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Related Manuals for Yamaha FZ1-N

FZ1-N(V)

FZ1-S(V)

2006

SERVICE MANUAL

2D1-28197-E0

EAS20040

FZ1-N (V)/FZ1-S (V)

SERVICE MANUAL

©2005 by Yamaha Motor Co., Ltd.

First edition, December 2005

All rights reserved.

Any reproduction or unauthorized use without the written permission of Yamaha Motor Co.,

Ltd. is expressly prohibited.

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!

WARNING

CAUTION:

NOTE:

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.

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 is shown at the top of each page “1”.

• Sub-section titles appear in smaller print than the section title “2”.

• To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section “3”.

• Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step “4”.

• Symbols indicate parts to be lubricated or replaced “5”.

Refer to “SYMBOLS”.

• A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc “6”.

• Jobs requiring more information (such as special tools and technical data) are described sequentially “7”.

EAS20100

SYMBOLS

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

NOTE:

The following symbols are not relevant to every vehicle.

1 2 3

16.Replace the part

4

7

5

8

.

T

R

.

6

9

12

15

E

B

10

G

13

LS

11

M

14

M

16

LT

New

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®)

EAS20110

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

1

2

PERIODIC CHECKS AND ADJUSTMENTS

3

CHASSIS

ENGINE

COOLING SYSTEM

FUEL SYSTEM

6

7

4

5

ELECTRICAL SYSTEM

TROUBLESHOOTING

8

9

GENERAL INFORMATION

IDENTIFICATION

……………………………………………………………………………… 1-1

VEHICLE IDENTIFICATION NUMBER…………………………………………… 1-1

MODEL LABEL…………………………………………………………………………… 1-1

FEATURES

……………………………………………………………………………………… 1-2

FI SYSTEM

……………………………………………………………………………………… 1-3

INSTRUMENT FUNCTIONS

………………………………………………………………. 1-4

IMPORTANT INFORMATION

…………………………………………………………….. 1-8

PREPARATION FOR REMOVAL AND DISASSEMBLY…………………….. 1-8

REPLACEMENT PARTS ……………………………………………………………… 1-8

GASKETS, OIL SEALS AND O-RINGS………………………………………….. 1-8

LOCK WASHERS/PLATES AND COTTER PINS …………………………….. 1-8

BEARINGS AND OIL SEALS ……………………………………………………….. 1-9

CIRCLIPS ………………………………………………………………………………….. 1-9

CHECKING THE CONNECTIONS

……………………………………………………. 1-10

SPECIAL TOOLS

…………………………………………………………………………… 1-11

1

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.

IDENTIFICATION

1-1

FEATURES

EAS20170

FEATURES

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 air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.

As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection

(FI) system, in place of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors.

The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions.

1. Ignition coil

2. Air filter case

3. Intake air temperature sensor

4. Fuel delivery hose

5. Fuel tank

6. Fuel pump

7. Intake air pressure sensor

8. Throttle position sensor

9. Sub-throttle position sensor

10.Fuel injector

11.Catalytic converter

12.Crankshaft position sensor

13.Coolant temperature sensor

1-2

14.Spark plug

15.Cylinder identification sensor

16.Battery

17.ECU

18.Atomospheric pressure sensor

19.Relay unit (fuel pump relay)

20.Engine trouble warning light

21.Lean angle sensor

22.Air cut-off valve

23.O

2

sensor

FI SYSTEM

ET2D1001

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

2

, 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 remain 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, speed sensor and O

2

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.

1. Fuel pump

2. Fuel injector

3. Ignition coil

4. ECU (engine control unit)

5. Intake air temperature sensor

6. Throttle position sensor

7. Sub-throttle position sensor

8. O

2

sensor

9. Catalytic converter

10.Coolant temperature sensor

11.Crankshaft position sensor

12.Intake air pressure sensor

1-3

13.Throttle body

14.Air filter case

A. Fuel system

B. Air system

C. Control system

ET2D1002

INSTRUMENT FUNCTIONS

Multi-function meter unit

INSTRUMENT FUNCTIONS

kilometers and miles, press the “SELECT” button for at least one second.

