timing chain guide bolt Camshaft sprocket bolt Oil/water pump assembly bolt Oil/water pump assembly bolt Oil pump housing cover bolt

M8 M12 M6 M6 M6 M6 M6 M7 M8 M6 M6

4 1 3 3 8 8 4 4 3 2 3

Specified angle 125135 90 Nm (9.0 mkg, 65 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 14 Nm (1.4 mkg, 10 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 20 Nm (2.0 mkg, 14 ftlb) 24 Nm (2.4 mkg, 17 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb)

See NOTE.
M
E
LT

LT

LT

2-16

TIGHTENING TORQUES
Item Drain cock bolt Coolant delivery pipe bolt Oil/water pump driven sprocket bolt Oil filter cartridge Oil filter cartridge union bolt Oil level switch bolt Engine oil drain bolt Oil delivery pipe 1 bolt Oil delivery pipe 2 bolt Oil delivery pipe 3 bolt Oil/water pump drive chain guide bolt Intake air pressure sensor bolt Intake manifold joint bolt Throttle body bolt Left side cover bracket bolt Exhaust pipe nut Exhaust pipe cover screw clamp Rear cylinder exhaust pipe bolt Exhaust pipe band bolt Muffler band bolt O2 sensor Muffler bracket and frame bolt Muffler bracket and muffler bolt Crankcase stud bolt Left crankcase bolt Right crankcase bolt Generator cover bolt Crankshaft end screw Timing mark accessing screw Stator coil bolt Crankshaft position sensor/stator assembly lead holder bolt Crankshaft position sensor bolt Coolant delivery 1 cover bolt Coolant delivery 2 cover bolt Oil baffle plate 1 bolt Thread Qty size M6 M6 M6 M20 M20 M6 M14 M6 M6 M6 M6 M6 M6 M6 M6 M8 M6 M6 M8 M8 M18 M10 M10 M12 M6 M10 M6 M36 M14 M6 M6 M6 M6 M6 M6 2 3 1 1 1 2 1 2 1 2 2 2 4 3 2 4 6 2 2 1 1 3 2 6 19 3 10 1 1 3 2 1 9 4 7 Tightening torque 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 15 Nm (1.5 mkg, 11 ftlb) 17 Nm (1.7 mkg, 12 ftlb) 70 Nm (7.0 mkg, 50 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 43 Nm (4.3 mkg, 31 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 20 Nm (2.0 mkg, 14 ftlb) 6 Nm (0.6 mkg, 4.3 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) 44 Nm (4.4 mkg, 32 ftlb) 53 Nm (5.3 mkg, 38 ftlb) 35 Nm (3.5 mkg, 25 ftlb) 15 Nm (1.5 mkg, 11 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 36 Nm (3.6 mkg, 25 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 6 Nm (0.6 mkg, 4.3 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb)
LT LT LT

Remarks

LT

LT

LT

See NOTE.

LT

LT

LT

LT

LT

2-17

TIGHTENING TORQUES
Item Oil baffle plate 2 bolt Crankcase bearing retainer bolt Primary drive gear bearing plate bolt Starter clutch bolt Primary drive gear cover bolt Primary drive gear nut Clutch cover bolt Clutch cable holder bolt Clutch cover plate Damper cover bolt Clutch boss nut Clutch spring plate retainer bolt Shift shaft spring stopper Neutral switch Speed sensor bolt Starter motor bolt Starter motor lead nut Radiator filler pipe bolt Front cylinder thermostat inlet pipe 1 bolt Front cylinder thermostat inlet pipe 2 bolt Rear cylinder thermostat inlet pipe 1 bolt Rear cylinder thermostat inlet pipe 2 bolt Rear cylinder thermostat inlet pipe 2 bolt Thermostat cover inlet pipe bolt Coolant temperature sensor Coolant reservoir bolt Radiator outlet pipe bolt Coolant drain bolt Radiator bolt Thread Qty size M6 M6 M6 M8 M6 M18 M6 M6 M6 M6 M20 M6 M8 M10 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M12 M6 M6 M12 M6 3 4 2 6 12 1 8 2 6 6 1 6 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 2 Tightening torque 10 Nm (1.0 mkg, 7.2 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 24 Nm (2.4 mkg, 17 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb)
E

Remarks
LT

LT

LT

LT

100 Nm (10.0 mkg, 72 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 125 Nm (12.5 mkg, 90 ftlb) 8 Nm (0.8 mkg, 5.8 ftlb) 22 Nm (2.2 mkg, 16 ftlb) 20 Nm (2.0 mkg, 14 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 18 Nm (1.8 mkg, 13 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 2 Nm (0.2 mkg, 1.4 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb)

Use the lock washer.

Stake.

LT

LT

LT

LT

LT

2-18

TIGHTENING TORQUES
NOTE:

Connecting rod bolt Tighten the connecting rod bolts to 15 Nm (1.5 mkg, 11 ftlb), and then tighten them further to reach the specified angle 125135.
NOTE:

Exhaust pipe cover screw clamp Do not retighten the exhaust pipe cover screw clamps; always replace them with new ones if they are loosened.
Camshaft assembly tightening sequence
A B

1 3 2 4

1 3 2 4

A. Front cylinder camshaft assembly B. Rear cylinder camshaft assembly Cylinder head tightening sequence
A B

1 5

5 2
A. Front cylinder head B. Rear cylinder head

2-19

TIGHTENING TORQUES
EAS20350

CHASSIS TIGHTENING TORQUES Item Engine bracket bolt (right front upper side) Engine bracket bolt (left front upper side) Engine mounting bolt (front upper side) Engine mounting nut (front lower side) Engine mounting nut (rear upper side) Engine bracket bolt (rear upper side) Engine mounting nut (rear lower side) Engine bracket bolt (rear lower side) Down tube and frame bolt Ignition coil bolt Ignition coil bracket bolt Rear shock absorber assembly lower nut Rear shock absorber assembly upper nut Pivot shaft nut Relay arm and frame nut Connecting arm and relay arm nut Connecting arm and swingarm nut Drive belt upper guard bolt Drive belt lower guard and swingarm bolt Drive belt lower guard plate bolt (upper side) Drive belt lower guard plate bolt (lower side) Upper bracket pinch bolt Steering stem nut Lower ring nut (initial tightening torque) Lower ring nut (final tightening torque) Thread Qty size M10 M10 M12 M12 M12 M10 M12 M10 M10 M6 M6 M10 M10 M16 M10 M12 M12 M6 M6 M6 M6 M8 M22 M30 M30 2 2 4 1 1 2 1 2 4 4 2 1 1 1 1 1 1 3 2 1 1 2 1 1 1 Tightening torque 48 Nm (4.8 mkg, 35 ftlb) 48 Nm (4.8 mkg, 35 ftlb) 30 Nm (3.0 mkg, 22 ftlb) 88 Nm (8.8 mkg, 64 ftlb) 88 Nm (8.8 mkg, 64 ftlb) 48 Nm (4.8 mkg, 35 ftlb) 88 Nm (8.8 mkg, 64 ftlb) 48 Nm (4.8 mkg, 35 ftlb) 48 Nm (4.8 mkg, 35 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 48 Nm (4.8 mkg, 35 ftlb) 48 Nm (4.8 mkg, 35 ftlb) 85 Nm (8.5 mkg, 61 ftlb) 48 Nm (4.8 mkg, 35 ftlb) 59 Nm (5.9 mkg, 43 ftlb) 59 Nm (5.9 mkg, 43 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 20 Nm (2.0 mkg, 14 ftlb) 110 Nm (11.0 mkg, 80 ftlb) 52 Nm (5.2 mkg, 37 ftlb) 18 Nm (1.8 mkg, 13 ftlb) See NOTE. See NOTE.
LT LT LT

Remarks
LT

LT

2-20

TIGHTENING TORQUES
Item Lower bracket pinch bolt Front fork cap bolt Damper rod bolt Lower front fork cover bolt Main switch and upper bracket bolt Rear handlebar holder nut Front handlebar holder bolt Front brake master cylinder holder bolt Front brake lever bolt Front brake lever nut Clutch lever holder bolt Grip end Front brake hose union bolt Front brake hose holder and lower bracket bolt Front brake hose holder bolt Front brake hose joint bolt Front fender bolt Front brake hose guide bolt Headlight bracket bolt Headlight body bolt Front turn signal light bracket bolt Front turn signal light nut Air temperature sensor screw Meter assembly bolt Meter assembly cover bracket bolt Meter assembly cover bolt Fuel cock screw Fuel pump bolt Fuel sender bolt Fuel tank bracket bolt Sub-fuel tank bolt Canister bolt (California only) Seat lock bracket bolt Front wheel axle Front wheel axle pinch bolt Thread Qty size M8 M38 M12 M6 M8 M12 M8 M6 M6 M6 M6 M16 M10 M6 M6 M6 M8 M6 M8 M6 M8 M10 M5 M8 M6 M6 M6 M5 M6 M8 M6 M6 M6 M16 M8 4 2 2 4 2 2 4 2 1 1 1 2 3 1 1 1 4 2 2 4 2 2 1 2 2 2 2 6 2 2 3 2 2 1 1 Tightening torque 23 Nm (2.3 mkg, 17 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 30 Nm (3.0 mkg, 22 ftlb) 18 Nm (1.8 mkg, 13 ftlb) 30 Nm (3.0 mkg, 22 ftlb) 32 Nm (3.2 mkg, 23 ftlb) 28 Nm (2.8 mkg, 20 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 30 Nm (3.0 mkg, 22 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 11 Nm (1.1 mkg, 8.0 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 6 Nm (0.6 mkg, 4.3 ftlb) 8 Nm (0.8 mkg, 5.8 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 59 Nm (5.9 mkg, 43 ftlb) 20 Nm (2.0 mkg, 14 ftlb)
LT LT LT LT LT LT

Remarks

2-21

TIGHTENING TORQUES
Item Front brake caliper bracket bolt Front brake caliper bolt Front brake disc bolt Bleed screw (front brake caliper) Rear wheel axle nut Drive belt adjusting locknut Rear brake caliper bolt Rear brake disc bolt Bleed screw (rear brake caliper) Rear brake hose union bolt Rear brake hose guide bolt Rear brake hose holder bolt Rear wheel pulley nut Rear wheel drive hub stud bolt Rear fender bracket, rear fender, and frame bolt Passenger seat bracket, rear feeder, and frame bolt Passenger seat guide, rear fender, and frame bolt Passenger seat bolt License plate bracket and rear fender bolt Rear turn signal light nut Left side cover bolt Relay cover bolt Sub-fuel tank cover bolt Coolant reservoir cover bolt Side panel bolt (left and right) Positive battery lead bolt (starter relay side) Starter motor lead bolt (starter relay side) Relay bracket and frame bolt Battery box bolt Sidestand bracket bolt Sidestand switch bolt Sidestand nut Shift rod locknut Shift arm bolt Thread Qty size M10 M10 M8 M7 M10 M8 M10 M8 M7 M10 M6 M6 M12 M12 M8 M8 M8 M8 M6 M10 M6 M6 M6 M6 M6 M6 M6 M6 M6 M10 M5 M10 M6 M6 4 4 12 2 1 2 2 6 1 2 2 1 5 5 4 2 2 2 2 2 1 1 1 4 2 1 1 2 4 2 2 1 2 1 Tightening torque 40 Nm (4.0 mkg, 29 ftlb) 27 Nm (2.7 mkg, 19 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 6 Nm (0.6 mkg, 4.3 ftlb) 150 Nm (15.0 mkg, 110 ftlb) 16 Nm (1.6 mkg, 11 ftlb) 27 Nm (2.7 mkg, 19 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 6 Nm (0.6 mkg, 4.3 ftlb) 30 Nm (3.0 mkg, 22 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 95 Nm (9.5 mkg, 68 ftlb) 30 Nm (3.0 mkg, 22 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 16 Nm (1.6 mkg, 11 ftlb) 16 Nm (1.6 mkg, 11 ftlb) 16 Nm (1.6 mkg, 11 ftlb) 11 Nm (1.1 mkg, 8.0 ftlb) 11 Nm (1.1 mkg, 8.0 ftlb) 4 Nm (0.4 mkg, 2.9 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 56 Nm (5.6 mkg, 40 ftlb) 4 Nm (0.4 mkg, 2.9 ftlb) 56 Nm (5.6 mkg, 40 ftlb) 8 Nm (0.8 mkg, 5.8 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb)
LT LT

Remarks

LS
LT

LS
LT

LT

2-22

TIGHTENING TORQUES
Item Rear brake pedal arm bolt Rear brake master cylinder bolt Rear brake master cylinder bracket bolt Rider footrest assembly bolt (left and right) Passenger footrest bolt (left and right) Horn bracket and down tube bolt Coolant reservoir cover bracket bolt Locknut (rear brake master cylinder) Brake fluid reservoir bolt Rectifier/regulator cover bolt Rectifier/regulator bolt Drive pulley nut Drive pulley cover bolt Drive pulley cover plate bolt Drive pulley cover housing Windshield bolt* Windshield bracket bolt (upper side)* Windshield bracket bolt (lower side)* Sidebag bolt (left and right)* Backrest bolt* Sidebag bracket bolt (left and right)* * For XVS13CTW(C)
NOTE:

Thread Qty size M6 M8 M8 M10 M8 M8 M6 M8 M6 M6 M6 M22 M6 M6 M8 M8 M10 M8 M6 M8 M8 1 2 2 4 4 1 2 1 1 2 2 1 5 4 5 4 2 2 8 4 8

Tightening torque 7 Nm (0.7 mkg, 5.1 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 64 Nm (6.4 mkg, 46 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 30 Nm (3.0 mkg, 22 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 16 Nm (1.6 mkg, 11 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 140 Nm (14.0 mkg, 100 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 24 Nm (2.4 mkg, 17 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 48 Nm (4.8 mkg, 35 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 18 Nm (1.8 mkg, 13 ftlb) 23 Nm (2.3 mkg, 17 ftlb) 23 Nm (2.3 mkg, 17 ftlb)

Remarks

LT

LT

LT

LT

Stake.

LT

1. First, tighten the lower ring nut to approximately 52 Nm (5.2 mkg, 37 ftlb) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 18 Nm (1.8 mkg, 13 ftlb) with a torque wrench.

2-23

LUBRICATION POINTS AND LUBRICANT TYPES

EAS20360

LUBRICATION POINTS AND LUBRICANT TYPES

EAS20370

ENGINE Lubrication point Oil seals (lip) O-rings Bearings Cylinder head nuts and washers Connecting rods (small end and big end) Crankshaft journals Pistons Piston pins (outer surface) Buffer boss Camshaft cam lobes and camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Rocker arm shafts Camshaft carrier bolts Oil pump rotors (inner and outer) and oil/water pump housing Cylinder head bolts Starter clutch idle gear shaft Starter clutch idle gear Starter clutch gear (inner and outer surfaces) Torque limiter Primary driven gear (inner surface) Clutch push rod Oil/water pump drive sprocket (inner surface) Clutch thrust washers Clutch boss nut and washer Transmission gears (wheel and pinion) and collar Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal (lip) Crankcase (mating surface)
LS LS

Lubricant
LS LS

E E E E E E E
M M

E E E E E E E E E E

E E E
M

E E

Yamaha bond No.1215 (Three Bond No.1215) Yamaha bond No.1215 (Three Bond No.1215)

Stator coil assembly lead grommet

2-24

LUBRICATION POINTS AND LUBRICANT TYPES

EAS20380

CHASSIS Lubrication point Steering bearings and upper bearing dust cover (lip) Lower bearing dust seal (lip) Front wheel oil seals (lip) Rear wheel oil seal (lip) Rear wheel drive hub oil seal (lip) Rear wheel drive hub (mating surface) Brake pedal shaft (pivoting point) Shift pedal (pivoting point) Sidestand (pivoting point) and metal-to-metal moving parts Throttle grip tube guide (inner surface) and throttle cables Brake lever (pivoting point) and metal-to-metal moving parts Brake master cylinder push rod (contact surface) Clutch lever (pivoting point) and metal-to-metal moving parts Swingarm pivot bearings (inner surface) Swingarm pivot oil seals (lip) Rear shock absorber assembly upper bolt Connecting arm and swingarm collar (outer surface) Relay arm bearings (inner surface) Relay arm oil seals (lip) Pivot shaft (outer surface) Rear wheel axle (outer surface) Lubricant
LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS

2-25

LUBRICATION POINTS AND LUBRICANT TYPES

2-26

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20390

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20400

ENGINE OIL LUBRICATION CHART

16 13 14 15 13 12

10

11

8 7

3 2 1

2-27

LUBRICATION SYSTEM CHART AND DIAGRAMS

1. Oil strainer 2. Oil/water pump assembly 3. Oil delivery pipe 3 4. Relief valve assembly 5. Drive axle 6. Oil filter cartridge 7. Main axle 8. Main gallery 9. Crankcase 10. Front cylinder piston oil nozzle 11. Rear cylinder piston oil nozzle 12. Rear cylinder timing chain tensioner 13. Valve stem end (intake side) 14. Rear cylinder camshaft 15. Front cylinder timing chain tensioner 16. Front cylinder camshaft

2-28

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20410

LUBRICATION DIAGRAMS

2 A-A

2-29

LUBRICATION SYSTEM CHART AND DIAGRAMS

1. Oil filter cartridge 2. Oil delivery pipe 3 3. Relief valve assembly

2-30

LUBRICATION SYSTEM CHART AND DIAGRAMS

2 3

2-31

LUBRICATION SYSTEM CHART AND DIAGRAMS

1. Camshaft 2. Oil nozzle 3. Crankshaft

2-32

LUBRICATION SYSTEM CHART AND DIAGRAMS

2 1

2-33

LUBRICATION SYSTEM CHART AND DIAGRAMS

1. Oil delivery pipe 1 2. Timing chain tensioner

2-34

LUBRICATION SYSTEM CHART AND DIAGRAMS

2 3

2-35

LUBRICATION SYSTEM CHART AND DIAGRAMS

1. 2. 3. 4. 5. 6. Drive axle Oil delivery pipe 2 Main axle Oil delivery pipe 3 Oil/water pump assembly Oil strainer

2-36

COOLING SYSTEM DIAGRAMS

EAS20420

COOLING SYSTEM DIAGRAMS

A
6 5

A-A

2-37

COOLING SYSTEM DIAGRAMS

1. 2. 3. 4. 5. 6. Rear cylinder thermostat inlet pipe 1 Front cylinder thermostat inlet pipe 1 Coolant delivery cover 2 Coolant delivery cover 1 Drain cock Oil/water pump assembly

2-38

COOLING SYSTEM DIAGRAMS

A B A 1 3 B

3 2

B-B A-A

2-39

COOLING SYSTEM DIAGRAMS

1. 2. 3. 4. Radiator outlet hose Radiator outlet pipe Coolant delivery pipe Oil/water pump assembly

2-40

COOLING SYSTEM DIAGRAMS

1 10

4 13 7

10

C B 1 2 3 4

9 6 8 9

6 7

10

10

11

12 12

2-41

COOLING SYSTEM DIAGRAMS

1. Rear cylinder thermostat inlet pipe 1 2. Front cylinder thermostat inlet pipe 1 3. Rear cylinder thermostat inlet hose 4. Front cylinder thermostat inlet hose 5. Coolant reservoir hose 6. Rear cylinder thermostat inlet pipe 2 7. Thermostat assembly 8. Thermostat cover inlet hose 9. Thermostat cover inlet pipe 10. Radiator inlet hose 11. Radiator 12. Radiator outlet hose 13. Front cylinder thermostat inlet pipe 2

2-42

CABLE ROUTING
EAS20430

CABLE ROUTING
6 5
ER LOW

7 F

6 E 3

5 5 8 G

A-A

B-B C
2 1

A B B A
8

6 7

D D

6 7 5 3 2

6 7

D-D

22

23

9 21 19 18 17 C 20 10 H 11 12 13

16 15

14

2-43

CABLE ROUTING
1. Clutch switch lead 2. Clutch cable 3. Left handlebar switch lead 4. Right handlebar switch lead 5. Front brake hose 6. Throttle cable (accelerator cable) 7. Throttle cable (decelerator cable) 8. Front brake switch lead 9. Radiator fan motor lead 10. Fuel tank overflow hose 11. Canister purge hose (California only) 12. Canister charge hose (California only) 13. Canister (California only) 14. Canister breather hose (California only) 15. Starter motor lead 16. Starter motor 17. Rear brake light switch 18. Horn 19. Rear brake light switch lead 20. Horn lead 21. Radiator fan motor 22. Sidestand switch lead 23. Sidestand switch A. Pass the clutch cable and left handlebar switch lead through the guide, making sure to route the lead to the outside of the cable. B. Pass the throttle cables and right handlebar switch lead through the guide, making sure to route the lead to the outside of the cables. C. Fasten the starter motor lead securely to the engine mounting boss with a plastic locking tie, making sure that the tie does not contact the engine bracket on the frame. D. Pass the front brake hose through the guide. E. Fit the rubber strap end without the tab onto the holder, wrap the strap around the front brake hose and holder, and then fit the end with the tab onto the holder, making sure to face the tab downward. F. 3050 G. Install the front brake hose with its paint mark facing forward. H. Route the sidestand switch lead over the shift rod.

2-44

CABLE ROUTING

D D
1

A
5 6 A 4 B

G
F 10 12 E D 1 2 3 9 8

F-F

D-D

B
G

9 3 8 2 2

G-G

E-E C

H 11 I

2-45

CABLE ROUTING
1. Wire harness 2. Front right turn signal light 3. Front left turn signal light 4. Main switch couplers 5. Front right turn signal light coupler 6. Front left turn signal light coupler 7. Meter assembly couplers 8. Air temperature sensor lead 9. Meter assembly lead 10. Main switch lead 11. Headlight lead 12. Air temperature sensor A. Route the main switch lead that branches off from the wire harness behind the other leads. B. Route the meter assembly lead that branches off from the wire harness in front of the meter assembly couplers and front turn signal light couplers, and then wrap the protective covering around the lead and couplers. C. Fasten the wire harness, front turn signal light leads, meter assembly lead, and air temperature sensor lead with the plastic band, making sure to align the white tape on the wire harness, front turn signal light leads, and meter assembly lead with the band. D. Route the main switch lead behind the wire harness and meter assembly lead. E. Fasten the main switch lead at the white tape to the plastic band bracket with a plastic locking tie. F. Wrap the protective covering around the main switch couplers. G. Fasten the headlight lead with the holder. H. To headlight I. To wire harness

2-46

CABLE ROUTING

20

C
B

C
U 4 2 20 20

R S

4 2 20

C-C

11 12 10 C 8 D E F 7 5 6 4 2 3 B 1 A 9 G H 13

E E

F
G
P

I J 14 K L M

H
L N 15 O 16 18 Q 17

19

X 23 24 12 1

V 10 22 2 4

H-H
25

11

21

F-F

E-E

2-47

CABLE ROUTING
1. Wire harness 2. Coolant reservoir hose 3. Rear cylinder spark plug cap 4. Clutch cable 5. Throttle position sensor lead 6. Rear cylinder intake air pressure sensor hose 7. Right handlebar switch couplers 8. Front cylinder intake air pressure sensor hose 9. Thermostat cover inlet hose 10. Right handlebar switch lead 11. Throttle cable (accelerator cable) 12. Throttle cable (decelerator cable) 13. Front brake hose 14. Radiator inlet hose 15. Horn 16. Rear brake light switch 17. Brake fluid reservoir hose 18. O2 sensor 19. O2 sensor coupler 20. Fuel hose 21. Resonator hose joint 22. Fuel tank 23. Rear brake light switch lead 24. Horn lead 25. Lean angle sensor A. Fasten the clutch cable and coolant reservoir hose with the holder, making sure to position the holder 1520 mm (0.590.79 in) to the rear of the holder (indicated with an asterisk in the illustration) that is attached to the frame. B. Fasten the clutch cable with the plastic band. Face the end of the plastic band inward. C. Fasten the resonator hose joint, wire harness, and right handlebar switch lead with the plastic band. D. Make sure that the throttle cable (decelerator cable) does not contact the frame, the throttle cable (accelerator cable) does not contact the rear cylinder thermostat inlet hose, and the throttle cables do not contact each other. E. Route the rear cylinder spark plug lead to the inside of the front cylinder intake air pressure sensor hose and front cylinder resonator hose. F. Fasten the wire harness by sliding the plastic holder on the wire harness onto the stud on the frame. G. Route the throttle cables to the inside of the thermostat cover inlet hose and under the wire harness, making sure that the cables are not pinched by the harness. H. Route the rear brake light switch lead and horn lead to the inside of the thermostat cover inlet hose. I. Fasten the rear brake light switch lead and horn lead to the frame with the tie, making sure to face the end of the tie inward. J. Pass a plastic locking tie through the space between the frame and the frame support, and then fasten the rear brake light switch lead and horn lead to the frame with the tie, making sure to face the end of the tie inward. K. Fasten the rear brake light switch lead and horn lead with the holder. Face the fastener of the holder outward. L. Fasten the rear brake light switch lead and horn lead with a plastic locking tie, making sure to align the tie with the frame weld. Face the end of the plastic locking tie inward, and then cut off the excess end of the tie. M. Fasten the rear brake light switch lead and horn lead with a plastic locking tie. Face the end of the plastic locking tie inward, and then cut off the excess end of the tie. N. Fasten the rear brake light switch lead and horn lead with the holder, making sure to align the tape on each lead with the holder. Face the fastener of the holder outward. O. Fasten the rear brake light switch lead and horn lead with a plastic locking tie, making sure to install the tie on the protective sleeve of each lead. Face the end of the plastic locking tie inward, and then cut off the excess end of the tie. P. Make sure that there is no slack in the rear brake light switch lead and horn lead in the area shown in the illustration. Q. Be sure not to pinch the O2 sensor lead when installing the coolant reservoir cap cover. R. To fuel pump S. To coolant reservoir T. To clutch cover U. Pass the clutch cable through the guides. V. Fasten the right handlebar switch lead with the plastic band, making sure to install the band on the leads protective sleeve, not the lead itself. W. Face the end of the plastic band downward, angled inward. Make sure that the end of the plastic band does not contact the fuel pipe. X. Be sure to install the throttle cable (decelerator cable), identified by the longer nut, on the outer side of the throttle cable pulley. Y. To O2 sensor

2-48

CABLE ROUTING

E D F 4 6

A-A

C-C

8 C

C A
B

1 2

D
7 B 6 5 A

C
4

A
3

4 6

D-D

2-49

CABLE ROUTING
1. 2. 3. 4. 5. 6. 7. 8. A. Horn Rear brake light switch Rear brake master cylinder Brake fluid reservoir hose Coolant reservoir breather hose Rear brake hose Rear brake caliper Brake fluid reservoir Fasten the rear brake hose and brake fluid reservoir hose with the plastic bands, making sure to align the white paint marks on the brake fluid reservoir hose with the bands. Install the rear brake hose onto the rear brake caliper, making sure that the brake pipe touches the projection on the caliper. Face the ends of the hose clamp inward. Face the end of the hose clamp upward as shown in the illustration. Install the brake fluid reservoir hose onto the rear brake master cylinder, making sure that the brake pipe touches the projection on the rear brake master cylinder bracket. Insert the projection on the plastic band completely into the hole in the coolant reservoir cover bracket. Less than 3 mm (0.12 in)

B. C. D. E.

F. G.

2-50

CABLE ROUTING

23 1 22 24 25 22 22 2 T

23

S 21

S 24

13 22

A-A B-B
A 1 2 3 4 5 6 7 8 9 10 B 11 12 C

C-C

D E

C
R Q P

13

B
14

O N 20 19 M 18

16

15

G F

G G F F

L K J 26 27 27 U

E
I

17

26

F-F

G-G

E-E

D-D

2-51

CABLE ROUTING
1. Left handlebar switch lead 2. Clutch cable 3. Front brake hose 4. Meter assembly lead 5. Sidestand switch coupler 6. Oil level switch coupler 7. Radiator fan motor coupler 8. Front cylinder intake air pressure sensor 9. Coolant temperature sensor coupler 10. Rear cylinder intake air pressure sensor 11. Left handlebar switch couplers 12. Rear cylinder ignition coil 13. Sub-wire harness couplers 14. Front cylinder ignition coil 15. Rear cylinder thermostat inlet hose 16. Front cylinder thermostat inlet hose 17. Oil level switch 18. Starter motor lead 19. Radiator fan motor lead 20. Front cylinder spark plug cap 21. Front cylinder spark plug lead 22. Wire harness 23. Fuel tank 24. Coolant reservoir hose 25. Right handlebar switch lead 26. Oil level switch lead 27. Sidestand switch lead A. Route the meter assembly lead under the left handlebar switch lead and clutch cable. B. Fasten the left handlebar switch lead and front cylinder spark plug lead with a plastic locking tie. Be sure to install the plastic locking tie on the left handlebar switch leads protective sleeve and position it 1015 mm (0.390.59 in) from the end of the sleeve. Face the end of the plastic locking tie inward, and then cut off the excess end of the tie. C. Black connectors D. White connectors E. Connect the ignition coil leads with the I marks to the front cylinder ignition coil. Route the ignition coil lead with the black terminal to the outside of the wire harness. F. Route the sub-wire harness to the inside of the fuel pipe in the area shown in the illustration. G. To engine H. Route the front cylinder spark plug lead to the outside of the rear cylinder spark plug lead. I. Fasten the sidestand switch lead, starter motor lead, and oil level switch lead with plastic locking ties. Face the end of each plastic locking tie downward, and then cut off the excess end of the tie. J. The starter motor lead, neutral switch lead, and sidestand switch lead may be routed in any order in the area shown in the illustration. K. Fasten the starter motor lead at the positioning tape to the engine mounting boss with a plastic locking tie. Position the buckle of the plastic locking tie in front of the boss, with the end facing upward, and then cut off the excess end of the tie to 15 mm (0.59 in) or less. L. Fasten the starter motor lead and sidestand switch lead with a plastic locking tie. Face the end of the plastic locking tie rearward, and then cut off the excess end of the tie. M. Fasten the sidestand switch lead and oil level switch lead with the holder. Face the fastener of the holder outward. N. Route the radiator fan motor lead to the front of the fuel tank breather hose and fuel tank overflow hose. O. Fasten the sidestand switch lead, oil level switch lead, and radiator fan motor lead with the holder. Face the fastener of the holder outward. P. Route the sidestand switch lead, radiator fan motor lead, and oil level switch lead to the front of the radiator inlet hose. Q. Fasten the sidestand switch lead to the frame with a plastic locking tie. The oil level switch lead and radiator fan motor lead may also be fastened with the plastic locking tie. Face the end of the plastic locking tie rearward, making sure that it does not contact the left side panel. R. Fasten the sidestand switch lead, oil level switch lead, and radiator fan motor lead with the plastic band. Face the end of the plastic band rearward. Do not install the plastic band on the couplers or the sections of the leads that are not covered by the protective sleeves. S. Cut off the excess end of the plastic locking tie and position the cut end within the area shown in the illustration. T. Fasten the leads (to sub-wire harness) that branch off from the wire harness below the frame weld. U. Fasten the sidestand switch lead, oil level switch lead, and radiator fan motor lead with a plastic locking tie. The leads may be fastened in any order.

2-52

CABLE ROUTING

4 11

T U 2

C-C

12

B
D 1 E 2 3 7 8 9 10 11 H

B 4 6
5

F G

C C

C A

A
B

I 12

F E

13

S I J K O R 16 Q P N M 15 L 14

19

V 17

20 18

F-F E-E D-D

2-53

CABLE ROUTING
1. Headlight relay 2. Stator coil coupler 3. Radiator fan motor relay 4. Turn signal relay 5. Tail/brake light wire harness coupler 6. Starter relay 7. Speed sensor lead 8. Neutral switch lead 9. Fuse box 10. Main fuse 11. Tail/brake light wire harness 12. Crankshaft position sensor coupler 13. Relay unit 14. Rectifier/regulator 15. Starter motor lead 16. Neutral switch 17. Wire harness 18. Neutral switch lead 19. Sidestand switch lead 20. Crankshaft position sensor/stator assembly lead A. Fasten the crankshaft position sensor/stator assembly lead and speed sensor lead with the holder. B. Position the ground lead in the range shown in the illustration, 15 or less to the front or rear of the vertical line shown in the illustration. C. Connect the lead with white tape to the headlight relay and connect the lead without white tape to the radiator fan motor relay. D. Fasten the headlight relay lead, speed sensor lead, and neutral switch lead with a plastic locking tie, making sure to install the tie on the headlight relay leads protective sleeve, 1030 mm (0.39 1.18 in) from the end of the sleeve. Cut off the excess end of the plastic locking tie. E. Pass the crankshaft position sensor/stator assembly lead, and tail/brake light wire harness through the guide. F. To negative battery terminal G. To positive battery terminal H. To tail/brake light assembly I. Route the starter motor lead, ground lead, speed sensor lead, and neutral switch lead to the inside of the wire harness. J. Pass the crankshaft position sensor lead and tail/brake light wire harness through the guide, and then fasten them to the lower section of the guide with a plastic locking tie. Face the end of the plastic locking tie downward, angled inward, and then cut off the excess end of the tie. K. Insert the projection on the wire harness holder completely into the hole in the sub-fuel tank bracket. L. Fasten the speed sensor lead, crankshaft position sensor/stator assembly lead, ground lead, neutral switch lead, starter motor lead, and rectifier/regulator lead with a plastic locking tie, making sure to position the tie 10 mm (0.39 in) or less to the front or rear of the front edge of the frame. Face the end of the plastic locking tie upward, and then cut off the excess end of the tie down to the buckle, making sure that there are no sharp edges. M. Route the starter motor lead to the inside of the frame. N. Fasten the starter motor lead to the frame with a plastic locking tie. Face the end of the plastic locking tie downward, and then cut off the excess end of the tie to 10 mm (0.39 in) or less. O. Fasten the starter motor lead with a plastic locking tie. Position the plastic locking tie 20 mm (0.79 in) or less from the engine serial number. Face the end of the plastic locking tie downward, and then cut off the excess end of the tie. P. 20 mm (0.79 in) Q. Install the neutral switch lead terminal so that the lead is routed rearward. Make sure that there is no slack in the neutral switch lead. R. Fasten the sidestand switch lead with a plastic locking tie, making sure to fit the tie in the gap between the sidestand bracket and the frame boss. Face the end of the plastic locking tie forward, and then cut off the excess end of the tie. S. Route the oil level switch lead to the outside of the shift rod. T. Install the stator coil coupler completely onto the tab on the relay bracket. U. Insert the projections on the couplers completely into the holes in the relay bracket. V. Install the ground lead terminal with the drive pulley housing bolt, making sure that the crimped section of the terminal that secures the ground lead is facing inward as shown in the illustration.

2-54

CABLE ROUTING

5 30 29 P 28 27 26 25 24 2 3 4 23 22 O A B 5 6 7 C 8 9 Q 31 E 18 R 17 S 16 1 2 29 29 6

B-B

A
21 20

B
N

C
D 32 F

19 G 18

33

H U 10

D C
17 16 M 12 15 L K 14 J I 13

D
11

14

13

11 35

34

2-55

CABLE ROUTING
1. Wire harness 2. Coolant reservoir hose 3. Throttle cable (accelerator cable) 4. Throttle cable (decelerator cable) 5. Front cylinder intake air pressure sensor hose 6. Rear cylinder intake air pressure sensor hose 7. Right handlebar switch couplers 8. Throttle position sensor 9. Rear cylinder spark plug lead 10. Air vent hose 11. Negative battery lead terminal 12. Fuel cock hose 13. Battery 14. Positive battery lead terminal 15. Tail/brake light wire harness 16. ECU (engine control unit) 17. Main fuse 18. Fuse box 19. Starter relay coupler 20. Sub-wire harness couplers 21. Rear cylinder ignition coil 22. Left handlebar switch couplers 23. Rear cylinder intake air pressure sensor coupler 24. Front cylinder spark plug lead 25. Front cylinder intake air pressure sensor coupler 26. Sidestand switch coupler 27. Oil level switch coupler 28. Radiator fan motor coupler 29. Clutch cable 30. Left handlebar switch lead 31. Turn signal relay 32. Relay unit 33. Negative battery lead 34. Lean angle sensor 35. Starter motor lead A. Fasten the coolant reservoir hose to the plastic locking tie with the clamp. B. Align the white tape on the right handlebar switch lead with the rear end of the frame weld. C. Route the clutch cable to the inside of the wire harness where the leads (to throttle position sensor and right handlebar switch couplers) branch off from the harness. D. Fasten the wire harness with a plastic locking tie. Face the end of the plastic locking tie downward, angled inward, and then cut off the excess end of the tie. E. Be sure to route the clutch cable over any cable, lead, pipe, or hose that it crosses in the area shown in the illustration. F. To fuel sender G. Insert the projections on the wire harness holders completely into the holes in the frame. H. Route the fuel sender lead under the air vent hose. I. Fasten the starter relay lead, neutral switch lead, and speed sensor lead with a plastic locking tie, making sure to position the tie to the inside of the starter relay. Face the end of the plastic locking tie upward, and then cut off the excess end of the tie. J. Fasten the neutral switch lead and speed sensor lead with a plastic locking tie. K. Slide the boot over the neutral switch coupler and speed sensor coupler, making sure that they are covered completely. L. To tail/brake light assembly M. Fasten the tail/brake light wire harness with the holder. N. Fasten the wire harness, clutch cable, and subwire harness that branches off from the wire harness with a plastic locking tie, making sure that the tie does not contact the protective tape on the frame. O. Fasten the wire harness and right handlebar switch lead on the right side of the frame and fasten the wire harness on the left side of the frame with a plastic locking tie, making sure to install the tie on the harness protective tape. Do not fasten the coolant reservoir hose and clutch cable. P. Route the rear cylinder spark plug lead under the U-shaped fuel pipe. Q. Install the turn signal relay completely onto the tab on the battery box. R. Install the fuse box completely onto the tab on the battery box. S. Install the main fuse completely onto the tab on the battery box. T. Install the cover completely onto the ECU couplers. U. Route the positive battery lead under the negative battery lead, making sure not to route it on top of the relay unit.

2-56

CABLE ROUTING

3D8

3D8

10

11 12 13 14

AB

17

16

15

2-57

CABLE ROUTING
1. Front cylinder intake air pressure sensor hose 2. Front cylinder intake air pressure sensor 3. Rear cylinder intake air pressure sensor hose 4. Rear cylinder intake air pressure sensor 5. Front cylinder thermostat inlet hose 6. Right handlebar switch lead 7. Wire harness 8. Rear cylinder thermostat inlet hose 9. Front cylinder resonator hose 10. Sub-wire harness 11. Rear cylinder resonator hose 12. Sub-wire harness couplers 13. Fuel hose 14. Throttle position sensor 15. Crankcase breather hose 16. ISC (idle speed control) unit 17. Canister purge hose (California only) A. Install the front cylinder intake air pressure sensor hose with its yellow paint mark facing outward. B. Install the rear cylinder intake air pressure sensor hose with its white paint mark facing outward. C. Route the front cylinder intake air pressure sensor hose and rear cylinder intake air pressure sensor hose over the rear cylinder resonator hose and front cylinder resonator hose. D. Fasten the wire harness and right handlebar switch lead with a plastic locking tie. E. Route the canister purge hose (California only) under the rear cylinder thermostat inlet hose and front cylinder thermostat inlet hose.

2-58

CABLE ROUTING

2-59

CABLE ROUTING
1. Rear cylinder thermostat inlet hose 2. Right handlebar switch lead 3. Wire harness 4. Front cylinder resonator hose 5. Front cylinder intake air pressure sensor hose 6. Canister purge hose (California only) 7. Throttle position sensor 8. Rear cylinder intake air pressure sensor hose 9. Rear cylinder resonator hose 10. Sub-wire harness couplers 11. Fuel hose 12. Injectors 13. Front cylinder thermostat inlet hose 14. Rear cylinder intake air pressure sensor 15. Front cylinder intake air pressure sensor A. Face the ends of the hose clamp inward. B. Face the ends of the hose clamp outward. C. Align the hose clamp with the white paint mark on the canister purge hose (California only) and face the ends of the clamp forward. D. Route the canister purge hose (California only) to the outside of the front cylinder resonator hose, and then install it onto the throttle body pipe up to the bend in the pipe, making sure to face the white paint mark on the hose upward. E. 24 mm (0.080.16 in) F. Route the canister purge hose (California only) under the front cylinder intake air pressure sensor hose and rear cylinder intake air pressure sensor hose. G. Fasten the sub-wire harness at the white tape with a plastic locking tie. H. Face the ends of the hose clamp rearward. I. Face the ends of the hose clamp forward. J. Install the front cylinder intake air pressure sensor hose with its white paint mark facing outward. K. Install the rear cylinder intake air pressure sensor hose with its yellow paint mark facing outward. L. 01 mm (00.04 in)

2-60

CABLE ROUTING

2 1

B 3

F
12 13 11 A 10 9 C D

C B
8 L 5

A
J

14

E
1 K 3

1 7 14 8

16

E-E 15 B
7

F-F

17 E F G

D D
J 19 20 21 1 15 16 10 19 1 20 I

H 9

C
9

D-D
7

22

18

2-61

CABLE ROUTING
1. Fuel tank overflow hose 2. Fuel tank 3. Fuel tank breather hose (fuel tank to hose joint) 4. Air vent hose 5. Sub-fuel tank 6. Fuel pump 7. Fuel hose 8. Crankcase breather hose 9. Fuel cock hose 10. Fuel cock 11. Hose joint 12. Fuel tank breather hose (hose joint to rollover valve) 13. Rollover valve 14. Fuel tank breather hose (except for California) 15. Sidestand switch lead 16. Oil level switch lead 17. Fuel sender lead 18. Fuel sender 19. Fuel tank breather hose (rollover valve to canister) (California only) 20. Canister purge hose (California only) 21. Canister (California only) 22. Canister breather hose (California only) A. Route the fuel tank overflow hose, identified by the paint mark, over the fuel tank breather hose (fuel tank to hose joint). B. Do not face the ends of the hose clamps inward. C. Install the air vent hose to the fuel tank with its white paint mark facing downward. D. Face the crimped section of the hose clamp downward. E. Install the air vent hose with its paint mark facing upward. F. Face the ends of the hose clamp upward. G. Install the fuel cock hose with its yellow paint mark facing upward. H. Face the crimped section of the hose clamp upward. I. Face the crimped section of the hose clamp downward, making sure that it does not contact the fuel tank. J. Face the fastener of the holder outward. K. Be sure not to pinch the fuel tank overflow hose and fuel tank breather hose (fuel tank to hose joint) when installing the fuel tank. L. Face the open ends of the holder downward.

2-62

CABLE ROUTING

2-63

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE ............................................................................ 3-1 INTRODUCTION....................................................................................... 3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM................................................................................................... 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART....................... 3-1 ENGINE ........................................................................................................... 3-4 ADJUSTING THE VALVE CLEARANCE .................................................. 3-4 SYNCHRONIZING THE THROTTLE BODIES ......................................... 3-6 ADJUSTING THE THROTTLE CABLE FREE PLAY ................................ 3-8 CHECKING THE SPARK PLUGS............................................................. 3-9 CHECKING THE IGNITION TIMING......................................................... 3-9 MEASURING THE COMPRESSION PRESSURE.................................. 3-10 CHECKING THE ENGINE OIL LEVEL ................................................... 3-11 CHANGING THE ENGINE OIL ............................................................... 3-12 ADJUSTING THE CLUTCH LEVER FREE PLAY................................... 3-13 REPLACING THE AIR FILTER ELEMENT ............................................. 3-14 CHECKING THE INTAKE MANIFOLD JOINTS...................................... 3-15 CHECKING THE FUEL LINE .................................................................. 3-15 CHECKING THE CRANKCASE BREATHER HOSE .............................. 3-15 CHECKING THE EXHAUST SYSTEM ................................................... 3-16 CHECKING THE CANISTER (California only)........................................ 3-16 CHECKING THE COOLANT LEVEL....................................................... 3-16 CHECKING THE COOLING SYSTEM.................................................... 3-17 CHANGING THE COOLANT .................................................................. 3-17 CHASSIS ....................................................................................................... 3-20 ADJUSTING THE FRONT BRAKE LEVER FREE PLAY........................ 3-20 ADJUSTING THE REAR DISC BRAKE .................................................. 3-20 CHECKING THE BRAKE FLUID LEVEL ................................................ 3-21 CHECKING THE FRONT BRAKE PADS................................................ 3-21 CHECKING THE REAR BRAKE PADS .................................................. 3-21 CHECKING THE FRONT BRAKE HOSES ............................................. 3-22 CHECKING THE REAR BRAKE HOSES ............................................... 3-22 ADJUSTING THE REAR BRAKE LIGHT SWITCH................................. 3-22 BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-22 ADJUSTING THE SHIFT PEDAL............................................................ 3-24 ADJUSTING THE DRIVE BELT SLACK ................................................. 3-24 CHECKING AND ADJUSTING THE STEERING HEAD......................... 3-26 CHECKING THE FRONT FORK............................................................. 3-27 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-27 CHECKING THE TIRES ......................................................................... 3-28 CHECKING THE WHEELS ..................................................................... 3-29 CHECKING AND LUBRICATING THE CABLES .................................... 3-29 LUBRICATING THE LEVERS................................................................. 3-30 LUBRICATING THE PEDAL ................................................................... 3-30 LUBRICATING THE SIDESTAND .......................................................... 3-30 LUBRICATING THE REAR SUSPENSION ............................................ 3-30

ELECTRICAL SYSTEM ................................................................................ 3-31 CHECKING AND CHARGING THE BATTERY....................................... 3-31 CHECKING THE FUSES ........................................................................ 3-31 REPLACING THE HEADLIGHT BULB ................................................... 3-31 ADJUSTING THE HEADLIGHT BEAM ................................................... 3-32

PERIODIC MAINTENANCE
EAS20450

PERIODIC MAINTENANCE
EAS20460

INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.
EAU17600

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

INITIAL No. ITEM ROUTINE ODOMETER READINGS 8000 mi 12000 mi 16000 mi 20000 mi 600 mi 4000 mi (25000 (31000 (13000 (19000 (1000 km) (7000 km) km) km) km) km) or or or or or or 1 month 6 months 12 months 18 months 24 months 30 months

1 * Fuel line

Spark plugs

3 * Valve clearance 4 * Crankcase breather system 5 * Fuel injection 6 * Exhaust system Evaporative emission control sys7 * tem (For California only)

Check fuel hoses for cracks or damage. Replace if necessary. Check condition. Adjust gap and clean. Replace every 8000 mi (13000 km) or 12 months. Check and adjust valve clearance when engine is cold. Check breather hose for cracks or damage. Replace if necessary. Adjust synchronization. Check for leakage. Tighten if necessary. Replace gasket(s) if necessary. Check control system for damage. Replace if necessary.

Replace.

Replace.

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
EAU32183

GENERAL MAINTENANCE AND LUBRICATION CHART

INITIAL No. ITEM ROUTINE ODOMETER READINGS 8000 mi 12000 mi 16000 mi 20000 mi 600 mi 4000 mi (13000 (19000 (25000 (31000 (1000 km) (7000 km) km) km) km) km) or or or or or or 1 month 6 months 12 months 18 months 24 months 30 months

1 * Air filter element 2 * Clutch 3 * Front brake

4 * Rear brake

5 * Brake hoses 6 * Wheels

Check condition and damage. Replace if necessary. Check operation. Adjust or replace cable. Check operation, fluid level, and for fluid leakage. Replace brake pads if necessary. Check operation, fluid level, and for fluid leakage. Replace brake pads if necessary. Check for cracks or damage. Replace. Check runout and for damage. Replace if necessary.