Tachometer

1. Coolant temperature display/air intake temperature display

2. Speedometer

3. Tachometer

4. Odometer/tripmeter/fuel reserve tripmeter

5. “SELECT” button

6. “RESET” button

7. Clock

8. Fuel meter

EW2D1005

WARNING

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

The multi-function meter unit is equipped with the following:

• a speedometer (which shows the riding speed)

• a tachometer (which shows engine speed)

• an odometer (which shows the total distance traveled)

• two tripmeters (which show the distance traveled since they were last set to zero)

• a fuel reserve tripmeter (which shows the distance traveled since the left segment of the fuel meter started flashing)

• a clock

• a fuel meter

• a coolant temperature display

• an air intake temperature display

• a self-diagnosis device

• an LCD and tachometer brightness control mode

NOTE:

• Be sure to turn the key to “ON” before using the “SELECT” and “RESET” buttons.

• For the U.K. only: To switch the speedometer and odometer/tripmeter displays between

1. Tachometer

2. Tachometer red zone

The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range.

When the key is turned to “ON”, the tachometer needle will sweep once across the r/min range and then return to zero r/min in order to test the electrical circuit.

EC2D1007

CAUTION:

Do not operate the engine in the tachometer red zone.

Red zone: 12000 r/min and above

Clock mode

1. Clock

2. Speedometer

The clock is displayed when the key is turned to “ON”. In addition, the clock can be displayed for 10 seconds by pushing the “SELECT” button when the main switch is in the “OFF” or

“LOCK” position.

To set the clock

1. Turn the key to “ON”.

2. Push the “SELECT” button and “RESET” button together for at least two seconds.

1-4

INSTRUMENT FUNCTIONS

3. When the hour digits start flashing, push the “RESET” button to set the hours.

4. Push the “SELECT” button, and the minute digits will start flashing.

5. Push the “RESET” button to set the minutes.

6. Push the “SELECT” button and then release it to start the clock.

Odometer and tripmeter modes

1. Odometer/tripmeter/fuel reserve tripmeter

Push the “SELECT” button to switch the display between the odometer mode “ODO” and the tripmeter modes “TRIP A” and “TRIP B” in the following order:

TRIP A

→

TRIP B

→

ODO

→

TRIP A

When the fuel amount in the fuel tank decreases to 3.4 L (0.90 US gal) (0.75

Imp.gal), the left segment of the fuel meter will start flashing, and the odometer display will automatically change to the fuel reserve tripmeter mode “FTRIP” and start counting the distance traveled from that point. In that case, push the “SELECT” button to switch the display between the various tripmeter and odometer modes in the following order:

F-TRIP

→

TRIP A

→

TRIP B

→

ODO

→

F-

TRIP

To reset a tripmeter, select it by pushing the

“SELECT” button, and then push the “RESET” button for at least one second. If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km (3 mi).

Fuel meter

1. Fuel meter

The fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter disappear towards “E” (Empty) as the fuel level decreases. When only one segment is left near “E”, refuel as soon as possible.

NOTE:

This fuel meter is equipped with a self-diagnosis system. If the electrical circuit is defective, the following cycle will be repeated until the malfunction is corrected: “E” (Empty), “F” (Full) and symbol “ ” will flash eight times, then go off for approximately 3 seconds. If this occurs, have a Yamaha dealer check the electrical circuit.

Coolant temperature mode

1. Coolant temperature display

The coolant temperature display indicates the temperature of the coolant.

Push the “RESET” button to switch the coolant temperature display to the air intake temperature display.

NOTE:

When the coolant temperature display is selected, “C” is displayed for one second, and then the coolant temperature is displayed.

EC2D1011

CAUTION:

Do not operate the engine if it is overheated.

1-5

Air intake temperature mode

1. Air intake temperature display

The air intake temperature display indicates the temperature of the air drawn into the air filter case. Push the “RESET” button to switch the coolant temperature display to the air intake temperature display.

NOTE:

• Even if the air intake temperature is set to be displayed, the coolant temperature warning light comes on when the engine overheats.

• When the key is turned to “ON”, the coolant temperature is automatically displayed, even if the air intake temperature was displayed prior to turning the key to “OFF”.

• When the air intake temperature display is selected, “A” is displayed for one second, and then the air intake temperature is displayed.

Self-diagnosis device

INSTRUMENT FUNCTIONS

light will flash, and then the display will indicate a two-digit error code (e.g., 51, 52, 53).

NOTE:

If the display indicates error code 52, this could be caused by transponder interference. If this error code appears, try the following.

1. Use the code re-registering key to start the engine.

NOTE:

Make sure there are no other immobilizer keys close to the main switch, and do not keep more than one immobilizer key on the same key ring!

Immobilizer system keys may cause signal interference, which may prevent the engine from starting

2. If the engine starts, turn it off and try starting the engine with the standard keys.

3. If one or both of the standard keys do not start the engine, take the vehicle, the code re-registering key and both standard keys to a Yamaha dealer and have the standard keys re-registered.

If the display indicates any error codes, note the code number, and then have a Yamaha dealer check the vehicle.

EC2D1012

CAUTION:

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

LCD and tachometer brightness control mode

1. Error code display

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 display will indicate a two-digit error code (e.g.,

11, 12, 13).

This model is also equipped with a self-diagnosis device for the immobilizer system.

If any of the immobilizer system circuits are defective, the immobilizer system indicator

1-6

1. Tachometer panel

2. Tachometer needle

3. LCD

4. Brightness level

This function allows you to adjust the brightness of the LCD and the tachometer panel and needle to suit the outside lighting conditions.

To set the brightness

1. Turn the key to “OFF”.

2. Push and hold the “SELECT” button.

3. Turn the key to “ON”, and then release the

“SELECT” button after five seconds.

4. Push the “RESET” button to select the desired brightness level.

5. Push the “SELECT” button to confirm the selected brightness level. The display will return to the odometer or tripmeter mode.

INSTRUMENT FUNCTIONS

1-7

IMPORTANT INFORMATION

EAS20180

IMPORTANT INFORMATION

EAS20190

PREPARATION FOR REMOVAL AND DISAS-

SEMBLY

1. Before removal and disassembly, remove all dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning equipment.

Refer to «SPECIAL TOOLS» on page 1-11.

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.

EAS20210

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.

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

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. Oil

2. Lip

3. Spring

4. Grease

EAS20220

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.

1-8

EAS20230

BEARINGS AND OIL SEALS

Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible.

When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

ECA13300

CAUTION:

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

IMPORTANT INFORMATION

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.

1-9

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.

CHECKING THE CONNECTIONS

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)

1-10

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 number starting with “YM-”, “YU-”, or “ACC-”.

• For others, use part number starting with “90890-”.

Tool name/Tool No.

Piston pin puller set

90890-01304

Piston pin puller

YU-01304

Illustration

Reference pages

5-71

Radiator cap tester

90890-01325

Radiator pressure tester

YU-24460-01

6-3

Radiator cap tester adapter

90890-01352

Radiator pressure tester adapter

YU-33984

Steering nut wrench

90890-01403

Spanner wrench

YU-33975

Ring nut wrench

90890-01268

Spanner wrench

YU-01268

Damper rod holder

90890-01423

Damping rod holder

YM-01423

6-3

3-27, 4-59

4-59

4-51, 4-52

1-11

Tool name/Tool No.

Oil filter wrench

90890-01426

YU-38411

Rod holder

90890-01434

Damper rod holder double ended

YM-01434

Rod puller

90890-01437

Universal damping rod bleeding tool set

YM-A8703

Rod puller attachment (M10)

90890-01436

Universal damping rod bleeding tool set

YM-A8703

Fork spring compressor

90890-01441

YM-01441

Fork seal driver

90890-01442

Adjust table fork seal driver (36-46 mm)

YM-01442

Vacuum gauge

90890-03094

Carburetor synchronizer

YU-44456

Illustration

SPECIAL TOOLS

Reference pages

3-13

4-53

3-7

4-50, 4-55

4-54

4-54

4-50, 4-55

1-12

Tool name/Tool No.