Every 4 years

3-1

PERIODIC MAINTENANCE
INITIAL No. ITEM ROUTINE ODOMETER READINGS

8000 mi 12000 mi 16000 mi 20000 mi 600 mi 4000 mi (13000 (19000 (25000 (31000 (1000 km) (7000 km) km) km) km) km) or or or or or or 1 month 6 months 12 months 18 months 24 months 30 months

7 * Tires

8 * Wheel bearings 9 * Swingarm pivot bearings 10 * Drive belt

11 * Steering bearings

12 * Chassis fasteners 13 14 Brake and clutch lever pivot shafts Brake and shift pedal pivot shafts Sidestand pivot

15

16 * Sidestand switch 17 * Front fork Shock absorber 18 * assembly 19 * 20 Rear suspension link pivots Engine oil

Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. Check bearings for smooth operation. Replace if necessary. Check bearing assemblies for looseness. Moderately repack with lithium-soap-based grease. Check belt tension. Adjust if necessary. Check bearing assemblies for looseness. Moderately repack with lithium-soap-based grease every 16000 mi (25000 km) or 24 months. Check all chassis fitting and fasteners. Correct if necessary. Apply lithium-soap-based grease (all-purpose grease) lightly. Apply lithium-soap-based grease (all-purpose grease) lightly. Check operation. Apply lithium-soap-based grease (all-purpose grease) lightly. Check operation and replace if necessary. Check operation and for oil leakage. Replace if necessary. Check operation and for oil leakage. Replace if necessary. Apply lithium-soap-based grease lightly. Change (warm engine before draining). Replace. Check hoses for cracks or damage. Replace if necessary. Change with ethylene glycol anti-freeze coolant every 24 months. Check operation. Apply Yamaha chain and cable lube or engine oil SAE 10W-30 thoroughly. Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable.

Repack.

Every 2500 mi (4000 km)

Repack.

21 * Engine oil filter cartridge

Change.

22 * Cooling system

23 *

Front and rear brake switches

24 * Control cables

Throttle grip 25 * housing and cable

3-2

PERIODIC MAINTENANCE
INITIAL No. ITEM ROUTINE ODOMETER READINGS

8000 mi 12000 mi 16000 mi 20000 mi 600 mi 4000 mi (13000 (19000 (25000 (31000 (1000 km) (7000 km) km) km) km) km) or or or or or or 1 month 6 months 12 months 18 months 24 months 30 months

26 *

Lights, signals and switches

Check operation. Adjust headlight beam.

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:

From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.
EAU17650

NOTE:

Air filter This models air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas. Hydraulic brake service After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged.

3-3

ENGINE
EAS20470

ENGINE
EAS20530

ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves.
NOTE:

Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: Rider seat Left side cover Refer to GENERAL CHASSIS on page 4-1. Fuel tank Refer to FUEL TANK on page 7-1. Front cylinder left cover Front cylinder right cover Rear cylinder left cover Rear cylinder right cover Refer to ENGINE REMOVAL on page 5-1. 2. Remove: Throttle body Intake manifold assembly Refer to THROTTLE BODIES on page 7-7. 3. Drain: Coolant Refer to CHANGING THE COOLANT on page 3-17. 4. Remove: Front cylinder thermostat inlet hose Rear cylinder thermostat inlet hose Refer to THERMOSTAT on page 6-4. 5. Disconnect: Spark plug caps Refer to ENGINE REMOVAL on page 5-1. 6. Remove: Spark plugs Refer to CAMSHAFTS on page 5-12. 7. Remove: Damper cover 1 Damper 2 Timing mark accessing screw 3 Crankshaft end screw 4

3
8. Remove: Plastic locking tie 1 Plastic locking tie 2

2 1

9. Remove: Front cylinder tappet covers 1

10.Remove: Rear cylinder tappet covers 1

11.Measure: Valve clearance Out of specification Adjust.

3-4

ENGINE
Valve clearance (cold) Intake 0.090.13 mm (0.00350.0051 in) Exhaust 0.140.18 mm (0.00550.0071 in)

Front cylinder a. Turn the crankshaft counterclockwise.

Rear cylinder a. Turn the crankshaft counterclockwise from the front cylinder piston TDC by 300 degrees. b. When the rear cylinder piston is at TDC on the compression stroke, align the TDC mark c on the generator rotor with the slot d in the generator cover.
NOTE:

When the piston is at TDC on the compression stroke, there should be clearance between the valve stem tips and their respective rocker arm adjusting screws. If there is no clearance, rotate the crankshaft counterclockwise one turn.

b. When the front cylinder piston is at TDC on the compression stroke, align the TDC mark a on the generator rotor with the slot b in the generator cover.
NOTE:

When the piston is at TDC on the compression stroke, there should be clearance between the valve stem tips and their respective rocker arm adjusting screws. If there is no clearance, rotate the crankshaft counterclockwise one turn.

c. Measure the valve clearance with a thickness gauge. Thickness gauge 90890-03180 Feeler gauge set YU-26900-9

a
12.Adjust: Valve clearance

a. Loosen the locknut 1.

c. Measure the valve clearance with a thickness gauge. Thickness gauge 90890-03180 Feeler gauge set YU-26900-9

1
b. Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip.

3-5

ENGINE
Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 c. Turn the adjusting screw 3 in direction a or b with the tappet adjusting tool 4 until the specified valve clearance is obtained. Tappet adjusting tool 90890-04154 YM-04154 Direction a Valve clearance is increased. Direction b Valve clearance is decreased. 15.Install: Crankshaft end screw (along with the O-ring New ) Timing mark accessing screw (along with the O-ring New ) Damper Damper cover Crankshaft end screw 10 Nm (1.0 mkg, 7.2 ftlb) Timing mark accessing screw 6 Nm (0.6 mkg, 4.3 ftlb) Damper cover bolt 10 Nm (1.0 mkg, 7.2 ftlb)

16.Install: All removed parts

NOTE:

For installation, reverse the removal procedure.

EAS20570

SYNCHRONIZING THE THROTTLE BODIES

T.

4 2

NOTE:

Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the vehicle on a level surface.
NOTE:

d. Hold the adjusting screw to prevent it from moving and tighten the locknut to specification. Locknut (rocker arm adjusting screw) 14 Nm (1.4 mkg, 10 ftlb)

Place the vehicle on a suitable stand. 2. Remove: Rider seat Refer to GENERAL CHASSIS on page 4-1. Fuel tank Refer to FUEL TANK on page 7-1. 3. Disconnect: Front cylinder intake air pressure sensor hose 1 Rear cylinder intake air pressure sensor hose 2

e. Measure the valve clearance again. f. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained.

13.Install: Rear cylinder tappet covers Front cylinder tappet covers Rear cylinder tappet cover bolt 10 Nm (1.0 mkg, 7.2 ftlb) Front cylinder tappet cover bolt 10 Nm (1.0 mkg, 7.2 ftlb)

14.Install: Plastic locking ties

T.

R
T.

2 1

3-6

ENGINE
4. Install: Vacuum gauge 1 Digital tachometer Vacuum gauge 90890-03094 Carburetor synchronizer YU-44456
A

1
5. Install: Fuel tank Refer to FUEL TANK on page 7-1. 6. Adjust: Throttle body synchronization a. Measure the vacuum pressure of the front cylinder throttle body and rear cylinder throttle body. b. Using the throttle body with the lowest vacuum pressure as the standard, turn the air screw 1 of the other throttle body to adjust its vacuum pressure. c. If the vacuum pressure of the throttle body with the lower pressure is out of specification, adjust it to specification first, and then synchronize the throttle bodies.

A. Front cylinder throttle body B. Rear cylinder throttle body NOTE:

After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. If the air screw is removed, turn the screw 3/4 turn in and be sure to synchronize the throttle body.
ECA14900

CAUTION:

Do not use the throttle valve adjusting screws to adjust the throttle body synchronization. Vacuum gauge 90890-03094 Carburetor synchronizer YU-44456

3-7

ENGINE
Intake vacuum 32.037.3 kPa (9.411.0 inHg) (240280 mmHg)
NOTE:

Throttle cable free play 4.06.0 mm (0.160.24 in) 2. Remove: Rider seat Refer to GENERAL CHASSIS on page 4-1. Fuel tank Refer to FUEL TANK on page 7-1. 3. Adjust: Throttle cable free play

The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (10 mm Hg).

7. Measure: Engine idling speed Out of specification Adjust. Make sure that the vacuum pressure is within specification. 8. Stop the engine and remove the measuring equipment. 9. Connect: Rear cylinder intake air pressure sensor Front cylinder intake air pressure sensor 10.Adjust: Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3-8. Throttle cable free play 4.06.0 mm (0.160.24 in) 11.Install: Rider seat Refer to GENERAL CHASSIS on page 4-1.
EAS20630

Throttle body side a. Loosen the locknut 1 on the accelerator cable. b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. Direction a Throttle cable free play is increased. Direction b Throttle cable free play is decreased.

c. Tighten the locknut.

1 b a 2

ADJUSTING THE THROTTLE CABLE FREE PLAY

NOTE:

Prior to adjusting the throttle cable free play, the engine idling speed and throttle body synchronization should be adjusted properly. 1. Check: Throttle cable free play a Out of specification Adjust.

NOTE:

If the specified throttle cable free play cannot be obtained on the throttle body side of the cable, use the adjusting nut on the handlebar side.

SELECT

Handlebar side a. Slide back the throttle cable holder 1. b. Loosen the locknut 2. c. Turn the adjusting nut 3 in direction a or b until the specified throttle cable free play is obtained. Direction a Throttle cable free play is increased. Direction b Throttle cable free play is decreased.

RESET

3-8

ENGINE
d. Tighten the locknut. e. Slide the throttle cable holder to its original position. 7. Measure: Spark plug gap a (with a wire thickness gauge) Out of specification Regap. Spark plug gap 0.80.9 mm (0.0310.035 in)

3 a

1 b

4. Install: Fuel tank Refer to FUEL TANK on page 7-1. Rider seat Refer to GENERAL CHASSIS on page 4-1.
EAS20680

8. Install: Spark plug Spark plug 13 Nm (1.3 mkg, 9.4 ftlb)

CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: Front cylinder left cover Rear cylinder right cover Refer to ENGINE REMOVAL on page 5-1. 2. Disconnect: Spark plug cap 3. Remove: Spark plug
ECA13320

NOTE:

Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: Spark plug cap 10.Install: Rear cylinder right cover Front cylinder left cover Refer to ENGINE REMOVAL on page 5-1.
EAS20700

T.

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. 4. Check: Spark plug type Incorrect Change. Manufacturer/model NGK/LMAR7A-9 5. Check: Electrode Damage/wear Replace the spark plug. Insulator Abnormal color Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: Spark plug (with a spark plug cleaner or wire brush)

CHECKING THE IGNITION TIMING

NOTE:

Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Remove: Front cylinder covers Refer to ENGINE REMOVAL on page 5-1. 2. Remove: Damper cover 1 Damper 2 Timing mark accessing screw 3 (along with the O-ring)

3-9

ENGINE
NOTE:

The ignition timing is not adjustable.

5. Install: Timing mark accessing screw (along with the O-ring New ) Damper Damper cover Timing mark accessing screw 6 Nm (0.6 mkg, 4.3 ftlb) Damper cover bolt 7 Nm (0.7 mkg, 5.1 ftlb)

3
3. Connect: Timing light 1 Digital tachometer Timing light 90890-03141 Inductive clamp timing light YU-03141

6. Install: Front cylinder covers Refer to ENGINE REMOVAL on page 5-1.

EAS20710

MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders.
NOTE:

Insufficient compression pressure will result in a loss of performance.

1
4. Check: Ignition timing

a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed 9501050 r/min

b. Check that slot a in the generator cover is within the firing range b on the generator rotor. Incorrect firing range Check the ignition system.

1. Measure: Valve clearance Out of specification Adjust. Refer to ADJUSTING THE VALVE CLEARANCE on page 3-4. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Remove: Front cylinder covers Rear cylinder covers Refer to ENGINE REMOVAL on page 5-1. 4. Disconnect: Spark plug caps 5. Remove: Spark plug
ECA13340

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.

6. Install: Compression gauge 1

T.

3-10

ENGINE
Compression gauge 90890-03081 Engine compression tester YU-33223 Compression pressure (with oil applied into the cylinder) Reading Higher than without oil Same as without oil Diagnosis Piston ring(s) wear or damage Repair. Piston, valves, cylinder head gasket or piston possibly defective Repair.

1
8. Install: Spark plug 7. Measure: Compression pressure Out of specification Refer to steps (c) and (d). Standard compression pressure (at sea level) 1450 kPa/400 r/min (206.2 psi/400 r/min) (14.5 kgf/cm/400 r/min) Minimummaximum 12001500 kPa (170.7213.3 psi) (12.015.0 kgf/cm)

Spark plug 13 Nm (1.3 mkg, 9.4 ftlb)

9. Connect: Spark plug caps 10.Install: Rear cylinder covers Front cylinder covers Refer to ENGINE REMOVAL on page 5-1.
EAS20750

CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface.
NOTE:

a. Set the main switch to ON. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm, 14 psi).

Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Check: Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark Add the recommended engine oil to the proper level.

T.

NOTE:

c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. Carbon deposits Eliminate. d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure again. Refer to the following table.

b a

3-11

ENGINE
Type YAMALUBE 4 (20W40) or SAE20W40 Recommended engine oil grade API service SG type or higher, JASO standard MA
0 10 30 50 70 90 110 130 F

4. Drain: Engine oil (completely from the crankcase) 5. If the oil filter cartridge is also to be replaced, perform the following procedure.

a. Remove the oil filter cartridge 1 with an oil filter wrench 2. Oil filter wrench 90890-01469 YM-01469

YAMALUBE 4 (20W40) or SAE 20W40

20 10
ECA13380

10

20

30

40 50 C

1 2

CAUTION:

Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives. Do not allow foreign materials to enter the crankcase. 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Check the engine oil level again.
NOTE:

b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil.
ECA13390

CAUTION:

Make sure the O-ring 3 is positioned correctly in the groove of the oil filter cartridge.

Before checking the engine oil level, wait a few minutes until the oil has settled.
EAS20780

CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: Engine oil drain bolt 1 (along with the gasket)

c. Tighten the new oil filter cartridge to specification with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 mkg, 12 ftlb)

6. Install: Engine oil drain bolt (along with the gasket New )

T.

Engine oil drain bolt 43 Nm (4.3 mkg, 31 ftlb)

T.

3-12

ENGINE
7. Fill: Crankcase (with the specified amount of the recommended engine oil) Engine oil quantity Total amount 3.70 L (3.91 US qt) (3.26 Imp.qt) Without oil filter cartridge replacement 3.20 L (3.38 US qt) (2.82 Imp.qt) With oil filter cartridge replacement 3.40 L (3.59 US qt) (2.99 Imp.qt) 8. Start the engine, warm it up for several minutes, and then turn it off. 9. Check: Engine (for engine oil leaks) 10.Check: Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3-11. 11.Remove: Left side cover Refer to GENERAL CHASSIS on page 4-1. Throttle body Refer to THROTTLE BODIES on page 7-7. 12.Check: Engine oil pressure

b. Start the engine and keep it idling until engine oil starts to seep from the oil check bolts. If no engine oil comes out after one minute, turn the engine off so that it will not seize. c. Check the engine oil passages, the oil filter cartridge and the oil pump for damage or leakage. Refer to OIL PUMP on page 5-73. d. Start the engine after solving the problem(s) and check the engine oil pressure again. e. Tighten the oil check bolts to specification. Oil check bolt 15 Nm (1.5 mkg, 11 ftlb)

13.Install: Throttle body Refer to THROTTLE BODIES on page 7-7. Left side cover Refer to GENERAL CHASSIS on page 4-1.
EAS20870

ADJUSTING THE CLUTCH LEVER FREE PLAY 1. Check: Clutch lever free play a Out of specification Adjust. Clutch lever free play 5.010.0 mm (0.200.39 in)

T.

a. Slightly loosen the front cylinder oil check bolt 1 and rear cylinder oil check bolt 2.

2. Adjust: Clutch lever free play Handlebar side a. Loosen the locknut 1. b. Turn the adjusting bolt 2 in direction a or b until the specified clutch lever free play is obtained.

3-13

ENGINE
Direction a Clutch lever free play is increased. Direction b Clutch lever free play is decreased. c. Tighten the locknut 1. 4. Install: Right side panel Left side panel Refer to FUEL TANK on page 7-1.
EAS20960

REPLACING THE AIR FILTER ELEMENT 1. Remove: Air filter case cover 1

NOTE:

If the specified clutch lever free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side.

2. Remove: Air filter element 1

3. Remove: Left side panel Right side panel Refer to FUEL TANK on page 7-1. Engine side a. Slide back the rubber cover 1. b. Loosen the locknut 2. c. Turn the adjusting nut 3 in direction a or b until the specified clutch lever free play is obtained. Direction a Clutch cable free play is increased. Direction b Clutch cable free play is decreased. d. Slide the rubber cover to its original position. e. Tighten the locknut.

3. Check: Air filter element Damage Replace.

NOTE:

The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 4. Install: Air filter element Air filter case cover
ECA3D81015

CAUTION:

3 b

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 throttle body synchronization, leading to poor engine performance and possible overheating.

3-14

ENGINE
NOTE:
ECA3D81009

When installing the air filter element into the air filter case, make sure that the sealing surfaces are aligned to prevent any air leaks.
EAS3D81008

CAUTION:

Make sure the fuel tank breather hose and fuel tank overflow hose are routed correctly.

3 1 2 4 5

CHECKING THE INTAKE MANIFOLD JOINTS 1. Remove: Left side cover Refer to GENERAL CHASSIS on page 4-1. Fuel tank Refer to FUEL TANK on page 7-1. Front cylinder thermostat inlet hose Rear cylinder thermostat inlet hose Refer to THERMOSTAT on page 6-4. 2. Check: Intake manifold joints 1 Cracks/damage Replace.

3. Install: Fuel tank Refer to FUEL TANK on page 7-1. Rider seat Refer to GENERAL CHASSIS on page 4-1.
EAS21070

1
3. Install: Rear cylinder thermostat inlet hose Front cylinder thermostat inlet hose Refer to THERMOSTAT on page 6-4. Fuel tank Refer to FUEL TANK on page 7-1. Left side cover Refer to GENERAL CHASSIS on page 4-1.
EAS21030

CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: Rider seat Air filter case Refer to GENERAL CHASSIS on page 4-1. Fuel tank Refer to FUEL TANK on page 7-1. Intake manifold assembly Refer to THROTTLE BODIES on page 7-7. 2. Check: Crankcase breather hose 1 Cracks/damage Replace. Loose connection Connect properly.

CHECKING THE FUEL LINE The following procedure applies to all of the fuel, air vent and breather hoses. 1. Remove: Rider seat Refer to GENERAL CHASSIS on page 4-1. Fuel tank Refer to FUEL TANK on page 7-1. 2. Check: Fuel hose 1 Air vent hose 2 Fuel cock hose 3 Fuel tank breather hose 4 Fuel tank overflow hose 5 Cracks/damage Replace. Loose connection Connect properly.

ECA13450

CAUTION:

Make sure the crankcase breather hose is routed correctly. 3. Install: Fuel tank Refer to FUEL TANK on page 7-1. Air filter case

3-15

ENGINE
Rider seat Refer to GENERAL CHASSIS on page 4-1.
EAS21080

CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Check: Front cylinder exhaust pipe 1 Rear cylinder exhaust pipe 2 Muffler 3 Cracks/damage Replace. Gaskets 4 Gaskets 5 Exhaust gas leaks Replace. 2. Check: Tightening torques Exhaust pipe nuts 6 Front cylinder exhaust pipe and rear cylinder exhaust pipe bolt 7 Muffler and rear cylinder exhaust pipe bolt 8 Muffler bracket and frame bolts 9 Muffler bracket and muffler bolts 10 Exhaust pipe nut 20 Nm (2.0 mkg, 14 ftlb) Front cylinder exhaust pipe and rear cylinder exhaust pipe bolt 12 Nm (1.2 mkg, 8.7 ftlb) Muffler and rear cylinder exhaust pipe bolt 12 Nm (1.2 mkg, 8.7 ftlb) Muffler bracket and frame bolt 53 Nm (5.3 mkg, 38 ftlb) Muffler bracket and muffler bolt 35 Nm (3.5 mkg, 25 ftlb)

3 8

2 6 7 5

4 New

New 4 1

10

(3) 9

EAS21090

CHECKING THE CANISTER (California only) 1. Check: Canister 1 Canister purge hose 2 Canister charge hose 3 Canister breather hose 4 Cracks/damage Replace.

T.

2 3

1 4
EAS21110

CHECKING THE COOLANT LEVEL 1. Stand the vehicle on a level surface.

NOTE:

Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Check: Coolant level The coolant level should be between the maximum level mark a and minimum level mark b. Below the minimum level mark Add the recommended coolant to the proper level.

3-16

ENGINE
NOTE:

Before checking the coolant level, wait a few minutes until the coolant has settled.
EAS21120

a b
NOTE:

To add coolant, remove the coolant reservoir cap cover 1 and coolant reservoir cap 2.

CHECKING THE COOLING SYSTEM 1. Remove: Front cylinder exhaust pipe Refer to ENGINE REMOVAL on page 5-1. 2. Check: Radiator cover 1 Radiator 2 Radiator inlet hose 3 Radiator outlet hose 4 Radiator outlet pipe 5 Cracks/damage Replace. Refer to RADIATOR on page 6-1.

5 1 4

3. Install: Front cylinder exhaust pipe Refer to ENGINE REMOVAL on page 5-1.
EAS21130

ECA13470

CAUTION:

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. Use only distilled water. However, if distilled water is not available, soft water may be used. 3. Install: Coolant reservoir cap Coolant reservoir cap cover 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check: Coolant level

CHANGING THE COOLANT 1. Remove: Fuel tank Refer to FUEL TANK on page 7-1. Muffler Coolant reservoir cover Refer to ENGINE REMOVAL on page 5-1. 2. Remove: Radiator cap 1

3-17

ENGINE
EWA13030

WARNING

A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause 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. 3. Remove: Coolant drain bolt (radiator) 1 (along with the copper washer) 4. Disconnect: Radiator outlet hose 2

7. Remove: Coolant reservoir 1 Coolant reservoir cap 2

2 1

1 2

8. Drain: Coolant (from the coolant reservoir) 9. Install: Coolant reservoir Coolant reservoir bolt 7 Nm (0.7 mkg, 5.1 ftlb)

T.

5. Drain: Coolant (from the engine and radiator) 6. Remove: Rear brake hose plastic holder 1 Rear brake hose guide bolts 2 Rear brake hose holder 3

10.Install: Rear brake hose holder Rear brake hose guide bolts Rear brake hose clamp Rear brake hose holder bolt 7 Nm (0.7 mkg, 5.1 ftlb) Rear brake hose guide bolt 7 Nm (0.7 mkg, 5.1 ftlb)

T.

1
11.Connect: Radiator outlet hose 12.Install: Coolant drain bolt (radiator) (along with the copper washer New ) Coolant drain bolt (radiator) 2 Nm (0.2 mkg, 1.4 ftlb)

T.

3-18

ENGINE
13.Fill: 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) Radiator capacity (including all routes) 2.10 L (2.22 US qt) (1.85 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.45 L (0.48 US qt) (0.40 Imp.qt) Handling notes for coolant Coolant is potentially harmful and should be handled with special care.
EWA13040

a
16.Install: Coolant reservoir cap 17.Start the engine, warm it up for several minutes, and then stop it. 18.Check: Coolant level Refer to CHECKING THE COOLANT LEVEL on page 3-16.
NOTE:

WARNING

Before checking the coolant level, wait a few minutes until the coolant has settled. 19.Install: Coolant reservoir cover Muffler Refer to ENGINE REMOVAL on page 5-1. Fuel tank Refer to FUEL TANK on page 7-1.

If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor. If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. If coolant is swallowed, induce vomiting and get immediate medical attention.
ECA13480

CAUTION:

Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. Use only distilled water. However, if distilled water is not available, soft water may be used. If coolant comes into contact with painted surfaces, immediately wash them with water. Do not mix different types of antifreeze. 14.Install: Radiator cap 15.Fill: Coolant reservoir (with the recommended coolant to the maximum level mark a)

3-19

CHASSIS
EAS21140 EAS21190

CHASSIS
EAS21150

ADJUSTING THE FRONT BRAKE LEVER FREE PLAY 1. Check: Front brake lever free play a Out of specification Adjust. Front brake lever free play 2.05.0 mm (0.080.20 in) 2. Adjust: Front brake lever free play a. Loosen the locknut 1. b. Turn the adjusting screw 2 in direction a or b until the specified brake lever free play is obtained. Direction b Brake lever free play is increased. Direction c Brake lever free play is decreased.

ADJUSTING THE REAR DISC BRAKE 1. Check: Brake pedal adjusting bolt position Check that the end a of the brake pedal adjusting bolt is visible through the hole b. Incorrect Adjust.

2. Adjust: Brake pedal adjusting bolt position a. Loosen the locknut 1. b. Adjust the brake pedal adjusting bolt 2 position by turning the adjusting bolt in or out so that its end is visible through the hole.

2 c

b
2
c. Tighten the locknut.
EWA13050

c. Tighten the locknut 1 to specification. Locknut 16 Nm (1.6 mkg, 11 ftlb)

WARNING
T.

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 braking performance.
ECA3D81018

EWA3D81002

WARNING

CAUTION:

After adjusting the brake lever free play, make sure there is no brake drag.

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.
ECA3D81019

CAUTION:

After adjusting the brake pedal adjusting bolt position, make sure there is no brake drag.

3-20

CHASSIS
3. Adjust: Rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3-22.
EAS21240

When refilling, be careful that water does not enter the front brake master cylinder reservoir and brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
ECA13540

CHECKING THE BRAKE FLUID LEVEL 1. Stand the vehicle on a level surface.
NOTE:

CAUTION:

Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Check: Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Recommended fluid DOT 4
A

Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.
NOTE:

In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal.
EAS21250

LOWER

CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: Front brake pad Wear indicators a almost touch the brake disc Replace the brake pads as a set. Refer to FRONT BRAKE on page 4-22.

UP

LOWER

EAS21260

A. Front brake B. Rear brake

EWA3D81007

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.

CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: Rear brake pad Wear indicators a almost touch the brake disc Replace the brake pads as a set. Refer to REAR BRAKE on page 4-34.

3-21

CHASSIS
2. Check: Brake hose clamp Loose Tighten the clamp bolt. 3. Hold the vehicle upright and apply the brake several times. 4. Check: Brake hoses Brake fluid leakage Replace the damaged hose. Refer to REAR BRAKE on page 4-34.
EAS21330

EAS21280

CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: Brake hoses 1 Cracks/damage/wear Replace.

ADJUSTING THE REAR BRAKE LIGHT SWITCH

NOTE:

The rear brake light switch is operated by movement of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1. Check: Rear brake light operation timing Incorrect Adjust. 2. Adjust: Rear brake light operation timing a. Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time. Direction a Brake light comes on sooner. Direction b Brake light comes on later.

1 1

2. Check: Brake hose clamp Loose Tighten the clamp bolt. 3. Hold the vehicle upright and apply the brake several times. 4. Check: Brake hoses Brake fluid leakage Replace the damaged hose. Refer to FRONT BRAKE on page 4-22.
EAS21290

1 2 a b

CHECKING THE REAR BRAKE HOSES 1. Check: Brake hoses 1 Cracks/damage/wear Replace.

EAS21350

BLEEDING THE HYDRAULIC BRAKE SYSTEM

EWA13100

WARNING

Bleed the hydraulic brake system whenever: the system is disassembled.

3-22

CHASSIS
a brake hose is loosened, disconnected or replaced. the brake fluid level is very low. brake operation is faulty. 1. Remove: Rider seat Sub-fuel tank cover Refer to GENERAL CHASSIS on page 4-1. 2. Remove: Brake fluid reservoir bolt 1
B A

2 1

1 2

1
NOTE: A. Front B. Rear

Remove the brake fluid reservoir bolt, and then remove the brake fluid reservoir cap screws. Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or 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. 3. Install: Brake fluid reservoir
NOTE:

d. Put the other end of the hose into an open 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. h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. Bleed screw (front brake caliper) 6 Nm (0.6 mkg, 4.3 ftlb) Bleed screw (rear brake caliper) 6 Nm (0.6 mkg, 4.3 ftlb)

Install the brake fluid reservoir temporarily.

T.

4. Bleed: Hydraulic brake system

a. Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). c. Connect a clear plastic hose 1 tightly to the bleed screw 2.

k. Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the recommended brake fluid. Refer to CHECKING THE BRAKE FLUID LEVEL on page 3-21.

3-23

CHASSIS
EWA13110

WARNING

After bleeding the hydraulic brake system, check the brake operation.

5. Tighten: Brake fluid reservoir bolt Bleed fluid reservoir bolt 7 Nm (0.7 mkg, 5.1 ftlb) LOCTITE

a b

6. Install: Sub-fuel tank cover Rider seat Refer to GENERAL CHASSIS on page 4-1.
EAS21380

ADJUSTING THE SHIFT PEDAL

NOTE:

The shift pedal position is determined by the installed shift rod length a. 1. Measure: Installed shift rod length a Incorrect Adjust. Installed shift rod length 255259 mm (10.0410.20 in)

2. Adjust: Installed shift rod length a. Loosen both locknuts 1. b. Turn the shift rod 2 in direction a or b to obtain the correct shift rod length.

Direction a Installed shift rod length is increased. Direction b Installed shift rod length is decreased.

T.

c. Tighten the locknuts to specification. Locknut 8 Nm (0.8 mkg, 5.8 ftlb)

d. Make sure the installed shift rod length is within specification.

EAS21430

ADJUSTING THE DRIVE BELT SLACK

NOTE:

The drive belt slack must be checked at the tightest point on the belt.
ECA14950

CAUTION:

A drive belt 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 belt slack within the specified limits.
NOTE:

Measure the drive belt slack when the engine is cold, and when the drive belt is dry. 1. Stand the vehicle on a level surface.

T.

EWA13120

WARNING

Securely support the vehicle so that there is no danger of it falling over.

NOTE:

Place the vehicle on the sidestand and or on a suitable stand so that the rear wheel is elevated. 2. Check: Drive belt slack a Out of specification Adjust.

3-24

CHASSIS

1 a
b. Loosen both locknuts 2. c. Turn both adjusting bolts 3 in direction a or b until the specified drive belt slack is obtained. Direction a Drive belt is tightened. Direction b Drive belt is loosened.

Drive belt slack (on the sidestand) 5.07.0 mm (0.200.28 in) Drive belt slack (on a suitable stand) 4.06.0 mm (0.160.24 in) Belt tension gauge 90890-03170 Rear drive belt tension gauge YM-03170
NOTE:

b
The level marks of the level window on the lower drive belt cover are in units of 5 mm (0.20 in). Use them as a standard for measuring the drive belt slack. Measure the drive belt slack when the drive belt has been pushed with 4.5 kg (10 lb) of pressure using a belt tension gauge 1.

a 2 3

NOTE:

Using the alignment marks on each side of the swingarm, make sure that both belt pullers are in the same position for proper wheel alignment. d. Tighten the locknuts to specification. Locknut 16 Nm (1.6 mkg, 11 ftlb)

T.

6 8 10 12 14

e. Tighten the rear wheel axle nut to specification. Rear wheel axle nut 150 Nm (15.0 mkg, 110 ftlb)

3. Remove: Muffler Refer to ENGINE REMOVAL on page 5-1. 4. Adjust: Drive belt slack

NOTE:

Place the vehicle on a suitable stand so that the rear wheel is elevated. a. Loosen the rear wheel axle nut 1.

5. Install: Muffler Refer to ENGINE REMOVAL on page 5-1.

T.

3-25

CHASSIS
EAS21510

CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the vehicle on a level surface.
EWA13120

WARNING

Securely support the vehicle so that there is no danger of it falling over.

NOTE:

Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Check: Steering head Grasp the bottom of the front fork legs and gently rock the front fork. Blinding/looseness Adjust the steering head.
T.

Steering nut wrench 90890-01403 Spanner wrench YU-33975 Lower ring nut (initial tightening torque) 52 Nm (5.2 mkg, 37 ftlb)

c. Loosen the lower ring nut 4 completely and then tighten it to specification with a steering nut wrench.
EWA13140

WARNING

Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 18 Nm (1.8 mkg, 13 ftlb)

3. Remove: Upper bracket Refer to FRONT FORK on page 4-50. 4. Adjust: Steering head

a. Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3.

d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to STEERING HEAD on page 4-59. e. Install the rubber washer 3. f. Install the upper ring nut 2.
NOTE:

Install the upper ring nut and lower ring nut with their sharp-edged sides a facing each other. g. Finger tighten the upper ring nut 2, and 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:

T.

b. Tighten the lower ring nut 4 to specification with a steering nut wrench 5.
NOTE:

Set the torque wrench at a right angle to the steering nut wrench.

Make sure the lock washer tabs b sit correctly in the ring nut slots c.

3-26

CHASSIS
Spring preload
ECA13590

CAUTION:

Never go beyond the maximum or minimum adjustment positions. 1. Remove: Rear cylinder exhaust pipe Coolant reservoir cover Refer to ENGINE REMOVAL on page 5-1. 2. Disconnect: Fuel hose 1 (from sub-fuel tank) Refer to FUEL TANK on page 7-1.

5. Install: Upper bracket Refer to FRONT FORK on page 4-50.

EAS21530

CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface.

EWA13120

WARNING

Securely support the vehicle so that there is no danger of it falling over. 2. Check: Inner tube Damage/scratches Replace. Oil seal Oil leakage Replace. 3. Hold the vehicle upright and apply the front brake. 4. Check: Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement Repair. Refer to FRONT FORK on page 4-50. 3. Adjust: Spring preload a. Adjust the spring preload with the special wrench 1 and wrench handle 2 included in the owners tool kit. b. Turn the adjusting ring 3 in direction a or b. c. Align the desired position on the adjusting ring with the stopper 4. Direction a Spring preload is decreased (suspension is softer). Direction b Spring preload is increased (suspension is harder). Spring preload adjusting positions Minimum 1 Standard 4 Maximum 9

EAS21590

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

EWA13120

WARNING

Securely support the vehicle so that there is no danger of it falling over.

3-27

CHASSIS
Tire air pressure (measured on cold tires) Loading condition 090 kg (0198 lb) Front 250 kPa (36 psi) (2.50 kgf/cm) Rear 280 kPa (41 psi) (2.80 kgf/cm) Loading condition XVS13AW(C) 90210 kg (198 463 lb) XVS13CTW(C) 90190 kg (198 419 lb) Front 250 kPa (36 psi) (2.50 kgf/cm) Rear 280 kPa (41 psi) (2.80 kgf/cm) Maximum load XVS13AW(C) 210 kg (463 lb) XVS13CTW(C) 190 kg (419 lb) * Total weight of rider, passenger, cargo and accessories
EWA13190

1 b

3 2 a

4 3

8 9 56 7 12 34

4. Connect: Fuel hose Refer to FUEL TANK on page 7-1. 5. Install: Rear cylinder exhaust pipe Coolant reservoir cover Refer to ENGINE REMOVAL on page 5-1.
EAS21650

CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: Tire pressure Out of specification Regulate.

WARNING

It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: Tire surfaces Damage/wear Replace the tire.

EWA13180

WARNING

The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. Operation of an overloaded vehicle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE VEHICLE.

1. Tire tread depth 2. Side wall 3. Wear indicator

Wear limit (front) 1.0 mm (0.04 in) Wear limit (rear) 1.0 mm (0.04 in)

3-28

CHASSIS
EWA14080

WARNING

Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. When using a tube tire, be sure to install the correct tube. Always replace a new tube tire and a new tube as a set. To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. Patching a punctured tube is not 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.

Rear tire Size 170/70B 16M/C 75H Manufacturer/model DUNLOP/K555 Manufacturer/model BRIDGESTONE/EXEDRA G722 G
EWA13210

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: Install the tire with the mark pointing in the direction of wheel rotation. Align the mark 2 with the valve installation point.

A. Tire B. Wheel

Tube wheel Tubeless wheel

EWA14090

Tube tire only Tube or tubeless tire

EAS21670

WARNING

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 vehicle. Front tire Size 130/9016M/C 67H Manufacturer/model DUNLOP/D404F X Manufacturer/model BRIDGESTONE/EXEDRA G721

CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: Wheel Damage/out-of-round Replace.
EWA13260

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.
EAS21690

CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables.

3-29

CHASSIS
EWA13270

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: Outer cable Damage Replace. 2. Check: 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.
EAS21700

LUBRICATING THE LEVERS Lubricate the pivoting points and metal-to-metal moving parts of the levers. Recommended lubricant Lithium-soap-based grease
EAS21710

LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. Recommended lubricant Lithium-soap-based grease
EAS21720

LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium-soap-based grease
EAS21740

LUBRICATING THE REAR SUSPENSION Lubricate the pivoting points and metal-to-metal moving parts of the rear suspension. Recommended lubricant Molybdenum disulfide grease

3-30

ELECTRICAL SYSTEM
EAS21750

ELECTRICAL SYSTEM
EAS21760

6. Remove: Headlight bulb 6

CHECKING AND CHARGING THE BATTERY Refer to ELECTRICAL COMPONENTS on page 8-67.
EAS21770

CHECKING THE FUSES Refer to ELECTRICAL COMPONENTS on page 8-67.

EAS21790

5 6

REPLACING THE HEADLIGHT BULB 1. Remove: Turn signal light bracket cover 1

EWA13320

WARNING

Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 7. Install: Headlight bulb New Secure the new headlight bulb with the headlight bulb holder.
ECA13690

CAUTION:

2. Remove: Headlight lens unit 2

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. 8. Attach: Headlight bulb holder 9. Install: Bulb cover 10.Connect: Headlight coupler 11.Install: Headlight lens unit Turn signal light bracket cover

3. Disconnect: Headlight coupler 3 4. Remove: Bulb cover 4

4 3
5. Detach: Headlight bulb holder 5

3-31

ELECTRICAL SYSTEM
EAS21810

ADJUSTING THE HEADLIGHT BEAM 1. Adjust: Headlight beam (vertically) a. Turn the adjusting screw 1 with a screw driver in direction a or b. Direction a Headlight beam is raised. Direction b Headlight beam is lowered.

b 1

2. Adjust: Headlight beam (horizontally) a. Turn the adjusting screw 1 with a screw driver in direction a or b. Direction a Headlight beam moves to the left. Direction b Headlight beam moves to the right.

a 1

3-32

ELECTRICAL SYSTEM

3-33

CHASSIS
GENERAL CHASSIS ...................................................................................... 4-1 FRONT WHEEL .............................................................................................. 4-9 REMOVING THE FRONT WHEEL ......................................................... 4-11 DISASSEMBLING THE FRONT WHEEL................................................ 4-11 CHECKING THE FRONT WHEEL .......................................................... 4-11 ASSEMBLING THE FRONT WHEEL...................................................... 4-12 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-12 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC) ................. 4-13 REAR WHEEL............................................................................................... 4-15 REMOVING THE REAR WHEEL (DISC)................................................ 4-20 DISASSEMBLING THE REAR WHEEL .................................................. 4-20 CHECKING THE REAR WHEEL ............................................................ 4-20 CHECKING THE REAR BRAKE CALIPER BRACKET........................... 4-20 CHECKING THE REAR WHEEL DRIVE HUB........................................ 4-20 CHECKING AND REPLACING THE REAR WHEEL PULLEY ............... 4-20 ASSEMBLING THE REAR WHEEL ........................................................ 4-21 ADJUSTING THE REAR WHEEL STATIC BALANCE ........................... 4-21 INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ...................... 4-21 FRONT BRAKE............................................................................................. 4-22 INTRODUCTION..................................................................................... 4-27 CHECKING THE FRONT BRAKE DISCS............................................... 4-27 REPLACING THE FRONT BRAKE PADS .............................................. 4-28 REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-29 DISASSEMBLING THE FRONT BRAKE CALIPERS ............................. 4-29 CHECKING THE FRONT BRAKE CALIPERS........................................ 4-29 ASSEMBLING THE FRONT BRAKE CALIPERS ................................... 4-30 INSTALLING THE FRONT BRAKE CALIPERS...................................... 4-30 REMOVING THE FRONT BRAKE MASTER CYLINDER....................... 4-31 CHECKING THE FRONT BRAKE MASTER CYLINDER ....................... 4-31 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-31 INSTALLING THE FRONT BRAKE MASTER CYLINDER ..................... 4-32 REAR BRAKE ............................................................................................... 4-34 INTRODUCTION..................................................................................... 4-40 CHECKING THE REAR BRAKE DISC ................................................... 4-40 REPLACING THE REAR BRAKE PADS ................................................ 4-40 REMOVING THE REAR BRAKE CALIPER ............................................ 4-41 DISASSEMBLING THE REAR BRAKE CALIPER .................................. 4-41 CHECKING THE REAR BRAKE CALIPER............................................. 4-42 ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-42 INSTALLING THE REAR BRAKE CALIPER........................................... 4-42 REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-43 CHECKING THE REAR BRAKE MASTER CYLINDER.......................... 4-43 ASSEMBLING THE REAR BRAKE MASTER CYLINDER ..................... 4-44 INSTALLING THE REAR BRAKE MASTER CYLINDER........................ 4-44

HANDLEBAR ................................................................................................ 4-45 REMOVING THE HANDLEBAR.............................................................. 4-47 CHECKING THE HANDLEBAR .............................................................. 4-47 INSTALLING THE HANDLEBAR ............................................................ 4-47 FRONT FORK ............................................................................................... 4-50 REMOVING THE FRONT FORK LEGS.................................................. 4-54 DISASSEMBLING THE FRONT FORK LEGS........................................ 4-54 CHECKING THE FRONT FORK LEGS .................................................. 4-55 ASSEMBLING THE FRONT FORK LEGS.............................................. 4-55 INSTALLING THE FRONT FORK LEGS ................................................ 4-57 STEERING HEAD ......................................................................................... 4-59 REMOVING THE LOWER BRACKET .................................................... 4-61 CHECKING THE STEERING HEAD....................................................... 4-61 INSTALLING THE STEERING HEAD..................................................... 4-61 REAR SHOCK ABSORBER ASSEMBLY .................................................... 4-63 HANDLING THE REAR SHOCK ABSORBER........................................ 4-65 DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-65 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY .................. 4-65 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-65 CHECKING THE CONNECTING ARM AND RELAY ARM..................... 4-66 INSTALLING THE RELAY ARM ............................................................. 4-66 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-66 SWINGARM .................................................................................................. 4-68 REMOVING THE SWINGARM ............................................................... 4-70 CHECKING THE SWINGARM ................................................................ 4-70 INSTALLING THE SWINGARM .............................................................. 4-70 BELT DRIVE ................................................................................................. 4-72 REMOVING THE DRIVE BELT AND DRIVE PULLEY ........................... 4-73 CHECKING THE DRIVE BELT ............................................................... 4-73 INSTALLING THE DRIVE BELT AND DRIVE PULLEY.......................... 4-73

GENERAL CHASSIS
EAS21830

GENERAL CHASSIS
Removing the windshield (for XVS13CT)
23 Nm (2.3 m kg, 17 ft Ib) 48 Nm (4.8 m kg, 35 ft Ib)
T T

Order

1 2

23 Nm (2.3 m kg, 17 ft Ib)

23 Nm (2.3 m kg, 17 ft Ib)

Turn signal light bracket cover 1 2 Windshield Windshield bracket (left and right) 1 2

Job/Parts to remove

Qty

Remarks Refer to GENERAL CHASSIS on page 4-1.

For installation, reverse the removal procedure.

4-1

GENERAL CHASSIS
Removing the sidebags and backrest (for XVS13CT)
23 Nm (2.3 m kg, 17 ft Ib)
R
T T

23 Nm (2.3 m kg, 17 ft Ib)

LT

Order

23 Nm (2.3 m kg, 17 ft Ib)

4 3 (4)
LT

(4)

5 2

3 4

5 1 (4)
T

23 Nm (2.3 m kg, 17 ft Ib) 18 Nm (1.8 m kg, 13 ft Ib)

R

23 Nm (2.3 m kg, 17 ft Ib)

(4)
18 Nm (1.8 m kg, 13 ft Ib)
Job/Parts to remove Qty Remarks
R

NOTE:
Water can be harmful to untreated leather. Use Yamaha Saddle Soap or another quality brand according to the manufacturers directions to clean the leather on the sidebags. Polish the dry leather with a soft cloth, and then treat with Yamaha Mink Oil or another high-quality leather protectant for increased water resistance.

Sidebag (left and right)

2 3 4 5 6

Backrest Passenger footrest (left and right) Sidebag bracket plate Sidebag bracket (left and right) Backrest bracket (left and right)

1 2 2 2 2 For installation, reverse the removal procedure.

4-2

GENERAL CHASSIS
Removing the rider seat and left side cover
16 Nm (1.6 m kg, 11 ft Ib)
R

7 Nm (0.7 m kg, 5.1 ft Ib)

3 6 5
7 Nm (0.7 m kg, 5.1 ft Ib)
R

4 Nm (0.4 m kg, 2.9 ft Ib)

7 Nm (0.7 m kg, 5.1 ft Ib)

Order 1 2 3 4 5 6 7 Rider seat

Job/Parts to remove

Qty 1 1 1 1 1 1 1 Disconnect.

Remarks

Passenger seat Sub-fuel tank cover Relay cover Seat lock cable Seat lock bracket Left side cover

For installation, reverse the removal procedure.

4-3

GENERAL CHASSIS
Removing the headlight

7 Nm (0.7 m kg, 5.1 ft Ib)

4 8 3 6 5

7 1 2
7 Nm (0.7 m kg, 5.1 ft Ib)

Order 1 2 3 4 5 6 7 8

Job/Parts to remove Turn signal light bracket cover Headlight lens unit Headlight coupler Turn signal light coupler Meter assembly coupler Main switch coupler Plastic band bracket Headlight body

Qty 1 1 1 2 3 2 1 1 Disconnect. Disconnect. Disconnect. Disconnect.

Remarks

For installation, reverse the removal procedure.

4-4

GENERAL CHASSIS
Removing the battery

1 8 2 5

7 Nm (0.7 m kg, 5.1 ft Ib)

7 (4) 15 11 12

3 14 4

10 9 9

13

Order

Job/Parts to remove Rider seat/Sub-fuel tank cover

Qty

Remarks Refer to GENERAL CHASSIS on page 4-1.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Battery cover band Battery cover Tool kit Tool kit tray Negative battery lead Positive battery lead Battery Battery band ECU coupler ECU (engine control unit) Fuse box Main fuse Relay unit Rear brake fluid reservoir bolt

1 1 1 1 1 1 1 1 2 1 1 1 1 1 Disconnect. Disconnect. Disconnect.

4-5

GENERAL CHASSIS
Removing the battery

1 8 2 5

7 Nm (0.7 m kg, 5.1 ft Ib)

7 (4) 15 11 12

3 14 4

10 9 9

13

Order 15 Battery box

Job/Parts to remove

Qty 1

Remarks

For installation, reverse the removal procedure.

4-6

GENERAL CHASSIS
Removing the air filter case

4 Nm (0.4 m kg, 2.9 ft Ib)

New

New 5

(4)

1
10 Nm (1.0 m kg, 7.2 ft Ib)
T

Order 1 2 3 4 5

Job/Parts to remove Air filter case cover Air filter element Air filter case bracket Crankcase breather hose Air filter case

Qty 1 1 1 1 1 Disconnect.

Remarks

For installation, reverse the removal procedure.

4-7

GENERAL CHASSIS
Removing the relays
7 Nm (0.7 m kg, 5.1 ft Ib)

3 4 2 1

10

5 6
7 Nm (0.7 m kg, 5.1 ft Ib)

11 7

Order

Job/Parts to remove Rider seat/Sub-fuel tank cover/Battery box

Qty

Remarks Refer to GENERAL CHASSIS on page 4-1.

1 2 3 4 5 6 7 8 9 10 11

Positive battery lead Starter motor lead Starter relay coupler Starter relay Crankshaft position sensor coupler Tail/brake light wire harness coupler Stator coil coupler Turn signal relay Radiator fan motor relay Headlight relay Relay bracket

1 1 1 1 1 1 1 1 1 1 1

Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect.

For installation, reverse the removal procedure.

4-8

FRONT WHEEL
EAS21870

FRONT WHEEL
Removing the front wheel and brake discs
40 Nm (4.0 m kg, 29 ft Ib)
R

59 Nm (5.9 m kg, 43 ft Ib) 23 Nm (2.3 m kg, 17 ft Ib) 20 Nm (2.0 m kg, 14 ft Ib)

R R

1 3

5
40 Nm (4.0 m kg, 29 ft Ib)
T

Order

LT

6 (6) 2 1

6
LT

(6) 4 5
Job/Parts to remove Qty Remarks

23 Nm (2.3 m kg, 17 ft Ib)

NOTE:
Place the vehicle on a suitable stand so that the front wheel is elevated. Reflectors 1 2 3 4 5 6 Front brake caliper Front wheel axle pinch bolt Front wheel axle Front wheel Collar Front brake disc 2 1 1 1 2 2 For installation, reverse the removal procedure. Loosen. Refer to FRONT BRAKE on page 4-22.

4-9

FRONT WHEEL
Disassembling the front wheel

New 1

LS

3 2 1 New

LS

Order 1 2 3 Oil seal

Job/Parts to remove

Qty 2 2 1

Remarks

Wheel bearing Spacer

For assembly, reverse the disassembly procedure.

4-10

FRONT WHEEL
EAS21900

REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface.

EWA13120

WARNING

Securely support the vehicle so that there is no danger of it falling over. 2. Remove: Front brake calipers
NOTE:

Do not apply the brake lever when removing the brake calipers. 3. Elevate: Front wheel
NOTE:

EAS21920

Place the vehicle on a suitable stand so that the front wheel is elevated.
EAS21910

CHECKING THE FRONT WHEEL 1. Check: Wheel axle Roll the wheel axle on a flat surface. Bends Replace.
EWA13460

WARNING

DISASSEMBLING THE FRONT WHEEL 1. Remove: Oil seals Wheel bearings a. Clean the outside of the front wheel hub. b. Remove the oil seals 1 with a flathead screwdriver.
NOTE:

Do not attempt to straighten a bent wheel axle.

To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface. 2. Check: Tire Front wheel Damage/wear Replace. Refer to CHECKING THE TIRES on page 3-28 and CHECKING THE WHEELS on page 3-29. 3. Measure: Radial wheel runout 1 Lateral wheel runout 2 Over the specified limits Replace. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)

c. Remove the wheel bearings 3 with a general bearing puller.

4-11

FRONT WHEEL

4. Check: Wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings. Oil seals Damage/wear Replace.

EAS21970

ADJUSTING THE FRONT WHEEL STATIC BALANCE

NOTE:

After replacing the tire, wheel or both, the front wheel static balance should be adjusted. Adjust the front wheel static balance with the brake discs installed. 1. Remove: Balancing weight(s) 2. Find: Front wheels heavy spot
NOTE:

EAS21960

ASSEMBLING THE FRONT WHEEL 1. Install: Wheel bearings New Oil seals New a. Install the new wheel bearings and oil seals in the reverse order of disassembly.
ECA3D81004

Place the front wheel on a suitable balancing stand. a. Spin the front wheel. b. When the front wheel stops, put an X1 mark at the bottom of the wheel.

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.

c. Turn the front wheel 90 so that the X1 mark is positioned as shown. d. Release the front wheel. e. When the wheel stops, put an X2 mark at the bottom of the wheel.

4-12

FRONT WHEEL

a. Turn the front wheel and make sure it stays at each position shown.

f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot. g. The spot where all the marks come to rest is the front wheels heavy spot X.

b. If the front wheel does not remain stationary at all of the positions, rebalance it.

EAS22000

3. Adjust: Front wheel static balance

a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot X.

INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC) The following procedure applies to both of the brake discs. 1. Install: Front brake disc Front brake disc bolt 23 Nm (2.3 mkg, 17 ftlb) LOCTITE

NOTE:

Tighten the brake disc bolts in stages and in a crisscross pattern.

NOTE:

T.

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.

2. Check: Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4-27. 3. Lubricate: Oil seal lips Recommended lubricant Lithium-soap-based grease 4. Install: Front wheel

4. Check: Front wheel static balance

4-13

FRONT WHEEL
NOTE:

Install the tire and wheel with the marks 1 pointing in the direction of wheel rotation.

5. Tighten: Front wheel axle Front wheel axle pinch bolt Front wheel axle 59 Nm (5.9 mkg, 43 ftlb) Front wheel axle pinch bolt 20 Nm (2.0 mkg, 14 ftlb)

ECA3D81011

CAUTION:

Before tightening the wheel axle, push down hard on the handlebar several times and check if the front fork rebounds smoothly. 6. Install: Front brake calipers Front brake caliper bolt 40 Nm (4.0 mkg, 29 ftlb)

EWA3D81008

WARNING

Make sure the brake hoses are routed properly.

T.

R
T.

4-14

REAR WHEEL
EAS22020

REAR WHEEL
Removing the rear fender
16 Nm (1.6 m kg, 11 ft Ib)
T T

23 Nm (2.3 m kg, 17 ft Ib)

23 Nm (2.3 m kg, 17 ft Ib)

3 6 4 2

Order

Job/Parts to remove Rider seat/Passenger seat/Seat lock bracket/Tool kit tray

Qty

Remarks Refer to GENERAL CHASSIS on page 4-1.

1 2 3 4 5 6

Tail/brake light wire harness coupler Rear fender bracket Passenger seat bracket Passenger seat guide Rear fender assembly Mudguard

1 2 1 1 1 1

Disconnect.

For installation, reverse the removal procedure.

4-15

REAR WHEEL
Removing the rear wheel
27 Nm (2.7 m kg, 19 ft Ib)
T

16 Nm (1.6 m kg, 11 ft Ib) 150 Nm (15.0 m kg, 110 ft lb)

T

5 7 6
LS

9 4
16 Nm (1.6 m kg, 11 ft Ib)

5 10 1 3 11 12 3
LS

Order

8
LS

14 13
27 Nm (2.7 m kg, 19 ft Ib)
Remarks

Job/Parts to remove

Qty

NOTE:
Place the vehicle on a suitable stand so that the rear wheel is elevated. Muffler 1 2 3 4 5 6 7 8 9 10 11 12 13 Rear brake caliper Rear brake pad Brake pad spring Drive belt adjusting locknut Drive belt adjusting bolt Rear wheel axle nut Washer Rear wheel axle Right drive belt puller Left drive belt puller Rear brake caliper bracket Collar Collar 1 2 2 2 2 1 1 1 1 1 1 1 1 Black Silver Loosen. Loosen. Refer to ENGINE REMOVAL on page 5-1.

4-16

REAR WHEEL
Removing the rear wheel
27 Nm (2.7 m kg, 19 ft Ib)
T

16 Nm (1.6 m kg, 11 ft Ib) 150 Nm (15.0 m kg, 110 ft lb)

T

5 7 6
LS

9 4
16 Nm (1.6 m kg, 11 ft Ib)

5 10 1 3 11 12 3
LS

Order 14 Rear wheel

8
LS

14 13
27 Nm (2.7 m kg, 19 ft Ib)
Remarks

Job/Parts to remove

Qty 1

For installation, reverse the removal procedure.

4-17

REAR WHEEL
Removing the rear brake disc and rear wheel drive hub
23 Nm (2.3 m kg, 17 ft Ib)

(6)

Order 1 2 3 4 5 6 7 8 9 10 11

LT

LS

10 11

6 7 8 5 9 4 3

Job/Parts to remove Rear brake disc Rear wheel pulley Oil seal Circlip Rear wheel drive hub Circlip Bearing Collar Bearing Rear wheel drive hub damper Rear wheel

Qty 1 1 1 1 1 1 1 1 1 6 1

Remarks

For installation, reverse the removal procedure.

4-18

REAR WHEEL
Disassembling the rear wheel

New 3

4 New 5 6

LS

Order 1 2 3 4 5 6 Collar Bearing Oil seal Circlip Bearing Spacer

Job/Parts to remove

Qty 1 1 1 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

4-19

REAR WHEEL
EAS28760

REMOVING THE REAR WHEEL (DISC) 1. Stand the vehicle on a level surface.
EWA13120

WARNING

Securely support the vehicle so that there is no danger of it falling over.

NOTE:

Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: Rear brake caliper
NOTE:

Do not depress the brake pedal when removing the brake caliper. 3. Loosen: Drive belt adjusting locknuts 1 Drive belt adjusting bolts 2

Oil seals Refer to CHECKING THE FRONT WHEEL on page 4-11. 2. Check: Tire Rear wheel Damage/wear Replace. Refer to CHECKING THE TIRES on page 3-28 and CHECKING THE WHEELS on page 3-29. 3. Measure: Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4-11. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
EAS3D81016

CHECKING THE REAR BRAKE CALIPER BRACKET 1. Check: Rear brake caliper bracket Cracks/damage Replace.
EAS22110

4. Remove: Rear wheel axle nut Rear wheel axle Rear wheel
NOTE:

CHECKING THE REAR WHEEL DRIVE HUB 1. Check: Rear wheel drive hub Cracks/damage Replace. Rear wheel drive hub dampers Damage/wear Replace.
EAS22130

Push the rear wheel forward and remove the drive belt from the rear wheel pulley.
EAS22080

DISASSEMBLING THE REAR WHEEL 1. Remove: Oil seals Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4-11.
EAS22090

CHECKING AND REPLACING THE REAR WHEEL PULLEY 1. Check: Rear wheel pulley Surface plating has come off Replace the rear wheel pulley. Bent teeth Replace the rear wheel pulley. 2. Replace: Rear wheel pulley a. Remove the self-locking nuts and the rear wheel pulley. b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the pulley. c. Install the new rear wheel pulley.

CHECKING THE REAR WHEEL 1. Check: Rear wheel axle Rear wheel Wheel bearings

4-20

REAR WHEEL
Rear wheel pulley self-locking nut 95 Nm (9.5 mkg, 68 ftlb) Rear brake disc bolt 23 Nm (2.3 mkg, 17 ftlb) LOCTITE

NOTE:

Tighten the self-locking nuts in stages and in a crisscross pattern.

EAS22140

ASSEMBLING THE REAR WHEEL 1. Install: Wheel bearings New Oil seals New Refer to ASSEMBLING THE FRONT WHEEL on page 4-12.
EAS22150

ADJUSTING THE REAR WHEEL STATIC BALANCE

NOTE:

After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust: Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4-12.
EAS28770

INSTALLING THE REAR WHEEL (REAR BRAKE DISC) 1. Lubricate: Rear wheel axle Oil seal lips Recommended lubricant Lithium-soap-based grease 2. Install: Rear brake disc

T.

T.

NOTE:

Apply locking agent (LOCTITE) to the threads of the brake disc bolts. Tighten the brake disc bolts in stages and in a crisscross pattern.

3. Check: Rear brake disc Refer to CHECKING THE REAR BRAKE DISC on page 4-40. 4. Install: Rear wheel axle Washer Rear wheel axle nut
NOTE:

Temporarily tighten the wheel axle nut. 5. Adjust: Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3-24. 6. Tighten: Rear wheel axle nut Rear wheel axle nut 150 Nm (15.0 mkg, 110 ftlb)

7. Install: Rear brake caliper Rear brake caliper 27 Nm (2.7 mkg, 19 ftlb)

LT

EWA13500

WARNING

Make sure the brake hose is routed properly.

T.

R
T.

4-21

FRONT BRAKE
EAS22210

FRONT BRAKE
Removing the front brake pads

7 1

6 Nm (0.6 m kg, 4.3 ft Ib)

27 Nm (2.7 m kg, 19 ft Ib)

R
T

2
LS

4 2
27 Nm (2.7 m kg, 19 ft Ib)

4 5 6
Qty Remarks The following procedure applies to both of the front brake calipers.

Order

Job/Parts to remove

1 2 3 4 5 6 7

Reflector Front brake caliper retaining bolt Front brake caliper Front brake pad Brake pad shim Front brake pad spring Front brake pad support

1 2 1 2 1 1 2 For installation, reverse the removal procedure.

4-22

FRONT BRAKE
Removing the front brake master cylinder
10 Nm (1.0 m kg, 7.2 ft Ib)
T

2 3 4

11

7 1
7 Nm (0.7 m kg, 5.1 ft Ib)
R

LS

12

New 9 8
T

13

7 Nm (0.7 m kg, 5.1 ft Ib)

30 Nm (3.0 m kg, 22 ft Ib)

10
Qty Remarks Drain. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-22. 1 1 1 1 1 1 2 1 2 1 1 1 1 For installation, reverse the removal procedure. Disconnect.

Order Brake fluid 1 2 3 4 5 6 7 8 9 10 11 12 13

Job/Parts to remove

Right rearview mirror Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Brake lever Spring Front brake light switch connector Front brake hose union bolt Copper washer Front brake hose Front brake master cylinder holder Front brake master cylinder Front brake light switch

4-23

FRONT BRAKE
Disassembling the front brake master cylinder

3 New 2 New 1

Order 1 2 3 4 Dust boot Circlip

Job/Parts to remove

Qty 1 1 1 1

Remarks

Brake master cylinder kit Brake master cylinder body

For assembly, reverse the disassembly procedure.

4-24

FRONT BRAKE
Removing the front brake calipers

4
40 Nm (4.0 m kg, 29 ft Ib)
R

2 New

1
T

30 Nm (3.0 m kg, 22 ft Ib)

Order

Job/Parts to remove

Qty

Remarks The following procedure applies to both of the front brake calipers.

Reflector Brake fluid 1 2 3 4 5 Front brake hose union bolt Copper washer Front brake hose Front brake caliper bracket bolt Front brake caliper 1 2 1 2 1

Refer to FRONT BRAKE on page 4-22. Drain. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-22.

For installation, reverse the removal procedure.

4-25

FRONT BRAKE
Disassembling the front brake calipers

6 Nm (0.6 m kg, 4.3 ft Ib)

LS

1 6 2
LS

9
LS

7 New 8
LS

27 Nm (2.7 m kg, 19 ft Ib)

4 7 New 8
Order Job/Parts to remove Qty Remarks

The following procedure applies to both of the front brake calipers. 1 2 3 4 5 6 7 8 9 Front brake caliper retaining bolt Brake pad spring Brake pad Brake pad shim Brake pad support Brake caliper bracket Brake caliper piston seal Brake caliper piston Bleed screw 2 1 2 1 2 1 4 2 1 For assembly, reverse the disassembly procedure.

4-26

FRONT BRAKE
EAS22220

INTRODUCTION
EWA14100

WARNING

Brake disc deflection limit 0.12 mm (0.0047 in)

Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: Never disassemble brake components unless absolutely necessary. If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. Never use solvents on internal brake components. Use only clean or new brake fluid for cleaning brake components. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. Avoid brake fluid coming into contact with the eyes as it can cause serious injury. FIRST AID FOR BRAKE FLUID ENTERING THE EYES: Flush with water for 15 minutes and get immediate medical attention.
EAS22240

a. Place the vehicle on a suitable stand so that the front wheel is elevated. b. Before measuring the front brake disc deflection, turn the handlebar 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 mm (0.08 in) below the edge of the brake disc. 4. Measure: Brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification Replace. Brake disc thickness limit 4.5 mm (0.18 in)

CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs. 1. Remove: Front wheel Refer to FRONT WHEEL on page 4-9. 2. Check: Brake disc Damage/galling Replace. 3. Measure: Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc.

5. Adjust: Brake disc deflection

a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. Brake disc bolt 23 Nm (2.3 mkg, 17 ftlb) LOCTITE

NOTE:

Tighten the brake disc bolts in stages and in a crisscross pattern.

T.

4-27

FRONT BRAKE
2. Install: Brake pads Brake pad spring
NOTE:

Always install new brake pads and a new brake pad spring as a set.

d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc.

a. Connect a clear plastic hose 1 tightly to the bleed screw 2. Put the other end of the hose into an open container.

6. Install: Front wheel Refer to FRONT WHEEL on page 4-9.

EAS22260

REPLACING THE FRONT BRAKE PADS

NOTE:

When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1. Measure: Brake pad wear limit a Out of specification Replace the brake pads as a set. Brake pad lining thickness (inner) 6.0 mm (0.24 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (outer) 6.0 mm (0.24 in) Limit 0.8 mm (0.03 in)

b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 mkg, 4.3 ftlb)

d. Install a new brake pad shim, new brake pads, and a new brake pad spring.

3. Lubricate: Front brake caliper retaining bolts Recommended lubricant Lithium-soap-based grease
ECA14150

CAUTION:

Do not allow grease to contact the brake pads. Remove any excess grease. 4. Install: Brake caliper retaining bolts Brake caliper retaining bolt 27 Nm (2.7 mkg, 19 ftlb)

T.

R
T.

5. Check: Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level.

4-28

FRONT BRAKE
Refer to CHECKING THE BRAKE FLUID LEVEL on page 3-21.

2 New

LOWER

2 New

6. Check: Brake lever operation Soft or spongy feeling Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-22.
EAS22300

a. Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper.
EWA3D81009

WARNING

REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers.
NOTE:

Cover the brake caliper pistons with a rag. Be careful not to get injured when the piston are expelled from the brake caliper. Never try to pry out the brake caliper piston.

Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: Front brake hose union bolt 1 Copper washers Front brake hose 2

b. Remove the brake caliper piston seals.

EAS22390

CHECKING THE FRONT BRAKE CALIPERS Recommended brake component replacement schedule

1
NOTE:

Brake pads Piston seals Brake hoses Brake fluid

If necessary Every two years Every four years Every two years and whenever the brake is disassembled

Put the end of the brake hose into a container and pump out the brake fluid carefully.
EAS22350

DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. 1. Remove: Brake caliper pistons 1 Brake caliper piston seals 2

1. Check: Brake caliper pistons 1 Rust/scratches/wear Replace the brake caliper pistons. Brake caliper cylinders 2 Scratches/wear Replace the brake caliper assembly.

4-29

FRONT BRAKE
Brake caliper body 3 Cracks/damage Replace the brake caliper assembly. Brake fluid delivery passages (brake caliper body) Obstruction Blow out with compressed air.
EWA13600

Front brake hose union bolt 30 Nm (3.0 mkg, 22 ftlb)

EWA13530

WARNING

WARNING

Whenever a brake caliper is disassembled, replace the piston seals.

Proper brake hose routing is essential to insure safe vehicle operation. Refer to CABLE ROUTING on page 2-43.
ECA14170

CAUTION:

When installing the brake hose onto the brake caliper 1, make sure the brake pipe a touches the projection b on the brake caliper.

T.

2 a
2. Check: Brake caliper bracket Cracks/damage Replace.
EAS22410

3
2. Remove: Front brake caliper 3. Install: Brake pad supports Brake pads Brake pad spring Front brake caliper Front brake caliper retaining bolt 27 Nm (2.7 mkg, 19 ftlb) Front brake caliper bracket bolt 40 Nm (4.0 mkg, 29 ftlb)

ASSEMBLING THE FRONT BRAKE CALIPERS

EWA13620

WARNING

Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake components as they will cause the piston seals to swell and distort. Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended fluid DOT 4
EAS22440

INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. 1. Install: Front brake caliper 1 (temporarily) Copper washers New Front brake hose 2 Front brake hose union bolt 3

Refer to REPLACING THE FRONT BRAKE PADS on page 4-28. 4. Fill: Brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended fluid DOT 4
EWA3D81010

WARNING

Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

T.

4-30

FRONT BRAKE
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 master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
ECA13540

NOTE:

To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.

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 on page 3-22. 6. Check: Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL on page 3-21.
EAS22500

LOWER

CHECKING THE FRONT BRAKE MASTER CYLINDER 1. Check: Brake master cylinder Damage/scratches/wear Replace. Brake fluid delivery passages (brake master cylinder body) Obstruction Blow out with compressed air. 2. Check: Brake master cylinder kit Damage/scratches/wear Replace. 3. Check: Brake master cylinder reservoir Cracks/damage Replace. Brake master cylinder reservoir diaphragm Damage/wear Replace. 4. Check: Brake hoses Cracks/damage/wear Replace.
EAS22520

7. Check: Brake lever operation Soft or spongy feeling Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-22.
EAS22490

ASSEMBLING THE FRONT BRAKE MASTER CYLINDER

EWA13520

WARNING

REMOVING THE FRONT BRAKE MASTER CYLINDER

NOTE:

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 fluid DOT 4

Before removing the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: Front brake hose union bolt 1 Copper washers 2 Front brake hose 3

4-31

FRONT BRAKE
EAS22530

INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: Brake master cylinder 1 Front brake master cylinder holder 2 Front brake master cylinder holder bolt 10 Nm (1.0 mkg, 7.2 ftlb)

3050

2 1
3. Fill: Brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended fluid DOT 4
EWA13540

NOTE:

Install the brake master cylinder holder with the UP mark facing up. Align the end of the brake master cylinder holder with the punch mark a on the handlebar. First, tighten the upper bolt, then the lower bolt.

2. Install: Copper washers New Front brake hose 1 Front brake hose union bolt 2 Front brake hose union bolt 30 Nm (3.0 mkg, 22 ftlb)

EWA13530

WARNING

Proper brake hose routing is essential to insure safe vehicle operation. Refer to CABLE ROUTING on page 2-43.
NOTE:

Install the brake hose to the front brake master cylinder within the angle shown in the illustration. While holding the brake hose, tighten the union bolt. Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, and leads). Correct if necessary.

T.

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 master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
ECA13540

T.

CAUTION:

Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-22. 5. Check: Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL on page 3-21.

4-32

FRONT BRAKE

LOWER

6. Check: Brake lever operation Soft or spongy feeling Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-22.

4-33

REAR BRAKE
EAS22550

REAR BRAKE
Removing the rear brake pads

6 Nm (0.6 m kg, 4.3 ft Ib)

4 3

LS

4 2

1
27 Nm (2.7 m kg, 19 ft Ib)
Job/Parts to remove Rear brake caliper retaining bolt Rear brake caliper Rear brake pad Brake pad spring Qty 2 1 2 2 For installation, reverse the removal procedure. Remarks
T

Order 1 2 3 4

4-34

REAR BRAKE
Removing the rear brake master cylinder

1 2 3
LT

13

10

7 11 12
T

16 Nm (1.6 m kg, 11 ft Ib)

New 9 5
7 Nm (0.7 m kg, 5.1 ft Ib) 30 Nm (3.0 m kg, 22 ft Ib) 23 Nm (2.3 m kg, 17 ft Ib)
T
T

8
23 Nm (2.3 m kg, 17 ft Ib)
R

Order Brake fluid

1 2 3 4 5 6 7 8 9 10 11 12

Sub-fuel tank cover Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose Locknut (rear brake master cylinder) Brake pedal adjusting bolt Rear brake hose union bolt Copper washer Rear brake hose Rear brake master cylinder bracket Rear brake master cylinder cover 1 1 1 1 1 1 1 1 2 1 1 1

Job/Parts to remove

Qty

Remarks Drain. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-22. Refer to GENERAL CHASSIS on page 4-1.

Loosen. Loosen.

4-35

REAR BRAKE
Removing the rear brake master cylinder

1 2 3
LT

13

10

7 11 12
T

16 Nm (1.6 m kg, 11 ft Ib)

New 9 5
7 Nm (0.7 m kg, 5.1 ft Ib) 30 Nm (3.0 m kg, 22 ft Ib) 23 Nm (2.3 m kg, 17 ft Ib)
T
T

8
23 Nm (2.3 m kg, 17 ft Ib)
R

Order 13

Rear brake master cylinder

Job/Parts to remove

Qty 1

Remarks

For installation, reverse the removal procedure.

4-36

REAR BRAKE
Disassembling the rear brake master cylinder

1 2 New 4 New 3 New 5

6 New
LS

Order 1 2 3 4 5 6 7 Dust boot Circlip

Job/Parts to remove

Qty 1 1 1 1 1 1 1

Remarks

Brake master cylinder kit Circlip Brake hose joint O-ring Brake master cylinder body

For assembly, reverse the disassembly procedure.

4-37

REAR BRAKE
Removing the rear brake caliper

5
LS

2 New
R

1
30 Nm (3.0 m kg, 22 ft Ib)

27 Nm (2.7 m kg, 19 ft Ib)

Order Brake fluid 1 2 3 4 5

Job/Parts to remove

Qty

Remarks Drain. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-22.

Rear brake hose union bolt Copper washer Rear brake hose Rear brake caliper retaining bolt Rear brake caliper

1 2 1 2 1 For installation, reverse the removal procedure.

4-38

REAR BRAKE
Disassembling the rear brake caliper

6 Nm (0.6 m kg, 4.3 ft Ib)

New 2

LS

Order 1 2 3

Job/Parts to remove Brake caliper piston Brake caliper piston seal Bleed screw

Qty 1 2 1

Remarks

For assembly, reverse the disassembly procedure.

4-39

REAR BRAKE
EAS22560

INTRODUCTION
EWA14100

Refer to CHECKING THE FRONT BRAKE DISCS on page 4-27. Brake disc thickness limit 5.5 mm (0.22 in) 5. Adjust: Brake disc deflection Refer to CHECKING THE FRONT BRAKE DISCS on page 4-27. Brake disc bolt 23 Nm (2.3 mkg, 17 ftlb) LOCTITE

WARNING

Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: Never disassemble brake components unless absolutely necessary. If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. Never use solvents on internal brake components. Use only clean or new brake fluid for cleaning brake components. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. Avoid brake fluid coming into contact with the eyes as it can cause serious injury. FIRST AID FOR BRAKE FLUID ENTERING THE EYES: Flush with water for 15 minutes and get immediate medical attention.
EAS22570

6. Install: Rear wheel Refer to REAR WHEEL on page 4-15.

EAS22580

REPLACING THE REAR BRAKE PADS

NOTE:

When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1. Measure: Brake pad wear limit a Out of specification Replace the brake pads as a set. Brake pad lining thickness (inner) 5.8 mm (0.23 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (outer) 5.8 mm (0.23 in) Limit 0.8 mm (0.03 in)

T.

CHECKING THE REAR BRAKE DISC 1. Remove: Rear wheel Refer to REAR WHEEL on page 4-15. 2. Check: Brake disc Damage/galling Replace. 3. Measure: Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc. Refer to CHECKING THE FRONT BRAKE DISCS on page 4-27. Brake disc deflection limit 0.15 mm (0.0059 in)
NOTE:

Measure the deflection 1.5 mm (0.06 in) below the edge of the brake disc. 4. Measure: Brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification Replace. 2. Install: Brake pads Brake pad springs

4-40

REAR BRAKE
NOTE:

Always install new brake pads and brake pad springs as a set. a. Connect a clear plastic hose 1 tightly to the bleed screw 2. Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper piston into the brake caliper with your fingers.

Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-22.

EAS22590

REMOVING THE REAR BRAKE CALIPER

NOTE:

Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: Rear brake hose union bolt 1 Copper washers 2 Rear brake hose 3
NOTE:

Put the end of the brake hose into a container and pump out the brake fluid carefully.

c. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 mkg, 4.3 ftlb)

3. Install: Rear brake caliper Rear brake caliper retaining bolt 27 Nm (2.7 mkg, 19 ftlb)

4. Check: Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL on page 3-21.

5. Check: Brake pedal operation Soft or spongy feeling Bleed the brake system.

T.

2
EAS22600

R
T.

DISASSEMBLING THE REAR BRAKE CALIPER 1. Remove: Brake caliper piston Brake caliper piston seals

a. Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper.
EWA13550

WARNING

UP

LOWER

Cover the brake caliper piston with a rag. Be careful not to get injured when the piston is expelled from the brake caliper. Never try to pry out the brake caliper piston.

4-41

REAR BRAKE
b. Remove the brake caliper piston seals.

EAS22640

Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended fluid DOT 4
EAS22670

CHECKING THE REAR BRAKE CALIPER Recommended brake component replacement schedule Brake pads Piston seals Brake hoses Brake fluid If necessary Every two years Every four years Every two years and whenever the brake is disassembled

INSTALLING THE REAR BRAKE CALIPER 1. Install: Rear brake caliper 1 (temporarily) Copper washers New Rear brake hose 2 Rear brake hose union bolt 3 Rear brake hose union bolt 30 Nm (3.0 mkg, 22 ftlb)

1. Check: Brake caliper piston 1 Rust/scratches/wear Replace the brake caliper piston. Brake caliper cylinder 2 Scratches/wear Replace the brake caliper assembly. Brake caliper body 3 Cracks/damage Replace the brake caliper assembly. Brake fluid delivery passages (brake caliper body) Obstruction Blow out with compressed air.
EWA13610

EWA13530

WARNING

Proper brake hose routing is essential to insure safe vehicle operation. Refer to CABLE ROUTING on page 2-43.
ECA14170

CAUTION:

WARNING

When installing the brake hose onto the brake caliper 1, make sure the brake pipe a touches the projection b on the brake caliper.

T.

Whenever a brake caliper is disassembled, replace the brake caliper piston seals.

3 1
1 3 a 2

2
EAS22650

ASSEMBLING THE REAR BRAKE CALIPER

EWA13620

WARNING

Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake components as they will cause the piston seals to swell and distort.

2. Remove: Rear brake caliper 3. Install: Brake pads Brake pad springs Rear brake caliper Refer to REPLACING THE REAR BRAKE PADS on page 4-40. Rear brake caliper retaining bolt 27 Nm (2.7 mkg, 19 ftlb)

T.

4-42

REAR BRAKE
4. Fill: Brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended fluid DOT 4
EWA13090 EAS22700

REMOVING THE REAR BRAKE MASTER CYLINDER

NOTE:

Before removing the rear brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: Rear brake hose union bolt 1 Copper washers 2 Rear brake hose 3
NOTE:

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.
ECA13540

To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.

CAUTION:

Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.
EAS22720

5. Bleed: Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-22. 6. Check: Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL on page 3-21.

UP

LOWER

CHECKING THE REAR BRAKE MASTER CYLINDER 1. Check: Brake master cylinder Damage/scratches/wear Replace. Brake fluid delivery passages (brake master cylinder body) Obstruction Blow out with compressed air. 2. Check: Brake master cylinder kit Damage/scratches/wear Replace. 3. Check: Brake fluid reservoir Cracks/damage Replace. Brake fluid reservoir diaphragm Cracks/damage Replace. 4. Check: Brake hoses Cracks/damage/wear Replace.

7. Check: Brake pedal operation Soft or spongy feeling Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-22.

4-43

REAR BRAKE
EAS22730 EWA13090

ASSEMBLING THE REAR BRAKE MASTER CYLINDER

EWA13520

WARNING

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 fluid DOT 4
EAS22750

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.
ECA13540

INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: Copper washers 1 New Rear brake hose 2 Rear brake hose union bolt 3 Rear brake hose union bolt 30 Nm (3.0 mkg, 22 ftlb)

CAUTION:

Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 3. Bleed: Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-22. 4. Check: Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL on page 3-21.

EWA13530

WARNING

Proper brake hose routing is essential to insure safe vehicle operation. Refer to CABLE ROUTING on page 2-43.
ECA3D81005

CAUTION:

When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a on the brake caliper bracket as shown.

2. Fill: Brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended fluid DOT 4

T.

LOWER

a
5. Check: Brake lever operation Soft or spongy feeling Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-22. 6. Adjust: Brake pedal adjusting bolt position Refer to ADJUSTING THE REAR DISC BRAKE on page 3-20.

1 New

4-44

HANDLEBAR
EAS22840

HANDLEBAR
Removing the handlebar

16
T

7 Nm (0.7 m kg, 5.1 ft Ib) 23 Nm (2.3 m kg, 17 ft Ib) 28 Nm (2.8 m kg, 20 ft Ib)

5 1

R R
T

7 Nm (0.7 m kg, 5.1 ft Ib)

1
LT

17 2 7 6
LS LS

Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

R
T

13 14
LS

20 2 18 10 21 6 19
10 Nm (1.0 m kg, 7.2 ft Ib) 23 Nm (2.3 m kg, 17 ft Ib)
R
T

18

4 3

15
LT

9 8

11 12 8

11

32 Nm (3.2 m kg, 23 ft Ib)

23 Nm (2.3 m kg, 17 ft Ib)

7 Nm (0.7 m kg, 5.1 ft Ib)

Job/Parts to remove Rearview mirror Plastic clamp Front brake light switch connector Front brake master cylinder holder Front brake master cylinder assembly Right handlebar switch Throttle cable Grip end Throttle grip Clutch switch coupler Left handlebar switch Handlebar grip Clutch cable Clutch lever Clutch switch Meter assembly cover Qty 2 4 2 1 1 1 2 2 1 1 1 1 1 1 1 1 Disconnect. Disconnect. Disconnect. Disconnect. Remarks

4-45

HANDLEBAR
Removing the handlebar

16
T

7 Nm (0.7 m kg, 5.1 ft Ib) 23 Nm (2.3 m kg, 17 ft Ib) 28 Nm (2.8 m kg, 20 ft Ib)

5 1

R R
T

7 Nm (0.7 m kg, 5.1 ft Ib)

1
LT

17 2 7 6
LS LS

Order 17 18 19 20 21

R
T

13 14
LS

20 2 18 10 21 6 19
10 Nm (1.0 m kg, 7.2 ft Ib) 23 Nm (2.3 m kg, 17 ft Ib)
R
T

18

4 3

15
LT

9 8

11 12 8

11

32 Nm (3.2 m kg, 23 ft Ib)

23 Nm (2.3 m kg, 17 ft Ib)

7 Nm (0.7 m kg, 5.1 ft Ib)

Job/Parts to remove Meter assembly cover bracket Front handlebar holder Handlebar Meter assembly Rear handlebar holder Qty 1 2 1 1 1 For installation, reverse the removal procedure. Remarks

4-46

HANDLEBAR
EAS22860

REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface.

EWA13120

Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position.
NOTE:

WARNING

Securely support the vehicle so that there is no danger of it falling over. 2. Remove: Handlebar grip 1
NOTE:

Align the punch mark a on the handlebar with the match mark b on the rear handlebar holder.

2 1 a

Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.

b
3. Install: Clutch lever 1 Clutch cable 2 Clutch lever bolt 7 Nm (0.7 mkg, 5.1 ftlb)

T.

EAS22880

CHECKING THE HANDLEBAR 1. Check: Handlebar Bends/cracks/damage Replace.

EWA13690

NOTE:

Align the mating surfaces of the clutch lever with the punch mark a on the handlebar.

WARNING

1 2

Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
EAS22930

INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface.

EWA13120

WARNING

a
4. Install: Left handlebar switch 1
NOTE:

Securely support the vehicle so that there is no danger of it falling over. 2. Install: Handlebar 1 Front handlebar holders 2 Front handlebar holder bolt 28 Nm (2.8 mkg, 20 ftlb)

Align the mating surfaces of the left handlebar switch with the punch mark a on the handlebar.

ECA3D81006

CAUTION:

First, tighten the bolts on the lower side of the front handlebar holder, and then on the upper side.

T.

4-47

HANDLEBAR

1 a
5. Install: Handlebar grip 1

1
7. Install: Right handlebar switch 1
NOTE:

a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag.
EWA13700

Align the projection a on the right handlebar switch with the hole b in the handlebar.

1 b

WARNING

Do not touch the handlebar grip until the rubber adhesive has fully dried.
NOTE:

There should be less than 3 mm (0.12 in) of clearance a between the handlebar grip and left handlebar switch.

8. Install: Front brake master cylinder 1 Front brake master cylinder holder 2 Front brake master cylinder holder bolt 10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

T.

6. Connect: Throttle cable (decelerator cable) 1 (to the right handlebar switch 2)
NOTE:

Install the front brake master cylinder holder with the UP mark facing up. Align the end of the front brake master cylinder holder with the punch mark a on the handlebar. First, tighten the upper bolt, then the lower bolt.

Rotate the right handlebar switch and screw it onto the end of the throttle cable.

4-48

HANDLEBAR
9. Adjust: Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3-13. Clutch lever free play 5.010.0 mm (0.200.39 in) 10.Adjust: Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3-8. Throttle cable free play 4.06.0 mm (0.160.24 in)

4-49

FRONT FORK
EAS22950

FRONT FORK
Removing the front fork legs
110 Nm (11.0 m kg, 80 ft lb)

6
20 Nm (2.0 m kg, 14 ft Ib)
R

18 Nm (1.8 m kg, 13 ft Ib)

10 11 12

6 5

13
20 Nm (2.0 m kg, 14 ft Ib)
T

7 Nm (0.7 m kg, 5.1 ft Ib)

4 2 1 3
23 Nm (2.3 m kg, 17 ft Ib)
T

14

2 3 15
23 Nm (2.3 m kg, 17 ft Ib)
T

1
7 Nm (0.7 m kg, 5.1 ft Ib)
Qty

23 Nm (2.3 m kg, 17 ft Ib)

Remarks

Order

Job/Parts to remove

The following procedure applies to both of the front fork legs. Windshield bracket (left and right) Headlight body Front wheel Rear handlebar holder 1 2 3 4 5 6 7 8 Front reflector Brake hose guide Reflector bracket Front fender Main switch coupler Upper bracket pinch bolt Cap bolt Steering stem nut 2 2 2 1 2 2 1 1 Disconnect. Loosen. Loosen. For XVS13CT only Refer to GENERAL CHASSIS on page 4-1. Refer to GENERAL CHASSIS on page 4-1. Refer to FRONT WHEEL on page 4-9. Refer to HANDLEBAR on page 4-45.

4-50

FRONT FORK
Removing the front fork legs
110 Nm (11.0 m kg, 80 ft lb)

6
20 Nm (2.0 m kg, 14 ft Ib)
R

18 Nm (1.8 m kg, 13 ft Ib)

10 11 12

6 5

13
20 Nm (2.0 m kg, 14 ft Ib)
T

7 Nm (0.7 m kg, 5.1 ft Ib)

4 2 1 3
23 Nm (2.3 m kg, 17 ft Ib)
T

14

2 3 15
23 Nm (2.3 m kg, 17 ft Ib)
T

1
7 Nm (0.7 m kg, 5.1 ft Ib)
Qty 1 1 1 2 2 1 1 For installation, reverse the removal procedure. Loosen.

23 Nm (2.3 m kg, 17 ft Ib)

Remarks

Order 9 10 11 12 13 14 15

Job/Parts to remove Upper bracket Upper front fork cover Upper front fork cover spacer Lower front fork cover bolt Lower bracket pinch bolt Lower front fork cover Front fork leg

4-51

FRONT FORK
Disassembling the front fork legs
23 Nm (2.3 m kg, 17 ft Ib)
LS

1
New 2

3 12 4 5 6 New 7 New 13 New 14 15 New

16 New 10 17 18

19

11

9 New 8
LT

30 Nm (3.0 m kg, 22 ft Ib)

Order

Job/Parts to remove

Qty

Remarks The following procedure applies to both of the front fork legs.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Cap bolt O-ring Spacer Spring seat Fork spring Dust seal Oil seal clip Damper rod bolt Copper washer Damper rod Rebound spring Inner tube Oil seal Washer Outer tube bushing Inner tube bushing

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

4-52

FRONT FORK
Disassembling the front fork legs
23 Nm (2.3 m kg, 17 ft Ib)
LS

1
New 2

3 12 4 5 6 New 7 New 13 New 14 15 New

16 New 10 17 18

19

11

9 New 8
LT

30 Nm (3.0 m kg, 22 ft Ib)

Order 17 18 19 Spring

Job/Parts to remove

Qty 1 1 1

Remarks

Oil flow stopper Outer tube

For assembly, reverse the disassembly procedure.

4-53

FRONT FORK
EAS22960

REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface.
EWA13120

WARNING

Securely support the vehicle so that there is no danger of it falling over.

NOTE:

Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Loosen: Lower bracket pinch bolts
EWA3D81004

3. Remove: Damper rod bolt 1 Copper washer

NOTE:

WARNING

Before loosening the lower bracket pinch bolts, support the front fork leg.
EAS22980

While holding the damper rod with the damper rod holder 2 and T-handle 3, loosen the damper rod bolt. Damper rod holder 90890-01460 T-handle 90890-01326 T-handle 3/8" drive 60 cm long YM-01326

DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Drain: Fork oil
NOTE:

Stroke the outer tube several times while draining the fork oil.

4. Remove: Inner tube 2. Remove: Dust seal 1 Oil seal clip 2 (with a flathead screwdriver)
ECA14180

CAUTION:

a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully.
ECA14190

Do not scratch the inner tube.

CAUTION:

Excessive force will damage the oil seal and bushing. A damaged oil seal or bushing must be replaced. Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged.

4-54

FRONT FORK
ECA14200

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.
EAS23020

EAS23010

CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: Inner tube Outer tube Bends/damage/scratches Replace.
EWA13650

ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
EWA13660

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:

WARNING

Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: Spring free length a Out of specification Replace. Fork spring free length 345.5 mm (13.60 in) Limit 339.4 mm (13.36 in)

When assembling the front fork leg, be sure to replace the following parts: Inner tube bushing 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 bushing 1 New Damper rod 2 Rebound spring Spring 3 Oil flow stopper 4
ECA3D81007

CAUTION:

Allow the damper rod to slide slowly down the inner tube 5 until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. 3. Check: Damper rod Damage/wear Replace. Obstruction Blow out all of the oil passages with compressed air. Oil flow stopper Damage Replace.

3 4 5 2 1 New

4-55

FRONT FORK
2. Lubricate: Inner tubes outer surface Recommended oil Yamaha fork oil 10WT 3. Install: Inner tube (in the outer tube) 4. Install: Copper washer New Damper rod bolt 5. Tighten: Damper rod bolt 1 Damper rod bolt 30 Nm (3.0 mkg, 22 ftlb) LOCTITE 7. Install: Oil seal 1 New (with the fork seal driver 2)
ECA14220

CAUTION:

Make sure the numbered side of the oil seal faces up.
NOTE:

NOTE:

While holding the damper rod assembly with the damper rod holder 2 and T-handle 3, tighten the damper rod bolt. Damper rod holder 90890-01460 T-handle 90890-01326 T-handle 3/8" drive 60 cm long YM-01326

6. Install: Outer tube bushing 1 New Washer (with the fork seal driver 2) Fork seal driver 90890-01442 Adjustable fork seal driver (3646 mm) YM-01442

T.

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.

2 1 New

8. Install: Oil seal clip 1 New

4-56

FRONT FORK
NOTE:

Adjust the oil seal clip so that it fits into the outer tubes groove.
NOTE:

Level 105.0 mm (4.13 in)

While filling the front fork leg, keep it upright. After filling, slowly pump the front fork leg up and down to distribute the fork oil.

9. Install: Dust seal 1 New (with the fork seal driver weight 2) Fork seal driver 90890-01442 Adjustable fork seal driver (3646 mm) YM-01442 12.Install: Spring Spring seat Spacer Cap bolt (along with the O-ring New )
NOTE:

Before installing the cap bolt, lubricate its Oring with grease. Temporarily tighten the cap bolt.
EAS23050

10.Fill: Front fork leg (with the specified amount of the recommended fork oil) Quantity 490.0 cm (16.57 US oz) (17.28 Imp.oz) Recommended oil Yamaha fork oil 10WT 11.Measure: Front fork leg oil level a (from the top of the inner tube, with the outer tube fully compressed and without the fork spring) Out of specification Correct.

INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: Lower front fork cover 1 Front fork leg 2 Upper bracket 3 Temporarily tighten the upper and lower bracket pinch bolts.
NOTE:

Make sure the inner tube end is flush with the top of the upper bracket.

4-57

FRONT FORK
Cap bolt

3 2
T.

Cap bolt 23 Nm (2.3 mkg, 17 ftlb)

Upper bracket pinch bolt

1
EWA13680
T.

Upper bracket pinch bolt 23 Nm (2.3 mkg, 17 ftlb)

2. Tighten: Lower bracket pinch bolts Lower bracket pinch bolt 23 Nm (2.3 mkg, 17 ftlb)

WARNING

Make sure the brake hoses are routed properly.

NOTE:

Tighten the lower bracket pinch bolts to specification twice. Tighten the upper and lower bolts alternately, starting with the upper bolts. 3. Remove: Upper bracket 4. Tighten: Lower front fork cover bolts Lower front fork cover bolt 18 Nm (1.8 mkg, 13 ftlb)

5. Install: Upper front fork cover spacer 1 Upper front fork cover 2 Upper bracket
NOTE:

Align the grooves a in the upper front fork cover spacer 1, and groove b in the upper front fork cover 2 with the lower front fork cover bolts 3.

6. Tighten: Steering stem nut Steering stem nut 110 Nm (11.0 mkg, 80 ftlb)

T.

R
T.

2 b a 3 b 1 a 3

T.

4-58

STEERING HEAD
EAS23090

STEERING HEAD
Removing the lower bracket
1st 52 Nm (5.2 m kg, 37 ft lb) 2nd 18 Nm (1.8 m kg, 13 ft lb)
LS

7 Nm (0.7 m kg, 5.1 ft Ib)

LS

7 8 9 10 12 13 14 19 15

LT

2 1 3 6 5
LT

11 19 16 18

LS

10 Nm (1.0 m kg, 7.2 ft Ib)

LT LT

17 4

23 Nm (2.3 m kg, 17 ft Ib)

23 Nm (2.3 m kg, 17 ft Ib)

Order

Job/Parts to remove Upper bracket/Front fork legs

Qty

Remarks Refer to FRONT FORK on page 4-50.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Headlight bracket Air temperature sensor coupler Air temperature sensor Front turn signal light Front brake hose holder Front brake hose joint Lock washer Upper ring nut Rubber washer Lower ring nut Lower bracket Upper bearing cover Upper bearing inner race Upper bearing Washer

1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 Disconnect.

4-59

STEERING HEAD
Removing the lower bracket
1st 52 Nm (5.2 m kg, 37 ft lb) 2nd 18 Nm (1.8 m kg, 13 ft lb)
LS

7 Nm (0.7 m kg, 5.1 ft Ib)

LS

7 8 9 10 12 13 14 19 15

LT

2 1 3 6 5
LT

11 19 16 18

LS

10 Nm (1.0 m kg, 7.2 ft Ib)

LT LT

17 4

23 Nm (2.3 m kg, 17 ft Ib)

23 Nm (2.3 m kg, 17 ft Ib)

Order 16 17 18 19

Job/Parts to remove Lower bearing Dust seal Lower bearing inner race Bearing outer race

Qty 1 1 1 2

Remarks

For installation, reverse the removal procedure.

4-60

STEERING HEAD
EAS23110

REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface.

EWA13120

WARNING

Securely support the vehicle so that there is no danger of it falling over. 2. Remove: Upper ring nut Rubber washer Lower ring nut 1 Lower bracket
EWA13730

a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new dust seal and new bearing races.
ECA14270

CAUTION:

If the bearing race is not installed properly, the steering head pipe could be damaged.
NOTE:

WARNING

Securely support the lower bracket so that there is no danger of it falling.

NOTE:

Always replace the bearings and bearing races as a set. Whenever the steering head is disassembled, replace the dust seal.

Remove the lower ring nut with the steering nut wrench 2. Steering nut wrench 90890-01403 Spanner wrench YU-33975

EAS23120

CHECKING THE STEERING HEAD 1. Wash: Bearings Bearing races Recommended cleaning solvent Kerosene 2. Check: Bearings Bearing races Damage/pitting Replace. 3. Replace: Bearings Bearing races

4. Check: Upper bracket Lower bracket (along with the steering stem) Bends/cracks/damage Replace.
EAS23140

INSTALLING THE STEERING HEAD 1. Lubricate: Upper bearing Lower bearing Bearing races Recommended lubricant Lithium-soap-based grease

4-61

STEERING HEAD
2. Install: Lower ring nut 1 Rubber washer 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3-26.

3. Install: Front brake hose joint 1 Front brake hose holder 2

NOTE:

Make sure that the projection a on the lower bracket contacts the side b of the front brake hose joint 1. Align the projection c on the front brake hose holder with the hole d in the lower bracket.

a d

2 1 b

4. Install: Front fork legs Upper bracket Refer to FRONT FORK on page 4-50.

4-62

REAR SHOCK ABSORBER ASSEMBLY

EAS23160

REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly

4 4
48 Nm (4.8 m kg, 35 ft Ib) 48 Nm (4.8 m kg, 35 ft Ib)
R

6 6

11

10 7

3 3 12

2
59 Nm (5.9 m kg, 43 ft Ib)

3 6
LS

9 New 11

Order

New 9
LS

10 8 2

LS

1
Job/Parts to remove Battery box/Relay bracket Muffler/Coolant reservoir cover Coolant Coolant reservoir Sub-fuel tank Rear wheel 1 2 3 4 5 6 7 Connecting arm nut/Washer/Bolt Connecting arm Rear shock absorber assembly lower nut/Washer/Bolt/Collar Rear shock absorber assembly upper nut/Bolt Rear shock absorber assembly Relay arm nut/Bolt/Spacer/Collar Relay arm 2/2/2 2 1/1/1/1 1/1 1 1/1/1/1 1 Qty Remarks Refer to GENERAL CHASSIS on page 4-1. Refer to ENGINE REMOVAL on page 5-1. Drain. Refer to CHANGING THE COOLANT on page 3-17. Refer to RADIATOR on page 6-1. Refer to FUEL TANK on page 7-1. Refer to REAR WHEEL on page 4-15.