Compression gauge

90890-03081

Engine compression tester

YU-33223

Valve spring compressor

90890-04019

YM-04019

Valve spring compressor attachment

90890-04108

Valve spring compressor adapter (22 mm)

YM-04108

Valve spring compressor attachment

90890-04114

Valve spring compressor adapter

YM-04114

Middle driven shaft bearing driver

90890-04058

Bearing driver (40 mm)

YM-04058

Mechanical seal installer

90890-04078

Water pump seal installer

YM-33221-A

Universal clutch holder

90890-04086

YM-91042

Illustration

SPECIAL TOOLS

Reference pages

3-11

5-23, 5-29

5-23, 5-29

5-23, 5-29

6-12

6-12

5-47, 5-51

1-13

Tool name/Tool No.

Valve guide remover (ø4)

90890-04111

Valve guide remover (4.0 mm)

YM-04111

Valve guide remover (ø4.5)

90890-04116

Valve guide remover (4.5 mm)

YM-04116

Valve guide installer (ø4)

90890-04112

Valve guide installer (4.0 mm)

YM-04112

Valve guide installer (ø4.5)

90890-04117

Valve guide installer (4.5 mm)

YM-04117

Valve guide reamer (ø4)

90890-04113

Valve guide reamer (4.0 mm)

YM-04113

Valve guide reamer (ø4.5)

90890-04118

Valve guide reamer (4.5 mm)

YM-04118

Ignition checker

90890-06754

Opama pet-4000 spark checker

YU-34487

Illustration

SPECIAL TOOLS

Reference pages

5-25

5-25

5-25

5-25

5-25

5-25

8-104

1-14

Tool name/Tool No.

Yamaha bond No.1215

(Three Bond No.1215®)

90890-85505

Digital circuit tester

90890-03174

Model 88 Multimeter with tachometer

YU-A1927

Pivot shaft wrench

90890-01518

Frame spanner socket

YM-01518

Pivot shaft wrench adapter

90890-01476

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

Oil pressure gauge

90890-03153

Pressure gauge

YU-03153

Oil pressure gauge adapter

90890-03139

Illustration

SPECIAL TOOLS

Reference pages

5-67, 6-12

7-9, 7-10

5-7

5-7

1-10, 5-41, 8-

95, 8-96, 8-97,

8-100, 8-102, 8-

103, 8-104, 8-

105, 8-106, 8-

107, 8-108, 8-

109, 8-110, 8-

111, 8-112

3-14

3-14

1-15

Tool name/Tool No.

Vacuum/pressure pump gauge set

90890-06756

Valve lapper

90890-04101

Valve lapping tool

YM-A8998

Fuel pressure adapter

90890-03176

YM-03176

Pressure gauge

90890-03153

YU-03153

Camshaft wrench

90890-04143

YM-04143

Illustration

SPECIAL TOOLS

7-8

Reference pages

3-5

7-8

3-14, 7-8

5-11, 5-16

1-16

1-17

SPECIAL TOOLS

SPECIFICATIONS

GENERAL SPECIFICATIONS

……………………………………………………………. 2-1

ENGINE SPECIFICATIONS

……………………………………………………………….. 2-1

CHASSIS SPECIFICATIONS

…………………………………………………………….. 2-8

ELECTRICAL SPECIFICATIONS

……………………………………………………… 2-10

TIGHTENING TORQUES

…………………………………………………………………. 2-12

GENERAL TIGHTENING TORQUE SPECIFICATIONS………………….. 2-12

ENGINE TIGHTENING TORQUES ……………………………………………… 2-13

CHASSIS TIGHTENING TORQUES ……………………………………………. 2-17

LUBRICATION POINTS AND LUBRICANT TYPES

……………………………. 2-20

ENGINE …………………………………………………………………………………… 2-20

CHASSIS …………………………………………………………………………………. 2-22

LUBRICATION SYSTEM CHART AND DIAGRAMS

…………………………… 2-23

ENGINE OIL LUBRICATION CHART …………………………………………… 2-23

LUBRICATION DIAGRAMS ………………………………………………………… 2-25

COOLING SYSTEM DIAGRAMS

……………………………………………………… 2-35

CABLE ROUTING

………………………………………………………………………….. 2-39

2

GENERAL SPECIFICATIONS

EAS20280

GENERAL SPECIFICATIONS

Model

Model 2D11 (EUR)