4-63

REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly

4 4
48 Nm (4.8 m kg, 35 ft Ib) 48 Nm (4.8 m kg, 35 ft Ib)
R

6 6

11

10 7

3 3 12

2
59 Nm (5.9 m kg, 43 ft Ib)

3 6
LS

9 New 11

Order 8 9 10 11 12 Spacer Oil seal Bearing Bearing Bearing

New 9
LS

10 8 2

LS

1
Job/Parts to remove Qty 1 2 2 1 1 For installation, reverse the removal procedure. Remarks

4-64

REAR SHOCK ABSORBER ASSEMBLY

EAS23180

HANDLING THE REAR SHOCK ABSORBER

EWA13740

NOTE:

WARNING

Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: Connecting arm nuts 1 Connecting arm bolts 2 Connecting arms 3 Rear shock absorber assembly lower nut 4 Rear shock absorber assembly lower bolt 5
NOTE:

This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber. Do not tamper or attempt to open the rear shock absorber. Do not subject the rear shock absorber to an open flame or any other source of high heat. High heat can cause an explosion due to excessive gas pressure. Do not deform or damage the rear shock absorber in any way. Rear shock absorber damage will result in poor damping performance.
EAS23190

While removing the connecting arm bolts, hold the swingarm so that it does not drop down.

2 3

3 1 45 2

DISPOSING OF A REAR SHOCK ABSORBER 1. Gas pressure must be released before disposing of a rear shock absorber. To release the gas pressure, drill a 23 mm (0.080.12 in) hole through the rear shock absorber at a point 1520 mm (0.600.79 in) from its end as shown.
EWA13760

3. Remove: Rear shock absorber assembly upper nut Rear shock absorber assembly upper bolt 1 Rear shock absorber assembly 2
NOTE:

WARNING

Raise the swingarm and then remove the rear shock absorber assembly from between the swingarm and relay arm.

Wear eye protection to prevent eye damage from released gas or metal chips.

2
EAS23240

EAS23230

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the vehicle on a level surface.
EWA13120

WARNING

Securely support the vehicle so that there is no danger of it falling over.

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: Rear shock absorber rod Bends/damage Replace the rear shock absorber assembly. Rear shock absorber Gas leaks/oil leaks Replace the rear shock absorber assembly.

4-65

REAR SHOCK ABSORBER ASSEMBLY

Spring Damage/wear Replace the rear shock absorber assembly. Bushing Damage/wear Replace. Spacer Damage/scratches Replace. Bolts Bends/damage/wear Replace.
EAS23260

a 3 4 4

CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: Connecting arms Relay arm Damage/wear Replace. 2. Check: Bearings Oil seals Damage/pitting Replace. 3. Check: Spacers Damage/scratches Replace.
EAS23270

1 a

A. Left side B. Right side

EAS23310

INSTALLING THE RELAY ARM 1. Lubricate: Spacers Bearings Recommended lubricant Lithium-soap-based grease 2. Install: Bearings 1, 2, and 3 (to the relay arm) Oil seals 4 New (to the relay arm) Installed depth of bearing a 4.5 mm (0.18 in)

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: Spacer Recommended lubricant Lithium-soap-based grease 2. Tighten: Relay arm nut Relay arm nut 48 Nm (4.8 mkg, 35 ftlb)

3. Install: Rear shock absorber assembly

NOTE:

Raise the swingarm and then install the rear shock absorber assembly from between the swingarm and relay arm. 4. Tighten: Rear shock absorber assembly upper nut Rear shock absorber assembly upper nut 48 Nm (4.8 mkg, 35 ftlb)

Rear shock absorber assembly lower nut

T.

R
T.

4-66

REAR SHOCK ABSORBER ASSEMBLY

Rear shock absorber assembly lower nut 48 Nm (4.8 mkg, 35 ftlb)

5. Install: Connecting arms

NOTE:

When installing the connecting arms, lift up the swingarm.

T.

4-67

SWINGARM
EAS23330

SWINGARM
Removing the swingarm

LS

13

14 16

15 16
LS

14

13 9
LS

85 Nm (8.5 m kg, 61 ft Ib)

7 Nm (0.7 m kg, 5.1 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib)

LT

12 5 4 8 2 1 3 6 11 12
LS

10 5 4

16 Nm (1.6 m kg, 11 ft Ib)

Order

10 11 12 13 14

1 2 3 4 5 6 7 8 9

R
T

Job/Parts to remove Connecting arms Rectifier/regulator cover Rectifier/regulator coupler Rectifier/regulator Drive belt adjusting bolt Drive belt adjusting locknut Drive belt upper guard Drive belt lower guard Pivot shaft nut Pivot shaft Swingarm Spacer Bearing Dust cover Washer

Qty

Remarks Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4-63.

1 2 1 2 2 1 1 1 1 1 1 2 2 2 Disconnect.

4-68

SWINGARM
Removing the swingarm

LS

13

14 16

15 16
LS

14

13 9
LS

85 Nm (8.5 m kg, 61 ft Ib)

7 Nm (0.7 m kg, 5.1 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib)

LT

12 5 4 8 2 1 3 6 11 12
LS

10 5 4

16 Nm (1.6 m kg, 11 ft Ib)

Order 15 16 Spacer Bearing

R
T

Job/Parts to remove

Qty 1 2

Remarks

For installation, reverse the removal procedure.

4-69

SWINGARM
EAS23350

REMOVING THE SWINGARM 1. Stand the vehicle on a level surface.

EWA13120

Bends Replace.
EWA13770

WARNING

WARNING

Securely support the vehicle so that there is no danger of it falling over.

NOTE:

Do not attempt to straighten a bent pivot shaft.

Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Measure: Swingarm side play Swingarm vertical movement

a. Measure the tightening torque of the pivot shaft nut. Pivot shaft nut 85 Nm (8.5 mkg, 61 ftlb)

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 the swingarm vertical movement is not smooth or if there is binding, check the spacers, bearings, washers, and dust covers.

3. Wash: Pivot shaft Dust covers Spacers Washers Bearings Recommended cleaning solvent Kerosene 4. Check: Dust covers Spacer Washers Damage/wear Replace. 5. Check: Bearings Damage/pitting Replace. 6. Check: Spacers Damage/scratches Replace.
EAS28780

EAS23360

CHECKING THE SWINGARM 1. Check: Swingarm Bends/cracks/damage Replace. 2. Check: Pivot shaft Roll the pivot shaft on a flat surface.

T.

INSTALLING THE SWINGARM 1. Lubricate: Bearings Spacers Dust covers Pivot shaft Recommended lubricant Lithium-soap-based grease 2. Install: Bearings 1

4-70

SWINGARM

1
A

1
B

a
2. Swingarm A. Left side B. Right side

Installed depth a 01.0 mm (00.04 in) 3. Install: Pivot shaft nut Pivot shaft nut 85 Nm (8.5 mkg, 61 ftlb)

4. Install: Rectifier/regulator
NOTE:

When installing the rectifier/regulator, first tighten the upper bolt, then the lower bolt. Rectifier/regulator bolt 7 Nm (0.7 mkg, 5.1 ftlb)

5. Adjust: Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3-24.

T.

R
T.

4-71

BELT DRIVE
EAS23510

BELT DRIVE
Removing the drive belt

1 4
R

New 3
140 Nm (14.0 m kg, 100 ft lb)
R

10 Nm (1.0 m kg, 7.2 ft Ib)

LT

10 Nm (1.0 m kg, 7.2 ft Ib)

10 Nm (1.0 m kg, 7.2 ft Ib)

Order Rear wheel Swingarm 1 2 3 4 Drive pulley cover Drive belt Drive pulley nut Drive pulley 1 1 1 1 For installation, reverse the removal procedure. Job/Parts to remove Qty Remarks Refer to REAR WHEEL on page 4-15. Refer to SWINGARM on page 4-68.

4-72

BELT DRIVE
EAS23520

REMOVING THE DRIVE BELT AND DRIVE PULLEY

NOTE:

Loosen the drive pulley nut before removing the rear wheel. 1. Loosen: Drive pulley nut
NOTE:

When loosening the drive pulley nut, press down on the brake pedal so the drive pulley does not move.
EAS23530

CHECKING THE DRIVE BELT 1. Clean: Drive belt

3. Check: Drive pulley Rear wheel pulley Bent teeth Replace the drive belt and pulleys as a set.
EAS23540

a. Wipe the drive belt with a clean cloth. b. Put the drive belt in a mixture of mild detergent and water. Then, remove any dirt from the drive belt. c. Remove the drive belt from the mixture and rinse it off with clean water. Then, let the drive belt thoroughly dry.

INSTALLING THE DRIVE BELT AND DRIVE PULLEY 1. Install: Drive belt
ECA14710

CAUTION:

Install the drive belt facing the same way it was removed. Do not twist the drive belt when installing it. 2. Install: Swingarm Refer to SWINGARM on page 4-68. Rear wheel Refer to REAR WHEEL on page 4-15. 3. Tighten: Drive pulley nut Drive pulley nut 140 Nm (14.0 mkg, 100 ftlb) LOCTITE

T.

2. Check: Drive belt

ECA14690

NOTE:

CAUTION:

To protect the drive belt from damage, handle it with care. The drive belt can not be bent smaller than 127 mm (5 in) a. The removed drive belt can not be twisted inside out.

Stake the drive pulley nut at the cutouts a in the drive axle. When tightening the drive pulley nut, press down on the brake pedal so the drive pulley does not move.

4-73

BELT DRIVE

4. Tighten: Drive pulley cover plate bolt

NOTE:

Tighten the drive pulley cover plate bolts temporarily, and then tighten them in proper tightening sequence as shown.

5. Adjust: Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3-24.

4-74

BELT DRIVE

4-75

ENGINE
ENGINE REMOVAL ........................................................................................ 5-1 INSTALLING THE EXHAUST PIPE COVER SCREW CLAMPS .............. 5-2 INSTALLING THE CYLINDER COVERS.................................................. 5-5 INSTALLING THE SHIFT ARM................................................................. 5-5 INSTALLING THE ENGINE .................................................................... 5-10 CAMSHAFTS ................................................................................................ 5-12 REMOVING THE CAMSHAFT ASSEMBLIES ........................................ 5-15 REMOVING THE ROCKER ARMS AND CAMSHAFTS ......................... 5-16 CHECKING THE CAMSHAFTS .............................................................. 5-17 CHECKING THE CAMSHAFT SPROCKETS ......................................... 5-17 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-17 CHECKING THE TIMING CHAIN TENSIONERS ................................... 5-18 INSTALLING THE CAMSHAFTS AND ROCKER ARMS........................ 5-19 INSTALLING THE CAMSHAFT ASSEMBLIES....................................... 5-20 INSTALLING THE CYLINDER HEAD COVERS..................................... 5-23 CYLINDER HEADS ....................................................................................... 5-24 REMOVING THE CYLINDER HEADS .................................................... 5-25 CHECKING THE CYLINDER HEADS..................................................... 5-25 INSTALLING THE CYLINDER HEADS................................................... 5-25 VALVES AND VALVE SPRINGS ................................................................. 5-27 REMOVING THE VALVES ..................................................................... 5-28 CHECKING THE VALVES AND VALVE GUIDES .................................. 5-28 CHECKING THE VALVE SEATS............................................................ 5-30 CHECKING THE VALVE SPRINGS ....................................................... 5-31 INSTALLING THE VALVES .................................................................... 5-32 CYLINDERS AND PISTONS ........................................................................ 5-34 REMOVING THE PISTONS.................................................................... 5-35 CHECKING THE CYLINDERS AND PISTONS ...................................... 5-35 CHECKING THE PISTON RINGS .......................................................... 5-36 CHECKING THE PISTON PINS ............................................................. 5-37 INSTALLING THE PISTONS AND CYLINDERS .................................... 5-38 GENERATOR AND STARTER CLUTCH ..................................................... 5-40 REMOVING THE GENERATOR............................................................. 5-43 REMOVING THE STARTER CLUTCH ................................................... 5-43 CHECKING THE STARTER CLUTCH.................................................... 5-43 CHECKING THE TORQUE LIMITER...................................................... 5-44 INSTALLING THE STARTER CLUTCH.................................................. 5-44 INSTALLING THE GENERATOR ........................................................... 5-44

CLUTCH ........................................................................................................ 5-46 REMOVING THE CLUTCH ..................................................................... 5-51 REMOVING THE PRIMARY DRIVE GEAR ............................................ 5-51 CHECKING THE FRICTION PLATES .................................................... 5-51 CHECKING THE CLUTCH PLATES....................................................... 5-52 CHECKING THE CLUTCH SPRING PLATE .......................................... 5-52 CHECKING THE CLUTCH HOUSING.................................................... 5-52 CHECKING THE CLUTCH BOSS........................................................... 5-52 CHECKING THE PRESSURE PLATE .................................................... 5-53 CHECKING THE PRIMARY DRIVE GEAR............................................. 5-53 CHECKING THE PRIMARY DRIVEN GEAR .......................................... 5-53 CHECKING THE PULL LEVER SHAFT AND PULL ROD ...................... 5-53 CHECKING THE OIL/WATER PUMP DRIVE SPROCKET AND OIL/WATER PUMP DRIVE CHAIN ........................................................ 5-53 INSTALLING THE PRIMARY DRIVE GEAR........................................... 5-53 INSTALLING THE CLUTCH.................................................................... 5-54 SHIFT SHAFT ............................................................................................... 5-57 CHECKING THE SHIFT SHAFT ............................................................. 5-58 CHECKING THE STOPPER LEVER ...................................................... 5-58 INSTALLING THE SHIFT SHAFT ........................................................... 5-58 BALANCER GEARS ..................................................................................... 5-59 CHECKING THE RIGHT BALANCER GEARS ....................................... 5-61 CHECKING THE LEFT BALANCER GEARS ......................................... 5-61 INSTALLING THE RIGHT BALANCER GEARS ..................................... 5-61 INSTALLING THE LEFT BALANCER GEARS ....................................... 5-61 ELECTRIC STARTER ................................................................................... 5-62 CHECKING THE STARTER MOTOR ..................................................... 5-64 ASSEMBLING THE STARTER MOTOR................................................. 5-65 CRANKCASE ................................................................................................ 5-66 DISASSEMBLING THE CRANKCASE ................................................... 5-70 CHECKING THE CRANKCASE.............................................................. 5-70 CHECKING THE BEARINGS AND OIL SEAL ........................................ 5-70 CHECKING THE OIL DELIVERY PIPES AND COOLANT DELIVERY PIPE ....................................................................................................... 5-70 CHECKING THE TIMING CHAINS ......................................................... 5-70 CHECKING THE OIL/WATER PUMP DRIVEN SPROCKET.................. 5-70 CHECKING THE OIL NOZZLES............................................................. 5-70 INSTALLING THE BEARING RETAINERS ............................................ 5-71 ASSEMBLING THE CRANKCASE ......................................................... 5-71 OIL PUMP ..................................................................................................... 5-73 CHECKING THE OIL PUMP ................................................................... 5-74 CHECKING THE RELIEF VALVE ........................................................... 5-74 CHECKING THE OIL STRAINER ........................................................... 5-75 ASSEMBLING THE OIL PUMP .............................................................. 5-75 INSTALLING THE OIL/WATER PUMP ASSEMBLY............................... 5-75

CRANKSHAFT .............................................................................................. 5-76 REMOVING THE CONNECTING RODS ................................................ 5-77 CHECKING THE CRANKSHAFT AND CONNECTING RODS............... 5-77 INSTALLING THE CONNECTING RODS............................................... 5-79 INSTALLING THE CRANKSHAFT ASSEMBLY ..................................... 5-80 TRANSMISSION ........................................................................................... 5-81 CHECKING THE SHIFT FORKS ............................................................ 5-85 CHECKING THE SHIFT DRUM ASSEMBLY.......................................... 5-85 CHECKING THE TRANSMISSION......................................................... 5-85 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE.............................. 5-86 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ...... 5-86

ENGINE REMOVAL
EAS23710

ENGINE REMOVAL
Removing the muffler and exhaust pipes
7 Nm (0.7 m kg, 5.1 ft Ib) 44 Nm (4.4 m kg, 32 ft Ib) 6 Nm (0.6 m kg, 4.3 ft Ib)
T

4 Nm (0.4 m kg, 2.9 ft Ib)

Order 1 2 3 4 5 6 7 8 9 10 11

R R
T

1 (3)
7 Nm (0.7 m kg, 5.1 ft Ib)

11 2

10

New 6 New 4 5 New 7 New New

R

20 Nm (2.0 m kg, 14 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib)

R

6 Nm (0.6 m kg, 4.3 ft Ib)

New (3)
R

New 9 8 New

6 New

53 Nm (5.3 m kg, 38 ft Ib)

35 Nm (3.5 m kg, 25 ft Ib)

12 Nm (1.2 m kg, 8.7 ft Ib) 20 Nm (2.0 m kg, 14 ft Ib)

Remarks

Job/Parts to remove Coolant reservoir cap cover O2 sensor coupler Muffler Gasket Rear cylinder exhaust pipe Gasket Gasket Front cylinder exhaust pipe Muffler bracket O2 sensor Coolant reservoir cover

Qty 1 1 1 1 1 2 1 1 1 1 1 Disconnect.

For installation, reverse the removal procedure.

5-1

ENGINE REMOVAL
EAS3D81019

INSTALLING THE EXHAUST PIPE COVER SCREW CLAMPS 1. Install: Exhaust pipe cover screw clamps New Exhaust pipe cover screw clamp 6 Nm (0.6 mkg, 4.3 ftlb)

NOTE:

Do not retighten the exhaust pipe cover screw clamps; always replace them with new ones if they are loosened.

T.

5-2

ENGINE REMOVAL
Removing the sidestand and drive pulley housing
64 Nm (6.4 m kg, 46 ft Ib) 8 Nm (0.8 m kg, 5.8 ft Ib)
T

R
T

11
8 Nm (0.8 m kg, 5.8 ft Ib)
R

6 9
8 Nm (0.8 m kg, 5.8 ft Ib)
T

10
LT

24 Nm (2.4 m kg, 17 ft Ib)

1
8 Nm (0.8 m kg, 5.8 ft Ib)

13 8

12 (5)

Order Drive belt

LT

3 5
LT

2 4
10 Nm (1.0 m kg, 7.2 ft Ib) 56 Nm (5.6 m kg, 40 ft Ib)
Remarks Refer to BELT DRIVE on page 4-72. Refer to REAR BRAKE on page 4-34. California only. Refer to THROTTLE BODIES on page 7-7.
T T

64 Nm (6.4 m kg, 46 ft Ib) 8 Nm (0.8 m kg, 5.8 ft Ib)

Qty
T

Rear brake master cylinder Canister 1 2 3 4 5 6 7 8 9 10 11 12 Sidestand switch coupler Sidestand Shift arm Shift rod Left footrest assembly Rear brake light switch Right footrest assembly Front cylinder left cover Front cylinder right cover Rear cylinder left cover Rear cylinder right cover Ground lead 1 1 1 1 1 1 1 1 1 1 1 1

Job/Parts to remove

Disconnect.

Disconnect.

5-3

ENGINE REMOVAL
Removing the sidestand and drive pulley housing
64 Nm (6.4 m kg, 46 ft Ib) 8 Nm (0.8 m kg, 5.8 ft Ib)
T

R
T

11
8 Nm (0.8 m kg, 5.8 ft Ib)
R

6 9
8 Nm (0.8 m kg, 5.8 ft Ib)
T

10
LT

24 Nm (2.4 m kg, 17 ft Ib)

1
8 Nm (0.8 m kg, 5.8 ft Ib)

13 8

12 (5)

Order 13

LT

3 5
LT

2 4
10 Nm (1.0 m kg, 7.2 ft Ib) 56 Nm (5.6 m kg, 40 ft Ib)
Remarks
T T

64 Nm (6.4 m kg, 46 ft Ib) 8 Nm (0.8 m kg, 5.8 ft Ib)

Qty 1
T

Drive pulley housing

Job/Parts to remove

For installation, reverse the removal procedure.

5-4

ENGINE REMOVAL
EAS3D81039

INSTALLING THE CYLINDER COVERS 1. Install: Rear cylinder right cover 1 Rear cylinder left cover 2 Front cylinder right cover 3 Front cylinder left cover 4 Cylinder cover bolt 8 Nm (0.8 mkg, 5.8 ftlb)

NOTE:

Tighten the cover bolts temporarily, and then tighten the front bolt, then the rear bolt, to specification.

T.

1 2 3

EAS3D81018

INSTALLING THE SHIFT ARM 1. Install: Shift arm 1 Shift arm bolt 10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

Align the I mark a in the shift shaft with the punch mark b in the shift arm.

2. Adjust: Shift rod length Refer to ADJUSTING THE SHIFT PEDAL on page 3-24.

T.

5-5

ENGINE REMOVAL
Disconnecting the leads and hoses

1 4 5

11

10

3
Order Job/Parts to remove Sub-fuel tank cover Radiator Thermostat Intake manifold assembly Starter motor 1 2 3 4 5 6 7 8 9 10 Oil level switch coupler Spark plug cap Crankcase breather hose Stator coil coupler Crankshaft position sensor coupler Speed sensor coupler Neutral switch coupler Neutral switch connector Horn connector Horn 1 2 1 1 1 1 1 1 2 1 Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. Qty Remarks Refer to GENERAL CHASSIS on page 4-1. Refer to RADIATOR on page 6-1. Refer to THERMOSTAT on page 6-4. Refer to THROTTLE BODIES on page 7-7. Refer to ELECTRIC STARTER on page 5-62. Disconnect. Disconnect.

5-6

ENGINE REMOVAL
Disconnecting the leads and hoses

1 4 5

11

10

3
Order 11 Job/Parts to remove Rubber cover Qty 1 For assembly, reverse the removal procedure. Remarks

5-7

ENGINE REMOVAL
Removing the down tube and engine
7 Nm (0.7 m kg, 5.1 ft Ib) 88 Nm (8.8 m kg, 64 ft Ib) 48 Nm (4.8 m kg, 35 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib)
R R

48 Nm (4.8 m kg, 35 ft Ib)

16

Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

R
T

4 11

1
LT

12 13 (4)
LT

8 2 15 14 10
LT

18

19

17
LT LT

20
30 Nm (3.0 m kg, 22 ft Ib)

LT

5 5 6 7 3
R

6
48 Nm (4.8 m kg, 35 ft Ib)

48 Nm (4.8 m kg, 35 ft Ib)

88 Nm (8.8 m kg, 64 ft Ib)

R

88 Nm (8.8 m kg, 64 ft Ib)

Remarks

Job/Parts to remove Sub-fuel tank bracket bolt Coolant reservoir cover bracket Engine mounting nut (front lower side) Engine mounting bolt (front lower side) Down tube bolt (front side) Down tube bolt (rear side) Down tube Engine mounting nut (rear upper side) Engine mounting bolt (rear upper side) Engine mounting nut (rear lower side) Engine mounting bolt (rear lower side) Engine bracket bolt (rear upper side) Engine bracket (rear upper side) Engine bracket bolt (rear lower side) Engine bracket (rear lower side) Engine mounting bolt (front left upper side) Engine mounting bolt (front right upper side)

Qty 2 1 1 1 2 2 1 1 1 1 1 2 1 2 1 2 2

5-8

ENGINE REMOVAL
Removing the down tube and engine
7 Nm (0.7 m kg, 5.1 ft Ib) 88 Nm (8.8 m kg, 64 ft Ib) 48 Nm (4.8 m kg, 35 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib)
R R

48 Nm (4.8 m kg, 35 ft Ib)

16

Order 18 19 20 Engine

R
T

4 11

1
LT

12 13 (4)
LT

8 2 15 14 10
LT

18

19

17
LT LT

20
30 Nm (3.0 m kg, 22 ft Ib)

LT

5 5 6 7 3
R

6
48 Nm (4.8 m kg, 35 ft Ib)

48 Nm (4.8 m kg, 35 ft Ib)

88 Nm (8.8 m kg, 64 ft Ib)

R

88 Nm (8.8 m kg, 64 ft Ib)

Remarks

Job/Parts to remove

Qty 1 4 1

Engine bracket bolt (front upper side) Engine bracket (front upper side)

For installation, reverse the removal procedure.

5-9

ENGINE REMOVAL
EAS23720

INSTALLING THE ENGINE 1. Install: Engine bracket (front upper side) 1 Engine bracket bolts (front upper side) 2 Engine bracket bolt (front upper side) 30 Nm (3.0 mkg, 22 ftlb)

12
LT

5 17

9 13 7

10

2. Install: Engine 3 Engine mounting bolts (front right upper side) 4 Engine mounting bolts (front left upper side) 5 Engine bracket (rear lower side) 6 Engine bracket bolts (rear lower side) 7 Engine bracket (rear upper side) 8 Engine bracket bolts (rear upper side) 9 Engine mounting bolt (rear lower side) 10 Engine mounting nut (rear lower side) 11 Engine mounting bolt (rear upper side) 12 Engine mounting nut (rear upper side) 13 Down tube 14 Down tube bolts (rear side) 15 Down tube bolts (front side) 16 Engine mounting bolt (front lower side) 17 Engine mounting nut (front lower side) 18
NOTE:

Apply locking agent (LOCTITE) to the threads of the engine mounting bolts (front right upper side), engine bracket bolts (rear lower side), engine bracket bolts (rear upper side), down tube bolts (front side), and down tube bolts (rear side). Do not tighten the bolts and nuts.

T.

(4) 6 4
LT LT LT

11

LT

16

15

18

14

3. Tighten: Engine bracket bolts (rear lower side) 7 Engine bracket bolts (rear upper side) 9 Down tube bolts (front side) 15 Down tube bolts (rear side) 16 Engine bracket bolt (rear lower side) 48 Nm (4.8 mkg, 35 ftlb) LOCTITE Engine bracket bolt (rear upper side) 48 Nm (4.8 mkg, 35 ftlb) LOCTITE Down tube bolt (front side) 48 Nm (4.8 mkg, 35 ftlb) LOCTITE Down tube bolt (rear side) 48 Nm (4.8 mkg, 35 ftlb) LOCTITE

T.

9 7 16

15

5-10

ENGINE REMOVAL
4. Tighten: Engine mounting bolts (front right upper side) 4 Engine mounting bolts (front left upper side) 5 Engine mounting nut (rear lower side) 11 Engine mounting nut (rear upper side) 13 Engine mounting nut (front lower side) 16 Engine mounting bolt (front right upper side) 48 Nm (4.8 mkg, 35 ftlb) LOCTITE Engine mounting bolt (front left upper side) 48 Nm (4.8 mkg, 35 ftlb) LOCTITE Engine mounting nut (rear lower side) 88 Nm (8.8 mkg, 64 ftlb) Engine mounting nut (rear upper side) 88 Nm (8.8 mkg, 64 ftlb) Engine mounting nut (front lower side) 88 Nm (8.8 mkg, 64 ftlb)

T.

13

11

16

5-11

CAMSHAFTS
EAS23740

CAMSHAFTS
Removing the cylinder head covers
10 Nm (1.0 m kg, 7.2 ft Ib) 6 Nm (0.6 m kg, 4.3 ft Ib)
T

10 Nm (1.0 m kg, 7.2 ft Ib)

T

10 Nm (1.0 m kg, 7.2 ft Ib)

New
LS

Order Engine 1 2 3 4 5 6 7 8 9 10 11 12 13 Tappet cover

7 9 8 6

New
LS

LS

6 New 4 8 6

1 3 3 2
LS

New
6 Nm (0.6 m kg, 4.3 ft Ib)

5 New 3 1 4

LS

11

New

New 12 13 13 13 10
LS

13

12 New

FWD
10 Nm (1.0 m kg, 7.2 ft Ib)
T

Job/Parts to remove

Qty

Remarks Refer to ENGINE REMOVAL on page 5-1.

4 2 3 2 1 7 2 2 1 1 1 2 4 For installation, reverse the removal procedure. l = 45 mm (1.77 in) l = 55 mm (2.17 in) l = 30 mm (1.18 in) l = 55 mm (2.17 in) l = 45 mm (1.77 in) l = 30 mm (1.18 in)

Front cylinder head cover bolt Front cylinder head cover bolt Front cylinder head cover bolt Front cylinder head cover bracket Rear cylinder head cover bolt Rear cylinder head cover bolt Rear cylinder head cover bolt Rear cylinder head cover bracket Front cylinder head cover Rear cylinder head cover Cylinder head cover gasket Dowel pin

5-12

CAMSHAFTS
Removing the camshaft assemblies
10 Nm (1.0 m kg, 7.2 ft Ib)
T T

R
T

20 Nm (2.0 m kg, 14 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib)

R

(4)

9
R

10 Nm (1.0 m kg, 7.2 ft Ib)

(4)
E

7 8 New 2
New 3
E

10
10 Nm (1.0 m kg, 7.2 ft Ib) 13 Nm (1.3 m kg, 9.4 ft Ib)
T

Order 1 2 3 4 5 6 7 8 9 10 11 Spark plug

5 11 9

3 New 1

5 6 New

FWD
20 Nm (2.0 m kg, 14 ft Ib) 13 Nm (1.3 m kg, 9.4 ft Ib)
Remarks
T T

10 Nm (1.0 m kg, 7.2 ft Ib)

Job/Parts to remove

Qty 2 2 2 1 2 1 1 1 2 1 1

Timing chain tensioner Timing chain tensioner gasket Rear cylinder timing chain tensioner housing Pin Rear cylinder timing chain tensioner housing gasket Front cylinder timing chain tensioner housing Front cylinder timing chain tensioner housing gasket Camshaft sprocket Rear cylinder camshaft assembly Front cylinder camshaft assembly

For installation, reverse the removal procedure.

5-13

CAMSHAFTS
Removing the rocker arms and camshafts
14 Nm (1.4 m kg, 10 ft Ib)

1 2
14 Nm (1.4 m kg, 10 ft Ib)
T

New 7

1 2

10 1

EX

IN

IN
Order

EX
Qty Remarks The following procedure applies to both of the camshaft assemblies

Job/Parts to remove

1 2 3 4 5 6 7 8 9 10

Locknut Valve clearance adjusting screw Intake rocker arm shaft Exhaust rocker arm shaft Intake rocker arm Exhaust rocker arm Circlip Front cylinder camshaft Rear cylinder camshaft Camshaft carrier

4 4 1 1 1 1 1 1 1 1

Loosen.

For installation, reverse the removal procedure.

5-14

CAMSHAFTS
EAS3D81020

REMOVING THE CAMSHAFT ASSEMBLIES 1. Align: I mark on the front cylinder camshaft sprocket (with the arrow mark on the front cylinder camshaft carrier)

Front cylinder a. Turn the crankshaft counterclockwise. b. When the front cylinder piston is at TDC on the compression stroke, align the TDC mark a on the generator rotor with the slot b in the generator cover.

3. Remove: Front cylinder camshaft sprocket

NOTE:

NOTE:

To position the front cylinder piston at TDC on the compression stroke, align the I mark c on the camshaft sprocket with the arrow mark d on the front cylinder camshaft carrier.

While holding the camshaft sprocket with the rotor holding tool 1, loosen the camshaft sprocket bolts 2. To prevent the timing chain from falling into the crankcase, fasten it with a wire. Rotor holding tool 90890-01235 Universal magneto & rotor holder YU-01235

2 1

c
4. Remove: Front cylinder camshaft assembly
NOTE:

Loosen the bolts in the proper sequence as shown.

A 4 2 3 1 B
A. Intake side B. Exhaust side

2. Remove: Front cylinder timing chain tensioner 1

NOTE:

Never remove a timing chain tensioner when the engine is mounted.

5-15

CAMSHAFTS
5. Align: I mark on the rear cylinder camshaft sprocket (with the arrow mark on the rear cylinder camshaft carrier)

EAS3D81034

Rear cylinder a. Turn the crankshaft counterclockwise from the front cylinder piston TDC by 300 degrees. b. When the rear cylinder piston is at TDC on the compression stroke, align the TDC mark a on the generator rotor with the slot b in the generator cover.

REMOVING THE ROCKER ARMS AND CAMSHAFTS The following procedure applies to all of the rocker arms and camshafts. 1. Remove: Intake rocker arm shaft Exhaust rocker arm shaft Intake rocker arm Exhaust rocker arm
NOTE:

Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2. Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 90890-01084 YU-01083-3

NOTE:

To position the rear cylinder piston at TDC on the compression stroke, align the I mark c on the camshaft sprocket with the arrow mark d on the rear cylinder camshaft carrier.

2 1

2. Remove: Circlip 1 Camshaft 2

NOTE:

Position the camshaft as shown in the illustration so that the camshaft lobes will not catch on the camshaft carrier during removal.

6. Remove: Rear cylinder timing chain tensioner Rear cylinder camshaft sprocket Rear cylinder camshaft assembly
NOTE:

Never remove a timing chain tensioner when the engine is mounted. Remove the parts using the same procedure as for the front cylinder camshaft assembly.

5-16

CAMSHAFTS
EAS23840 EAS23870

CHECKING THE CAMSHAFTS 1. Check: Camshaft lobes Blue discoloration/pitting/scratches Replace the camshaft. 2. Measure: Camshaft lobe dimensions a and b Out of specification Replace the camshaft. Camshaft lobe dimensions Intake A 42.98843.088 mm (1.6924 1.6964 in) Limit 42.888 mm (1.6885 in) Intake B 37.04537.145 mm (1.4585 1.4624 in) Limit 36.945 mm (1.4545 in) Exhaust A 43.15643.256 mm (1.6991 1.7030 in) Limit 43.056 mm (1.6951 in) Exhaust B 37.11837.218 mm (1.4613 1.4653 in) Limit 37.018 mm (1.4574 in)

CHECKING THE CAMSHAFT SPROCKETS 1. Check: Camshaft sprockets More than 1/4 tooth wear a Replace the camshaft sprocket and the timing chain as a set.

a. b. 1. 2.

1/4 tooth Correct Timing chain roller Camshaft sprocket

EAS23880

CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts. 1. Check: Rocker arm Rocker arm roller Damage/wear Replace. 2. Check: Rocker arm shaft Blue discoloration/excessive wear/pitting/scratches Replace or check the lubrication system. 3. Measure: Rocker arm inside diameter Out of specification Replace. Rocker arm inside diameter 12.00012.018 mm (0.4724 0.4731 in)

3. Check: Camshaft oil passage Obstruction Blow out with compressed air.

5-17

CAMSHAFTS
4. Measure: Rocker arm shaft outside diameter a Out of specification Replace. Rocker arm shaft outside diameter 11.97611.991 mm (0.4715 0.4721 in)

1 2

3 5

4
1. 2. 3. 4. 5. 6. 7.

Timing chain tensioner rod Timing chain tensioner spring seat Timing chain tensioner inner spring Timing chain tensioner clip 1 Timing chain tensioner clip 2 Timing chain tensioner outer spring Timing chain tensioner housing

5. Calculate: Rocker-arm-to-rocker-arm-shaft clearance

NOTE:

Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Out of specification Replace the defective part(s). Rocker-arm-to-rocker-arm-shaft clearance 0.0090.042 mm (0.00040.0017 in) Limit 0.095 mm (0.0037 in)
EAS23970

2. Check: Timing chain tensioner housing Timing chain tensioner rod Timing chain tensioner spring seat Timing chain tensioner springs Timing chain tensioner clips Damage/wear Replace the as a set. 3. Assemble: Timing chain tensioner
NOTE:

Prior to installing the timing chain tensioner rod, drain the engine oil from the timing chain tensioner housing. a. Install the timing chain tensioner outer spring, timing chain tensioner clip 2 1, and clip 1 2.
NOTE:

CHECKING THE TIMING CHAIN TENSIONERS The following procedure applies to all of the timing chain tensioners. 1. Disassemble: Timing chain tensioner
NOTE:

Be sure to face the ends of timing chain tensioner clip 2 1 in the direction shown in the illustration and to fit timing chain tensioner clip 1 2 in the groove a in the timing chain tensioner housing.

Squeeze timing chain tensioner clip 2 5, and then remove the timing chain tensioner springs and timing chain tensioner rod.

a 1

5-18

CAMSHAFTS
b. Install the timing chain tensioner inner spring, timing chain tensioner spring seat, and timing chain tensioner rod. c. Squeeze timing chain tensioner clip 2 1, and then push the timing chain tensioner rod 3 into the timing chain tensioner housing.
NOTE:
EAS24040

INSTALLING THE CAMSHAFTS AND ROCKER ARMS The following procedure applies to all of the rocker arms and camshafts. 1. Lubricate: Camshaft Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 2. Install: Camshaft 1 Circlip 2 New
NOTE:

Do not release timing chain tensioner clip 2 while pushing the rod into the housing, otherwise the rod may be ejected.

3 1

d. Align the groove b in the timing chain tensioner rod with timing chain tensioner clip 1 2, and then squeeze the clip to fit it into the groove.
NOTE:

Make sure that the timing chain tensioner rod is secured by the clip, otherwise the rod may be ejected.

Position the camshaft as shown in the illustration so that the camshaft lobes will not catch on the camshaft carrier during installation. Position the opening between the ends of the circlip in the 90 range a shown in the illustration. The front cylinder camshaft is identified by the punch mark b. The rear cylinder camshaft does not have a punch mark.

a New 2

2 b

1
3. Lubricate: Rocker arm shafts Recommended lubricant Engine oil 4. Install: Rocker arms Rocker arm shafts
NOTE:

Make sure that the notches a in the rocker arm shafts are aligned vertically as shown in the illustration.

5-19

CAMSHAFTS
ECA3D81017

CAUTION:

A 1 3 2 4

Make sure the cotouts in the rocker arm shafts faces inward.

a a
A. Intake side B. Exhaust side

3. Install: Front cylinder camshaft sprocket

EAS3D81021

INSTALLING THE CAMSHAFT ASSEMBLIES 1. Install: Front cylinder camshaft assembly 1

NOTE:

Be sure to install the camshaft assembly with the punch mark a onto the front cylinder. The rear cylinder camshaft assembly does not have a punch mark.

Front cylinder a. Turn the crankshaft counterclockwise. b. When the front cylinder piston is at TDC on the compression stroke, align the TDC mark a on the generator rotor with the slot b in the generator cover.

1 a
c. Install the timing chain 1 onto the front cylinder camshaft sprocket 2, then install the camshaft sprocket onto the camshaft, and then finger tighten the camshaft sprocket bolts 3.
ECA13740

2. Tighten: Front cylinder camshaft assembly bolts

NOTE:

Tighten the bolts in the proper sequence as shown. Front cylinder camshaft assembly bolt 10 Nm (1.0 mkg, 7.2 ftlb)

CAUTION:

Do not turn the crankshaft when installing the camshaft(s) to avoid damage or improper valve timing.
NOTE:

T.

To position the front cylinder piston at TDC on the compression stroke, align the I mark c on the camshaft sprocket with the arrow mark d on the front cylinder camshaft carrier. The front cylinder camshaft is identified by the punch mark e. The rear cylinder camshaft does not have a punch mark.

5-20

CAMSHAFTS
When installing the front cylinder camshaft sprocket, be sure to keep the timing chain as tight as possible on the exhaust side.

d 3

1 c e 2 3
3

2 1 New

d. Remove the wire from the timing chain.

4. Tighten: Front cylinder camshaft sprocket bolts 1

NOTE:

While holding the camshaft sprocket with the rotor holding tool 2, tighten the camshaft sprocket bolts. Rotor holding tool 90890-01235 Universal magneto & rotor holder YU-01235

6. Install: Rear cylinder camshaft assembly 1

NOTE:

Be sure to install the camshaft assembly without a punch mark onto the rear cylinder.

2 1

1
7. Tighten: Rear cylinder camshaft assembly bolts 5. Install: Front cylinder timing chain tensioner gasket 1 New Front cylinder timing chain tensioner 2 Front cylinder timing chain tensioner bolt 10 Nm (1.0 mkg, 7.2 ftlb)
NOTE:

Tighten the bolts in the proper sequence as shown. Rear cylinder camshaft assembly bolt 10 Nm (1.0 mkg, 7.2 ftlb)

T.

NOTE:

The arrow mark a on the front cylinder timing chain tensioner should face up. Push the end of the front cylinder timing chain guide (intake side) 3 to release the timing chain tensioner rod.

T.

5-21

CAMSHAFTS
A

When installing the rear cylinder camshaft sprocket, be sure to keep the timing chain as tight as possible on the intake side.

3 2

d 3

1 c

4
B

2 3

A. Intake side B. Exhaust side

8. Install: Rear cylinder camshaft sprocket Rear cylinder a. Turn the crankshaft counterclockwise from the front cylinder piston TDC by 300 degrees. b. When the rear cylinder piston is at TDC on the compression stroke, align the TDC mark a on the generator rotor with the slot b in the generator cover.

d. Remove the wire from the timing chain.

9. Tighten: Rear cylinder camshaft sprocket bolts 1

NOTE:

While holding the camshaft sprocket with the rotor holding tool 2, tighten the camshaft sprocket bolts. Rotor holding tool 90890-01235 Universal magneto & rotor holder YU-01235

2 1
c. Install the timing chain 1 onto the rear cylinder camshaft sprocket 2, then install the camshaft sprocket onto the camshaft, and then finger tighten the camshaft sprocket bolts 3.
ECA13740

CAUTION:

10.Install: Rear cylinder timing chain tensioner gasket 1 New Rear cylinder timing chain tensioner 2 Rear cylinder timing chain tensioner bolt 10 Nm (1.0 mkg, 7.2 ftlb)

Do not turn the crankshaft when installing the camshaft(s) to avoid damage or improper valve timing.
NOTE:

T.

To position the rear cylinder piston at TDC on the compression stroke, align the I mark c on the camshaft sprocket with the arrow mark d on the rear cylinder camshaft carrier. The rear cylinder camshaft assembly does not have a punch mark. Be sure to install the camshaft assembly without a punch mark onto the rear cylinder.

NOTE:

The arrow mark a on the rear timing chain tensioner should face up. Push the end of the rear cylinder timing chain guide (exhaust side) 3 to release the timing chain tensioner rod.

5-22

CAMSHAFTS
Front cylinder head cover bracket 1 Front cylinder head cover bolt 10 Nm (1.0 mkg, 7.2 ftlb)

T.

a 2 1 New

Bolts 2: l = 30 mm (1.18 in) Bolts 3: l = 45 mm (1.77 in) Bolts 4: l = 55 mm (2.17 in)

3 3

4 1
A. Intake side B. Exhaust side

4 B 2

11.Measure: Valve clearance Out of specification Adjust. Refer to ADJUSTING THE VALVE CLEARANCE on page 3-4.
EAS3D81035

INSTALLING THE CYLINDER HEAD COVERS 1. Install: Rear cylinder head cover Rear cylinder head cover bracket 1 Rear cylinder head cover bolt 10 Nm (1.0 mkg, 7.2 ftlb)

Bolts 2: l = 30 mm (1.18 in) Bolts 3: l = 45 mm (1.77 in) Bolts 4: l = 55 mm (2.17 in)

A. Intake side B. Exhaust side

2. Install: Front cylinder head cover

T.

2 3

4 1 3
B

4 2

5-23

CYLINDER HEADS
EAS24110

CYLINDER HEADS
Removing the cylinder heads
13 Nm (1.3 m kg, 9.4 ft Ib)
T

13 Nm (1.3 m kg, 9.4 ft Ib)

E E

15 Nm (1.5 m kg, 11 ft Ib)

1 (4)
65 Nm (6.5 m kg, 47 ft Ib)
T

New

65 Nm (6.5 m kg, 47 ft Ib)

E

(4)

4 New
New

1 5 4 New 5

FWD
15 Nm (1.5 m kg, 11 ft Ib)
Job/Parts to remove Camshaft assemblies 1 2 3 4 5 Oil check bolt Front cylinder head Rear cylinder head Cylinder head gasket Dowel pin 2 1 1 2 4 For installation, reverse the removal procedure. Qty Remarks Refer to CAMSHAFTS on page 5-12.
R

Order

5-24

CYLINDER HEADS
EAS24150

REMOVING THE CYLINDER HEADS 1. Remove: Cylinder head bolts Cylinder head nuts
NOTE:

Loosen the nuts and bolts in the proper sequence as shown. Loosen each nut and bolt 1/2 of a turn at a time. After all of the bolts and nuts are fully loosened, remove them.
A

6 2

2. Check: Cylinder heads Damage/scratches Replace. 3. Measure: Cylinder head warpage Out of specification Resurface the cylinder head. Warpage limit 0.03 mm (0.0012 in) a. Place a straightedge 1 and a thickness gauge 2 across the cylinder head.

5
B

3 3 5

2 6
A. Front cylinder head B. Rear cylinder head
EAS24170

CHECKING THE CYLINDER HEADS The following procedure applies to all of the cylinder heads. 1. Eliminate: Combustion chamber carbon deposits (with a rounded scraper)
NOTE:

b. Measure the warpage. c. If the limit is exceeded, resurface the cylinder head as follows. d. Place 400600 grit wet sandpaper on a surface plate and resurface the cylinder head using a figure-eight sanding pattern.
NOTE:

Do not use a sharp instrument to avoid damaging or scratching: Spark plug bore threads Valve seats

To ensure an even surface, rotate the cylinder head several times.

EAS24230

INSTALLING THE CYLINDER HEADS 1. Tighten: Cylinder head nuts Cylinder head bolts

5-25

CYLINDER HEADS
Cylinder head nut 65 Nm (6.5 mkg, 47 ftlb) Cylinder head bolt 13 Nm (1.3 mkg, 9.4 ftlb)

NOTE:

Lubricate the cylinder head nuts and washers with engine oil. Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them in two stages.
A

T.

1 5

2
B

4 2

5 1
A. Front cylinder head B. Rear cylinder head

5-26

VALVES AND VALVE SPRINGS

EAS24270

VALVES AND VALVE SPRINGS

Removing the valves and valve springs

2
M

1 1 2 6 New 3 7 8
M

1 2
M

2
M

New 6 3 7 8

6 New 3 7 7 8

New 6 3

E E

5
Order Job/Parts to remove

4
Qty Remarks The following procedure applies to both cylinders.

Cylinder heads 1 2 3 4 5 6 7 8 Valve cotter Upper spring seat Valve spring Intake valve Exhaust valve Valve stem seal Lower spring seat Valve guide 8 4 4 2 2 4 4 4

Refer to CYLINDER HEADS on page 5-24.

For installation, reverse the removal procedure.

5-27

VALVES AND VALVE SPRINGS

EAS24280

REMOVING THE VALVES The following procedure applies to all of the valves and related components.
NOTE:

Before removing the internal parts of the cylinder head (e.g., valves, valve springs, and valve seats), make sure the valves properly seal. 1. Check: Valve sealing Leakage at the valve seat Check the valve face, valve seat, and valve seat width. Refer to CHECKING THE VALVE SEATS on page 5-30. a. Pour a clean solvent a into the intake and exhaust ports. b. Check that the valves properly seal.
NOTE:

3. Remove: Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring seat 5
NOTE:

Identify the position of each part very carefully so that it can be reinstalled in its original place.

There should be no leakage at the valve seat 1.

EAS24290

2. Remove: Valve cotters

NOTE:

Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2. Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attachment 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1

CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure: Valve-stem-to-valve-guide clearance Out of specification Replace the valve guide. Valve-stem-to-valve-guide clearance = Valve guide inside diameter a Valve stem diameter b

5-28

VALVES AND VALVE SPRINGS

Valve-stem-to-valve-guide clearance (intake) 0.0100.037 mm (0.00040.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.0250.052 mm (0.00100.0020 in) Limit 0.100 mm (0.0039 in) b. Install the new valve guide with the valve guide installer 2 and valve guide remover 1. Valve guide position 14.514.9 mm (0.5710.587 in)

a. Valve guide position

c. After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valve-guide clearance.

NOTE:

2. Replace: Valve guide

NOTE:

After replacing the valve guide, reface the valve seat. Valve guide remover (6) 90890-04064 Valve guide remover (6.0 mm) YM-04064-A Valve guide installer (6) 90890-04065 Valve guide installer (6.0 mm) YM-04065-A Valve guide reamer (6) 90890-04066 Valve guide reamer (6.0 mm) YM-04066

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. a. Remove the valve guide with the valve guide remover 1.

3. Eliminate: Carbon deposits (from the valve face and valve seat)

5-29

VALVES AND VALVE SPRINGS

4. Check: Valve face Pitting/wear Grind the valve face. Valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve. 5. Measure: Valve margin thickness a Out of specification Replace the valve. Valve margin thickness D (intake) 1.151.45 mm (0.04530.0571 in) Valve margin thickness D (exhaust) 1.151.45 mm (0.04530.0571 in) 1. Eliminate: Carbon deposits (from the valve face and valve seat) 2. Check: Valve seat Pitting/wear Replace the cylinder head. 3. Measure: Valve seat width a Out of specification Replace the cylinder head. Valve seat width C (intake) 1.001.20 mm (0.03940.0472 in) Valve seat width C (exhaust) 1.001.20 mm (0.03940.0472 in)

6. Measure: Valve stem runout Out of specification Replace the valve.

NOTE:

a. Apply Mechanics blueing dye (Dykem) b onto the valve face.

When installing a new valve, always replace the valve guide. If the valve is removed or replaced, always replace the valve stem seal. Valve stem runout 0.010 mm (0.0004 in) b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impression. d. Measure the valve seat width.
NOTE:

Where the valve seat and valve face contacted one another, the blueing will have been removed.
EAS24300

CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats.

4. Lap: Valve face Valve seat

5-30

VALVES AND VALVE SPRINGS

NOTE:

After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. a. Apply a coarse lapping compound a to the valve face.
ECA13790

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.

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.

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. j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat.

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:

EAS24310

For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.

CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: Valve spring free length a Out of specification Replace the valve spring. Free length (intake) 42.43 mm (1.67 in) Limit 40.31 mm (1.59 in) Free length (exhaust) 42.43 mm (1.67 in) Limit 40.31 mm (1.59 in)

5-31

VALVES AND VALVE SPRINGS

2. Measure: Compressed valve spring force a Out of specification Replace the valve spring. Installed compression spring force (intake) 171197 N (38.4444.29 lbf) (17.4420.09 kgf) Installed compression spring force (exhaust) 171197 N (38.4444.29 lbf) (17.4420.09 kgf) Installed length (intake) 35.00 mm (1.38 in) Installed length (exhaust) 35.00 mm (1.38 in)

EAS24340

INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: Valve stem end (with an oil stone)

2. Lubricate: Valve stem 1 Valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Lubricate: Valve stem end (with the recommended lubricant)
b. Installed length

3. Measure: Valve spring tilt a Out of specification Replace the valve spring. Spring tilt (intake) 2.5/1.9 mm Spring tilt (exhaust) 2.5/1.9 mm

Recommended lubricant Engine oil

4. Install: Lower spring seat 1

5-32

VALVES AND VALVE SPRINGS

Valve stem seal 2 New Valve 3 Valve spring 4 Upper spring seat 5 (into the cylinder head)
NOTE:

Make sure each valve is installed in its original place. Install the valve springs with the larger pitch a facing up.

6. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.
ECA13800

CAUTION:

Hitting the valve tip with excessive force could damage the valve.

b. Smaller pitch

5. Install: Valve cotters

NOTE:

Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2. Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attachment 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1

5-33

CYLINDERS AND PISTONS

EAS24360

CYLINDERS AND PISTONS

Removing the cylinders and pistons

1 3
New 5

10 1 11
E

10 11 12 9 12
New 7 New 7 New

9
E

7 6 2
E

8 7 New

New 4

FW
Order

Job/Parts to remove Cylinder heads

Qty

Remarks Refer to CYLINDER HEADS on page 5-24.

1 2 3 4 5 6 7 8 9 10 11 12

Timing chain guide Front cylinder Rear cylinder Front cylinder gasket Rear cylinder gasket Dowel pin Circlip Piston pin Piston Top ring 2nd ring Oil ring

2 1 1 1 1 4 4 2 2 2 2 2 For installation, reverse the removal procedure.

5-34

CYLINDERS AND PISTONS

EAS24380

REMOVING THE PISTONS The following procedure applies to all of the pistons. 1. Remove: Piston pin clips 1 Piston pin 2 Piston 3
ECA13810

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.

CAUTION:

Do not use a hammer to drive the piston pin out.

NOTE:

Before removing the piston pin clips, cover the crankcase opening with a clean rag to prevent the piston pin clips from falling into the crankcase. Before removing the piston pin, deburr the piston pin clips groove and the pistons pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller set 4. Piston pin puller set 90890-01304 Piston pin puller YU-01304

EAS24410

CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Check: Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: Piston-to-cylinder clearance a. Measure the cylinder bore C with the cylinder bore gauge.

3 1 2

NOTE:

Measure the cylinder bore C by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements. Bore 100.000100.010 mm (3.9370 3.9374 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.050 mm (0.0020 in) C = maximum of D1D6 T = maximum of D1 or D2 - maximum of D5 or D6

2. Remove: Top ring 2nd ring Oil ring

R = maximum of D1, D3 or D5 - minimum of D2, D4 or D6

5-35

CYLINDERS AND PISTONS

EAS24430

CHECKING THE PISTON RINGS The following procedure applies to all of the piston rings. 1. Measure: Piston ring side clearance Out of specification Replace the piston and piston rings as a set.
NOTE:

b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. c. Measure the piston skirt diameter D a with the micrometer. Piston Diameter D 99.95599.970 mm (3.9352 3.9358 in)

Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring Top ring Ring side clearance 0.0300.080 mm (0.0012 0.0032 in) Limit 0.130 mm (0.0051 in) 2nd ring Ring side clearance 0.0300.070 mm (0.0012 0.0028 in) Limit 0.130 mm (0.0051 in)

b. 8 mm (0.31 in) from the bottom edge of the piston

d. If out of specification, replace the piston and piston rings as a set. e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore C Piston skirt diameter P Piston-to-cylinder clearance 0.0300.055 mm (0.00120.0022 in) Limit 0.15 mm (0.0059 in) f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.

2. Install: Piston ring (into the cylinder)

NOTE:

Level the piston ring in the cylinder with the piston crown.

5-36

CYLINDERS AND PISTONS

Piston pin outside diameter 22.99123.000 mm (0.9052 0.9055 in) Limit 22.971 mm (0.9044 in)

a. 10 mm (0.39 in)

3. Measure: Piston ring end gap Out of specification Replace the piston ring.
NOTE:

The oil ring expander spacer end gap cannot be measured. If the oil ring rails gap is excessive, replace all three piston rings. Piston ring Top ring End gap (installed) 0.200.35 mm (0.00790.0138 in) Limit 0.60 mm (0.0236 in) 2nd ring End gap (installed) 0.450.60 mm (0.01770.0236 in) Limit 0.95 mm (0.0374 in) Oil ring End gap (installed) 0.200.70 mm (0.00790.0276 in)
EAS24440

3. Measure: Piston pin bore diameter b Out of specification Replace the piston. Piston pin bore inside diameter 23.00423.015 mm (0.9057 0.9061 in) Limit 23.045 mm (0.9073 in)

CHECKING THE PISTON PINS The following procedure applies to all of the piston pins. 1. Check: Piston pin Blue discoloration/grooves Replace the piston pin and then check the lubrication system. 2. Measure: Piston pin outside diameter a Out of specification Replace the piston pin.

4. Calculate: Piston-pin-to-piston-pin-bore clearance Out of specification Replace the piston pin and piston as a set. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter b Piston pin outside diameter a Piston-pin-to-piston-pin-bore clearance 0.0040.024 mm (0.00016 0.00094 in)

5-37

CYLINDERS AND PISTONS

EAS24460

INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pistons and cylinders. 1. Install: Top ring 1 2nd ring 2 Oil ring expander 3 Lower oil ring rail 4 Upper oil ring rail 5
NOTE:

b 3 New
3. Lubricate: Piston Piston rings Cylinder (with the recommended lubricant) Recommended lubricant Engine oil 4. Offset: Piston ring end gaps
A

Be sure to install the piston rings so that the manufacturers marks or numbers face up.

d.e

2. Install: Piston 1 Piston pin 2 Piston pin clips 3 New

NOTE:

90

20

c
90

a.b
a. b. c. d. e. A. Top ring Upper oil ring rail Oil ring expander Lower oil ring rail 2nd ring forward

Apply engine oil onto the piston pin. Make sure the arrow mark a on the piston faces towards the front side of the cylinder. Before installing the piston pin clips, cover the crankcase opening with a clean rag to prevent the clips from falling into the crankcase. Install the piston pin clips so that the clip ends are 3 mm (0.12 in) b or more from the cutout in the piston. Reinstall each piston into its original cylinder.

5. Install: Rear cylinder gasket 1 Front cylinder gasket 2

A A

A. Intake side B. Exhaust side

5-38

CYLINDERS AND PISTONS

6. Install: Cylinder 1
NOTE:

While compressing the piston rings with one hand, install the cylinder with the other hand. Pass the timing chain and timing chain guide through the timing chain cavity.

5-39

GENERATOR AND STARTER CLUTCH

EAS24480

GENERATOR AND STARTER CLUTCH

Removing the stator coil

2
10 Nm (1.0 m kg, 7.2 ft Ib)
R

1
LT

LT

10 11 6
LT

7 New 8

LS

LS

New

(12)
New

(6) 4 3

New
LS

7 Nm (0.7 m kg, 5.1 ft Ib)

Job/Parts to remove Left side cover Engine oil Canister Drive pulley cover Left footrest assembly/Sidestand

6 Nm (0.6 m kg, 4.3 ft Ib)

Qty

10 Nm (1.0 m kg, 7.2 ft Ib)

Remarks

Order

Refer to GENERAL CHASSIS on page 4-1. Drain. Refer to CHANGING THE ENGINE OIL on page 3-12. For California only. Refer to THROTTLE BODIES on page 7-7. Refer to BELT DRIVE on page 4-72. Refer to ENGINE REMOVAL on page 5-1. 1 1 1 1 1 1 1 2 Disconnect. Disconnect.

1 2 3 4 5 6 7 8

Stator coil coupler Crankshaft position sensor coupler Damper cover Generator cover damper Left side cover bracket Generator cover Generator cover gasket Dowel pin

5-40

GENERATOR AND STARTER CLUTCH

Removing the stator coil

2
10 Nm (1.0 m kg, 7.2 ft Ib)
R

1
LT

LT

10 11 6
LT

7 New 8

LS

LS

New

(12)
New

(6) 4 3

New
LS

7 Nm (0.7 m kg, 5.1 ft Ib)

Job/Parts to remove

6 Nm (0.6 m kg, 4.3 ft Ib)

Qty 1 1 1

10 Nm (1.0 m kg, 7.2 ft Ib)

Remarks

Order 9 10 11

Crankshaft position sensor/stator assembly lead holder Crankshaft position sensor Stator coil

For installation, reverse the removal procedure.

5-41

GENERATOR AND STARTER CLUTCH

Removing the generator rotor and starter clutch

4
R
T

90 Nm (9.0 m kg, 65 ft Ib)

24 Nm (2.4 m kg, 17 ft Ib)

1
LT

7 5 6
E E

(6)

Order 1 2 3 4 5 6 7

Job/Parts to remove Generator rotor Starter clutch Woodruff key Starter clutch gear Torque limiter Starter clutch idle gear shaft Starter clutch idle gear

Qty 1 1 1 1 1 1 1

Remarks

For installation, reverse the removal procedure.

5-42

GENERATOR AND STARTER CLUTCH

EAS24490

REMOVING THE GENERATOR 1. Remove: Generator rotor bolt 1 Washer Starter clutch bolts 2
NOTE:

While holding the generator rotor 3 with the sheave holder 4, loosen the generator rotor bolt. Do not allow the sheave holder to touch the projection on the generator rotor. Sheave holder 90890-01701 Primary clutch holder YS-01880-A

2
EAS24560

REMOVING THE STARTER CLUTCH 1. Remove: Starter clutch bolts Starter clutch
NOTE:

3 2 1 2 4
2. Remove: Generator rotor 1 (with the flywheel puller 2) Woodruff key
ECA13880

While holding the generator rotor 1 with the sheave holder 2, loosen the starter clutch bolts. Sheave holder 90890-01701 Primary clutch holder YS-01880-A

CAUTION:

To protect the end of the crankshaft, place an appropriate sized socket between the flywheel puller sets center bolt and the crankshaft.
NOTE:

EAS24570

Install the flywheel puller bolts to the threaded holes of the starter clutch. Make sure the flywheel puller is centered over the generator rotor. Flywheel puller 90890-01362 Heavy duty puller YU-33270-B

CHECKING THE STARTER CLUTCH 1. Check: Starter clutch rollers Damage/wear Replace. 2. Check: Starter clutch idle gear Starter clutch gear Burrs/chips/roughness/wear Replace the defective part(s). 3. Check: Starter clutch gears contacting surfaces Damage/pitting/wear Replace the starter clutch gear. 4. Check: Starter clutch operation

5-43

GENERATOR AND STARTER CLUTCH

a. Install the starter clutch gear 1 onto the generator rotor 2 and hold the generator rotor. b. When turning the starter clutch gear clockwise A, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch gear counterclockwise B, it should turn freely, otherwise the starter clutch is faulty and must be replaced.
EAS24500

INSTALLING THE GENERATOR 1. Install: Generator rotor Washer Generator rotor bolt
NOTE:

B 2

EAS3D81022

CHECKING THE TORQUE LIMITER 1. Check: Torque limiter Damage/wear Replace.

NOTE:

Clean the tapered portion of the crankshaft and the generator rotor hub. When installing the generator rotor, make sure the woodruff key is properly seated in the keyway of the crankshaft. Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil. 2. Tighten: Generator rotor bolt 1 Generator rotor bolt 90 Nm (9.0 mkg, 65 ftlb)

Do not disassemble the torque limiter.

EAS24600

INSTALLING THE STARTER CLUTCH 1. Install: Starter clutch Starter clutch bolt 24 Nm (2.4 mkg, 17 ftlb) LOCTITE

NOTE:

While holding the generator rotor 2 with the sheave holder 3, tighten the generator rotor bolt. Sheave holder 90890-01701 Primary clutch holder YS-01880-A

T.

NOTE:

While holding the generator rotor 1 with the sheave holder 2, tighten the starter clutch bolts. Sheave holder 90890-01701 Primary clutch holder YS-01880-A

T.

1 3

5-44

GENERATOR AND STARTER CLUTCH

3. Apply: Sealant (onto the crankshaft position sensor/stator assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215)

5-45

CLUTCH
EAS25060

CLUTCH
Removing the clutch cover

8 New 9 7 9

6 2
(8)

1
10 Nm (1.0 m kg, 7.2 ft Ib)

New

4 3
7 Nm (0.7 m kg, 5.1 ft Ib)
Remarks Refer to ENGINE REMOVAL on page 5-1. Drain. Refer to CHANGING THE ENGINE OIL on page 3-12. 1 1 1 1 1 1 1 1 2 For installation, reverse the removal procedure. Disconnect.

(6)

Order

Job/Parts to remove Muffler/Coolant reservoir cover Engine oil

Qty

1 2 3 4 5 6 7 8 9

Clutch cable holder Clutch cable Pull lever Pull lever spring Damper cover Clutch cover damper Clutch cover Clutch cover gasket Dowel pin

5-46

CLUTCH
Removing the pull lever shaft

1
LS

New

5 4 3 New

2
LS

Order 1 2 3 4 5 Circlip

Job/Parts to remove

Qty 1 1 1 1 1

Remarks

Pull lever shaft Oil seal Bearing Bearing

For installation, reverse the removal procedure.

5-47

CLUTCH
Removing the clutch
10 Nm (1.0 m kg, 7.2 ft Ib)

22

21 19

23 18 17
LT

E E

20

16

125 Nm (12.5 m kg, 90 ft lb)

15

14 13 12 11 New New

9 7 6 5 10
E

(6)
LS E

4 3
T

8 Nm (0.8 m kg, 5.8 ft Ib)

Remarks

Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Job/Parts to remove Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Friction plate 1 Clutch plate Friction plate 2 Clutch boss nut Conical spring washer Wire circlip Clutch plate Friction plate 3 Clutch damper spring Clutch damper spring seat Clutch boss Thrust washer 1

Qty 1 1 1 1 1 1 7 7 1 1 1 1 1 1 1 1 1

Inside diameter: 124 mm (4.88 in) Inside diameter: 124 mm (4.88 in)

Inside diameter: 135 mm (5.31 in)

5-48

CLUTCH
Removing the clutch
10 Nm (1.0 m kg, 7.2 ft Ib)

22

21 19

23 18 17
LT

E E

20

16

125 Nm (12.5 m kg, 90 ft lb)

15

14 13 12 11 New New

9 7 6 5 10
E

(6)
LS E

4 3
T

8 Nm (0.8 m kg, 5.8 ft Ib)

Remarks

Order 18 19 20 21 22 23

Job/Parts to remove Clutch housing Collar Oil/water pump drive chain guide Oil/water pump drive chain Oil/water pump drive sprocket Thrust washer 2

Qty 1 1 1 1 1 1

For installation, reverse the removal procedure.

5-49

CLUTCH
Removing the primary drive gear

100 Nm (10.0 m kg, 72 ft lb)

7 6
LS

5 New 4

3
New New
LS

3
LT

1
E

10 Nm (1.0 m kg, 7.2 ft Ib)

Order Air filter case

New 2

(12)
10 Nm (1.0 m kg, 7.2 ft Ib)
Remarks Refer to GENERAL CHASSIS on page 4-1. Refer to REAR BRAKE on page 4-34. Refer to ENGINE REMOVAL on page 5-1. Refer to GENERATOR AND STARTER CLUTCH on page 5-40. 1 1 3 1 1 1 1 For installation, reverse the removal procedure.

Job/Parts to remove

Qty

Rear brake master cylinder Right footrest assembly/Rear brake light switch/Horn/Down tube Generator cover 1 2 3 4 5 6 7 Primary drive gear cover Primary drive gear cover gasket Dowel pin Primary drive gear nut Lock washer Spacer Primary drive gear

5-50

CLUTCH
EAS25080

REMOVING THE CLUTCH 1. Loosen: Clutch boss nut 1

NOTE:

Do not allow the sheave holder to touch the projection on the generator rotor. Sheave holder 90890-01701 Primary clutch holder YS-01880-A

While holding the clutch boss 2 with the universal clutch holder 3, loosen the clutch boss nut. Universal clutch holder 90890-04086 YM-91042

2 1 3
3
2. Remove: Clutch boss nut 1 Conical spring washer 2 Clutch boss assembly 3
NOTE:

There is a built-in damper between the clutch boss and the clutch plate. It is not necessary to remove the wire circlip 4 and disassemble the built-in damper unless there is serious clutch chattering.

4
EAS25100

4 2 1

CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: Friction plate Damage/wear Replace the friction plates as a set. 2. Measure: Friction plate thickness Out of specification Replace the friction plates as a set.
NOTE:

Measure each friction plate at four places.

EAS25090

REMOVING THE PRIMARY DRIVE GEAR 1. Straighten the lock washer tab. 2. Remove: Primary drive gear nut 1 Lock washer 2
NOTE:

Friction plate 1, 3 thickness 2.903.10 mm (0.1140.122 in) Wear limit 2.80 mm (0.1102 in)

While holding the generator rotor 3 with the sheave holder 4, loosen the primary drive gear nut.

5-51

CLUTCH

EAS25130

CHECKING THE CLUTCH SPRING PLATE 1. Check: Clutch spring plate Damage Replace. 2. Check: Clutch spring plate seat Damage Replace.
EAS25150

CHECKING THE CLUTCH HOUSING 1. Check: Clutch housing dogs Damage/pitting/wear Deburr the clutch housing dogs or replace the clutch housing.
NOTE:

Pitting on the clutch housing dogs will cause erratic clutch operation.

A. Friction plate 1 B. Friction plate 2 C. Friction plate 3

EAS25110

CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: Clutch plate Damage Replace the clutch plates as a set. 2. Measure: Clutch plate warpage (with a surface plate and thickness gauge 1) Out of specification Replace the clutch plates as a set. Warpage limit 0.20 mm (0.0079 in)

2. Check: Bearing Damage/wear Replace the bearing and clutch housing.

EAS25160

CHECKING THE CLUTCH BOSS 1. Check: Clutch boss splines Damage/pitting/wear Replace the clutch boss.
NOTE:

Pitting on the clutch boss splines will cause erratic clutch operation.

5-52

CLUTCH
Pull rod teeth 2 Damage/wear Replace the pull rod and pull lever shaft pinion gear as a set.

EAS25170

CHECKING THE PRESSURE PLATE 1. Check: Pressure plate Cracks/damage Replace. Bearing Damage/wear Replace.
EAS25200

2. Check: Pull rod bearing Damage/wear Replace.

EAS3D81028

CHECKING THE PRIMARY DRIVE GEAR 1. Check: Primary drive gear Damage/wear Replace the primary drive and primary driven gears as a set. Excessive noise during operation Replace the primary drive and primary driven gears as a set.
EAS25210

CHECKING THE PRIMARY DRIVEN GEAR 1. Check: Primary driven gear 1 Damage/wear Replace the primary drive and primary driven gears as a set. Excessive noise during operation Replace the primary drive and primary driven gears as a set.

CHECKING THE OIL/WATER PUMP DRIVE SPROCKET AND OIL/WATER PUMP DRIVE CHAIN 1. Check: Oil/water pump drive sprocket Cracks/damage/wear Replace the oil/water pump drive chain, and oil/water pump drive and driven sprockets as a set. 2. Check: Oil/water pump drive chain Damage/stiffness Replace the oil/water pump drive chain, and oil/water pump drive and driven sprockets as a set.
EAS25230

INSTALLING THE PRIMARY DRIVE GEAR 1. Install: Primary drive gear 1 Spacer 2 Lock washer 3 Primary drive gear nut Primary drive gear nut 100 Nm (10.0 mkg, 72 ftlb)

NOTE:

EAS25220

CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: Pull lever shaft pinion gear teeth 1

Make sure that the side of the primary drive gear 1 with the groove a is facing outward. Align the tab b on the lock washer 3 with the groove c in the spacer 2. While holding the generator rotor 4 with the sheave holder 5, tighten the primary drive gear nut. Do not allow the sheave holder to touch the projection on the generator rotor.

T.

5-53

CLUTCH
Lubricate the primary drive gear nut threads with engine oil. Sheave holder 90890-01701 Primary clutch holder YS-01880-A

a 2 1 3

c b
2. Install: Clutch housing 1
NOTE:

1 3 2 4

Fit the projections a on the oil/water pump drive sprocket into the grooves b in the clutch housing. Lubricate the clutch housing bearing with engine oil. Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly. After installing the clutch housing, make sure that the primary drive gear 2 and clutch housing primary driven gear 3 are aligned as shown in the illustration.

a 5
2. Bend lock washer tab along a flat side of the nut.
EAS25240

INSTALLING THE CLUTCH 1. Install: Oil/water pump drive sprocket 1 Oil/water pump drive chain 2 Oil/water pump drive chain guide 3
NOTE:

b a

Install the oil/water pump drive sprocket with its projections a facing outward. Oil/water pump drive chain guide bolt 10 Nm (1.0 mkg, 7.2 ftlb) LOCTITE 3. Install: Clutch boss assembly 1
NOTE:

T.

Install the clutch damper spring 2 with the OUTSIDE mark facing out. If the wire circlip 3 has been removed, carefully install a new one.

5-54

CLUTCH
6. Install: Friction plates 2 1 Clutch plates Friction plate 1 2
NOTE:

2 New 3
4. Install: Clutch boss 1 Washer Conical spring washer 2 Clutch boss nut 3 Clutch boss nut 125 Nm (12.5 mkg, 90 ftlb)

First, install a friction plate and then alternate between a clutch plate and a friction plate. Align the cutout in the tab of each friction plate 2 1 with the mark a on the clutch housing and align the cutout in the tab of friction plate 1 2 with the punch mark b on the housing.

b 2 a

b a

NOTE:

Lubricate the clutch boss nut threads and conical spring washer mating surfaces with engine oil. Install the conical spring washer 2 with the OUT mark a facing out. While holding the clutch boss with the universal clutch holder 4, tighten the clutch boss nut. Stake the clutch boss nut 3 at cutouts b in the main axle. Universal clutch holder 90890-04086 YM-91042

5. Lubricate: Friction plates Clutch plates (with the recommended lubricant) Recommended lubricant Engine oil

T.

1
7. Install: Clutch spring plate Clutch spring plate retainer Clutch spring plate retainer bolt 8 Nm (0.8 mkg, 5.8 ftlb)

NOTE:

Tighten the clutch spring plate retainer bolts in stages and in a crisscross pattern. 8. Install: Pull lever spring 1 Pull lever 2 Washer Circlip New
NOTE:

T.

1
a

3
b

Make sure that the mark a on the pull lever is facing forward. When installing the pull lever, push it and check that its punch mark b aligns with the mark c on the clutch cover. Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged.

5-55

CLUTCH
b c 1 a 2

9. Adjust: Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3-13.

5-56

SHIFT SHAFT
EAS25410

SHIFT SHAFT
Removing the shift shaft and stopper lever
LS

New New 3 4 5 6 2
E E

22 Nm (2.2 m kg, 16 ft Ib)

7
Order Job/Parts to remove Drive pulley cover Shift arm Primary drive gear cover 1 2 3 4 5 6 7 Shift shaft Stopper lever spring Circlip Stopper lever Collar Shift shaft spring Shift shaft spring stopper 1 1 1 1 1 1 1 Qty

LT

Remarks Refer to BELT DRIVE on page 4-72. Refer to ENGINE REMOVAL on page 5-1. Refer to CLUTCH on page 5-46.

For installation, reverse the removal procedure.

5-57

SHIFT SHAFT
EAS25420

CHECKING THE SHIFT SHAFT 1. Check: Shift shaft Bends/damage/wear Replace. Shift shaft spring Damage/wear Replace.
EAS25430

CHECKING THE STOPPER LEVER 1. Check: Stopper lever Bends/damage Replace. Roller turns roughly Replace the stopper lever.
EAS25450

INSTALLING THE SHIFT SHAFT 1. Install: Stopper lever 1 Stopper lever spring 2 Shift shaft 3
NOTE:

Lubricate the oil seal lips with lithium-soapbased grease. Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 4. Mesh the stopper lever with the shift drum segment assembly. Hook the end of the shift shaft spring onto the shift shaft spring stopper 5.

1 4 2

3 5

5-58

BALANCER GEARS
EAS3D81023

BALANCER GEARS
Removing the right balancer assembly

12 Nm (1.2 m kg, 8.7 ft Ib)

LT

LT

3 2 1
LT

12 Nm (1.2 m kg, 8.7 ft Ib)

Order

Job/Parts to remove Primary drive gear

Qty

Remarks Refer to CLUTCH on page 5-46.

1 2 3

Straight key Right balancer drive gear Right balancer assembly

1 1 1 For installation, reverse the removal procedure.

5-59

BALANCER GEARS
Removing the left balancer assembly

1
E

New

12 Nm (1.2 m kg, 8.7 ft Ib)

2
12 Nm (1.2 m kg, 8.7 ft Ib)
T

Order

Job/Parts to remove Generator rotor/Starter clutch idle gear

Qty

Remarks Refer to GENERATOR AND STARTER CLUTCH on page 5-40.

1 2

Left balancer drive gear Left balancer assembly

1 1 For installation, reverse the removal procedure.

5-60

BALANCER GEARS
EAS3D81024

CHECKING THE RIGHT BALANCER GEARS 1. Check: Right balancer drive gear Right balancer driven gear Right balancer driven gear bearing Damage/wear Replace the right balancer assembly.
EAS3D81025

2. Install: Left balancer drive gear 1

NOTE:

CHECKING THE LEFT BALANCER GEARS 1. Check: Left balancer drive gear Left balancer driven gear Left balancer driven gear bearing Damage/wear Replace the left balancer assembly.
EAS3D81026

Align the punch mark a in the left balancer driven gear with the punch mark b in the left balancer drive gear. Align the projection c on the left balancer drive gear with the punch mark d on the crankshaft when installing the gear.

1 c d b a

INSTALLING THE RIGHT BALANCER GEARS 1. Install: Right balancer assembly Right balancer assembly bolt 12 Nm (1.2 mkg, 8.7 ftlb) LOCTITE

2. Install: Right balancer drive gear 1 Straight key 2

NOTE:

Align the punch mark a in the right balancer driven gear with the punch mark b in the right balancer drive gear.

EAS3D81027

INSTALLING THE LEFT BALANCER GEARS 1. Install: Left balancer assembly Left balancer assembly bolt 12 Nm (1.2 mkg, 8.7 ftlb) LOCTITE

T.

b 1 a

T.

5-61

ELECTRIC STARTER
EAS24780

ELECTRIC STARTER
Removing the starter motor

10 Nm (1.0 m kg, 7.2 ft Ib)

10 Nm (1.0 m kg, 7.2 ft Ib)

Order 1 2

Job/Parts to remove Starter motor lead Starter motor

Qty 1 1 Disconnect.

Remarks

For installation, reverse the removal procedure.

5-62

ELECTRIC STARTER
Disassembling the starter motor

9 12 11 13 14 New 10

New 8 7 10
LS

4 3 New 5

LS

6 2 1 New
Qty 1 1 1 1 1 1 1 1 1 2 1 1 1 1 For assembly, reverse the disassembly procedure. Remarks

Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 O-ring

Job/Parts to remove

Starter motor front cover Lock washer Washer set Oil seal Bearing Armature assembly Washer set Starter motor rear cover Gasket Brush set (along with the brushes) Brush holder (along with the brushes) Brush holder bracket Starter motor yoke

5-63

ELECTRIC STARTER
EAS24790

CHECKING THE STARTER MOTOR 1. Check: Commutator Dirt Clean with 600 grit sandpaper. 2. Measure: Commutator diameter 1 Out of specification Replace the starter motor. Limit 27.0 mm (1.06 in)

Pocket tester 90890-03112 Analog pocket tester YU-03112-C Armature coil Commutator resistance 1 0.010.02 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.

3. Measure: Mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut (depth) 0.70 mm (0.03 in)
NOTE:

5. Measure: Brush length a Out of specification Replace the brushes as a set. Limit 5.00 mm (0.20 in)

The mica of the commutator must be undercut to ensure proper operation of the commutator.

4. Measure: Armature assembly resistances (commutator and insulation) Out of specification Replace the starter motor. a. Measure the armature assembly resistances with the pocket tester.

6. Measure: Brush spring force Out of specification Replace the brush springs as a set. Brush spring force 7.6510.01 N (27.5436.03 oz) (7801021 gf)

5-64

ELECTRIC STARTER
b a b

2
7. Check: Gear teeth Damage/wear Replace the gear. 8. Check: Bearing Damage/wear Replace the defective part(s).
EAS24800

ASSEMBLING THE STARTER MOTOR 1. Install: Brush seat

NOTE:

Align the tab a on the brush seat with the slot b in the starter motor yoke.

2. Install: Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3
NOTE:

Align the match marks a on the starter motor yoke with the match marks b on the starter motor front and rear covers.

5-65

CRANKCASE
EAS25540

CRANKCASE
Removing the oil delivery pipes and timing chains
10 Nm (1.0 m kg, 7.2 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) 20 Nm (2.0 m kg, 14 ft Ib)
T T

R
T

New
LS

New

5
New

10 Nm (1.0 m kg, 7.2 ft Ib)

LT

10 Nm (1.0 m kg, 7.2 ft Ib)

3 9
LT

New

R
T

LT

18 New 17
New
LS LS
R

(4) 11
New New
LT

LT

20 Nm (2.0 m kg, 14 ft Ib)

LS LT

New

LT

5 6

16 (9) 13
New
LS

14 15
New

10

2
LT
R

1
LS
T

10 Nm (1.0 m kg, 7.2 ft Ib) 17 Nm (1.7 m kg, 12 ft Ib)

R R

12
T

10 Nm (1.0 m kg, 7.2 ft Ib)

R

70 Nm (7.0 m kg, 50 ft lb) 20 Nm (2.0 m kg, 14 ft Ib)

Remarks

15 Nm (1.5 m kg, 11 ft Ib)

43 Nm (4.3 m kg, 31 ft Ib)

Qty

Order Engine Pistons Shift shaft

Job/Parts to remove

Refer to ENGINE REMOVAL on page 5-1. Refer to CYLINDERS AND PISTONS on page 5-34. Refer to SHIFT SHAFT on page 5-57. Refer to BALANCER GEARS on page 5-59. 1 1 1 1 2 2 1 1 1 1 1

Balancer assemblies 1 2 3 4 5 6 7 8 9 10 11 Oil level switch Engine oil drain bolt Neutral switch Oil delivery pipe 1 Timing chain guide Timing chain Coolant delivery pipe Speed sensor Spacer Oil filter cartridge Oil delivery pipe 2

5-66

CRANKCASE
Removing the oil delivery pipes and timing chains
10 Nm (1.0 m kg, 7.2 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) 20 Nm (2.0 m kg, 14 ft Ib)
T T

R
T

New
LS

New

5
New

10 Nm (1.0 m kg, 7.2 ft Ib)

LT

10 Nm (1.0 m kg, 7.2 ft Ib)

3 9
LT

New

R
T

LT

18 New 17
New
LS LS
R

(4) 11
New New
LT

LT

20 Nm (2.0 m kg, 14 ft Ib)

LS LT

New

LT

5 6

16 (9) 13
New
LS

14 15
New

10

2
LT
R

1
LS
T

10 Nm (1.0 m kg, 7.2 ft Ib) 17 Nm (1.7 m kg, 12 ft Ib)

R R

12
T

10 Nm (1.0 m kg, 7.2 ft Ib)

R

70 Nm (7.0 m kg, 50 ft lb) 20 Nm (2.0 m kg, 14 ft Ib)

Remarks

15 Nm (1.5 m kg, 11 ft Ib)

43 Nm (4.3 m kg, 31 ft Ib)

Qty 1 1 1 1 1 1 1

Order 12 13 14 15 16 17 18

Job/Parts to remove Oil delivery pipe 3 Coolant delivery cover 1 Coolant delivery cover 1 gasket Oil/water pump driven sprocket Circlip Coolant delivery cover 2 Coolant delivery cover 2 gasket

For installation, reverse the removal procedure.

5-67

CRANKCASE
Separating the crankcase
10 Nm (1.0 m kg, 7.2 ft Ib)
LT

10 Nm (1.0 m kg, 7.2 ft Ib)

(5)
LT

36 Nm (3.6 m kg, 25 ft Ib)

LT

Order 1 2 3 4 5 6 7 8

1 7 New 6
10 Nm (1.0 m kg, 7.2 ft Ib)
R

LT

10 Nm (1.0 m kg, 7.2 ft Ib)

8 3 3
New
LS LS

LT

(19) 5

4
New

LS

New
LS

New

10 Nm (1.0 m kg, 7.2 ft Ib)

Remarks

Job/Parts to remove Oil baffle plate 1 Left crankcase Dowel pin Joint pipe 1 Joint pipe 2 Oil baffle plate 2 Gasket Right crankcase

Qty 1 1 2 1 1 1 1 1

For installation, reverse the removal procedure.

5-68

CRANKCASE
Removing the oil seal and bearings
E

4
3
LS

New
LS E LT

12 Nm (1.2 m kg, 8.7 ft Ib)

4
LS E

3 2 New 1
LT

3 New

3
E LT

12 Nm (1.2 m kg, 8.7 ft Ib)

Order

3
LT

Job/Parts to remove Oil/water pump assembly Crankshaft Transmission

Qty

Remarks Refer to OIL PUMP on page 5-73. Refer to CRANKSHAFT on page 5-76. Refer to TRANSMISSION on page 5-81.

1 2 3 4

Bearing retainer Oil seal Bearing Oil nozzle

2 1 7 2 For installation, reverse the removal procedure.

5-69

CRANKCASE
EAS25560 EAS25580

DISASSEMBLING THE CRANKCASE 1. Remove: Crankcase bolts

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. M10 110 mm bolts 1 M6 120 mm bolts 2 M6 80 mm bolts 3
A

CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: Crankcase Cracks/damage Replace. Oil delivery passages Obstruction Blow out with compressed air.
EAS3D81029

1 2

CHECKING THE BEARINGS AND OIL SEAL 1. Check: Bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement Replace. Oil seals Damage/wear Replace.
EAS25600

3 3
A. Right crankcase B. Left crankcase

CHECKING THE OIL DELIVERY PIPES AND COOLANT DELIVERY PIPE The following procedure applies to all of the oil delivery pipes and joint pipe. 1. Check: Oil delivery pipe Joint pipe Damage Replace. Obstruction Wash and blow out with compressed air. 2. Check: Coolant delivery pipe Cracks/damage/wear Replace.
EAS25620

2. Remove: Left crankcase

ECA13900

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.

CHECKING THE TIMING CHAINS 1. Check: Timing chains Damage/stiffness Replace the timing chain and camshaft sprocket as a set.
EAS3D81030

CHECKING THE OIL/WATER PUMP DRIVEN SPROCKET 1. Check: Oil/water pump driven sprocket Cracks/damage/wear Replace the oil/water pump driven sprocket and the oil/water pump drive chain as a set.
EAS3D81036

CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles.

5-70

CRANKCASE
1. Check: Oil nozzle Damage/wear Replace the oil nozzle. Oil passage Obstruction Blow out with compressed air.
EAS3D81031

INSTALLING THE BEARING RETAINERS 1. Install: Bearing retainers 1

NOTE:

Install each bearing retainer 1 with its OUT mark a facing outward. Apply locking agent (LOCTITE) to the threads of the bearing retainer bolt. Bearing retainer bolt 12 Nm (1.2 mkg, 8.7 ftlb) LOCTITE

3. Install: Left crankcase (onto the right crankcase)

NOTE:

Tap lightly on the left crankcase with a soft-face hammer. 4. Install: Crankcase bolts (M10) Crankcase bolts (M6) Crankcase bolt (M10) 36 Nm (3.6 mkg, 25 ftlb) Crankcase bolt (M6) 10 Nm (1.0 mkg, 7.2 ftlb)

T.

a
T.

1
NOTE:

EAS25700

ASSEMBLING THE CRANKCASE 1. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces. 2. Apply: Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215)
NOTE:

Apply locking agent (LOCTITE) to the threads of the bolts 2. Tighten each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. M10 110 mm bolts: 1 M6 120 mm bolts: 2 M6 80 mm bolts: 3

Do not allow any sealant to come into contact with the oil gallery.

5-71

CRANKCASE
A

1 2

3 3
A. Right crankcase B. Left crankcase

5. Apply: Engine oil (onto the crankshaft pin bearings and oil delivery holes) 6. Check: Crankshaft and transmission operation Rough movement Repair.

5-72

OIL PUMP
EAS24910

OIL PUMP
Removing the oil/water pump assembly

8
T

24 Nm (2.4 m kg, 17 ft Ib)

10 Nm (1.0 m kg, 7.2 ft Ib)

8 4
LS

LS

New 12 New
LS

5 New
LS

New 1

6 7

9 10 New
LS

2 New
10 Nm (1.0 m kg, 7.2 ft Ib)

11

3
24 Nm (2.4 m kg, 17 ft Ib)

10 Nm (1.0 m kg, 7.2 ft Ib)

Job/Parts to remove Crankcase 1 2 3 4 5 6 7 8 9 Drain cock Relief valve assembly Oil/water pump assembly Dowel pin Joint pipe Oil pump housing Bearing Pin Oil pump outer rotor Oil pump inner rotor Pin Water pump housing 1 1 1 2 1 1 1 2 1 1 1 1 For installation, reverse the removal procedure. Qty Remarks Separate. Refer to CRANKCASE on page 5-66.

Order

10 11 12

5-73

OIL PUMP
EAS24960

CHECKING THE OIL PUMP 1. Check: Oil pump housing Water pump housing Cracks/damage/wear Replace the defective part(s). 2. Measure: Inner-rotor-to-outer-rotor-tip clearance a Outer-rotor-to-oil-pump-housing clearance b Oil-pump-housing-to-inner-rotor-and-outerrotor clearance c Out of specification Replace the oil/water pump assembly. Inner-rotor-to-outer-rotor-tip clearance Less than 0.12 mm (0.0047 in) Limit 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing clearance 0.090.19 mm (0.00350.0075 in) Limit 0.26 mm (0.0102 in) Oil-pump-housing-to-inner-andouter-rotor clearance 0.060.13 mm (0.00240.0051 in) Limit 0.20 mm (0.0079 in)

1. Inner rotor 2. Outer rotor 3. Oil/water pump housing

3. Check: Oil pump operation Rough movement Repeat steps (1) and (2) or replace the defective part(s).

EAS24970

CHECKING THE RELIEF VALVE 1. Check: Relief valve body 1 Relief valve 2 Spring 3 Spring retainer 4 Damage/wear Replace the defective part(s).

5-74

OIL PUMP

4 3 2
1 2 3 4

a a 1

EAS24990

CHECKING THE OIL STRAINER 1. Check: Oil strainer 1 Damage Replace. Contaminants Clean with solvent.

3. Check: Oil pump operation Refer to CHECKING THE OIL PUMP on page 5-74.
EAS25020

INSTALLING THE OIL/WATER PUMP ASSEMBLY 1. Install: Oil/water pump assembly Oil/water pump assembly bolt 24 Nm (2.4 mkg, 17 ftlb)

T.

ECA3D81020

CAUTION:

EAS25000

After tightening the bolts, make sure the oil/water pump assembly turns smoothly.

ASSEMBLING THE OIL PUMP 1. Lubricate: Inner rotor Outer rotor (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: Pin 1 Oil pump inner rotor 2 Oil pump outer rotor 3 Pins Oil pump housing 4
NOTE:

When installing the inner rotor, align the pin in the impeller shaft with the grooves a in the inner rotor. Oil pump housing bolt 10 Nm (1.0 mkg, 7.2 ftlb)

T.

5-75

CRANKSHAFT
EAS25960

CRANKSHAFT
Removing the crankshaft

4 5

1
E

3 3

New
M

2
M M
E

New New
1st 15 Nm (1.5 m kg, 11 ft lb) 2nd Specified angle 125135
T

Order Crankcase 1 2 3 4 5 Crankshaft

Job/Parts to remove

Qty

Remarks Separate. Refer to CRANKCASE on page 5-66.

1 2 2 2 2 For installation, reverse the removal procedure.

Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing

5-76

CRANKSHAFT
EAS26010

REMOVING THE CONNECTING RODS 1. Remove: Connecting rod caps 1 Connecting rods Big end bearings
NOTE:

Oil clearance (using plastigauge) 0.0300.054 mm (0.00120.0021 in) The following procedure applies to all of the connecting rods.
ECA13930

Identify the position of each big end bearing so that it can be reinstalled in its original place.

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 pin, and the inside of the connecting rod halves. b. Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap.
NOTE:

EAS26090

CHECKING THE CRANKSHAFT AND CONNECTING RODS 1. Measure: Crankshaft runout Out of specification Replace the crankshaft. Runout limit C 0.020 mm (0.0008 in)

Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap.

c. Put a piece of Plastigauge 1 on the crankshaft pin.

1
2. Check: Crankshaft journal surfaces Crankshaft pin surfaces Bearing surfaces Scratches/wear Replace the crankshaft. 3. Measure: Crankshaft-pin-to-big-end-bearing clearance Out of specification Replace the big end bearings.

d. Assemble the connecting rod halves.

5-77

CRANKSHAFT
NOTE: NOTE:

Do not move the connecting rod or crankshaft until the clearance measurement has been completed. Lubricate the bolts threads and nut seats with molybdenum disulfide grease. Make sure the projection c on the connecting rod faces towards the left side of the crankshaft. Make sure the characters d on both the connecting rod and connecting rod cap are aligned.

The numbers a stamped into the crankshaft web and the numbers b on the connecting rods are used to determine the replacement big end bearing sizes. P1P2 refer to the bearings shown in the crankshaft illustration.

P1

P2

e. Tighten the connecting rod bolts. Refer to INSTALLING THE CONNECTING RODS on page 5-79. f. Remove the connecting rod and big end bearings. Refer to REMOVING THE CONNECTING RODS on page 5-77. g. Measure the compressed Plastigauge width e on the crankshaft pin. If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings.

For example, if the connecting rod P1 and the crankshaft web P numbers are 5 and 1 respectively, then the bearing size for P1 is: P1 (connecting rod) - P (crankshaft) = 5 - 1 = 4 (green)

4. Select: Big end bearings (P1P2)

Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow

5-78

CRANKSHAFT
5. Measure: Crankshaft journal diameter a Out of specification Replace the crankshaft.
NOTE: NOTE:

Calculate the clearance by subtracting the crankshaft journal diameter from the crankshaft journal bearing inside diameter. Crankshaft-journal-to-crankshaftjournal-bearing clearance 0.0300.060 mm (0.00120.0024 in)
EAS26150

Measure the diameter of each crankshaft journal at two places. Crankshaft journal diameter 49.96849.980 mm (1.9672 1.9677 in)

INSTALLING THE CONNECTING RODS 1. Lubricate: Bolt threads (with the recommended lubricant) Recommended lubricant Molybdenum disulfide grease 2. Lubricate: Crankshaft pin Big end bearings Connecting rod inner surface (with the recommended lubricant) Recommended lubricant Engine oil 3. Install: Big end bearings Connecting rods Connecting rod caps (onto the crankshaft pin)
NOTE:

6. Measure: Crankshaft journal bearing inside diameter a Out of specification Replace the crankcase assembly.
NOTE:

Measure the inside diameter of each crankshaft journal bearing at two places. Crankshaft journal bearing inside diameter 50.01050.030 mm (1.9689 1.9697 in)

Align the projections a on the big end bearings with the notches b in the connecting rods and connecting rod caps. Be sure to reinstall each big end bearing in its original place. Make sure the projection c on each connecting rod faces towards the left side of the crankshaft. Make sure the characters d on both the connecting rod and connecting rod cap are aligned.

7. Calculate: Crankshaft-journal-to-crankshaft-journalbearing clearance Out of specification Replace the crankshaft and crankcase as a set.

5-79

CRANKSHAFT
Connecting rod bolt (final) Specified angle 125135

T.

d
EWA3D81006

WARNING

4. Tighten: Connecting rod nuts

EWA3D81005

When a bolt is tightened more than the specified angle, do not loosen and then retighten it. Replace the bolt with a new one and perform the procedure again.
ECA3D81012

CAUTION:

WARNING

Replace the connecting rod bolts and nuts with new ones. Clean the connecting rod bolts.
NOTE:

Do not use a torque wrench to tighten the bolt to the specified angle. Tighten the bolt until it is at the specified angle.

EAS26210

Tighten the connecting rod bolts using the following procedure. a. Tighten the connecting rod bolts to specification with a torque wrench. Connecting rod bolt (1st) 15 Nm (1.5 mkg, 11 ftlb)

INSTALLING THE CRANKSHAFT ASSEMBLY 1. Install: Crankshaft assembly

ECA3D81013

CAUTION:

b. Put a mark 1 on the corner of the connecting rod bolt 2 and the connecting rod cap 3.

To avoid scratching the crankshaft and to ease the installation procedure, lubricate each bearing with engine oil.
NOTE:

c. Tighten the connecting rod bolts further to reach the specified angle 125135.

T.

Align the right connecting rod with the rear cylinder sleeve hole.

5-80

TRANSMISSION
EAS26240

TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks

7 New

4 5
E

LS

3 2
E

Order Crankcase 1 2 3 4 5 6 7

Job/Parts to remove

Qty

Remarks Separate. Refer to CRANKCASE on page 5-66.

Long shift fork guide bar Short shift fork guide bar Shift drum assembly Shift fork 1 Shift fork 2 Main axle assembly Drive axle assembly

1 1 1 2 1 1 1 For installation, reverse the removal procedure.

5-81

TRANSMISSION
Disassembling the main axle assembly

New 1 2 New 3 4 New 5 6

M M

7 8

Order 1 2 3 4 5 6 7 8 9 Circlip

Job/Parts to remove

Qty 1 1 1 1 1 1 1 1 1

Remarks

2nd pinion gear Circlip 3rd/4th pinion gear Circlip Toothed washer 5th pinion gear Collar Main axle/1st pinion gear

For assembly, reverse the disassembly procedure.