2D13 (AUS)

3C31 (EUR)

3C33 (AUS)

3C37 (EUR)

3C39 (AUS)

Dimensions

Overall length

Overall width

Overall height

Seat height

Wheelbase

Ground clearance

Minimum turning radius

Weight

With oil and fuel

Maximum load

EAS20290

ENGINE SPECIFICATIONS

Engine

Engine type

Displacement

Cylinder arrangement

Bore

×

stroke

Compression ratio

Standard compression pressure (at sea level)

Starting system

Fuel

Recommended fuel

Fuel tank capacity

Fuel reserve amount

Engine oil

Lubrication system

Type

Recommended engine oil grade

Engine oil quantity

Total amount

Without oil filter cartridge replacement

With oil filter cartridge replacement

Oil filter

Oil filter type

Oil pump

Oil pump type

2-1

2140 mm (84.3 in)

770 mm (30.3 in)

1060 mm (41.7 in) (FZ1-N)

1205 mm (47.4 in) (FZ1-S)

815 mm (32.1 in)

1460 mm (57.5 in)

135 mm (5.31 in)

3000 mm (118.1 in)

214.0 kg (472 lb) (FZ1-N)

220.0 kg (485 lb) (FZ1-S)

196 kg (432 lb) (FZ1-N)

190 kg (419 lb) (FZ1-S)

Liquid cooled 4-stroke, DOHC

998.0 cm³ (60.90 cu.in)

Forward-inclined parallel 4-cylinder

77.0

×

53.6 mm (3.03

×

2.11 in)

11.50 : 1

1480 kPa/350 r/min (210.5 psi/350 r/min) (14.8 kgf/cm²/350 r/min)

Electric starter

Regular unleaded gasoline only

18.0 L (4.76 US gal) (3.96 Imp.gal)

3.4 L (0.90 US gal) (0.75 Imp.gal)

Wet sump

SAE10W30 or SAE10W40 or SAE15W40 or

SAE20W40 or SAE20W50

API service SE, SF, SG type or higher

3.80 L (4.02 US qt) (3.34 Imp.qt)

2.90 L (3.07 US qt) (2.55 Imp.qt)

3.10 L (3.28 US qt) (2.73 Imp.qt)

Paper

Trochoid

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

Cooling system

Radiator capacity (including all routes)

Coolant reservoir capacity (up to the maximum level mark)

Radiator cap opening pressure

Radiator core

Width

Height

Depth

Water pump

Water pump type

Reduction ratio

Max impeller shaft tilt limit

Spark plug (s)

Manufacturer/model

Spark plug gap

Cylinder head

Volume

Warpage limit*

ENGINE SPECIFICATIONS

0.010–0.100 mm (0.0004–0.0039 in)

0.18 mm (0.0071 in)

0.090–0.150 mm (0.0035–0.0059 in)

0.22 mm (0.0087 in)

0.06–0.13 mm (0.0024–0.0051 in)

0.20 mm (0.0079 in)

80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20 kgf/cm²)

600.0–680.0 kPa (87.0–98.6 psi) (6.00–6.80 kgf/cm²)

2.25 L (2.38 US qt) (1.98 Imp.qt)

0.25 L (0.26 US qt) (0.22 Imp.qt)

93.3–122.7 kPa (13.5–17.8 psi) (0.93–1.23 kgf/cm²)

222.6 mm (8.76 in)

360.0 mm (14.17 in)

22.0 mm (0.87 in)

Single suction centrifugal pump

65/43

×

25/32 (1.181)