5-82

TRANSMISSION
Disassembling the drive axle assembly

20

19 New 17 16 15 14
M M

18
M

New

13 12 11
M

10 9 8 7
M M

6 New 5 4 3

Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Washer

Job/Parts to remove

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Remarks

1st wheel gear Collar 5th wheel gear Circlip Toothed washer 4th wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 3rd wheel gear Toothed spacer Toothed washer Circlip Dog clutch Circlip Toothed washer

5-83

TRANSMISSION
Disassembling the drive axle assembly

20

19 New 17 16 15 14
M M

18
M

New

13 12 11
M

10 9 8 7
M M

6 New 5 4 3

Order 18 19 20

Job/Parts to remove 2nd wheel gear Collar Drive axle

Qty 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

5-84

TRANSMISSION
EAS26260 EAS26270

CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and shift fork guide bars. 1. Check: Shift fork cam follower 1 Shift fork pawls 2 Bends/damage/scoring/wear Replace the shift fork.

CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: Shift drum grooves Damage/scratches/wear Replace the shift drum assembly. Shift drum segment 1 Damage/wear Replace the shift drum assembly. Shift drum bearing 2 Damage/pitting Replace the shift drum assembly.

2. Check: Shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends Replace.
EWA12840

EAS26300

WARNING

Do not attempt to straighten a bent shift fork guide bar.

CHECKING THE TRANSMISSION 1. Measure: Main axle runout (with a centering device and dial gauge 1) Out of specification Replace the main axle. Main axle runout limit 0.08 mm (0.0032 in)

3. Check: Shift fork movement (along the shift fork guide bar) Rough movement Replace the shift forks and shift fork guide bar as a set.

2. Measure: Drive axle runout (with a centering device and dial gauge 1) Out of specification Replace the drive axle. Drive axle runout limit 0.08 mm (0.0032 in)

5-85

TRANSMISSION

a 1 New

b
3. Check: Transmission gears Blue discoloration/pitting/wear Replace the defective gear(s). Transmission gear dogs Cracks/damage/rounded edges Replace the defective gear(s). 2. Install: Toothed lock washer retainer 1 Toothed lock washer 2
NOTE:

With the toothed lock washer retainer 1 in the groove a in the drive axle, align the projection c on the retainer with an axle spline b, and then install the toothed lock washer 2. Be sure to align the projection on the toothed lock washer that is between the alignment marks e with the alignment mark d on the retainer.

b
4. Check: Transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect Reassemble the transmission axle assemblies. 5. Check: Transmission gear movement Rough movement Replace the defective part(s).
EAS3D81032

1 c a

d b 1 2 e

e
EAS26320

ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1. Install: Toothed washer Circlip 1 New
NOTE:

INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1. Install: Shift forks 1 1 Shift fork 2 2 Shift drum assembly 3 Long shift fork guide bar 4 Short shift fork guide bar 5
NOTE:

Install the circlip so that both ends a rest on the sides of a spline b with both axles aligned.

The embossed marks 3D8 on the shift forks should face towards the left side of the engine.

5-86

TRANSMISSION

2 5 3

4 1

2. Check: Transmission Rough movement Repair.

NOTE:

Apply engine oil to each gear and bearing thoroughly. Before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely.

5-87

COOLING SYSTEM
RADIATOR ...................................................................................................... 6-1 CHECKING THE RADIATOR.................................................................... 6-3 INSTALLING THE RADIATOR.................................................................. 6-3 THERMOSTAT ................................................................................................ 6-4 CHECKING THE THERMOSTAT ............................................................. 6-6 INSTALLING THE THERMOSTAT ASSEMBLY ....................................... 6-6 WATER PUMP ................................................................................................ 6-7 DISASSEMBLING THE WATER PUMP ................................................... 6-9 CHECKING THE WATER PUMP.............................................................. 6-9 ASSEMBLING THE WATER PUMP ......................................................... 6-9

RADIATOR
EAS26380

RADIATOR
Removing the radiator
7 Nm (0.7 m kg, 5.1 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib)
R
T

New

LS

11 15
LT

1 2 3 6 (3) 5 16 13

14

10

4
7 Nm (0.7 m kg, 5.1 ft Ib)
T

LT

12 New
T

2 Nm (0.2 m kg, 1.4 ft Ib)

7
7 Nm (0.7 m kg, 5.1 ft Ib)
Job/Parts to remove Rider seat/Sub-fuel tank cover Muffler/Coolant reservoir cover Fuel tank Coolant 1 2 3 4 5 6 7 8 9 10 Rear brake hose guide Rear brake hose holder Plastic holder Coolant reservoir breather hose Coolant reservoir hose Coolant reservoir cap Coolant reservoir Radiator cap Radiator fan motor coupler Radiator cover 1 1 1 1 1 1 1 1 1 1 Disconnect. Qty Remarks Refer to GENERAL CHASSIS on page 4-1. Refer to ENGINE REMOVAL on page 5-1. Refer to FUEL TANK on page 7-1. Drain. Refer to CHANGING THE COOLANT on page 3-17.
T

Order

6-1

RADIATOR
Removing the radiator
7 Nm (0.7 m kg, 5.1 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib)
R
T

New

LS

11 15
LT

1 2 3 6 (3) 5 16 13

14

10

4
7 Nm (0.7 m kg, 5.1 ft Ib)
T

LT

12 New
T

2 Nm (0.2 m kg, 1.4 ft Ib)

7
7 Nm (0.7 m kg, 5.1 ft Ib)
Job/Parts to remove Radiator inlet hose Coolant drain bolt Radiator Radiator outlet hose Radiator outlet pipe Radiator fan Qty 1 1 1 1 1 1 For installation, reverse the removal procedure. Disconnect. Remarks
T

Order 11 12 13 14 15 16

6-2

RADIATOR
EAS26390

CHECKING THE RADIATOR 1. Check: Radiator fins Obstruction Clean. Apply compressed air to the rear of the radiator. Damage Repair or replace.
NOTE:

Straighten any flattened fins with a thin, flathead screwdriver.

b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

4. Check: Radiator fan Damage Replace. Malfunction Check and repair. Refer to COOLING SYSTEM on page 8-27.
EAS26400

2. Check: Radiator hoses Radiator pipe Cracks/damage Replace. 3. Measure: Radiator cap opening pressure Below the specified pressure Replace the radiator cap. Radiator cap opening pressure 93.3122.7 kPa (13.517.8 psi) (0.931.23 kgf/cm) a. Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3. Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984

INSTALLING THE RADIATOR 1. Fill: Cooling system (with the specified amount of the recommended coolant) Refer to CHANGING THE COOLANT on page 3-17. 2. Check: Cooling system Leaks Repair or replace any faulty part. 3. Measure: Radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to CHECKING THE RADIATOR on page 6-3.

6-3

THERMOSTAT
EAS26440

THERMOSTAT
Removing the thermostat

10 Nm (1.0 m kg, 7.2 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib)
LT
R

9 13
10 Nm (1.0 m kg, 7.2 ft Ib)

New
R

18 Nm (1.8 m kg, 13 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib)

7
LT

6 17 8 14 New 18 11 New 15 10 5 16 New 12

LT

1 2

Order

Job/Parts to remove Rider seat/Left side cover Muffler/Front cylinder covers Fuel tank Coolant

Qty

Remarks Refer to GENERAL CHASSIS on page 4-1. Refer to ENGINE REMOVAL on page 5-1. Refer to FUEL TANK on page 7-1. Drain. Refer to CHANGING THE COOLANT on page 3-17.

1 2 3 4 5 6 7 8 9 10

Front cylinder thermostat inlet hose Front cylinder thermostat inlet pipe 1 Rear cylinder thermostat inlet hose Rear cylinder thermostat inlet pipe 1 Coolant temperature sensor coupler Coolant temperature sensor Radiator filler pipe Thermostat cover inlet hose Thermostat bracket Thermostat cover assembly

1 1 1 1 1 1 1 1 1 1 Disconnect.

6-4

THERMOSTAT
Removing the thermostat

10 Nm (1.0 m kg, 7.2 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib)
LT
R

9 13
10 Nm (1.0 m kg, 7.2 ft Ib)

New
R

18 Nm (1.8 m kg, 13 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib)

7
LT

6 17 8 14 New 18 11 New 15 10 5 16 New 12

LT

1 2

Order 11 12 13 14 15 16 17 18 Thermostat

Job/Parts to remove

Qty 1 1 1 1 1 1 1 1

Remarks

Thermostat housing assembly Radiator inlet hose Thermostat cover inlet pipe Thermostat cover Front cylinder thermostat inlet pipe 2 Rear cylinder thermostat inlet pipe 2 Thermostat housing

For installation, reverse the removal procedure.

6-5

THERMOSTAT
EAS26450

CHECKING THE THERMOSTAT 1. Check: Thermostat Does not open at 8295 C (179.6203.0 F) Replace.

2. Check: Thermostat housing cover Thermostat housing Thermostat pipes Thermostat hoses Radiator inlet hose Radiator filler pipe Cracks/damage/wear Replace.
EAS26480

INSTALLING THE THERMOSTAT ASSEMBLY 1. Install: Thermostat

NOTE:

a. Suspend the thermostat 1 in a container 2 filled with water. b. Slowly heat the water 3. c. Place a thermometer 4 in the water. d. While stirring the water, observe the thermostat and thermometers indicated temperature.

Install the thermostat with its breather hole a facing up.

2. Fill: Cooling system (with the specified amount of the recommended coolant) Refer to CHANGING THE COOLANT on page 3-17. 3. Check: Cooling system Leaks Repair or replace any faulty part. 4. Measure: Radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to CHECKING THE RADIATOR on page 6-3.
A. Fully closed B. Fully open NOTE:

If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious overheating or overcooling.

6-6

WATER PUMP
EAS26500

WATER PUMP
Removing the water pump

10 2 2 9
LS LS

10 Nm (1.0 m kg, 7.2 ft Ib)

LS

6 4

New

8 New

New

New
LS

3 1

New
LS

New
24 Nm (2.4 m kg, 17 ft Ib)
R

10 Nm (1.0 m kg, 7.2 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib)

Order

Job/Parts to remove

Qty

Remarks It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil.

Crankcase Oil pump rotors 1 2 3 4 5 6 7 8 9 Water pump housing cover Pin O-ring Impeller shaft Rubber damper holder Rubber damper Water pump seal Oil seal Bearing 1 2 1 1 1 1 1 1 1

Separate. Refer to CRANKCASE on page 5-66. Refer to OIL PUMP on page 5-73.

6-7

WATER PUMP
Removing the water pump

10 2 2 9
LS LS

10 Nm (1.0 m kg, 7.2 ft Ib)

LS

6 4

New

8 New

New

New
LS

3 1

New
LS

New
24 Nm (2.4 m kg, 17 ft Ib)
R

10 Nm (1.0 m kg, 7.2 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib)

Order 10

Job/Parts to remove Water pump housing

Qty 1

Remarks

For installation, reverse the removal procedure.

6-8

WATER PUMP
EAS26510 EAS26540

DISASSEMBLING THE WATER PUMP 1. Remove: Rubber damper holder 1 Rubber damper 2 (from the impeller, with a thin, flathead screwdriver)
NOTE:

Do not scratch the impeller shaft.

CHECKING THE WATER PUMP 1. Check: Water pump housing cover Water pump housing Impeller shaft Cracks/damage/wear Replace. 2. Check: Bearing Rough movement Replace.
EAS26560

ASSEMBLING THE WATER PUMP 1. Install: Oil seal 1 New (into the oil/water pump housing)
NOTE:

2. Remove: Water pump seal 1

NOTE:

Before installing the oil seal, apply tap water or coolant onto its outer surface. Install the oil seal with a socket that matches its outside diameter.

Remove the water pump seal from the inside of the water pump housing.

2. Install: Water pump seal 1 New

ECA14080

CAUTION:

3. Remove: Oil seal 1 Bearing 2

NOTE:

Never lubricate the water pump seal surface with oil or grease.
NOTE:

Remove the bearing and oil seal from the inside of the water pump housing.

Install the water pump seal with the special tools. Before installing the water pump seal, apply Yamaha bond No.1215 (Three Bond No.1215) 2 to the water pump housing 3.

6-9

WATER PUMP
Mechanical seal installer 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 90890-04058 Bearing driver 40 mm YM-04058 Yamaha bond No. 1215 90890-85505 (Three Bond No.1215) Impeller shaft tilt limit 0.15 mm (0.006 in)

1. Straightedge 2. Impeller

A. Push down 4. Mechanical seal installer 5. Middle driven shaft bearing driver

3. Install: Rubber damper 1 New Rubber damper holder 2 New

NOTE:

Before installing the rubber damper, apply tap water or coolant onto its outer surface.

4. Measure: Impeller shaft tilt Out of specification Repeat steps (3) and (4).
ECA14090

CAUTION:

Make sure the rubber damper and rubber damper holder are flush with the impeller.

6-10

WATER PUMP

6-11

FUEL SYSTEM
FUEL TANK .................................................................................................... 7-1 REMOVING THE FUEL TANK.................................................................. 7-5 REMOVING THE FUEL PUMP ................................................................. 7-5 CHECKING THE FUEL COCK.................................................................. 7-5 CHECKING THE FUEL COCK OPERATION ........................................... 7-5 CHECKING THE FUEL PUMP BODY ...................................................... 7-5 CHECKING THE ROLLOVER VALVE ...................................................... 7-5 INSTALLING THE FUEL PUMP................................................................ 7-6 INSTALLING THE FUEL TANK HOSES................................................... 7-6 THROTTLE BODIES ....................................................................................... 7-7 CHECKING THE INJECTORS................................................................ 7-11 CHECKING THE THROTTLE BODIES................................................... 7-11 CHECKING THE FUEL PRESSURE ...................................................... 7-11 ADJUSTING THE THROTTLE POSITION SENSOR ............................. 7-11 INSTALLING THE INTAKE MANIFOLD ASSEMBLY ............................. 7-12

FUEL TANK
EAS26620

FUEL TANK
Removing the fuel tank

New 10 New
8 Nm (0.8 m kg, 5.8 ft Ib)

23 Nm (2.3 m kg, 17 ft Ib)

1 New

New

Order

R R

2 3 New

New 11 New

7 8
7 Nm (0.7 m kg, 5.1 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib)
R

Job/Parts to remove Rider seat/Relay cover

Qty

Remarks Refer to GENERAL CHASSIS on page 4-1.

1 2 3 4

Fuel tank bolt Right side panel Left side panel Fuel sender coupler

2 1 1 1 Disconnect.

NOTE:
5 Fuel cock hose 1 Before removing the fuel cock hose, turn the fuel cock to OFF.

6 7 8 9 10

Air vent hose Fuel tank overflow hose Fuel tank breather hose (fuel tank to hose joint) Fuel tank Fuel sender

1 1 1 1 1

7-1

FUEL TANK
Removing the fuel tank

New 10 New
8 Nm (0.8 m kg, 5.8 ft Ib)

23 Nm (2.3 m kg, 17 ft Ib)

1 New

New

Order 11 Fuel cock

R R

2 3 New

New 11 New

7 8
7 Nm (0.7 m kg, 5.1 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib)
R

Job/Parts to remove

Qty 1

Remarks

For installation, reverse the removal procedure.

7-2

FUEL TANK
Removing the sub-fuel tank
10 Nm (1.0 m kg, 7.2 ft Ib)
R

(3) (3) (3)

5 New 4 (6)
6 Nm (0.6 m kg, 4.3 ft Ib)

2 1
Order Job/Parts to remove Rider seat/Sub-fuel tank cover/Battery box 1 2 3 4 5 6 Fuel pump coupler Fuel hose Sub-fuel tank Fuel pump bracket Fuel pump gasket Fuel pump 1 1 1 1 1 1 For installation, reverse the removal procedure. Qty Remarks Refer to GENERAL CHASSIS on page 4-1. Disconnect. Disconnect.

7-3

FUEL TANK
Removing the rollover valve and canister

5 2

LT

6
7 Nm (0.7 m kg, 5.1 ft Ib)

7
Order Job/Parts to remove Fuel tank/Side panels Front cylinder covers 1 2 3 4 5 6 7 Canister purge hose Fuel tank breather hose (rollover valve to canister) Fuel tank breather hose Fuel tank breather hose (hose joint to rollover valve) Rollover valve Canister Canister breather hose 1 1 1 1 1 1 1 California only California only For installation, reverse the removal procedure. Qty Remarks Refer to FUEL TANK on page 7-1. Refer to ENGINE REMOVAL on page 5-1. California only California only Except for California

7-4

FUEL TANK
EAS3D81001

REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: Fuel cock hose
NOTE:

2. Check: Fuel cock strainer Obstruction clean. Blow out the jets with compressed air. Damage Replace.
EAS26660

Before removing the fuel cock hose, turn the fuel cock to OFF.
EAS3D81002

CHECKING THE FUEL COCK OPERATION

NOTE:

After installing the fuel cock, check its operation. 1. Check: Fuel cock operation Out of specification Replace the fuel cock. Fuel flows. Fuel cock is OK. Fuel does not flow. Replace the fuel cock. a. Check that the fuel cock lever is turned to ON. b. Place a container under the end of the fuel cock.

REMOVING THE FUEL PUMP 1. Remove: Fuel hose

EWA3D81001

WARNING

Cover fuel hose connections with a cloth when disconnecting them. Residual pressure in the fuel lines could cause fuel to spurt out when removing the hoses.
NOTE:

To remove the fuel hose from the fuel pump, slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown, press the two buttons 2 on the sides of the connector, and then remove the hose. Remove the fuel hose manually without using any tools. Before removing the hose, place a few rags in the area under where it will be removed.

EAS26670

2. Remove: Fuel pump

ECA3D81001

CHECKING THE FUEL PUMP BODY 1. Check: Fuel pump body Obstruction Clean. Cracks/damage Replace the fuel pump assembly.
EAS3D81004

CAUTION:

Do not drop the fuel pump or give it a strong shock.

EAS26650

CHECKING THE ROLLOVER VALVE 1. Check: Rollover valve 1 Damage/faulty Replace.

NOTE:

CHECKING THE FUEL COCK 1. Check: Fuel cock Cracks/damage/wear Replace.

Check that air flows smoothly only in the direction of the arrow shown in the illustration. The rollover valve must be in an upright position when checking the airflow.

7-5

FUEL TANK
To install the fuel hose onto the fuel pump, slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown.

EAS3D81007

INSTALLING THE FUEL PUMP 1. Install: Fuel pump Fuel pump bolt 4 Nm (0.4 mkg, 2.9 ftlb)
EAS3D81040

NOTE:

Do not damage the installation surfaces of the sub-fuel tank when installing the fuel pump. Always use a new fuel pump gasket. Install the fuel pump as shown in the illustration. Align the projection a on the fuel pump with the slot in the fuel pump bracket and the indentation b in the sub-fuel tank. Tighten the fuel pump bolts in the proper tightening sequence as shown.

INSTALLING THE FUEL TANK HOSES 1. Install: Fuel tank breather hose (fuel tank to hose joint) 1 Fuel tank overflow hose 2
NOTE:

2. Install: Fuel hose

ECA3D81002

CAUTION:

When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position, otherwise the fuel hose will not be properly installed.
NOTE:

Install the fuel hose securely onto the fuel pump until a distinct click is heard.

T.

FWD
2

Install the fuel tank overflow hose and fuel tank breather hose (fuel tank to hose joint) as shown in the illustration, making sure that they are not pinched by the fuel tank 3.

b
3

5 1

2 1

a
4 6

7-6

THROTTLE BODIES
EAS26970

THROTTLE BODIES
Removing the throttle body and ISC (idle speed control) unit

3 New 7 8 6 9
LS

10

5 5

New

10 Nm (1.0 m kg, 7.2 ft Ib)

Qty Remarks Refer to GENERAL CHASSIS on page 4-1. Refer to FUEL TANK on page 7-1. 1 1 1 1 2 1 Disconnect. Disconnect.
ECA3D81003

Order

Job/Parts to remove Rider seat/Air filter case Fuel tank

1 2 3 4 5 6

Throttle position sensor coupler Canister purge hose Front cylinder intake air pressure sensor hose Rear cylinder intake air pressure sensor hose Throttle cable ISC (idle speed control) unit coupler

Disconnect. California only Disconnect.

CAUTION:
7 Throttle body 1 The throttle body should not be disassembled.

8 9

Gasket ISC (idle speed control) unit

1 1

7-7

THROTTLE BODIES
Removing the throttle body and ISC (idle speed control) unit

3 New 7 8 6 9
LS

10

5 5

New

10 Nm (1.0 m kg, 7.2 ft Ib)

Qty 1 For installation, reverse the removal procedure. Remarks

Order 10

Job/Parts to remove Throttle position sensor

7-8

THROTTLE BODIES
Removing the intake manifold assembly
10 Nm (1.0 m kg, 7.2 ft Ib)
T

6 1

7 Nm (0.7 m kg, 5.1 ft Ib)

5 4 3

4 Nm (0.4 m kg, 2.9 ft Ib)

8 10
R

9 7
4 Nm (0.4 m kg, 2.9 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib)
R

11
Order Job/Parts to remove Left side cover Front cylinder covers Front cylinder thermostat inlet hose/Rear cylinder thermostat inlet hose Throttle body 1 2 3 4 5 6 7 8 9 10 11 Left side cover bracket Ignition coil bracket bolt Front cylinder resonator hose Rear cylinder resonator hose Resonator hose joint Fuel hose Sub-wire harness coupler Intake manifold joint clamp screw Rear cylinder intake manifold joint Intake manifold assembly Front cylinder intake manifold joint 1 2 1 1 1 1 2 2 1 1 1 Qty

10 Nm (1.0 m kg, 7.2 ft Ib)

Remarks

Refer to GENERAL CHASSIS on page 4-1. Refer to ENGINE REMOVAL on page 5-1. Refer to THERMOSTAT on page 6-4. Refer to THROTTLE BODIES on page 7-7.

Disconnect. Disconnect. Loosen.

For installation, reverse the removal procedure.

7-9

THROTTLE BODIES
Disassembling the intake manifold
10 Nm (1.0 m kg, 7.2 ft Ib)
R

2 (4) 4 1

New New 4

New

New

6
Order 1 2 3 4 5 6 Job/Parts to remove Front cylinder injector coupler Rear cylinder injector coupler Sub-wire harness Injector Fuel pipe Intake manifold Qty 1 1 1 2 1 1 For assembly, reverse the disassembly procedure. Disconnect. Disconnect. Remarks

7-10

THROTTLE BODIES
EAS26980

CHECKING THE INJECTORS 1. Check: Injectors Damage Replace.

EAS26990

CHECKING THE THROTTLE BODIES 1. Check: Throttle bodies Cracks/damage Replace the throttle bodies as a set. 2. Check: Fuel passages Obstructions Clean. a. Wash the throttle bodies in a petroleumbased solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages with compressed air.
EAS3D81005

Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter 90890-03176 YM-03176

2 3 4
e. Start the engine. f. Measure the fuel pressure. Fuel pressure 324 kPa (46.1 psi) (3.24 kg/cm) Faulty Replace the fuel pump.

EAS27030

CHECKING THE FUEL PRESSURE 1. Check: Fuel pressure a. Remove the sub-fuel tank cover. Refer to GENERAL CHASSIS on page 4-1. b. Disconnect the fuel hose 1 from the fuel pump.
EWA3D81001

ADJUSTING THE THROTTLE POSITION SENSOR

NOTE:

Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: Throttle position sensor Refer to CHECKING THE THROTTLE POSITION SENSOR on page 8-89. 2. Adjust: Throttle position sensor angle a. Connect the throttle position sensor coupler to the throttle position sensor. b. Connect the digital circuit tester to the throttle position sensor. Positive tester probe yellow 1 Negative tester probe black/blue 2 Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927

WARNING

Cover fuel hose connections with a cloth when disconnecting them. Residual pressure in the fuel lines could cause fuel to spurt out when removing the hoses.

1
c. Connect the fuel pressure adapter 3 between the fuel hose 1 and fuel pump 2. d. Connect the pressure gauge 4 to the fuel pressure adapter 3.

7-11

THROTTLE BODIES
c. Turn the main switch to ON. d. Measure the throttle position sensor output voltage. e. Adjust the throttle position sensor angle so that the output voltage is within the specified range. Output voltage (at idle) 0.630.73 V f. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws 3.
NOTE:

Make sure that the projection b on the rear cylinder intake manifold joint contacts the projection c on the intake manifold assembly.

2 c b

1 3

2 3

c. Install the intake manifold assembly. Rear cylinder intake manifold joint bolt 10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

EAS3D81006

Lubricate the rear cylinder intake manifold joint and rear cylinder head mating surfaces with engine oil.

T.

INSTALLING THE INTAKE MANIFOLD ASSEMBLY 1. Install: Intake manifold assembly

a. Install the front cylinder intake manifold joint 1 to the front cylinder head. Front cylinder intake manifold joint bolt 10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

Install the front cylinder intake manifold joint with its projection a facing up as shown in the illustration.

b. Install the rear cylinder intake manifold joint 2 to the intake manifold assembly.

T.

7-12

THROTTLE BODIES

7-13

ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 8-1 CIRCUIT DIAGRAM .................................................................................. 8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION....................... 8-3 TROUBLESHOOTING .............................................................................. 8-4 ELECTRIC STARTING SYSTEM .................................................................... 8-7 CIRCUIT DIAGRAM .................................................................................. 8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION.......................... 8-9 TROUBLESHOOTING ............................................................................ 8-11 CHARGING SYSTEM ................................................................................... 8-13 CIRCUIT DIAGRAM ................................................................................ 8-13 TROUBLESHOOTING ............................................................................ 8-15 LIGHTING SYSTEM ...................................................................................... 8-17 CIRCUIT DIAGRAM ................................................................................ 8-17 TROUBLESHOOTING ............................................................................ 8-19 SIGNALING SYSTEM ................................................................................... 8-21 CIRCUIT DIAGRAM ................................................................................ 8-21 TROUBLESHOOTING ............................................................................ 8-23 COOLING SYSTEM ...................................................................................... 8-27 CIRCUIT DIAGRAM ................................................................................ 8-27 TROUBLESHOOTING ............................................................................ 8-29 FUEL INJECTION SYSTEM ......................................................................... 8-31 CIRCUIT DIAGRAM ................................................................................ 8-31 ECU SELF-DIAGNOSTIC FUNCTION.................................................... 8-33 SELF-DIAGNOSTIC FUNCTION TABLE................................................ 8-34 TROUBLESHOOTING METHOD............................................................ 8-36 DIAGNOSTIC MODE .............................................................................. 8-37 TROUBLESHOOTING DETAILS ............................................................ 8-43 FUEL PUMP SYSTEM .................................................................................. 8-63 CIRCUIT DIAGRAM ................................................................................ 8-63 TROUBLESHOOTING ............................................................................ 8-65

ELECTRICAL COMPONENTS ..................................................................... 8-67 CHECKING THE SWITCHES ................................................................. 8-71 CHECKING THE BULBS AND BULB SOCKETS ................................... 8-74 CHECKING THE FUSES ........................................................................ 8-75 CHECKING AND CHARGING THE BATTERY....................................... 8-75 CHECKING THE RELAYS ...................................................................... 8-79 CHECKING THE TURN SIGNAL RELAY ............................................... 8-80 CHECKING THE DIODES ...................................................................... 8-81 CHECKING THE IGNITION SPARK GAP .............................................. 8-82 CHECKING THE SPARK PLUG CAPS .................................................. 8-83 CHECKING THE IGNITION COILS ........................................................ 8-83 CHECKING THE CRANKSHAFT POSITION SENSOR ......................... 8-84 CHECKING THE LEAN ANGLE SENSOR ............................................. 8-84 CHECKING THE STARTER MOTOR OPERATION............................... 8-85 CHECKING THE STATOR COIL ............................................................ 8-85 CHECKING THE RECTIFIER/REGULATOR.......................................... 8-85 CHECKING THE HORN.......................................................................... 8-86 CHECKING THE OIL LEVEL SWITCH ................................................... 8-86 CHECKING THE FUEL SENDER ........................................................... 8-87 CHECKING THE FUEL LEVEL WARNING LIGHT................................. 8-87 CHECKING THE OIL LEVEL WARNING LIGHT .................................... 8-88 CHECKING THE SPEED SENSOR........................................................ 8-88 CHECKING THE RADIATOR FAN MOTOR ........................................... 8-88 CHECKING THE COOLANT TEMPERATURE SENSOR ...................... 8-88 CHECKING THE THROTTLE POSITION SENSOR............................... 8-89 CHECKING THE INTAKE AIR PRESSURE SENSORS......................... 8-89 CHECKING THE AIR TEMPERATURE SENSOR.................................. 8-90

L/W

EAS27110

EAS27090

15
BR A B C B/R L/W W/G R/B R/G Br/L R/B P/L G W W G Ch Y L Dg B Ch Dg B L/R Y V/G R/Y W/L P R/Y Y Gy W W Gy

12 13 14
Sb/W L/W L R/L L/R L/G L/Y Sb B/Y L/W R WIRE HARNESS SUB W REHARNESS SUB-W REHARNESS TA L/ BRAKE L GHT W RE HARNESS WIRE HARNESS WIRE HARNESS

L Sb W

LWR

B/W B W B W

B/W B/W B/W

B W B/W B/W B/W B W B/W Sb L/R R/L LG LY

B/R

(GRAY) L/W B/Y Sb R/L O Gy R LG Gy/W B3 B3 G G/Y G Y Y/B Br W P YG GW L P W L/R yB LB R/L R W R/B B/Br P/L B L R G B/Y Y/L Y B /L W/G L/W W Y Gy1

(BLACK)

CIRCUIT DIAGRAM

B/R

2 4
B R/G B B B (BLACK) Gy R Gy/R LG (BLACK) B B/R Sb R

17 18
B B RL B (DARK GREEN) BR O O R/W L/B Gy Gy

B/R

IGNITION SYSTEM

16 28

30

3 29
W/Y

B/R

30

Gy R BL B/W B/L L (BLACK) L L/W P/W P B/L Br W G/W (BLACK) Br/W W L R Y V /G Y RY P L Y B/L

B/L B Gy

20
L W/Y P O/R

19
B/L Y L

B/L L W/Y

R W

7
R

5
B B W RW RW B/LP/W L (BLACK)

21 27 31 22 23 26
RB Br W B/L Y/L B/L P L B/L P/W L

B/L Y L

R/G P/L W/G Br L

R G A V/G P/L A P W/G A W L B /L A Y VG P W/L Y

Br

Br L

ON OFF R/Y R/Y R/Y A

6 10
R/W R/W W (BLACK) B/L P L

L/Y

L/Y

8 9

L/B

L/B

Br

R/B R/Y A R/B

L/Y L/B

25
(BLACK) GW Y/G BY G Gy Y/B Gy B Gy/W B/L L Y/G B/L G/W B L (DARK GREEN) GY R/L L/R

11 24
L YG B/L

W G

Br/W

32
G B G G

(DARK GRAY) W B W W W Gy

8-1
B/Br B3 B3 Br Br R/Y RY Br/W W Y/R B Br P/W P B L/W Br GL Y/B Y/B Y/R Br/W B B/R R/W G/L W Gy B RW

33
Gy B Gy Gy W

( GRAY)

W B W

75

Br

74 34 35
B/L Gy/W

Br

Br

73

Br

R/W

72

R/Y

Br W R/W

48

Br W

61 63
RESET

49

47

B Gy B B W L (BLACK)

36 37 46
R/W Y/L Gy YR Sb W

71 64 50
GL L/Y B/Y B L/Y Y Dg Ch B /W Y L/Y B Br/W Ch Dg (BLUE) L/Y BY G Gy B Y YR G/L (BLACK) Y G BY P G R/Y Y/R (BLUE) Y/G BY B

R/W

G/Y

Br

Y P B P/W B B/Y Y G

P W P/B B Y/G B/Y B W

62 51 52

65 53
(L) N (R)

66

GY

Br/W

70

Gy/W R/W Gy B B/L

38 54
B G (BLACK) (BLACK) Ch Dg B B W (BLACK) Y Ch Dg (BLACK) G W G B

L/G

R W B/R

B/R R W

Br L W

L/W Br

(BLACK)

Br

44 45
W (BLACK)

G RG W Y/G P/W PB

Br

39 40 41
B

(BLACK)

Y L C Ch L G/L Y G Br G L/B B B LR B GL Y B Dg L

42
Ch C Dg

Y L

YLR

LR

BW

69 60

68

67

58
G L B GRAY)

57
L B (BLACK)

Ch Ch

Dg Dg

43 56 59
B B B L Ch B (GRAY) L Dg B (BLACK) B Ch B (GRAY) B Ch B (GRAY)

(BLACK)

(BLACK)

Y L/R

B B

55
Dg B (BLACK)

Y/L W R G G B Y/G (BLACK) RG W YL Y/G B G Dg B (BLACK) (BLACK)

Y Dg R W Sb Ch

P/W P B L /G

B C

Dg Y Ch Sb W R W

P/B P W L/G

IGNITION SYSTEM

IGNITION SYSTEM
3. Main fuse 5. Main switch 6. Battery 12.Relay unit 16.Neutral switch 18.Sidestand switch 20.Crankshaft position sensor 24.Lean angle sensor 27.ECU (engine control unit) 28.Rear cylinder ignition coil 29.Front cylinder ignition coil 30.Spark plug 65.Engine stop switch 73.Ignition fuse

8-2

IGNITION SYSTEM
EAS3D81009

ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to OFF, thereby preventing the spark plugs from producing a spark. However, the engine continues to run under the following conditions: The transmission is in gear (the neutral switch is open) and the sidestand is up (the sidestand switch is closed). The transmission is in neutral (the neutral switch is closed) and the sidestand is down (the sidestand switch is open).

2 1

4 5 10 11 9 7 8 6

1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. ECU (engine control unit) 9. Sidestand switch 10. Relay unit (diode) 11. Neutral switch

8-3

IGNITION SYSTEM
EAS27140

TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark).
NOTE:

Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Fuel tank 4. Battery box 5. Headlight lens unit 1. Check the fuses. (Main and ignition) Refer to CHECKING THE FUSES on page 8-75. OK 2. Check the battery. Refer to CHECKING AND CHARGING THE BATTERY on page 8-75. OK 3. Check the spark plugs. Refer to CHECKING THE SPARK PLUGS on page 3-9. OK 4. Check the ignition spark gap. Refer to CHECKING THE IGNITION SPARK GAP on page 8-82. NG 5. Check the spark plug caps. Refer to CHECKING THE SPARK PLUG CAPS on page 8-83. OK 6. Check the ignition coils. Refer to CHECKING THE IGNITION COILS on page 8-83. OK 7. Check the crankshaft position sensor. Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8-84. OK NG Replace the crankshaft position sensor/stator assembly. NG Replace the ignition coil(s). NG Replace the spark plug cap(s). OK Ignition system is OK. NG Regap or replace the spark plug(s). NG Clean the battery terminals. Recharge or replace the battery. NG Replace the fuse(s).

8-4

IGNITION SYSTEM
8. Check the main switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 9. Check the engine stop switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 10.Check the neutral switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 11.Check the sidestand switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 12.Check the relay unit (diode). Refer to CHECKING THE DIODES on page 8-81. OK 13.Check the lean angle sensor. Refer to CHECKING THE LEAN ANGLE SENSOR on page 8-84. OK 14.Check the entire ignition systems wiring. Refer to CIRCUIT DIAGRAM on page 8-1. OK Replace the ECU. NG Properly connect or repair the ignition systems wiring. NG Replace the lean angle sensor. NG Replace the relay unit. NG Replace the sidestand switch. NG Replace the neutral switch. NG Replace the right handlebar switch. NG Replace the main switch.

8-5

IGNITION SYSTEM

8-6

ELECTRIC STARTING SYSTEM

EAS27160

ELECTRIC STARTING SYSTEM

EAS27170

CIRCUIT DIAGRAM
L/W

15
L/W

B/R B/R

12 1
B/W B/W B/W B/W B/W B/W W W W B/W B/W B/W

Sb/W

L/W R

13 14
Sb/W L/W L R/L L/R L/G L/Y Sb B/Y L/W R

B/W B/W B/W (GRAY)

B/R

(BLACK)

B/R

L/W B/Y B

Sb

L /Y

L/ R R/L

L/G

Sb R/L L/G

4
R B/R R R/G B

Sb

17
B B B

18
B B L/G (BLACK) (BLACK)

16
R

3
B/R Gy

R/L B (DARK GREEN)

Gy R R

B/L

Gy

20
B/L

L W/Y B/L

P O/R B/W

19

B/L L W/Y

7 6
B B B Br L/Y L/B B B B R R

R W L L Y B/L

R Br

R Br/L

5
ON OFF

21 22 23

(BLACK) L

B/L Y L

L/Y L/B

L/Y L/B

R/W R/W

B/LP/W L (BLACK)

B/L P /W L B/L Br/W

10
R/W R/W W

B/L P

B/L P L

26
Br/W B/L

(BLACK)

11
R Br/W L Y/G B/L

25
B/L G/W

(BLACK)

24

L Y/G B/L

G/W B/L (DARK GREEN)

75
Br L

74
Br Br

73
Br R/W

72
R Br/W R/W B /W L R/W G/Y L G/Y Br Y P/B P/W B B/Y Y/G P/W P/B B Y/G B/Y B/W R/Y Br R/Y R/Y

Br

71 70
R/W B/R B B Br L/W (BLACK) Y Y Br (BLACK)

61 62 63

P/W P/B

B/R R/W

G/L L/W Br Y/B G/L Y/B

49

Br/W

Br

48
Y/R Br/W B

W Y/R B

64
RESET

65

66 50
B L/ Y Y Dg Ch B /W (BLUE) Y L/Y B Br/W Ch Dg (BLUE) B/Y P G R/Y Y/R

G/L

L/Y

B/Y

Br/W

Y/R

B/R R/W L/W Br

51
L/Y B/Y

53
52
(L) N (R)

Br

Y /G B/Y

G Gy B/Y Y/R G/L

(BLACK)
Y G

Ch Dg

Y L C C L B L (BLACK) B B/W (BLACK) B L Y B B B C B Y L/R B B L B B L/R Y L

Dg L
Y L/R L /R G /L Y G

69

68

67

60
L/B B B G/L Y

58
G B

59
B B

Ch L B (GRAY) L Ch B (GRAY) B

8-7

ELECTRIC STARTING SYSTEM

3. Main fuse 5. Main switch 6. Battery 8. Starter relay 9. Starter motor 10.Diode 1 12.Relay unit 13.Starting circuit cut-off relay 15.Diode 2 16.Neutral switch 18.Sidestand switch 52.Clutch switch 65.Engine stop switch 66.Start switch 73.Ignition fuse

8-8

ELECTRIC STARTING SYSTEM

EAS27180

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to and the main switch is set to ON (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met, the starting circuit cut-off relay is closed and the engine can be started by pressing the start switch.

15

13 1 2 12 3 4 5 6 7 8 8 9 b 8 10 a 11 14

8-9

ELECTRIC STARTING SYSTEM

a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Diode 2 7. Relay unit (starting circuit cut-off relay) 8. Relay unit (diode) 9. Clutch switch 10. Sidestand switch 11. Neutral switch 12. Diode 1 13. Starter relay 14. Start switch 15. Starter motor

8-10

ELECTRIC STARTING SYSTEM

EAS27190

TROUBLESHOOTING The starter motor fails to turn.

NOTE:

Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Fuel tank 4. Headlight lens unit 1. Check the fuses. (Main and ignition) Refer to CHECKING THE FUSES on page 8-75. OK 2. Check the battery. Refer to CHECKING AND CHARGING THE BATTERY on page 8-75. OK 3. Check the starter motor operation. Refer to CHECKING THE STARTER MOTOR OPERATION on page 8-85. NG 4. Check the starter motor. Refer to CHECKING THE STARTER MOTOR on page 5-64. OK 5. Check the relay unit (starting circuit cut-off relay). Refer to CHECKING THE RELAYS on page 8-79. OK 6. Check the relay unit (diode). Refer to CHECKING THE DIODES on page 8-81. OK 7. Check the diode 1. Refer to CHECKING THE DIODES on page 8-81. OK NG Replace the diode 1. NG Replace the relay unit. NG Replace the relay unit. NG Repair or replace the starter motor. OK The starter motor is OK. Perform the electric starting system troubleshooting, starting with step 5. NG Clean the battery terminals. Recharge or replace the battery. NG Replace the fuse(s).

8-11

ELECTRIC STARTING SYSTEM

8. Check the diode 2. Refer to CHECKING THE DIODES on page 8-81. OK 9. Check the starter relay. Refer to CHECKING THE RELAYS on page 8-79. OK 10.Check the main switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 11.Check the engine stop switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 12.Check the neutral switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 13.Check the sidestand switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 14.Check the clutch switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 15.Check the start switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 16.Check the entire starting systems wiring. Refer to CIRCUIT DIAGRAM on page 8-7. OK The starting system circuit is OK. NG Properly connect or repair the starting systems wiring. NG Replace the right handlebar switch. NG Replace the clutch switch. NG Replace the sidestand switch. NG Replace the neutral switch. NG Replace the right handlebar switch. NG Replace the main switch. NG Replace the starter relay. NG Replace the diode 2.

8-12

CHARGING SYSTEM
EAS27200

CHARGING SYSTEM
EAS27210

CIRCUIT DIAGRAM
L/W

15
L/W

B/R B/R

12 1
B/W B/W B/W B/W B/W B/W W W W B/W B/W B/W

Sb/W

L/W R

13 14
Sb/W L/W L R/L L/G L/Y Sb B/Y L/W

B/W B/W B/W (GRAY)

B/R

(BLACK)

B/R

L/W B/Y B

Sb

L/Y

L/R R/L

L/G

Sb R/L L/G

4
R B/R R R/G B

Sb

17
B B B

18
B B L/ G (BLACK) (BLACK)

16
R

3
B/R Gy

R/L B (DARK GREEN)

Gy R R

B/L

Gy

20
B/L

L W/Y B/L

P OR B/W

19

B/L L W/Y

7 6
B B B Br L/Y LB B B B R R

R W L L Y B/L

R Br

R Br/L

5
ON OFF

21 22 23

(BLACK) L

B/L Y L

L/Y L/B

L/Y L/B

R/W R/W

B/LP/W L (BLACK)

B/L P/W L B /L B /W

10
R/W R/W W

B/L P

B/L P L

26
Br/W B/L

(BLACK)

11
R Br/W L Y/G B/L

25
B/L G/W

(BLACK)

24

L Y/G B/L

G/W B/L (DARK GREEN)

75
Br L

74
Br Br

73
Br R/W

72
R Br/W R/W Br/W L R/W G/Y L G/Y Br Y P B P/W B B/Y Y/G P/W P/B B Y/G B/Y B W RY Br R/Y R/Y

71 70
R/W B/R B B Br L/W (BLACK) Y Y Br (BLACK)

61 62 63

P/W P/B

B/R R/W

G/L L/W Br Y/B

49
G/L Y/B

Br/W

Br

W Y/R B Br/W

64
RESET

65

66 50
B L/ Y Y Dg Ch Br/W (BLUE) Y LY B Br/W Ch Dg (BLUE) B/Y P G R/Y Y /R

G/L

L/Y

B/Y

Br/W

B/R R W L W Br

51
L/Y B/Y

53 52
(L) N (R)

Br

Y/G B /Y

G Gy B/Y Y /R G/L

(BLACK) Y G Ch

Y L C C L B L (BLACK) B B/W (BLACK) B L Y B B B C B Y L/R B B L B B L/R Y L Ch L Y L/R L/R G/L Y G

69

68

67

58
G Y B B

60
L/B B B G/L

59
B B

Ch L B (GRAY) L Ch B (GRAY)

8-13

CHARGING SYSTEM
1. 2. 3. 6. AC magneto Rectifier/regulator Main fuse Battery

8-14

CHARGING SYSTEM
EAS27230

TROUBLESHOOTING The battery is not being charged.

NOTE:

Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Rectifier/regulator cover 1. Check the fuse. (Main) Refer to CHECKING THE FUSES on page 8-75. OK 2. Check the battery. Refer to CHECKING AND CHARGING THE BATTERY on page 8-75. OK 3. Check the stator coil. Refer to CHECKING THE STATOR COIL on page 8-85. OK 4. Check the rectifier/regulator. Refer to CHECKING THE RECTIFIER/REGULATOR on page 8-85. OK 5. Check the entire charging systems wiring. Refer to CIRCUIT DIAGRAM on page 8-13. OK The charging system circuit is OK. NG Properly connect or repair the charging systems wiring. NG Replace the rectifier/regulator. NG Replace the crankshaft position sensor/stator assembly. NG Clean the battery terminals. Recharge or replace the battery. NG Replace the fuse.

8-15

CHARGING SYSTEM

8-16

L/W

EAS27250

EAS27240

15
B/R A B C B/R L/W W/G R/B R G Br L R/B P/L G W W G Ch Y L Dg B Ch Dg B LR Y V/G R/Y W/L P R/Y Y Gy W W Gy

12 13 14
Sb W L/W L R/L L/R L/G L Y Sb B/Y L/W R W RE HARNESS SUB W REHARNESS A L/ BRAKE L GHT W RE HARNESS SUB-W REHARNESS WIRE HARNESS WIRE HARNESS

L Sb W L/W R

B/W B W B/W

B/W B/W B/W

B/W B W BW BW B/W B W Sb L/R R/ L LG L/Y

BR

(GRAY) L/W BY Sb R/L O Gy R LG Gy/W B3 B3 G G/Y G Y Y/B Br W P Y/G G W L P/W L R yB LB R L R W R/B B/Br P/L B/L R/G B/Y Y/L Y Br/L W/G L/W W/Y Gy1

(BLACK)

CIRCUIT DIAGRAM

BR

2 4
B R/G B B B (BLACK) Gy R Gy/R LG (BLACK) B B/R Sb R

17 18
B B RL B (DARK GREEN) B/R O O R/W L/B Gy Gy

B/R

LIGHTING SYSTEM

16 28

30

3 29
W/Y

BR

30

Gy R B/L B/W B/L L (BLACK) L L/W P/W P B/L B /W G/W (BLACK) Br W WL RY VG Y RY P L Y B/L

B/L B Gy

20
L W/Y P O/R

19
BL Y L

B/L L W/Y

R W

7
R

5
B B W RW RW B/LP/W L (BLACK)

21 27 31 22 23 26
R/B Br W B/L Y/L BL P L BL P/W L

BL Y L

RG P/L W/G B /L

R G A V/G PL A P W/G A W/L B /L A Y VG P W/L Y

Br

Br/L

ON OFF RY R/Y RY A

6 10
RW RW W (BLACK) B/L P L

L/Y

L/Y

8 9

L/B

L/B

Br

RB R/Y A R/B

L/Y L/B

25
(BLACK) GW Y/G B/Y G Gy Y/B Gy/B Gy/W B/L L Y/G B/L G/W B L (DARK GREEN) GY RL L/R

11 24
L Y/G BL

W G

Br/W

32
G B G G

(DARK GRAY) W B W W W Gy

8-17
B Br B3 B3 Br Br R/Y RY Br W W Y/R B Br P/W P B LW Br G/L Y/B YB Y/R Br/W B BR R/W GL W Gy/B R/W

33
Gy B Gy Gy W

( GRAY)

W B W

75

Br

74 34 35
B/L Gy/W

Br

Br

73

Br

RW

72

R/Y

B /W R/W

48

Br W

61 63
RESET

49

47

B Gy B B W L (BLACK)

36 37 46
R/W Y/L Gy YR Sb/W

71 64 50
G/L LY B/Y B L/Y Y Dg Ch Br/W Y L/Y B Br/W Ch Dg (BLUE) L/Y B/Y G Gy B/Y Y/R GL (BLACK) Y G B/Y P G RY YR (BLUE) Y/G B/Y B

R/W

GY

Br

Y P/B P/W B B/Y Y/G

PW PB B Y G B Y B/W

62 51 52

65 53
(L) N (R)

66

G/Y

Br/W

70

Gy/W R/W Gy/B B/L

38 54
B G (BLACK) (BLACK) Ch Dg B B W (BLACK) Y Ch Dg (BLACK) G W G B

LG

R/W B/R

B/R R/W

Br L W

L/W Br

(BLACK)

Br

44 45
W (BLACK)

G R/G W Y/G P/W P/B

Br

39 40 41
B

(BLACK)

Y L

42
Ch L Dg L Y G Br G Y B Ch C Dg C

L G/L

Y L

Y L/R

L/R

BW

69 60
L/B B B L/R B GL

68

67

58
G L B (GRAY)

57
L B BLACK)

Ch Ch

Dg Dg

43 56 59
B B B L Ch B (GRAY) L Dg B (BLACK) B Ch B (GRAY) B Ch B (GRAY)

(BLACK)

(BLACK)

Y LR

B B

55
Dg B (BLACK)

Y/L W R/G G B Y/G (BLACK) R G W Y/L Y/G B G Dg B (BLACK) (BLACK)

Y Dg R/W Sb Ch

PWPB L/G

LIGHTING SYSTEM

B C B

Dg Y Ch b W R/W

P B P/W LG

LIGHTING SYSTEM
3. Main fuse 5. Main switch 6. Battery 27.ECU (engine control unit) 38.Multi-function meter 41.High beam indicator light 43.Meter light 49.Headlight relay 51.Dimmer switch 57.Front right turn signal light 58.Front left turn signal light 59.Headlight 60.Accessory light (OPTION) 67.License plate light 68.Tail/brake light 72.Headlight fuse 73.Ignition fuse 74.Signaling system fuse 75.Taillight fuse

8-18

LIGHTING SYSTEM
EAS27260

TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, position light, meter light and accessory light (OPTION).
NOTE:

Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Fuel tank 4. Headlight lens unit 1. Check the condition of each bulb and bulb socket. Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8-74. OK 2. Check the fuses. (Main, headlight, signaling system, ignition and taillight) Refer to CHECKING THE FUSES on page 8-75. OK 3. Check the battery. Refer to CHECKING AND CHARGING THE BATTERY on page 8-75. OK 4. Check the main switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 5. Check the dimmer switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 6. Check the headlight relay. Refer to CHECKING THE RELAYS on page 8-79. OK NG Replace the headlight relay. NG The dimmer switch is faulty. Replace the left handlebar switch. NG Replace the main switch. NG Clean the battery terminals. Recharge or replace the battery. NG Replace the fuse(s). NG Replace the bulb(s) and bulb socket(s).

8-19

LIGHTING SYSTEM
7. Check the entire lighting systems wiring. Refer to CIRCUIT DIAGRAM on page 8-17. OK Replace the ECU or meter assembly. NG Properly connect or repair the lighting systems wiring.

8-20

LW

EAS27280

EAS27270

15
B/R A B C B/R LW Gy W W Gy W G Ch Y L Dg B Ch Dg B LR Y G W W/G R B R/G Br/L R B P/L V/G R Y W/L P RY Y

12 13 14
Sb/W L/W L R L L/R L G L/Y Sb B/Y L/W R WIRE HARNESS SUB-W REHARNESS TA L/ BRAKE L GHT W RE HARNESS SUB-W REHARNESS W RE HARNESS WIRE HARNESS

Sb/W

L/W R

B/W B/W B/W

BW BW BW

B/W B/W B/ W B/W B/W B/W Sb LR R/L L/G L/Y

B/R

(GRAY) L/W B/Y Sb R/L L/G O Gy/R Gy W B3 B3 G GY G/Y Y B B /W P Y/G G/W Gy/B L/B L R/L R/W R B B Br P L B/L R/G B Y Y L Y Br L W G L/W W/Y Gy1 P/W L/R

(BLACK)

CIRCUIT DIAGRAM

B/R

2 4
B R/G B B B (BLACK) Gy/R Gy R L/G (BLACK) B B/R Sb R

17 18
B B R/L B (DARK GREEN) B/R O O R/W L/B Gy Gy

B/R

16 28

30

3 29
W/Y

SIGNALING SYSTEM

B/R

30

Gy R B/L B/W B/L L (BLACK) L LW PW P B/L B /W G/W (BLACK) Br W W/L R/Y V G Y R/Y P L Y BL

BL B Gy

20
L WY P O/R

19
B/L Y L

BL L WY

R W

7
R

5
B B W R/W R/W B LP/W L (BLACK)

21 27 31 22 23 26
R/B B /W B/L YL B/L P L B/L PW L

B/L Y L

RG PL WG Br/L R/G VG PL A P W G A W/L Br/L A Y

V/G P WL Y

Br

Br/L

ON OFF R/Y RY R/Y A

6 10
R W R/W W (BLACK) BL P L

LY

L/Y

8 9

LB

LB

Br

R/B RY A RB

LY LB

25
(BLACK) GW Y/G B/Y G Gy YB Gy/B Gy W B/L L Y/G B/L G W B/L (DARK GREEN) G/Y R/L L/R

11 24
L Y/G B/L

W G

Br W

32
G B G G

(DARK GRAY) W B W W W Gy

8-21
B/Br B3 B3 Br Br R/Y R/Y B /W W YR B Br P W P/B L/W Br G/L Y/B Y/ B Y/R Br W B B/R R/W G/L W Gy/B R/W

33
Gy B Gy Gy W

( GRAY)

W B W

75

Br

74 34 35
BL Gy W

Br

Br

73

Br

R/W

72

RY

B /W RW

48

/W

61 63
RESET

49

47

B Gy B B W L (BLACK)

36 37 46
R/W Y/L Gy Y/R Sb/W

71 64 50
G/L L/Y B/Y B LY Y Dg Ch Br/W Y LY B Br W Ch Dg (BLUE) L/Y B/Y G Gy B/Y Y/R G/L (BLACK) Y G B/Y P G R/Y Y/R (BLUE) YG B/Y B

R/W

G/Y

Br

Y P/B P/W B B/Y Y/G

P/W P B B Y G B Y B/W

62 51 52

65 53
(L) N (R)

66

G/Y

Br W

70

Gy W R W Gy/B B/L

38 54
B G (BLACK) (BLACK) Ch Dg B B W BLACK) Y Ch Dg (BLACK) G W G B

L/G

R/W B R

B/R R/W

Br L/W

L W Br

(BLACK)

Br

44 45
W (BLACK)

G R/G W Y /G PW P/B

Br

39 40 41
B

(BLACK)

L GL

Y L C C Y L Ch L Y G Br G L/B B B B L/R B G/L Y B Dg L Ch C Dg C

42 43 58
G L B (GRAY)

Y L/R

L/R

B/W

69 60

68

67

57
L B (BLACK)

Ch Ch

Dg Dg

(BLACK)

(BLACK)

Y L/R

B B

59
B

B L Ch B (GRAY)

56
L Dg B (BLACK) B Ch B (GRAY) B Ch B (GRAY)

55
Dg B (BLACK)

Y L W R/G G B Y/G (BLACK) R/G W Y/L Y/G B G Dg B (BLACK) (BLACK)

Y Dg R/W Sb Ch

P/W P/B LG

SIGNALING SYSTEM

B C B

Dg Y Ch Sb/W R/W

P/B P/W LG

SIGNALING SYSTEM
3. Main fuse 4. Backup fuse (odometer and clock) 5. Main switch 6. Battery 12.Relay unit 16.Neutral switch 19.Speed sensor 25.Coolant temperature sensor 27.ECU (engine control unit) 35.Fuel level warning light 36.Oil level warning light 37.Neutral indicator light 38.Multi-function meter 40.Coolant temperature warning light 42.Turn signal indicator light 44.Oil level switch 45.Fuel sender 47.Horn 48.Turn signal relay 53.Turn signal switch 54.Horn switch 55.Rear right turn signal light 56.Rear left turn signal light 57.Front right turn signal light 58.Front left turn signal light 62.Front brake light switch 68.Tail/brake light 70.Rear brake light switch 73.Ignition fuse 74.Signaling system fuse

8-22

SIGNALING SYSTEM
EAS27290

TROUBLESHOOTING Any of the following fail to light: turn signal light, brake light or an indicator light. The horn fails to sound. The speedometer fails to operate.
NOTE:

Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Fuel tank 4. Headlight lens unit 1. Check the fuses. (Main, signaling, ignition and backup) Refer to CHECKING THE FUSES on page 8-75. OK 2. Check the battery. Refer to CHECKING AND CHARGING THE BATTERY on page 8-75. OK 3. Check the main switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 4. Check the entire signaling systems wiring. Refer to CIRCUIT DIAGRAM on page 8-21. OK Check the condition of each of the signaling systems circuits. Refer to Checking the signaling system. Check the signaling system The horn fails to sound. 1. Check the horn switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 2. Check the horn. Refer to CHECKING THE HORN on page 8-86. OK NG Replace the horn. NG The horn switch is faulty. Replace the left handlebar switch. NG Properly connect or repair the signaling systems wiring. NG Replace the main switch. NG Clean the battery terminals. Recharge or replace the battery. NG Replace the fuse(s).

8-23

SIGNALING SYSTEM
3. Check the entire signaling systems wiring. Refer to CIRCUIT DIAGRAM on page 8-21. OK This circuit is OK. The brake light fails to come on. 1. Check the brake light bulb and socket. Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8-74. OK 2. Check the front brake light switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 3. Check the rear brake light switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 4. Check the entire signaling systems wiring. Refer to CIRCUIT DIAGRAM on page 8-21. OK This circuit is OK. The turn signal light, turn signal indicator light or both fail to blink. 1. Check the turn signal light bulbs and sockets. Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8-74. OK 2. Check the turn signal switch. Refer to CHECKING THE SWITCHES on page 8-71. OK NG The turn signal switch is faulty. Replace the left handlebar switch. NG Replace the turn signal light bulb(s), socket(s) or both. NG Properly connect or repair the signaling systems wiring. NG Replace the rear brake light switch. NG Replace the front brake light switch. NG Replace the brake light bulb, socket or both. NG Properly connect or repair the signaling systems wiring.

8-24

SIGNALING SYSTEM
3. Check the turn signal relay. Refer to CHECKING THE RELAYS on page 8-79. OK 4. Check the entire signaling systems wiring. Refer to CIRCUIT DIAGRAM on page 8-21. OK Replace the meter assembly. The neutral indicator light fails to come. 1. Check the neutral switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 2. Check the relay unit (diode). Refer to CHECKING THE DIODES on page 8-81. OK 3. Check the entire signaling systems wiring. Refer to CIRCUIT DIAGRAM on page 8-21. OK Replace the meter assembly. The oil level warning light fails to come. 1. Check the oil level switch. Refer to CHECKING THE OIL LEVEL SWITCH on page 8-86. OK 2. Check the entire signaling systems wiring. Refer to CIRCUIT DIAGRAM on page 8-21. OK Replace the meter assembly. NG Properly connect or repair the signaling systems wiring. NG Replace the oil level switch. NG Properly connect or repair the signaling systems wiring. NG Replace the relay unit. NG Replace the neutral switch. NG Properly connect or repair the signaling systems wiring. NG Replace the turn signal relay.

8-25

SIGNALING SYSTEM
The fuel level warning light fails to come. 1. Check the fuel sender. Refer to CHECKING THE FUEL SENDER on page 8-87. OK 2. Check the entire signaling systems wiring. Refer to CIRCUIT DIAGRAM on page 8-21. OK Replace the meter assembly. The coolant temperature warning light fails to come. 1. Check the coolant temperature sensor. Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8-88. OK 2. Check the entire signaling systems wiring. Refer to CIRCUIT DIAGRAM on page 8-21. OK Replace the ECU or meter assembly. The speedometer fails to operate. 1. Check the speed sensor. Refer to CHECKING THE SPEED SENSOR on page 8-88. OK 2. Check the entire signaling systems wiring. Refer to CIRCUIT DIAGRAM on page 8-21. OK Replace the ECU or meter assembly. NG Properly connect or repair the signaling systems wiring. NG Replace the speed sensor. NG Properly connect or repair the signaling systems wiring. NG Replace the coolant temperature sensor. NG Properly connect or repair the signaling systems wiring. NG Replace the fuel sender.

8-26

L/W

EAS27310

EAS27300

15
BR A B C B/R L/W W/G R/B R/G Br/L R/B P/L G W W G Ch Y L Dg B Ch Dg B L/R Y V/G R/Y W/L P R/Y Y Gy W W Gy

12 13 14
Sb/W L W L R/L L/R L/G L/Y Sb B/Y L/W R WIRE HARNESS SUB-W REHARNESS SUB-W REHARNESS WIRE HARNESS WIRE HARNESS TA L/ BRAKE L GHT W RE HARNESS

Sb W

LWR

B/W B W B W

B/W B/W B/W

B W B/W B/W B/W B W B/W Sb L/R R/L LG LY

B/ R

(GRAY) L/W B/Y Sb R/L O Gy R LG Gy/W B3 B3 G G/Y G Y Y/B Br W P YG GW L P W L/R yB LB R/L R W R/B B/Br P/L B L R G B/Y Y/L Y B /L W/G L/W W Y Gy1

(BLACK)

CIRCUIT DIAGRAM

B/R

2 4
B R/G B B B (BLACK) Gy R Gy/R LG (BLACK) B B/R Sb R

17 18
B B RL B (DARK GREEN) BR O O R/W L/B Gy Gy

B/R

COOLING SYSTEM

16 28

30

3 29
W/Y

B/R

30

Gy R BL BW B/L L (BLACK) L L/W P/W P B/L Br W GW (BLACK) Br/W W L R Y V /G Y RY P L Y B/L

B/L B Gy

20
L W/Y P O/R

19
B/L Y L

B/L L W/Y

R W

7
R

5
B B W RW RW B/LP/W L (BLACK)

21 27 31 22 23 26
RB Br W B L Y/L B/L P L B/L P/W L

B/L Y L

R/G P/L W/G Br L

R/G A V/G P/L A P W/G A W L B /L A Y VG P W/L Y

Br

Br L

ON OFF R/Y R/Y R/Y A

6 10
R/W R/W W (BLACK) B/L P L

L/Y

L/Y

8 9

L/B

L/B

Br

R/B R/Y A R/B

L/Y L/B

25
(BLACK) G/W Y/G BY G Gy Y/B Gy B Gy/W B/L L Y/G B/L G/W B L (DARK GREEN) G/Y R/L L/R

11 24
L YG B/L

W G

Br/W

32
G B G G

(DARK GRAY) W B W W W Gy

8-27
B/Br B3 B3 Br Br R/Y RY Br/W W Y/R B Br P/W P/B L/W Br GL Y/B Y/B Y/R Br/W B B/R R/W G/L W Gy B RW

33
Gy B Gy Gy W

( GRAY)

W B W

75

Br

74 34 35
B/L Gy/W

Br

Br

73

Br

R/W

72

R/Y

Br W R/W

48

Br W

61 63
RESET

49

47

B Gy B B W L (BLACK)

36 37 46
R/W Y/L Gy YR Sb W

71 64 50
GL L/Y B/Y B L/Y Y Dg Ch B /W Y L/Y B Br/W Ch Dg (BLUE) L/Y BY G Gy B Y YR G/L (BLACK) Y G BY P G R/Y Y/R (BLUE) Y/G BY B

R/W

G/Y

Br

Y P B P/W B B/Y Y G

P W P/B B Y/G B/Y B W

62 51 52

65 53
(L) N (R)

66

GY

Br/W

70

Gy/W R/W Gy B B/L

38 54
B G (BLACK) (BLACK) Ch Dg B B W (BLACK) Y Ch Dg (BLACK) G W G B

L/G

R W B/R

B/R R W

Br L W

L/W Br

(BLACK)

Br

44 45
W (BLACK)

G RG W Y/G P/W PB

Br

39 40 41
B

(BLACK)

L G/L

Y L CC Y L Ch L Y G Br G L/B B B LR B GL Y B L B (GRAY) Dg L Ch C Dg C

42 43 58
G L B (BLACK)

YLR

LR

BW

69 60

68

67

57

Ch Ch

Dg Dg

(BLACK)

(BLACK)

Y L/R

B B

59
B

B L Ch B (GRAY)

56
L Dg B (BLACK) B Ch B (GRAY) B Ch B (GRAY)

55
Dg B (BLACK)

Y /L W R G G B Y/G (BLACK)

Y Dg R W Sb Ch

P/W P B L /G

Dg B (BLACK)

R/G W Y L YG B G (BLACK)

Dg Y Ch Sb W R W

P/B P W L/G

COOLING SYSTEM

COOLING SYSTEM
3. Main fuse 5. Main switch 6. Battery 11.Radiator fan motor fuse 25.Coolant temperature sensor 27.ECU (engine control unit) 69.Radiator fan motor 71.Radiator fan motor relay 73.Ignition fuse

8-28

COOLING SYSTEM
EAS27320

TROUBLESHOOTING The radiator fan motor fails to turn.

NOTE:

Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Fuel tank 4. Headlight lens unit 1. Check the fuses. (Main, ignition and radiator fan motor) Refer to CHECKING THE FUSES on page 8-75. OK 2. Check the battery. Refer to CHECKING AND CHARGING THE BATTERY on page 8-75. OK 3. Check the main switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 4. Check the radiator fan motor. Refer to CHECKING THE RADIATOR FAN MOTOR on page 8-88. OK 5. Check the radiator fan motor relay. Refer to CHECKING THE RELAYS on page 8-79. OK 6. Check the coolant temperature sensor. Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8-88. OK 7. Check the entire cooling systems wiring. Refer to CIRCUIT DIAGRAM on page 8-27. OK Replace the ECU. NG Properly connect or repair the cooling systems wiring. NG Replace the coolant temperature sensor. NG Replace the radiator fan motor relay. NG Replace the radiator fan motor. NG Replace the main switch. NG Clean the battery terminals. Recharge or replace the battery. NG Replace the fuse(s).

8-29

COOLING SYSTEM

8-30

L/W

EAS27340

EAS27330

15
B/R A B C B/R L/W Gy W W Gy W G Ch Y L Dg B Ch Dg B LR Y G W W/G R/B R G Br L R/B P/L V G R/Y W/L P R/Y Y

12 13 14
Sb W L/W L R/L L R L/G L Y Sb B Y L/W R W RE HARNESS SUB-W REHARNESS SUB-W REHARNESS WIRE HARNESS WIRE HARNESS TA L/ BRAKE L GHT W RE HARNESS

Sb/W

L/W R

B/W B W B/W

B/W B/W B W

B/W B W BW BW B/W B W Sb L/R R/L L/G L/Y

BR

(GRAY) L/W BY Sb R/L O Gy R L/G Gy/W B3 B3 G G/Y G Y Y/B Br W P Y/G G W Gy B L/B L R L R/W R/B B/Br P/L B/L R/G B Y Y/L Y Br/L W/G L/W W/Y Gy1 P/W L R

(BLACK)

CIRCUIT DIAGRAM

BR

2 4
B R/G B B B (BLACK) Gy/R Gy/R LG (BLACK) B B/R Sb R

17 18
B B R/L B (DARK GREEN) B/R O O R/W L/B Gy Gy

BR

16 28

30

3 29
W/Y

BR

30

Gy R B/L B/W B/L L (BLACK) L L/W P/W P B/L Br W G/W (BLACK) Br W WL RY VG Y RY P L Y B/L

B/L B Gy

20
L W/Y P O/R

19
BL Y L

B/L L W/Y

R W

FUEL INJECTION SYSTEM

7
R

5
B B W B/LP/W L (BLACK) R/W R/W

21 27 31 22 23 26
R/B B /W B/L Y/L BL P L BL P/W L

BL Y L

RG P/L W/G B /L

RG A VG PL A P W/G A W/L Br/L A Y VG P W/L Y

Br

Br/L

ON OFF RY RY RY A

6 10
RW RW W (BLACK) B/L P L

L/Y

L/Y

8 9

L/B

L/B

Br

RB RY A RB

L/Y L/B

25
(BLACK) G/W Y/G B/Y G Gy Y/B Gy/B Gy/W B/L L Y/G B/L G/W B L (DARK GREEN) GY RL L/R

11 24
L Y/G BL

W G

Br W

32
G B G G

(DARK GRAY) W B W W W Gy

33
Gy B Gy B/Br B3 B3 Gy W

8-31
Br Br R/Y RY Br W W Y/R B Br P/W P B LW Br G/L Y/B YB YR Br/W B BR R/W GL W Gy/B R/W

( GRAY)

W B W

75

Br

74 34 35
B/L Gy/W

Br

Br

73

Br

RW

72

RY

Br W R/W

48

Br W

61 63
RESET

49

47

B Gy B B W L (BLACK)

36 37 46
R/W Y/L Gy Y/R Sb/W

71 64 50
G/L LY B/Y B L/Y Y Dg Ch Br/W Y L/Y B Br/W Ch Dg (BLUE) L/Y B/Y G Gy B/Y Y/R GL (BLACK) Y G B/Y P G RY YR (BLUE) Y/G B/Y B

R/W

GY

Br

Y P/B P/W B B/Y Y/G

PW PB B Y G B Y B/W

62 51 52

65 53
(L) N (R)

66

G/Y

Br/W

70

Gy/W R/W Gy/B B/L

38 54
B G (BLACK) (BLACK) Ch Dg B B W (BLACK) Y Ch Dg (BLACK) G W G B

LG

R/W B/R

B/R R/W

Br L W

L W Br

(BLACK)

Br

44 45
W (BLACK)

G R/G W Y/G P/W P/B

Br

39 40 41
B

(BLACK)

L G/L

Y L C C Y L Ch L Y G Br G L/B B B L/R B G/L Y B L B (GRAY) Dg L Ch Dg C

42 43 58
G L B (BLACK)

Y L/R

L/R

BW

69 60

68

67

57

Ch Ch

Dg Dg

(BLACK)

(BLACK)

Y LR

B B

59
B

B L Ch B (GRAY)

56
L Dg B (BLACK) B Ch B (GRAY) B Ch B (GRAY)

55
Dg B (BLACK)

Y/L W R/G G B Y/G (BLACK) R G W Y/L Y/G B G Dg B (BLACK) (BLACK)

Y Dg R/W Sb Ch

PWPB LG

FUEL INJECTION SYSTEM

B C B

Dg Y Ch b W R/W

P B P /W LG

FUEL INJECTION SYSTEM

3. Main fuse 5. Main switch 6. Battery 7. Fuel injection system fuse 12.Relay unit 14.Fuel pump relay 15.Diode 2 16.Neutral switch 17.Fuel pump 18.Sidestand switch 19.Speed sensor 20.Crankshaft position sensor 21.Throttle position sensor 22.Rear cylinder intake air pressure sensor 23.Front cylinder intake air pressure sensor 24.Lean angle sensor 25.Coolant temperature sensor 26.Air temperature sensor 27.ECU (engine control unit) 28.Rear cylinder ignition coil 29.Front cylinder ignition coil 30.Spark plug 31.ISC (idle speed control) unit 32.Front cylinder injector 33.Rear cylinder injector 38.Multi-function meter 39.Engine trouble warning light 46.O2 sensor 49.Headlight relay 63.Select switch 64.Reset switch 65.Engine stop switch 71.Radiator fan motor relay 73.Ignition fuse 74.Signaling system fuse

8-32

FUEL INJECTION SYSTEM

EAS27350

ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is stored in the memory of the ECU. To inform the rider that the fuel injection system is not functioning, the engine trouble warning light flashes when the start switch is being pushed to start the engine. If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appropriate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminating the engine trouble warning light. After the engine has been stopped, the lowest fault code number appears on the odometer/tripmeter/fuel reserve tripmeter/clock LCD. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is deleted. Engine trouble warning light indication and fuel injection system operation Warning light indication Flashing* ECU operation Warning provided when unable to start engine Fuel injection operation Operation stopped Operated with substitute characteristics in accordance with the description of the malfunction Vehicle operation Cannot be operated

Remains on

Malfunction detected

Can or cannot be operated depending on the fault code

* The warning light flashes when any one of the conditions listed below is present and the start switch is pushed: Lean angle sensor 12: Crankshaft position sensor 41: (open or short-circuit) 19: 30: Blue/black ECU lead (broken or disconnected) Lean angle sensor (latch up detected) 50: ECU internal malfunction (memory check error)

Checking the engine trouble warning light The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned to ON and it comes on while the start switch is being pushed. If the warning light does not come on under these conditions, the warning light (LED) may be defective.

8-33

FUEL INJECTION SYSTEM

a c

b d c

a. Main switch OFF b. Main switch ON c. Engine trouble warning light off

d. Engine trouble warning light on for 1.4 seconds

EAS27380

SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction. When an abnormal signal is received from a sensor, the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating, depending on the conditions. Self-Diagnostic Function table Fault code No. 12 Item Crankshaft position sensor Front cylinder intake air pressure sensor (open or short circuit) Front cylinder intake air pressure sensor (hose system) Throttle position sensor (open or short circuit) Blue/black ECU lead (broken or disconnected) Coolant temperature sensor Air temperature sensor (open or short circuit) O2 sensor Symptom No normal signals are received from the crankshaft position sensor. Front cylinder intake air pressure sensor: open or short circuit detected. Front cylinder intake air pressure sensor: hose system malfunction (clogged or detached hose). Throttle position sensor: open or short circuit detected. A break or disconnection of the blue/black lead of the ECU is detected. Able / unable to start Unable Able / unable to drive Unable

13

Able

Able

14

Able

Able

15

Able

Able

19 21 22 24

Unable

Unable Able Able Able

Coolant temperature sensor: open Able or short circuit detected. Air temperature sensor: open or short circuit detected. No normal signal is received from the O2 sensor. Able Able

8-34

FUEL INJECTION SYSTEM

Fault code No. 25 Able / unable to start Able Able / unable to drive Able

Item Rear cylinder intake air pressure sensor (open or short circuit) Rear cylinder intake air pressure sensor (hose system) Lean angle sensor (latch up detected) Front cylinder ignition coil (faulty ignition)

Symptom Rear cylinder intake air pressure sensor: open or short circuit detected. Rear cylinder intake air pressure sensor: hose system malfunction (clogged or detached hose). The vehicle has overturned.

26 30

Able Unable

Able Unable Able (depending on the number of faulty cylinders) Able (depending on the number of faulty cylinders) Able Unable

33

Able (depending Malfunction detected in the primaon the ry wire of the front cylinder ignition number of coil. faulty cylinders) Able (depending Malfunction detected in the primaon the ry wire of the rear cylinder ignition number of coil. faulty cylinders) Engine speed is high when the enAble gine is idling. Lean angle sensor: open or short circuit detected. No normal signals are received from the speed sensor. Open or short circuit is detected in the neutral switch. Unable

34

Rear cylinder ignition coil (faulty ignition) ISC valve (stuck fully open) Lean angle sensor (open or short circuit) Speed sensor

37 41

42 Neutral switch Fuel system voltage (monitoring voltage) Error in writing the amount of CO adjustment on EEPROM

Able

Able

43

The ECU is unable to monitor the battery voltage Able (an open or short circuit in the line to the ECU). Error is detected while reading or writing on EEPROM (CO adjustment value). Able

Able

44

Able

46

Vehicle system power Power supply to the fuel injection supply system is not normal. (monitoring voltage) Faulty ECU memory. (When this ECU internal malfuncmalfunction is detected in the tion ECU, the fault code number might (memory check error) not appear on the meter.) Engine idling stop Engine has been left idling. (The ECU automatically stops the engine after 20 minutes if it is left idling.)

Able

Able

50

Unable

Unable

70

Able

Able

8-35

FUEL INJECTION SYSTEM

Communication error with the meter Fault code No. Er-1 Item Symptom Able / unable to start Unable Able / unable to drive Unable

ECU internal malfuncNo signals are received from the tion ECU. (output signal error) ECU internal malfuncNo signals are received from the tion ECU within the specified duration. (output signal error) ECU internal malfuncData from the ECU cannot be retion ceived correctly. (output signal error) ECU internal malfuncNon-registered data has been retion ceived from the meter. (input signal error)

Er-2

Unable

Unable

Er-3

Unable

Unable

Er-4
EAS27400

Unable

Unable

TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on. 1. Check: Fault code number a. Check the fault code number displayed on the meter. b. Identify the faulty system with the fault code. Refer to Self-Diagnostic Function table. c. Identify the probable cause of the malfunction. Refer to Diagnostic code table. 2. Check and repair the probable cause of the malfunction. Fault code No. Check and repair. Refer to TROUBLESHOOTING DETAILS on page 8-43. Monitor the operation of the sensors and actuators in the diagnostic mode. Refer to Sensor operation table and Actuator operation table. No fault code No. Check and repair. Refer to Self-Diagnostic Function table.

4. Turn the main switch to OFF and back to ON, and then check that no fault code number is displayed.
NOTE:

If fault codes are displayed, repeat steps (1) to (4) until no fault code number is displayed. 5. Erase the malfunction history in the diagnostic mode. Refer to Sensor operation table (Diagnostic code No. 62).
NOTE:

Turning the main switch to OFF will not erase the malfunction history. The engine operation is not normal, but the engine trouble warning light does not come on. 1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to Sensor operation table and Actuator operation table. 01: Throttle position sensor (throttle angle) 30: Front cylinder ignition coil 31: Rear cylinder ignition coil 36: Front cylinder injector 37: Rear cylinder injector If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts. If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the engine.

3. Perform the ECU reinstatement action. Refer to Reinstatement method in the table in TROUBLESHOOTING DETAILS.

8-36

FUEL INJECTION SYSTEM

EAS27420

DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to OFF and set the engine stop switch to . 2. Disconnect the wire harness coupler from the fuel pump. 3. Press and hold the RESET switch 1 and the side of the SELECT switch 2 turn the main switch to ON, and continue to press the switches for 8 seconds or more.

2
SELECT

RESET

NOTE:

All displays on the meter disappear except the clock and odometer/trip meter/fuel reserve trip meter/clock displays. dIAG appears on the odometer/trip meter/fuel reserve trip meter/clock LCD. 4. Simultaneously press the side of the SELECT switch and the RESET switch for 2 seconds or more to activate the diagnostic mode. The diagnostic code number d01 appears on the clock LCD. 5. Set the engine stop switch to . 6. Select the diagnostic code number corresponding to the fault code number by pressing the SELECT and RESET switches.
NOTE:

To decrease the selected diagnostic code number, press the side of the SELECT switch. Press the side of the SELECT switch for 1 second or longer to automatically decrease the diagnostic code numbers. To increase the selected diagnostic code number, press the side of the switch. Press the side of the switch for 1 second or longer to automatically increase the diagnostic code numbers.

d01 d70
SELECT

RES

d70 d01

7. Verify the operation of the sensor or actuator. Sensor operation The data representing the operating conditions of the sensor appears on the odometer/trip meter/fuel reserve trip meter/clock LCD. Actuator operation Set the engine stop switch to to operate the actuator.

8-37

FUEL INJECTION SYSTEM

NOTE:

If the engine stop switch is set to

, set it to

, and then set it to

again.

8. Turn the main switch to OFF to cancel the diagnostic mode. Diagnostic code table Fault code No. Symptom Probable cause of malfunction Open or short circuit in wire harness. Defective crankshaft position sensor. Malfunction in crankshaft position sensor rotor. Malfunction in ECU. Improperly installed sensor. Open or short circuit in wire harness. Defective front cylinder intake air pressure sensor. Malfunction in ECU. Diagnostic code No.

12

No normal signals are received from the crankshaft position sensor.

13

Front cylinder intake air pressure sensor: open or short circuit detected.

03

14

Front cylinder intake air Front cylinder intake air pressure sensor pressure sensor: hose syshose is detached, clogged, kinked, or tem malfunction (clogged pinched. or detached hose). Malfunction in ECU.

03

15

Open or short circuit in wire harness. Throttle position sensor: Defective throttle position sensor. open or short circuit detect01 Malfunction in ECU. ed. Improperly installed throttle position sensor. A break or disconnection of Open circuit in wire harness (ECU coupler). the blue/black lead of the 20 Malfunction in ECU. ECU is detected. Coolant temperature sensor: open or short circuit detected. Open or short circuit in wire harness. Defective coolant temperature sensor. Malfunction in ECU. Improperly installed coolant temperature sensor.

19

21

06

22

Open or short circuit in wire harness. Air temperature sensor: Defective air temperature sensor. open or short circuit detect05 Malfunction in ECU. ed. Improperly installed air temperature sensor. No normal signal is received from the O2 sensor. Rear cylinder intake air pressure sensor: open or short circuit detected. Open or short circuit in wire harness. Defective O2 sensor. Malfunction in ECU. Improperly installed sensor. Open or short circuit in wire harness. Defective rear cylinder intake air pressure sensor. Malfunction in ECU.

24

25

04

26

Rear cylinder intake air Rear cylinder intake air pressure sensor pressure sensor: hose syshose is detached, clogged, kinked, or tem malfunction (clogged pinched. or detached hose). Malfunction in ECU.

04

8-38

FUEL INJECTION SYSTEM

Fault code No. 30 Diagnostic code No. 08

Symptom The vehicle has overturned.

Probable cause of malfunction Overturned. Malfunction in ECU.

33

Open or short circuit in wire harness. Malfunction detected in the Malfunction in front cylinder ignition coil. primary wire of the front Malfunction in ECU. cylinder ignition coil. Malfunction in a component of ignition cutoff circuit system. Open or short circuit in wire harness. Malfunction detected in the Malfunction in rear cylinder ignition coil. primary wire of the rear cyl- Malfunction in ECU. Malfunction in a component of ignition cutinder ignition coil. off circuit system.

30

34

31

37

Open or short circuit in wire harness. Open or short circuit in sub-wire harness. Malfunction in throttle body. Malfunction in throttle cables. ISC valve is stuck fully open due to disconEngine speed is high when nected ISC unit hose or coupler. (High en- 54 the engine is idling. gine idling speed is detected with the ISC valve stuck fully open even though signals for the valve to close are continuously being transmitted by the ECU.) Malfunction in ECU. Open or short circuit in wire harness. Lean angle sensor: open or Defective lean angle sensor. short circuit detected. Malfunction in ECU. No normal signals are received from the speed sensor. Open circuit is detected in the neutral switch. 08

41

42

Open circuit in wire harness. Defective speed sensor. Malfunction in speed sensor detected. 07 Defective neutral switch. 21 Malfunction in the engine side of the neutral switch. Malfunction in ECU. 09

43

The ECU is unable to monitor the battery voltage (an Open or short circuit in wire harness. open or short circuit in the Malfunction in ECU. line to the ECU).

44

Error is detected while Malfunction in ECU. (The CO adjustment reading or writing on EEvalue is not properly written on or read from 60 PROM (CO adjustment valthe internal memory). ue). Power supply to the fuel inMalfunction in the charging system. Refer to jection system is not norCHARGING SYSTEM on page 8-13. mal. Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number might not appear on the meter.)

46

50

Malfunction in ECU. (The program and data are not properly written on or read from the internal memory.)

8-39

FUEL INJECTION SYSTEM

Fault code No. Diagnostic code No.

Symptom

Probable cause of malfunction Open or short circuit in wire harness. Malfunction in meter. Malfunction in ECU. Defective wire connection of the ECU coupler. Improper connection in wire harness. Malfunction in meter. Malfunction in ECU. Improper connection in wire harness. Malfunction in meter. Malfunction in ECU. Improper connection in wire harness. Malfunction in meter. Malfunction in ECU.

Er-1

No signals are received from the ECU. No signals are received from the ECU within the specified duration. Data from the ECU cannot be received correctly. Non-registered data has been received from the meter.

Er-2

Er-3

Er-4

Sensor operation table Diagnostic code No. 01 Item Throttle angle Fully closed position Fully opened position 03 1222 87107 Check with throttle fully closed. Check with throttle fully open. Set the engine stop switch to , and then push the start switch . (If the display value changes, the performance is OK.) Set the engine stop switch to , and then push the start switch . (If the display value changes, the performance is OK.) Meter display Checking method

Pressure difference Displays the front cylinder in(atmospheric pressure and take air pressure. front cylinder intake air pressure) Pressure difference Displays the rear cylinder in(atmospheric pressure and take air pressure. rear cylinder intake air pressure) Air temperature

04

05

Displays the air temperature. Compare the actually measured intake air temperature with the meter display value. Displays the coolant temperature. Compare the actually measured coolant temperature with the meter display value.

06

Coolant temperature

8-40

FUEL INJECTION SYSTEM

Diagnostic code No. 07

Item Vehicle speed pulse 0999

Meter display

Checking method Check that the number increases when the rear wheel is rotated. The number is cumulative and does not reset each time the wheel is stopped. Remove the lean angle sensor and incline it more than 65 degrees. Set the engine stop switch to , and then compare with the actually measured battery voltage. (If the battery voltage is lower, perform recharging.) Set on/off the sidestand switch (with the transmission in gear). Shift the transmission.

08

Lean angle sensor Upright Overturned 0.41.4 3.74.4 Approximately 12.0

09

Fuel system voltage (battery voltage)

20

Sidestand switch Sidestand retracted Sidestand extended ON OFF ON OFF

21

Neutral switch Neutral In gear

60

EEPROM fault code display No history History exists 00 01 or 02 (Cylinder fault code) (If both cylinders are defective, the display alternates every two seconds.)

61

Malfunction history code display No history History exists 00 Fault codes 12-70 (If more than one code number is detected, the display alternates every two seconds to show all the detected code numbers. When all code numbers are shown, the display repeats the same process.)

8-41

FUEL INJECTION SYSTEM

Diagnostic code No. 62

Item Malfunction history code erasure No history History exists 0

Meter display

Checking method

To erase the history, set the engine stop switch to .

Up to 25 fault codes 0255

70

Control number

Actuator operation table Diagnostic code No. Item Actuation Checking method

30

Front cylinder ignition coil

Actuates the front cylinder ignition coil five times at oneCheck the spark five times. second intervals. Connect an ignition Illuminates the engine trouchecker. ble warning light. Actuates the rear cylinder igCheck the spark five times. nition coil five times at one Connect an ignition second intervals. checker. Illuminates the engine trouble warning light. Actuates the front cylinder injector five times at one-sec- Check the operating sound ond intervals. of the front cylinder injector Illuminates the engine troufive times. ble warning light. Actuates the rear cylinder injector five times at one-sec- Check the operating sound ond intervals. of the rear cylinder injector Illuminates the engine troufive times. ble warning light. Actuates the fuel pump relay five times at one-second intervals. Illuminates the engine trouCheck the operating sound ble warning light. of the fuel pump relay five (The engine trouble warning times. light is OFF when the relay is ON, and the engine trouble warning light is ON when the relay is OFF).

31

Rear cylinder ignition coil

36

Front cylinder injector

37

Rear cylinder injector

50

Fuel pump relay

8-42

FUEL INJECTION SYSTEM

Diagnostic code No.

Item

Actuation

Checking method

51

Radiator fan motor relay

Actuates the radiator fan motor relay for five cycles of five seconds. (ON 2 seconds, Check the operating sound OFF 3 seconds) of the radiator fan motor reIlluminates the engine troulay five times. ble warning light and rotates the radiator fan motor. Actuates the headlight relay for five cycles of five seconds. (ON 2 seconds, OFF 3 Check the operating sound seconds) of the headlight relay five Illuminates the engine troutimes. ble warning light and headlight. Actuates and fully closes the ISC valve, then opens it to the standby opening position when the engine is started. The ISC unit vibrates when This operation takes approxithe ISC valve operates. mately 12 seconds until it is completed. Illuminates the engine trouble warning light.

52

Headlight relay

54

ISC valve

EAS27460

TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the meter display according to the reinstatement method. Fault code No.: Code number displayed on the meter when the engine failed to work normally. Refer to Self-Diagnostic Function table. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated. Refer to DIAGNOSTIC MODE on page 8-37.

8-43

FUEL INJECTION SYSTEM

Fault code No. 12 Symptom No normal signals are received from the crankshaft position sensor. Check or maintenance job Check for looseness or pinching. Check the coupler for any pins that may be pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit. Between the crankshaft position sensor coupler and ECU coupler. (graygray) (black/blueblack/blue) Replace if defective. Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8-84. Reinstatement method Cranking the engine.

Diagnostic code No.

Order Item/components and probable cause 1 2 Installed condition of crankshaft position sensor. Connections Crankshaft position sensor coupler Main wire harness ECU coupler

Open or short circuit in wire harness.

Defective crankshaft position sensor.

8-44

FUEL INJECTION SYSTEM

Fault code No. 13 Symptom Front cylinder intake air pressure sensor: open or short circuit detected. 03 Front cylinder intake air pressure sensor Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Connections Front cylinder intake air pressure sensor coupler Main wire harness ECU coupler

Check the coupler for any pins Turning the that may be pulled out. main switch to Check the locking condition of ON. the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit. Between front cylinder intake air pressure sensor coupler and ECU coupler. (black/blueblack/blue) (pinkpink) (blueblue) Execute the diagnostic mode. (Code No.03) Replace if defective. Refer to CHECKING THE INTAKE AIR PRESSURE SENSORS on page 8-89.

Open or short circuit in wire harness.

Defective front cylinder intake air pressure sensor.

8-45

FUEL INJECTION SYSTEM

Fault code No. 14 Symptom Front cylinder intake air pressure sensor: hose system malfunction (clogged or detached hose). 03 Front cylinder intake air pressure sensor Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1

Front cylinder intake air pressure sen- Check the front cylinder intake Starting the ensor hose air pressure sensor hose condi- gine and opertion. ating it at idle. Repair or replace the sensor hose. Front cylinder intake air pressure sen- Check and repair the connecsor malfunction at intermediate election. trical potential. Replace it if there is a malfunction. Connections Front cylinder intake air pressure sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely. Execute the diagnostic mode. (Code No. 03) Replace if defective. Refer to CHECKING THE INTAKE AIR PRESSURE SENSORS on page 8-89.

Defective front cylinder intake air pressure sensor.

8-46

FUEL INJECTION SYSTEM

Fault code No. 15 Symptom Throttle position sensor: open or short circuit detected. 01 Throttle position sensor Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Installed condition of throttle position sensor.

Check for looseness or pinchTurning the ing. main switch to Check that the sensor is inON. stalled in the specified position. Check the coupler for any pins that may be pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit between throttle position sensor coupler and ECU coupler. (blueblue) (yellowyellow) (black/blueblack/blue)

Connections Throttle position sensor coupler Wire harness ECU coupler

Open or short circuit in wire harness.

Throttle position sensor lead open cir- Check for open circuit and recuit output voltage check. place the throttle position sensor. (black/blueyellow) Open circuit item Ground wire open circuit Output wire open circuit Power supply wire open circuit Output voltage 5V 0V 0V

Defective throttle position sensor.

Execute the diagnostic mode. (Code No. 01) Replace if defective. Refer to CHECKING THE THROTTLE POSITION SENSOR on page 8-89.

8-47

FUEL INJECTION SYSTEM

Fault code No. 19 Symptom A break or disconnection of the blue/black lead of the ECU is detected. 20 Sidestand switch Check or maintenance job Execute the diagnostic mode. (Code No. 20) Check the coupler for any pins that may be pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit between ECU and blue/black lead. Replace if defective. Refer to CHECKING THE SWITCHES on page 8-71. Reinstatement method If the transmission is in gear, retracting the sidestand. If the transmission is in neutral, reconnecting the wiring.

Diagnostic code No.

Order Item/components and probable cause 1 Connection Wire harness ECU coupler

Open or short circuit in wire harness.

Defective sidestand switch.

Fault code No.

21

Symptom Coolant temperature sensor: open or short circuit detected. 06 Coolant temperature sensor Check or maintenance job Reinstatement method Turning the main switch to ON.

Diagnostic code No.

Order Item/components and probable cause 1 2

Installed condition of coolant tempera- Check for looseness or pinching. ture sensor. Connections Check the coupler for any pins Coolant temperature sensor coupler that may be pulled out. Wire harness ECU coupler Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely. Open or short circuit in wire harness. Repair or replace if there is an open or short circuit between coolant temperature sensor coupler and ECU coupler. (black/blueblack/blue) (green/whitegreen/white)

Defective coolant temperature sensor. Execute the diagnostic mode. (Code No. 06) Replace if defective. Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8-88.

8-48

FUEL INJECTION SYSTEM

Fault code No. 22 Symptom Air temperature sensor: open or short circuit detected. 05 Air temperature sensor Check or maintenance job Check for looseness or pinching. Check the coupler for any pins that may be pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit between air temperature sensor coupler and ECU coupler. (brown/whitebrown/white) (black/blueblack/blue) Execute the diagnostic mode. (Code No. 05) Replace if defective. Refer to CHECKING THE AIR TEMPERATURE SENSOR on page 8-90. Reinstatement method Turning the main switch to ON.

Diagnostic code No.

Order Item/components and probable cause 1 2 Installed condition of air temperature sensor. Connections Air temperature sensor coupler Wire harness ECU coupler

Open or short circuit in wire harness.

Defective air temperature sensor.

8-49

FUEL INJECTION SYSTEM

Fault code No. 24 Symptom No normal signal is received from the O2 sensor. Check or maintenance job Check for looseness or pinching. Check the coupler for any pins that may be pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit. Between O2 sensor coupler and ECU coupler. (gray/whitegray/white) (red/whitered/white) (gray/blackgray/black) (black/blueblack/blue) Refer to CHECKING THE FUEL PRESSURE on page 7-11. Replace if defective. Reinstatement method Starting the engine and operating it at idle.

Diagnostic code No.

Order Item/components and probable cause 1 2 Installed condition of O2 sensor. Connections O2 sensor coupler Wire harness ECU coupler

Open or short circuit in wire harness.

Check fuel pressure.

Defective O2 sensor.

8-50

FUEL INJECTION SYSTEM

Fault code No. 25 Symptom Rear cylinder intake air pressure sensor: open or short circuit detected. 04 Rear cylinder intake air pressure sensor Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Connections Rear cylinder intake air pressure sensor coupler Wire harness ECU coupler

Check the coupler for any pins Turning the that may be pulled out. main switch to Check the locking condition of ON. the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit between rear cylinder intake air pressure sensor coupler and ECU coupler. (black/blueblack/blue) (pink/whitepink/white) (blueblue)

Open or short circuit in wire harness.

Defective rear cylinder intake air pres- Execute the diagnostic mode. sure sensor. (Code No. 04) Replace if defective. Refer to CHECKING THE INTAKE AIR PRESSURE SENSORS on page 8-89.

8-51

FUEL INJECTION SYSTEM

Fault code No. 26 Symptom Rear cylinder intake air pressure sensor: hose system malfunction (clogged or detached hose). 04 Rear cylinder intake air pressure sensor Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1

Rear cylinder intake air pressure sen- Check the rear cylinder intake Starting the ensor hose air pressure sensor hose condi- gine and opertion. ating it at idle. Repair or replace the sensor hose. Rear cylinder intake air pressure sen- Check and repair the connecsor malfunction at intermediate election. trical potential. Replace it if there is a malfunction. Connections Rear cylinder intake air pressure sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely.

Defective rear cylinder intake air pres- Execute the diagnostic mode. sure sensor. (Code No. 04) Replace if defective. Refer to CHECKING THE INTAKE AIR PRESSURE SENSORS on page 8-89. 30 Symptom The vehicle has overturned. 08 Lean angle sensor Check or maintenance job Raise the vehicle upright. Check for looseness or pinching. Check the coupler for any pins that may be pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely. Execute the diagnostic mode. (Code No. 08) Replace if defective. Refer to CHECKING THE LEAN ANGLE SENSOR on page 8-84. Reinstatement method Turning the main switch to ON (however, the engine cannot be restarted unless the main switch is first turned OFF).

Fault code No.

Diagnostic code No.

Order Item/components and probable cause 1 2 3 The vehicle has overturned. Installed condition of lean angle sensor. Connections Lean angle sensor coupler Wire harness ECU coupler

Defective lean angle sensor.

8-52

FUEL INJECTION SYSTEM

Fault code No. 33 Symptom Malfunction detected in the primary wire of the front cylinder ignition coil. 30, 32 Front cylinder ignition coil Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Connections Front cylinder ignition coil connector (primary coil side) Wire harness ECU coupler

Check the connector and couStarting the enpler for any pins that may be gine and operpulled out. ating it at idle. Check the locking condition of the connector and coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit. Between front cylinder ignition coil connector and ECU coupler. (orangeorange) Between front cylinder ignition coil connector and right handlebar switch coupler. (black/redblack/red) Execute the diagnostic mode. (Code No. 30) Check the primary and secondary coils for continuity. Replace if defective. Refer to CHECKING THE IGNITION COILS on page 8-83.

Open or short circuit in wire harness.

Defective front cylinder ignition coil.

8-53

FUEL INJECTION SYSTEM

Fault code No. 34 Symptom Malfunction detected in the primary wire of the rear cylinder ignition coil. 31, 33 Rear cylinder ignition coil Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Connections Rear cylinder ignition coil connector (primary coil side) Wire harness ECU coupler

Check the connector and couStarting the enpler for any pins that may be gine and operpulled out. ating it at idle. Check the locking condition of the connector and coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit. Between rear cylinder ignition coil connector and ECU coupler. (gray/redgray/red) Between rear cylinder ignition coil connector and right handlebar switch coupler. (black/redblack/red) Execute the diagnostic mode. (Code No. 31) Check the primary and secondary coils for continuity. Replace if defective. Refer to CHECKING THE IGNITION COILS on page 8-83.