0.15 mm (0.0059 in)

NGK/CR9EK

0.6–0.7 mm (0.024–0.028 in)

12.20–13.00 cm³ (0.74–0.79 cu.in)

0.10 mm (0.0039 in)

Camshaft

Drive system

Camshaft cap inside diameter

Camshaft journal diameter

Camshaft-journal-to-camshaft-cap clearance

Camshaft lobe dimensions

Intake A

Limit

Intake B

Limit

Exhaust A

Limit

Exhaust B

Limit

Chain drive (right)

22.500–22.521 mm (0.8858–0.8867 in)

22.459–22.472 mm (0.8842–0.8847 in)

0.028–0.062 mm (0.0011–0.0024 in)

32.500–32.600 mm (1.2795–1.2835 in)

32.400 mm (1.2756 in)

24.950–25.050 mm (0.9823–0.9862 in)

24.850 mm (0.9783 in)

30.699–30.799 mm (1.2086–1.2126 in)

30.599 mm (1.2047 in)

22.950–23.050 mm (0.9035–0.9075 in)

22.850 mm (0.8996 in)

2-2

ENGINE SPECIFICATIONS

Camshaft runout limit

Timing chain

Model/number of links

Tensioning system

Valve, valve seat, valve guide

Valve clearance (cold)

Intake

Exhaust

Valve dimensions

Valve head diameter A (intake)

Valve head diameter A (exhaust)

Valve face width B (intake)

Valve face width B (exhaust)

Valve seat width C (intake)

Valve seat width C (exhaust)

0.030 mm (0.0012 in)

RH2020/122

Automatic

0.11–0.20 mm (0.0043–0.0079 in)

0.21–0.25 mm (0.0083–0.0098 in)

23.40–23.60 mm (0.9213–0.9291 in)

24.90–25.10 mm (0.9803–0.9882 in)

1.760–2.900 mm (0.0693–0.1142 in)

1.760–2.900 mm (0.0693–0.1142 in)

0.90–1.10 mm (0.0354–0.0433 in)

0.90–1.10 mm (0.0354–0.0433 in)

Valve margin thickness D (intake)

Valve margin thickness D (exhaust)

0.50–0.90 mm (0.0197–0.0354 in)

0.50–0.90 mm (0.0197–0.0354 in)

Valve stem diameter (intake)

Limit

Valve stem diameter (exhaust)

2-3

3.975–3.990 mm (0.1565–0.1571 in)

3.945 mm (0.1553 in)

4.460–4.475 mm (0.1756–0.1762 in)

Limit

Valve guide inside diameter (intake)

Limit

Valve guide inside diameter (exhaust)

Limit

Valve-stem-to-valve-guide clearance (intake)

Limit

Valve-stem-to-valve-guide clearance (exhaust)

Limit

Valve stem runout

ENGINE SPECIFICATIONS

4.425 mm (0.1742 in)

4.000–4.012 mm (0.1575–0.1580 in)

4.050 mm (0.1594 in)

4.500–4.512 mm (0.1772–0.1776 in)

4.550 mm (0.1791 in)

0.010–0.037 mm (0.0004–0.0015 in)

0.080 mm (0.0032 in)

0.025–0.052 mm (0.0010–0.0020 in)

0.100 mm (0.0039 in)

0.010 mm (0.0004 in)

Cylinder head valve seat width (intake)

Cylinder head valve seat width (exhaust)

Valve spring

Inner spring

Free length (intake)

Free length (exhaust)

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)*

0.90–1.10 mm (0.0354–0.0433 in)

0.90–1.10 mm (0.0354–0.0433 in)

40.47 mm (1.59 in)

40.53 mm (1.60 in)

32.66 mm (1.29 in)

33.88 mm (1.33 in)

17.53 N/mm (100.10 lb/in) (1.79 kgf/mm)

22.86 N/mm (130.53 lb/in) (2.33 kgf/mm)

21.52 N/mm (122.88 lb/in) (2.19 kgf/mm)

27.99 N/mm (159.82 lb/in) (2.85 kgf/mm)

127.40–144.60 N (28.64–32.51 lb) (12.99–

14.74 kgf)

133.00–153.00 N (29.90–34.39 lb) (13.56–

15.60 kgf)

2.5

°

/1.8 mm

2.5

°

/1.8 mm

Winding direction (intake)

Winding direction (exhaust)

Cylinder

Bore

Taper limit

Out of round limit

Piston

Piston-to-cylinder clearance

Limit

Diameter D

Height H

2-4

Clockwise

Clockwise

77.000–77.010 mm (3.0315–3.0319 in)

0.050 mm (0.0020 in)

0.050 mm (0.0020 in)

0.010–0.035 mm (0.0004–0.0014 in)

0.12 mm (0.0047 in)

76.975–76.990 mm (3.0305–3.0311 in)

5.0 mm (0.20 in)

ENGINE SPECIFICATIONS

Offset

Offset direction

Piston pin bore inside diameter

Piston pin outside diameter

Piston ring

Top ring

Ring type

Dimensions (B

×

T)

End gap (installed)

Ring side clearance

2nd ring

Ring type

Dimensions (B

×

T)

End gap (installed)

Ring side clearance

Oil ring

Dimensions (B

×

T)

End gap (installed)

Connecting rod

Oil clearance (using plastigauge®)

Bearing color code

Crankshaft

Width A

Width B

Runout limit C

Big end side clearance D

0.50 mm (0.0197 in)

Intake side

17.002–17.013 mm (0.6694–0.6698 in)

16.991–17.000 mm (0.6689–0.6693 in)

Barrel

0.90

×

2.75 mm (0.04

×

0.11 in)

0.15–0.25 mm (0.0059–0.0098 in)

0.030–0.065 mm (0.0012–0.0026 in)

Taper

0.80

×

2.75 mm (0.03

×

0.11 in)

0.30–0.45 mm (0.0118–0.0177 in)

0.020–0.055 mm (0.0008–0.0022 in)

1.50

×

2.25 mm (0.06

×

0.09 in)

0.10–0.40 mm (0.0039–0.0157 in)

0.034–0.058 mm (0.0013–0.0023 in)

1.Blue 2.Black 3.Brown 4.Green

55.20–56.60 mm (2.173–2.228 in)

298.75–300.65 mm (11.76–11.84 in)

0.030 mm (0.0012 in)

0.160–0.262 mm (0.0063–0.0103 in)

2-5

Journal oil clearance (using plastigauge®)

Bearing color code

Clutch

Clutch type

Clutch release method

Clutch lever free play

Friction plate thickness

Wear limit

Plate quantity

Clutch plate thickness

Plate quantity

Warpage limit

Clutch spring free length

Spring quantity

Transmission

Transmission type

Primary reduction system

Primary reduction ratio

Secondary reduction system

Secondary reduction ratio

Operation

Gear ratio

1st

2nd

3rd

4th

5th

6th

Main axle runout limit

Drive axle runout limit

Shifting mechanism

Shift mechanism type

Shift fork guide bar bending limit

Shift fork thickness

Air filter

Air filter element

Fuel pump

Pump type

Model/manufacturer

Maximum consumption amperage

Output pressure

Fuel injection

Model/quantity

Manufacturer

Throttle body

Type/quantity

Manufacturer

ID mark

Throttle valve size

Throttle position sensor

Resistance

Output voltage (at idle)

ENGINE SPECIFICATIONS

0.014–0.037 mm (0.0006–0.0015 in)

0.White 1.Blue 2.Black 3.Brown 4.Green

Wet, multiple-disc

Outer pull, rack and pinion pull

10.0–15.0 mm (0.39–0.59 in)

2.90–3.10 mm (0.114–0.122 in)

2.80 mm (0.1102 in)

9 pcs

1.90–2.10 mm (0.075–0.083 in)

8 pcs

0.10 mm (0.0039 in)

52.50 mm (2.07 in)

6 pcs

Constant mesh 6-speed

Spur gear

65/43 (1.512)

Chain drive

45/17 