Open or short circuit in wire harness.

Defective rear cylinder ignition coil.

8-54

FUEL INJECTION SYSTEM

Fault code No. 37 Symptom Engine speed is high when the engine is idling. 54 ISC valve Check or maintenance job Check the throttle bodies. Refer to THROTTLE BODIES on page 7-7. Check the throttle cables. Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3-8. Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Throttle valve does not fully close.

ISC valve is stuck fully open due to disconnected ISC unit coupler. (High engine idling speed is detected with the ISC valve stuck fully open even though signals for the valve to close are continuously being transmitted by the ECU.)

ISC valve returns to its original position by turning the main switch to ON and back to OFF. Check that the ISC unit coupler Reinstated if the engine is not disconnected. idling speed is The ISC valve is stuck fully open if it does not operate when within specification after the main switch is turned to starting the enOFF. gine. (Touch the ISC unit with your hand and check if it is vibrating to confirm if the ISC valve is operating.) Execute the diagnostic mode. (Code No. 54) After the ISC valve is fully closed, it opens to the standby opening position when the engine is started. This operation takes approximately 12 seconds. Start the engine. If the error recurs, replace the throttle body assembly.

ISC valve is not moving correctly.

8-55

FUEL INJECTION SYSTEM

Fault code No. 41 Symptom Lean angle sensor: open or short circuit detected. 08 Lean angle sensor Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Connections Lean angle sensor coupler Wire harness ECU coupler

Check the coupler for any pins Turning the that may be pulled out. main switch to Check the locking condition of ON. the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit between lean angle sensor coupler and ECU coupler. (blueblue) (yellow/greenyellow/green) (black/blueblack/blue) Execute the diagnostic mode. (Code No. 08) Replace if defective. Refer to CHECKING THE LEAN ANGLE SENSOR on page 8-84.

Open or short circuit in lead.

Defective lean angle sensor.

8-56

FUEL INJECTION SYSTEM

Fault code No. 42 Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. A B 07 21 Speed sensor Neutral switch Check or maintenance job Check the coupler for any pins that may be pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit. Between speed sensor coupler and ECU coupler. (blueblue) (white/yellowwhite/yellow) (black/blueblack/blue) Replace if defective. Refer to TRANSMISSION on page 5-81. Execute the diagnostic mode. (Code No. 07) Replace if defective. Refer to CHECKING THE SPEED SENSOR on page 8-88. Reinstatement method Starting the engine, and activating the speed sensor by operating the vehicle at 20 to 30 km/h.

Diagnostic code No.

Order Item/components and probable cause A-1 Connections Speed sensor coupler Wire harness ECU coupler

A-2

Open or short circuit in speed sensor lead.

A-3

Gear for detecting vehicle speed has broken. Defective speed sensor.

A-4

8-57

FUEL INJECTION SYSTEM

Fault code No. 42 Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. A B 07 21 Speed sensor Neutral switch Check or maintenance job Check the coupler for any pins that may be pulled out. Check the locking condition of the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open circuit. Between neutral switch coupler and relay unit coupler (fuel pump relay). (sky bluesky blue) Between relay unit coupler and main switch. (blue/yellowblue/yellow) Between main switch and ECU coupler. (blue/blackblue/black) Reinstatement method Starting the engine, and activating the speed sensor by operating the vehicle at 20 to 30 km/h.

Diagnostic code No.

Order Item/components and probable cause B-1 Connections Neutral switch coupler Wire harness ECU coupler

B-2

Open circuit in neutral switch lead.

B-3

Faulty shift drum (neutral detection ar- Replace if defective. ea). Refer to TRANSMISSION on page 5-81. Defective neutral switch. Execute the diagnostic mode. (Code No. 21) Replace if defective. Refer to CHECKING THE SWITCHES on page 8-71.

B-4

8-58

FUEL INJECTION SYSTEM

Fault code No. 43 Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). 09 Fuel system voltage Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Connections Relay unit coupler (fuel pump relay) Wire harness ECU coupler

Check the coupler for any pins Starting the enthat may be pulled out. gine and oper Check the locking condition of ating it at idle. the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit. Between relay unit coupler (fuel pump relay) and ECU coupler. (blue/redblue/red) (red/bluered/blue) Between relay unit coupler (fuel pump relay) and starter relay coupler. (redred) Between relay unit coupler (fuel pump relay) and diode 2 coupler. (blue/whiteblue/white) Between diode 2 coupler and right handlebar switch coupler. (black/redblack/red) Execute the diagnostic mode. (Code No. 09) Replace if defective. If there is no malfunction with the relay unit (fuel pump relay), replace the ECU.

Open or short circuit in the wire harness.

Malfunction or open circuit in relay unit (fuel pump relay).

Fault code No.

44

Symptom Error is detected while reading or writing on EEPROM (CO adjustment value). 60 EEPROM improper cylinder indication Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Malfunction in ECU.

Execute the diagnostic mode. Turning the (Code No. 60) main switch to 1. Check the faulty cylinder. (If ON. multiple cylinders are defective, the numbers of the faulty cylinders are displayed alternately at 2-second intervals.) Replace ECU if defective.

8-59

FUEL INJECTION SYSTEM

Fault code No. 46 Symptom Power supply to the fuel injection system is not normal. Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Connection Wire harness ECU coupler

Check the coupler for any pins Starting the enthat may be pulled out. gine and oper Check the locking condition of ating it at idle. the coupler. If there is a malfunction, repair it and connect the coupler securely. Replace or charge the battery. Refer to CHECKING AND CHARGING THE BATTERY on page 8-75. Replace if defective. Refer to CHARGING SYSTEM on page 8-13. Repair or replace if there is an open or short circuit. Between battery and main fuse. (redred) Between main fuse and main switch coupler. (black/redred) Between main switch coupler and ignition fuse. (brownbrown) Between ignition fuse and ECU coupler. (red/whitered/white)

Faulty battery.

Malfunction in rectifier/regulator.

Open or short circuit in wire harness.

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.) Check or maintenance job Replace the ECU.
NOTE:

Diagnostic code No.

Order Item/components and probable cause 1 Malfunction in ECU.

Reinstatement method Turning the main switch to ON.

Do not perform this procedure with the main switch turned to ON.

8-60

FUEL INJECTION SYSTEM

Fault code No. Er-1 Symptom No signals are received from the ECU. Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Connections Wire harness ECU coupler Meter assembly coupler

Check the coupler for any pins Turning the that may be pulled out. main switch to Check the locking condition of ON. the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit between meter assembly coupler and ECU coupler. (yellow/blueyellow/blue) Replace the meter assembly. Replace the ECU.

Open or short circuit in wire harness.

3 4

Malfunction in meter assembly. Malfunction in ECU.

Fault code No.

Er-2 Symptom No signals are received from the ECU within the specified duration. Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Connections Wire harness ECU coupler Meter assembly coupler

Check the coupler for any pins Turning the that may be pulled out. main switch to Check the locking condition of ON. the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit between meter assembly coupler and ECU coupler. (yellow/blueyellow/blue) Replace the meter assembly. Replace the ECU.

Open or short circuit in wire harness.

3 4

Malfunction in meter assembly. Malfunction in ECU.

8-61

FUEL INJECTION SYSTEM

Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Connections Wire harness ECU coupler Meter assembly coupler

Check the coupler for any pins Turning the that may be pulled out. main switch to Check the locking condition of ON. the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit between meter assembly coupler and ECU coupler. (yellow/blueyellow/blue) Replace the meter assembly. Replace the ECU.

Open or short circuit in wire harness.

3 4

Malfunction in meter assembly. Malfunction in ECU.

Fault code No.

Er-4 Symptom Non-registered data has been received from the meter. Check or maintenance job Reinstatement method

Diagnostic code No.

Order Item/components and probable cause 1 Connections Wire harness ECU coupler Meter assembly coupler

Check the coupler for any pins Turning the that may be pulled out. main switch to Check the locking condition of ON. the coupler. If there is a malfunction, repair it and connect the coupler securely. Repair or replace if there is an open or short circuit between meter assembly coupler and ECU coupler. (yellow/blueyellow/blue) Replace the meter assembly. Replace the ECU.

Open or short circuit in wire harness.

3 4

Malfunction in meter assembly. Malfunction in ECU.

8-62

L/W

EAS27560

EAS27550

15
BR A B C BR L/W W G R/B R/G Br/L R/B P/L G W W G Ch Y L Dg B Ch Dg B L/R Y V/G R/Y W/L P R/Y Y Gy W W Gy

12 13 14
Sb/W L W L R/L L/R L/G L/Y Sb B/Y L W R WIRE HARNESS SUB-W REHARNESS SUB-W REHARNESS WIRE HARNESS WIRE HARNESS TA L/ BRAKE L GHT W RE HARNESS

L Sb/W LWR

B W B/W B W

B/W B/W B/W

B W B/W B/ W B/ W B W B/ W Sb L/R RL L/G LY

B/ R

(GRAY) L/W B/Y Sb RL O Gy R L/G Gy/W B3 B3 G G/Y G/Y Y/B Br W P YG GW Gy/B L B L R/L R W R/B B/Br P/L B L R G B/Y Y/L Y B /L W/G L/W W Y Gy1 P W L/R

(BLACK)

CIRCUIT DIAGRAM

B/R

2 4
B R/G B B B (BLACK) Gy R Gy/R L/G (BLACK) B BR Sb R

17 18
B B R/L B (DARK GREEN) BR O O R/W LB Gy Gy

B/R

16 28

30

3 29
W/Y

FUEL PUMP SYSTEM

B/R

30

Gy R BL BW B/L L (BLACK) L L/W P/W P B/L Br W GW (BLACK) Br/W W L R/Y V/G Y R/Y P L Y B/L

B/L B Gy

20
L W/Y P O/R

19
B/L Y L

B/L L W/Y

R W

7
R

5
B B W RW RW B/L /W L (BLACK)

21 27 31 22 23 26
R/B Br W B/L Y/L B/L P L B/L P/W L

B/L Y L

R/G P/L W/G Br L

R/G A V/G P/L A P W/G A W L Br L A Y VG P W/L Y

Br

Br L

ON OFF R/Y R/Y R/Y A

6 10
R/W R/W W (BLACK) B/L P L

L/Y

L/Y

8 9

L /B

L/B

Br

R/B R/Y A R/B

L/Y L/B

25
(BLACK) G/W YG BY G Gy Y/B Gy B Gy/W B/L L Y/G B L G/W B/L (DARK GREEN) G/Y R/L L/R

11 24
L YG B/L

W G

Br/W

32
G B G G

(DARK GRAY) W B W W W Gy

8-63
B/Br B3 B3 Br Br R/Y R/Y Br/W W Y/R B Br P/W P/B L/W Br GL Y/B Y/B Y/R Br/W B B/R R/W G/L W Gy B RW

33
Gy B Gy Gy W

( GRAY)

W B W

75

Br

74 34 35
B/L Gy/W

Br

Br

73

Br

R/W

72

R/Y

Br W R/W

48

Br W

61 63
RESET

49

47

B Gy B B W L (BLACK)

36 37 46
R/W Y/L Gy Y/R Sb W

71 64 50
GL L/Y B/Y B L/Y Y Dg Ch B /W Y L/Y B B /W Ch Dg (BLUE) LY BY G Gy B Y YR G/L (BLACK) Y G BY P G R/Y Y/R (BLUE) Y/G BY B

RW

G/Y

Br

Y PB PW B B/Y Y G

P/W P/B B Y/G B/Y B W

62 51 52

65 53
(L) N (R)

66

GY

Br/W

70

Gy/W R/W Gy B B L

38 54
B G (BLACK) (BLACK) Ch Dg B B W (BLACK) Y Ch Dg (BLACK) G W G B

L/G

R W B/R

BR RW

Br L W

L/W Br

(BLACK)

Br

44 45
W (BLACK)

G RG W YG P/W PB

Br

39 40 41
B

(BLACK)

L G/L

Y L C C Y L Ch L Y G Br G L/B B B LR B G/L Y B L B (GRAY) Dg L Ch C Dg C

42 43 58
G L B (BLACK)

Y L/R

L/R

B/W

69 60

68

67

57

Ch Ch

Dg Dg

(BLACK)

(BLACK)

Y L/R

B B

59
B

B L Ch B (GRAY)

56
L Dg B (BLACK) B Ch B (GRAY) B Ch B (GRAY)

55
Dg B (BLACK)

Y/L W R G G B YG (BLACK) R/G W Y L YG B G Dg B (BLACK) (BLACK)

Y Dg R W Sb Ch

P/W P B L/G

FUEL PUMP SYSTEM

B C B

Dg Y Ch Sb/W R W

P/B P W L/G

FUEL PUMP SYSTEM

3. Main fuse 5. Main switch 6. Battery 7. Fuel injection system fuse 14.Fuel pump relay 15.Diode 2 17.Fuel pump 27.ECU (engine control unit) 65.Engine stop switch 73.Ignition fuse

8-64

FUEL PUMP SYSTEM

EAS27570

TROUBLESHOOTING The fuel pump fails to operate.

NOTE:

Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Fuel tank 4. Battery box 5. Headlight lens unit 1. Check the fuses. (Main, ignition and fuel injection system) Refer to CHECKING THE FUSES on page 8-75. OK 2. Check the battery. Refer to CHECKING AND CHARGING THE BATTERY on page 8-75. OK 3. Check the main switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 4. Check the engine stop switch. Refer to CHECKING THE SWITCHES on page 8-71. OK 5. Check the relay unit (fuel pump relay). Refer to CHECKING THE RELAYS on page 8-79. OK 6. Check the fuel pump. Refer to CHECKING THE FUEL PUMP BODY on page 7-5. OK 7. Check the diode 2. Refer to CHECKING THE DIODES on page 8-81. OK NG Replace the diode 2. NG Replace the fuel pump. NG Replace the relay unit. NG The engine stop switch is faulty. Replace the right handlebar switch. NG Replace the main switch. NG Clean the battery terminals. Recharge or replace the battery. NG Replace the fuse(s).

8-65

FUEL PUMP SYSTEM

8. Check the entire fuel pump systems wiring. Refer to CIRCUIT DIAGRAM on page 8-63. OK Replace the ECU. NG Properly connect or repair the fuel pump systems wiring.

8-66

ELECTRICAL COMPONENTS
EAS27970

ELECTRICAL COMPONENTS
4

3
5 6

13 12

8 11 10 9

8-67

ELECTRICAL COMPONENTS
1. Coolant temperature sensor 2. Front cylinder intake air pressure sensor 3. Rear cylinder intake air pressure sensor 4. Rear cylinder ignition coil 5. Front cylinder ignition coil 6. Sub-wire harness 7. ECU (engine control unit) 8. Turn signal relay 9. Speed sensor 10. Neutral switch 11. Oil level switch 12. Horn 13. Air temperature sensor

8-68

ELECTRICAL COMPONENTS

1 2 20

19

18

14 13 17 16

11

9 3

5 4

10

15 12

8-69

ELECTRICAL COMPONENTS
1. Main switch 2. Rectifier/regulator 3. Fuse box 4. Headlight fuse 5. Backup fuse 6. Radiator fan motor fuse 7. Taillight fuse 8. Ignition fuse 9. Signaling system fuse 10. Main fuse 11. Battery 12. Lean angle sensor 13. Starter relay 14. Fuel injection system fuse 15. Relay unit 16. Radiator fan motor relay 17. Headlight relay 18. Sidestand switch 19. Rear brake light switch 20. Radiator fan motor

8-70

ELECTRICAL COMPONENTS
EAS27980

CHECKING THE SWITCHES

13
B B

1
R
Br/L (BLACK) L/Y L/B

R Br/L L/B L/Y ON OFF

12
L/Y B/Y

2
B B (BLACK)

L/Y B/Y (BLACK)

3 11
P B

10
Ch Br/W Dg B Y/R (L) (R)
B Br

4
Y/G B/Y RESET
Y L/Y B Br/W Ch Dg (BLUE)

9
Y R/Y G

5
P/W B/Y P/B
P/W P/B B Y/G B/Y B/W

B/Y P G R/Y Y/R

B/R R/W

6
R/W B/R

8
B

L/W Br

7
L/W B/W

8-71

ELECTRICAL COMPONENTS
1. Main switch 2. Rear brake light switch 3. Front brake light switch 4. Reset switch 5. Select switch 6. Engine stop switch 7. Start switch 8. Neutral switch 9. Dimmer switch 10. Turn signal switch 11. Horn switch 12. Clutch switch 13. Sidestand switch

8-72

ELECTRICAL COMPONENTS
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.
ECA14370

CAUTION:

Never insert the tester probes into the coupler terminal slots a. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads. Pocket tester 90890-03112 Analog pocket tester YU-03112-C
NOTE:

Before checking for continuity, set the pocket tester to 0 and to the 1 range. When checking for continuity, switch back and forth between the switch positions a few times.

The switches and their terminal connections are illustrated as in the following example of the main switch. The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row. The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by . There is continuity between the red and brown/blue leads, and between the blue/black and blue/yellow leads when the switch is set to ON.

b
R Br/L L/B L/Y ON OFF

R Br/L

L/Y L/B

8-73

ELECTRICAL COMPONENTS
EAS27990 EWA13320

CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect. No continuity Repair or replace the bulb, bulb socket or both. Types of bulbs The bulbs used on this vehicle are shown in the following illustration. Bulbs a and b are used for the headlights and usually use a bulb holder that must be detached before removing the bulb. The majority of these types of bulbs can be removed from their respective sockets by turning them counterclockwise. Bulbs c is used for turn signal and tail/brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise. Bulbs d and e are used for meter and indicator lights and can be removed from their respective sockets by carefully pulling them out.

WARNING

Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
ECA3D81021

CAUTION:

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. 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: Bulb (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C
NOTE:

Before checking for continuity, set the pocket tester to 0 and to the 1 range. a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2, and check the continuity. b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3, and check the continuity. c. If either of the readings indicates no continuity, replace the bulb.

Checking the condition of the bulbs The following procedure applies to all of the bulbs. 1. Remove: Bulb

8-74

ELECTRICAL COMPONENTS
Checking the condition of the bulb sockets The following procedure applies to all of the bulb sockets. 1. Check: Bulb socket (for continuity) (with the pocket tester) No continuity Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C
NOTE:

3. Replace: 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 Main Headlight Ignition Radiator fan motor Fuel injection system Signaling system Taillight Backup (odometer and clock) Spare Spare Spare
EWA13310

Amperage rating 50 A 20 A 15 A 20 A 10 A 10 A 10 A 10 A 20 A 15 A 10 A

Qty 1 1 1 1 1 1 1 1 1 1 1

Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. a. Install a good bulb into the bulb socket. b. Connect the pocket tester probes to the respective leads of the bulb socket. c. Check the bulb socket for continuity. If any of the readings indicates no continuity, replace the bulb socket.
EAS28000

CHECKING THE FUSES The following procedure applies to all of the fuses.
ECA13680

WARNING

CAUTION:

To avoid a short circuit, always set the main switch to OFF when checking or replacing a fuse. 1. Remove: Rider seat Refer to GENERAL CHASSIS on page 4-1. 2. Check: Fuse a. Connect the pocket tester to the fuse and check the continuity.
NOTE:

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: Rider seat Refer to GENERAL CHASSIS on page 4-1.

EAS28030

Set the pocket tester selector to 1. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. If the pocket tester indicates , replace the fuse.

CHECKING AND CHARGING THE BATTERY

EWA13290

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: Wear protective eye gear when handling or working near batteries.

8-75

ELECTRICAL COMPONENTS
Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL Skin Wash with water. Eyes Flush with water for 15 minutes and get immediate medical attention. INTERNAL Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.
ECA3D81014 ECA3D81022

CAUTION:

First, disconnect the negative battery lead 1, then the positive battery lead 2.

1 2

3. Remove: Battery 4. Check: Battery charge a. Connect a pocket tester to the battery terminals. Positive tester probe positive battery terminal Negative tester probe negative battery terminal
NOTE:

CAUTION:

This is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. Charging time, charging amperage and charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged according to the appropriate charging method. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.
NOTE:

The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive battery terminal is disconnected). No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V. b. Check the charge of the battery, as shown in the charts and the following example. Example Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge of the battery = 2030%

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: Rider seat Tool kit tray Refer to GENERAL CHASSIS on page 4-1. 2. Disconnect: Battery leads (from the battery terminals)

8-76

ELECTRICAL COMPONENTS
When charging a battery, be sure to remove it from the vehicle. (If charging has to be done with the battery mounted on the vehicle, disconnect the negative battery lead from the battery terminal.) To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! 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.

A. Open-circuit voltage (V) B. Charging time (hours) C. Relationship between the open-circuit voltage and the charging time at 20 C (68 F) D. These values vary with the temperature, the condition of the battery plates, and the electrolyte level.

A. Open-circuit voltage (V) B. Charging condition of the battery (%) C. Ambient temperature 20 C (68 F)

5. Charge: Battery (refer to the appropriate charging method)

EWA13300

WARNING

Do not quick charge a battery.

ECA13670

CAUTION:

Never remove the MF battery sealing caps. 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. If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery.

A. B. C. D. E.

Open-circuit voltage (V) Time (minutes) Charging Ambient temperature 20 C (68 F) Check the open-circuit voltage.

Charging method using a variable-current (voltage) charger a. Measure the open-circuit voltage prior to charging.

NOTE:

Voltage should be measured 30 minutes after the engine is stopped.

8-77

ELECTRICAL COMPONENTS
b. Connect a charger and ammeter to the battery and start charging.
NOTE: NOTE:

Set the charging voltage to 1617 V. If the setting is lower, charging will be insufficient. If too high, the battery will be overcharged. c. Make sure that the current is higher than the standard charging current written on the battery.
NOTE:

If the current is lower than the standard charging current written on the battery, this type of battery charger cannot charge the MF battery. A variable voltage charger is recommended. d. Charge the battery until the batterys charging voltage is 15 V.
NOTE:

Set the charging time to 20 hours (maximum). e. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery.

If the current is lower than the standard charging current written on the battery, set the charging voltage adjusting dial to 2024 V and monitor the amperage for 35 minutes to check the battery. Standard charging current is reached Battery is good. Standard charging current is not reached Replace the battery. d. Adjust the voltage so that the current is at the standard charging level. e. Set the time according to the charging time suitable for the open-circuit voltage. f. If charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging current. g. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery.

6. Install: Battery 7. Connect: Battery leads (to the battery terminals)

NOTE:

Route the positive battery lead under the negative battery lead, making sure not to route it on top of the relay unit.
ECA3D81023

CAUTION:

First, connect the positive battery lead 1, then the negative battery lead 2.

2 1 2

Charging method using a constant voltage charger a. Measure the open-circuit voltage prior to charging.

1
8. Check: Battery terminals Dirt Clean with a wire brush. Loose connection Connect properly. 9. Lubricate: Battery terminals Recommended lubricant Dielectric grease

NOTE:

Voltage should be measured 30 minutes after the engine is stopped. b. Connect a charger and ammeter to the battery and start charging. c. Make sure that the current is higher than the standard charging current written on the battery.

8-78

ELECTRICAL COMPONENTS
10.Install: Rider seat Tool kit tray Refer to GENERAL CHASSIS on page 4-1.
EAS28040

Relay unit (starting circuit cut-off relay)

1 3

2 4

+
CHECKING THE RELAYS Check each relay for continuity with the pocket tester. If the continuity reading is incorrect, replace the relay. Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1. Disconnect the relay from the wire harness. 2. Connect the pocket tester ( 1) and battery (12 V) to the relay terminal as shown. Check the relay operation. Out of specification Replace. Starter relay
1

Sb/W L /W

R/L L/R R

L / G L / Y Sb B / Y L/W

1. 2. 3. 4.

Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe

Result Continuity (between 3 and 4) Relay unit (fuel pump relay)

3
1
R R

3 2

+
w
L
Sb/W L /W L R/L L/R R L / G L / Y Sb B / Y L/W

2 4
1. 2. 3. 4. Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe

1
1. 2. 3. 4.

Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe

Result Continuity (between 3 and 4)

Result Continuity (between 3 and 4)

8-79

ELECTRICAL COMPONENTS
Headlight relay a. Connect the pocket tester (DC 20 V) to the turn signal relay terminal as shown.

3 4 2
Y/B G/L R/Y Br

+
1

Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe brown 1 Negative tester probe ground

1. 2. 3. 4.

Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe

Result Continuity (between 3 and 4) Radiator fan motor relay

3 4 2
G/Y L Br/W

+
1
R/W

b. Turn the main switch to ON. c. Measure the turn signal relay input voltage.

2. Check: Turn signal relay output voltage Out of specification Replace. Turn signal relay output voltage DC 12 V a. Connect the pocket tester (DC 20 V) to the turn signal relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe brown/white 1, yellow/red 2 or white 3 Negative tester probe ground

1. 2. 3. 4.

Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe

Result Continuity (between 3 and 4)

EAS3D81010

CHECKING THE TURN SIGNAL RELAY 1. Check: Turn signal relay input voltage Out of specification The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be repaired. Turn signal relay input voltage DC 12 V

8-80

ELECTRICAL COMPONENTS
Continuity Positive tester probe sky blue 1 Negative tester probe black/yellow 2 No continuity Positive tester probe black/yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe blue/yellow 3 No continuity Positive tester probe blue/yellow 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative tester probe sky blue/white 4 No continuity Positive tester probe sky blue/white 4 Negative tester probe sky blue 1 Continuity Positive tester probe blue/green 5 Negative tester probe blue/yellow 3 No continuity Positive tester probe blue/yellow 3 Negative tester probe blue/green 5

b. Turn the main switch to ON. c. Measure the turn signal relay output voltage.

EAS28050

CHECKING THE DIODES Relay unit (diode) 1. Check: Relay unit (diode) Out of specification Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C
NOTE:

The pocket tester or the analog pocket tester readings are shown in the following table.

3 5 4
Sb/W L / W L R/L L/R

2
L / G L / Y Sb B / Y L/W R

a. Disconnect the relay unit from the wire harness.

8-81

ELECTRICAL COMPONENTS
b. Connect the pocket tester ( 1) to the relay unit terminals as shown. c. Check the relay unit (diode) for continuity. d. Check the relay unit (diode) for no continuity.

Pocket tester 90890-03112 Analog pocket tester YU-03112-C

NOTE:

Diode 1 1. Check: Diode 1 Out of specification Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C
NOTE:

The pocket tester and the analog pocket tester readings are shown in the following table. Continuity Positive tester probe blue/white 1 Negative tester probe black/red 2 No continuity Positive tester probe black/red 2 Negative tester probe blue/white 1

The pocket tester and the analog pocket tester readings are shown in the following table. Continuity Positive tester probe white 1 Negative tester probe red/white 2 or red/white 3 No continuity Positive tester probe red/white 2 or red/white 3 Negative tester probe white 1

1
L/W B/R

3
R/W R/W W

a. Disconnect the diode 2 from the wire harness. b. Connect the pocket tester ( 1) to the diode 2 terminals as shown. c. Check the diode 2 for continuity. d. Check the diode 2 for no continuity.
EAS3D81017

1
a. Disconnect the diode 1 from the wire harness. b. Connect the pocket tester ( 1) to the diode 1 terminals as shown. c. Check the diode 1 for continuity. d. Check the diode 1 for no continuity. Diode 2 1. Check: Diode 2 Out of specification Replace.

CHECKING THE IGNITION SPARK GAP 1. Check: Ignition spark gap Out of specification Perform the ignition system troubleshooting, starting with step 5. Refer to TROUBLESHOOTING on page 8-4. Minimum ignition spark gap 6.0 mm (0.24 in)

8-82

ELECTRICAL COMPONENTS
NOTE:

If the ignition spark gap is within specification, the ignition system circuit is operating normally. a. Disconnect the spark plug cap from the spark plug. b. Connect the ignition checker 1 as shown. Ignition checker 90890-06754 Opama pet-4000 spark checker YM-34487

c. Measure the spark plug cap resistance.

EAS28100

CHECKING THE IGNITION COILS The following procedure applies to all of the ignition coils. 1. Check: Primary coil resistance Out of specification Replace. Primary coil resistance 2.162.64
2. Spark plug cap

c. Turn the main switch to ON and set the engine stop switch to . d. Measure the ignition spark gap a. e. Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs.

EAS28070

a. Disconnect the ignition coil connectors from the ignition coil terminals. b. Connect the pocket tester ( 1) to the ignition coil as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe black/red 1 Negative tester probe orange or gray/red 2

CHECKING THE SPARK PLUG CAPS The following procedure applies to all of the spark plug caps. 1. Check: Spark plug cap resistance Out of specification Replace. Resistance 10.0 k. a. Remove the spark plug cap from the spark plug lead. b. Connect the pocket tester ( 1k) to the spark plug cap as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C

c. Measure the primary coil resistance.

2. Check: Secondary coil resistance Out of specification Replace.

8-83

ELECTRICAL COMPONENTS
Secondary coil resistance 8.6412.96 k. a. Disconnect the spark plug cap from the ignition coil. b. Connect the pocket tester ( 1k) to the ignition coil as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe black/red 1 Negative tester probe spark plug lead 2

Positive tester probe gray 1 Negative tester probe black 2

B Gy

b. Measure the crankshaft position sensor resistance.

EAS28130

CHECKING THE LEAN ANGLE SENSOR 1. Remove: Lean angle sensor 2. Check: Lean angle sensor output voltage Out of specification Replace. Lean angle sensor output voltage Less than 65: 0.41.4 V More than 65: 3.74.4 V c. Measure the secondary coil resistance.

EAS28120

CHECKING THE CRANKSHAFT POSITION SENSOR 1. Disconnect: Crankshaft position sensor coupler (from the wire harness) 2. Check: Crankshaft position sensor resistance Out of specification Replace the crankshaft position sensor/stator assembly. Crankshaft position sensor resistance 248372 a. Connect the pocket tester ( 100) to the crankshaft position sensor coupler as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C

a. Connect the lean angle sensor coupler to the wire harness. b. Connect the pocket tester (DC 20 V) to the lean angle sensor coupler as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe yellow/green 1 Negative tester probe black/blue 2

8-84

ELECTRICAL COMPONENTS
EAS28150

CHECKING THE STATOR COIL 1. Disconnect: Stator coil coupler (from the wire harness) 2. Check: Stator coil resistance Out of specification Replace the crankshaft position sensor/stator assembly. c. Turn the main switch to ON. d. Tilt the lean angle sensor 65. e. Measure the lean angle sensor output voltage.

EAS3D81011

Stator coil resistance 0.1120.168 a. Connect the pocket tester ( 1) to the stator coil coupler as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe white 3 Positive tester probe white 2 Negative tester probe white 3

CHECKING THE STARTER MOTOR OPERATION 1. Check: Starter motor operation Does not operate Perform the electric starting system troubleshooting, starting with step 4. Refer to TROUBLESHOOTING on page 8-11. a. Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3.
EWA13810

WARNING

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. This check is likely to produce sparks, therefore, make sure no flammable gas or fluid is in the vicinity.

b. Measure the stator coil resistance.

EAS28170

b. Check the starter motor operation.

CHECKING THE RECTIFIER/REGULATOR 1. Check: Charging voltage Out of specification Replace the rectifier/regulator.

8-85

ELECTRICAL COMPONENTS
Charging voltage 14 V at 5000 r/min a. Attach the engine tachometer to the spark plug lead of the front cylinder. b. Connect the pocket tester (DC 20 V) to the rectifier/regulator coupler as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe black/red 1 Negative tester probe black 2

Positive tester probe horn terminal 1 Negative tester probe horn terminal 2

c. Measure the horn resistance.

2. Check: Horn sound Faulty sound Adjust or replace. a. Connect a battery (12 V) to the horn. b. Turn the adjusting screw in direction a or b until the specified horn sound is obtained.

B/W B/W B/W

B/R

2
a b

c. Start the engine and operate it run at approximately 5000 r/min. d. Measure the charging voltage.

EAS28180

CHECKING THE HORN 1. Check: Horn resistance Out of specification Replace. Coil resistance 1.011.11 a. Disconnect the horn connectors from the horn terminals. b. Connect the pocket tester ( 1) to the horn terminals. Pocket tester 90890-03112 Analog pocket tester YU-03112-C

EAS3D81012

CHECKING THE OIL LEVEL SWITCH 1. Drain: Engine oil 2. Remove: Oil level switch (from the crankcase) 3. Check: Oil level switch resistance Out of specification Replace the oil level switch. Oil level switch resistance Minimum level position 114126 Maximum level position 484536

8-86

ELECTRICAL COMPONENTS
a. Connect the pocket tester ( 100) to the oil level switch terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Minimum level position A Positive tester probe connector (white) 1 Negative tester probe body ground 2 Maximum level position B Positive tester probe connector (white) 1 Negative tester probe body ground 2

Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe green 1 Negative tester probe black 2

G B

b. Measure the fuel sender resistance.

EAS3D81014

b. Measure the oil level switch resistance.

EAS3D81013

CHECKING THE FUEL SENDER 1. Disconnect: Fuel sender coupler (from the wire harness) 2. Remove: Fuel sender (from the fuel tank) 3. Check: Fuel sender resistance Out of specification Replace the fuel sender. Fuel sender resistance 8301720 at 25 C (77 F) a. Connect the pocket tester ( 1) to the fuel sender terminals as shown.

CHECKING THE FUEL LEVEL WARNING LIGHT This model is equipped with a self-diagnosis device for the fuel level detection circuit. 1. Check: Fuel level warning light 1 (Turn the main switch to ON.) Warning light comes on for a few seconds, then goes off Warning light is OK. Warning light does not come on Replace the meter assembly. Warning light flashes eight times, then goes off for three seconds in a repeated cycle (malfunction detected in fuel sender or thermistor) Replace the fuel pump assembly.

8-87

ELECTRICAL COMPONENTS
EAS3D81015

CHECKING THE OIL LEVEL WARNING LIGHT This model is equipped with a self-diagnosis device for the oil level detection circuit. 1. Check: Oil level warning light 1 (Turn the main switch to ON.) Warning light comes on for a few seconds, then goes off Warning light is OK. Warning light does not come on Replace the meter assembly. Warning light flashes ten times, then goes off for 2.5 seconds in a repeated cycle (malfunction detected in oil level switch) Replace the oil level switch.

1
P O/R B/W L W/ Y B /L

2
b. Set the main switch to ON. c. Elevate the rear wheel and slowly rotate it. d. Measure the voltage of white/yellow and black/blue. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V.

EAS28250

CHECKING THE RADIATOR FAN MOTOR 1. Check: Radiator fan motor Faulty/rough movement Replace.

EAS28240

CHECKING THE SPEED SENSOR 1. Check: Speed sensor output voltage Out of specification Replace. Output voltage reading cycle 0.6 V to 4.8 V to 0.6 V to 4.8 V a. Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness side) as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe white/yellow 1 Negative tester probe black/blue 2

a. Disconnect the radiator fan motor coupler from the wire harness. b. Connect a battery (DC 12 V) as shown. Positive tester probe black/white 1 Negative tester probe black 2

c. Check the radiator fan motor movement.

EAS28260

CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: Coolant temperature sensor Refer to THERMOSTAT on page 6-4.
EWA14130

WARNING

Handle the coolant temperature sensor with special care.

8-88

ELECTRICAL COMPONENTS
Never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor is dropped, replace it. 2. Check: Coolant temperature sensor resistance Out of specification Replace. Coolant temperature sensor resistance 290354 at 80 C (176 F) a. Connect the pocket tester ( 100) to the coolant temperature sensor as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C

Resistance 4.06.0 k a. Connect the pocket tester ( 1k) to the throttle position sensor terminals as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe blue 1 Negative tester probe black/blue 2

3 1
B/L Y L

b. Measure the throttle position sensor maximum resistance.

b. Immerse the coolant temperature sensor 1 in a container filled with coolant 2.

NOTE:

3. Install: Throttle position sensor

NOTE:

Make sure the coolant temperature sensor terminals do not get wet. c. Place a thermometer 3 in the coolant. d. Slowly heat the coolant, and then let it cool down to the specified temperature. e. Measure the coolant temperature sensor resistance.

EAS28300

When installing the throttle position sensor, adjust its angle properly. Refer to ADJUSTING THE THROTTLE POSITION SENSOR on page 7-11.
EAS28410

CHECKING THE THROTTLE POSITION SENSOR 1. Remove: Throttle position sensor (from the throttle body) 2. Check: Throttle position sensor maximum resistance Out of specification Replace the throttle position sensor.

CHECKING THE INTAKE AIR PRESSURE SENSORS The following procedure applies to both of the intake air pressures. 1. Check: Intake air pressure sensor output voltage Out of specification Replace. Intake air pressure sensor output voltage 3.754.25 V a. Connect the pocket tester (DC 20 V) to the intake air pressure sensor coupler as shown.

8-89

ELECTRICAL COMPONENTS
Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe pink 1 or pink/white Negative tester probe black/blue 2

3 1

b. Immerse the air temperature sensor 1 in a container filled with water 2.

NOTE:

B/L P L

Make sure that the air temperature sensor terminals do not get wet. c. Place a thermometer 3 in the water. d. Slowly heat the water, and then let it cool down to the specified temperature. e. Measure the air temperature sensor resistance.

b. Set the main switch to ON. c. Measure the intake air pressure sensor output voltage.

EAS28420

CHECKING THE AIR TEMPERATURE SENSOR 1. Remove: Air temperature sensor

EWA3D81003

WARNING

Handle the air temperature sensor with special care. Never subject the air temperature sensor to strong shocks. If the air temperature sensor is dropped, replace it. 2. Check: Air temperature sensor resistance Out of specification Replace. Air temperature sensor resistance 290390 at 80 C (176 F) a. Connect the pocket tester ( 100) to the air temperature sensor terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C

8-90

ELECTRICAL COMPONENTS

8-91

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

TROUBLESHOOTING
EAS28450

TROUBLESHOOTING
EAS28460

4. Throttle body(-ies) Deteriorated or contaminated fuel Sucked-in air Electrical system 1. Battery Discharged battery Faulty battery 2. Fuse(s) Blown, damaged or incorrect fuse Improperly installed fuse 3. Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap 4. Ignition coil(s) Cracked or broken ignition coil body Broken or shorted primary or secondary coils Faulty spark plug lead 5. Ignition system Faulty ECU Faulty crankshaft position sensor Broken generator rotor Woodruff key 6. Switches and wiring Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty start switch Faulty sidestand switch Faulty clutch switch Improperly grounded circuit Loose connections 7. Starting system Faulty starter motor Faulty starter relay Faulty relay unit (starting circuit cut-off relay) Faulty starter clutch
EAS28490

GENERAL INFORMATION
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.
EAS28470

STARTING FAILURES Engine 1. Cylinder(s) and cylinder head(s) Loose spark plug Loose cylinder head or cylinder Damaged cylinder head gasket Damaged cylinder gasket Worn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timing Faulty valve spring Seized valve 2. Piston(s) and piston ring(s) Improperly installed piston ring Damaged, worn or fatigued piston ring Seized piston ring Seized or damaged piston 3. Air filter Improperly installed air filter Clogged air filter element 4. Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft Fuel system 1. Fuel tank Empty fuel tank Clogged fuel filter Clogged fuel tank breather hose Clogged fuel tank overflow hose Clogged rollover valve Deteriorated or contaminated fuel 2. Fuel pump Faulty fuel pump Faulty relay unit (fuel pump relay) 3. Fuel cock Clogged or damaged fuel hose

INCORRECT ENGINE IDLING SPEED Engine 1. Cylinder(s) and cylinder head(s) Incorrect valve clearance Damaged valve train components 2. Air filter Clogged air filter element

9-1

TROUBLESHOOTING
Fuel system 1. Throttle body(-ies) Damaged or loose throttle body joint Improperly synchronized throttle bodies Improper throttle cable free play Flooded throttle body Electrical system 1. Battery Discharged battery Faulty battery 2. Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap 3. Ignition coil(s) Broken or shorted primary or secondary coils Faulty spark plug lead Cracked or broken ignition coil 4. Ignition system Faulty ECU Faulty crankshaft position sensor Broken generator rotor Woodruff key
EAS28510

Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission
EAS28550

JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog
EAS28560

FAULTY CLUTCH Clutch slips 1. Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2. Engine oil Incorrect oil level Incorrect oil viscosity (low) Deteriorated oil Clutch drags 1. Clutch Unevenly tensioned clutch springs Warped pressure plate Bent clutch plate Swollen friction plate Bent clutch pull rod Broken clutch boss Burnt primary driven gear bushing Match marks not aligned 2. Engine oil Incorrect oil level Incorrect oil viscosity (high) Deteriorated oil

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to STARTING FAILURES on page 9-1. Engine 1. Air filter Clogged air filter element Fuel system 1. Fuel pump Faulty fuel pump
EAS28530

FAULTY GEAR SHIFTING Shifting is difficult Refer to Clutch drags.

EAS28540

SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork

9-2

TROUBLESHOOTING
EAS28600 EAS28610

OVERHEATING Engine 1. Clogged coolant passages Cylinder head(s) and piston(s) Heavy carbon buildup 2. Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality Cooling system 1. Coolant Low coolant level 2. Radiator Damaged or leaking radiator Faulty radiator cap Bent or damaged radiator fin 3. Water pump Damaged or faulty water pump 4. Thermostat Thermostat stays closed 5. Hose(s) and pipe(s) Damaged hose Improperly connected hose Damaged pipe Improperly connected pipe Fuel system 1. Throttle body(-ies) Damaged or loose throttle body joint 2. Air filter Clogged air filter element Chassis 1. Brake(s) Dragging brake Electrical system 1. Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat range 2. Ignition system Faulty ECU 3. Cooling system Faulty radiator fan motor relay Faulty coolant temperature sensor Faulty ECU

OVERCOOLING Cooling system 1. Thermostat Thermostat stays open

EAS28620

POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level
EAS28650

FAULTY FRONT FORK LEGS Leaking oil Bent, damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level (high) Loose damper rod assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O-ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level
EAS28670

UNSTABLE HANDLING 1. Handlebar Bent or improperly installed handlebar 2. Steering head components Improperly installed upper bracket Improperly installed lower bracket (improperly tightened ring nut) Bent steering stem Damaged ball bearing or bearing race 3. Front fork leg(s) Uneven oil levels (both front fork legs)

9-3

TROUBLESHOOTING
Unevenly tensioned fork spring (both front fork legs) Broken fork spring Bent or damaged inner tube Bent or damaged outer tube 4. Swingarm Worn bearing or bushing Bent or damaged swingarm 5. Rear shock absorber assembly Faulty rear shock absorber spring Leaking oil or gas 6. Tire(s) Uneven tire pressures (front and rear) Incorrect tire pressure Uneven tire wear 7. Wheel(s) Incorrect wheel balance Deformed cast wheel Damaged wheel bearing Bent or loose wheel axle Excessive wheel runout 8. Frame Bent frame Damaged steering head pipe Improperly installed bearing race
EAS28710

Faulty battery Incorrectly adjusted rear brake light switch Tail/brake light bulb life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt-out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown, damaged or incorrect fuse Turn signal flashes slowly Faulty turn signal relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn signal remains lit Faulty turn signal relay Burnt-out turn signal bulb Turn signal flashes quickly Incorrect turn signal bulb Faulty turn signal relay Burnt-out turn signal bulb Horn does not sound Improperly adjusted horn Damaged or faulty horn Faulty main switch Faulty horn switch Faulty battery Blown, damaged or incorrect fuse Faulty wire harness

FAULTY LIGHTING OR SIGNALING SYSTEM Headlight does not come on Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts (main switch) Burnt-out headlight bulb Headlight bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier/regulator Improperly grounded circuit Faulty main switch Headlight bulb life expired Tail/brake light does not come on Wrong tail/brake light bulb Too many electrical accessories Incorrect connection Burnt-out tail/brake light bulb Tail/brake light bulb burnt out Wrong tail/brake light bulb

9-4

XVS13AW(C)/XVS13CTW(C) 2007 WIRING DIAGRAM

15
A B C

12 13
WIRE HARNESS SUB WIREHARNESS WIRE HARNESS WIRE HARNESS SUB WIREHARNESS TAIL BRAKE LIGHT WIRE HARNESS

1 14

(GRAY)

(BLACK)

2 4 17 18
(BLACK) (BLACK)

16 28
(DARK GREEN)

30

3 29 19 27 31 30

20 7 21
(BLACK) A A A A

5 8 10 9
(BLACK) (BLACK)

ON OFF

6 22

23 26

(BLACK) A

11 24
(DARK GREEN)

25
(BLACK)

32
B

(DARK GRAY) B

33
B

( GRAY)

75

74 34 35 49 62
RESET

73

72 48 47 46
(BLACK)

71 63 50 51
(BLUE) (BLUE)

61 64 65 66

36 37

70

38 53 52
(BLACK) (L) N (R) (BLACK) (BLACK)

54

(BLACK)

(BLACK)

44 45
(BLACK)

39 40
(BLACK)

(BLACK)

41 42 58 57
C C

C C

69 67

68

43 60 59
(GRAY) (BLACK)

(BLACK)

(BLACK)

56
(GRAY) (GRAY) (BLACK) (BLACK)

55
(BLACK)

C (GRAY) (BLACK) (BLACK)

EAS28740

WIRING DIAGRAM
XVS13AW(C)/XVS13CTW(C) 2007 1. AC magneto 2. Rectifier/regulator 3. Main fuse 4. Backup fuse (odometer and clock) 5. Main switch 6. Battery 7. Fuel injection system fuse 8. Starter relay 9. Starter motor 10. Diode 1 11. Radiator fan motor fuse 12. Relay unit 13. Starting circuit cut-off relay 14. Fuel pump relay 15. Diode 2 16. Neutral switch 17. Fuel pump 18. Sidestand switch 19. Speed sensor 20. Crankshaft position sensor 21. Throttle position sensor 22. Rear cylinder intake air pressure sensor 23. Front cylinder intake air pressure sensor 24. Lean angle sensor 25. Coolant temperature sensor 26. Air temperature sensor 27. ECU (engine control unit) 28. Rear cylinder Ignition coil 29. Front cylinder Ignition coil 30. Spark plug 31. ISC (idle speed control ) unit 32. Front cylinder injector 33. Rear cylinder injector 34. Meter assembly 35. Fuel level warning light 36. Oil level warning light 37. Neutral indicator light 38. Multi-function meter 39. Engine trouble warning light 40. Coolant temperature warning light 41. High beam indicator light 42. Turn signal indicator light 43. Meter light 44. Oil level switch 45. Fuel sender 46. O2 sensor 47. Horn 48. Turn signal relay 49. Headlight relay 50. Left handlebar switch 51. Dimmer switch 52. Clutch switch

53. Turn signal switch 54. Horn switch 55. Rear right turn signal light 56. Rear left turn signal light 57. Front right turn signal light 58. Front left turn signal light 59. Headlight 60. Accessory light (OPTION) 61. Right handlebar switch 62. Front brake light switch 63. Select switch 64. Reset switch 65. Engine stop switch 66. Start switch 67. License plate light 68. Tail/brake light 69. Radiator fan motor 70. Rear brake light switch 71. Radiator fan motor relay 72. Headlight fuse 73. Ignition fuse 74. Signaling system fuse 75. Taillight fuse

EAS28750

COLOR CODE
B Br Ch Dg G Gy L O P R Sb W Y B/Br B/L B/R B/W B/Y Br/L Br/W G/L G/W G/Y Gy/B Gy/R Gy/W L/B L/G L/R L/W L/Y O/R P/B P/L P/W R/B R/G R/L R/W R/Y Sb/W V/G W/G W/L W/Y Y/B Y/G Y/L Y/R Black Brown Chocolate Dark green Green Gray Blue Orange Pink Red Sky blue White Yellow Black/Brown Black/Blue Black/Red Black/White Black/Yellow Brown/Blue Brown/White Green/Blue Green/White Green/Yellow Gray/Black Gray/Red Gray/White Blue/Black Blue/Green Blue/Red Blue/White Blue/Yellow Orange/Red Pink/Black Pink/Blue Pink/White Red/Black Red/Green Red/Blue Red/White Red/Yellow Sky blue/White Violet/Green White/Green White/Blue White/Yellow Yellow/Black Yellow/Green Yellow/Blue Yellow/Red

YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN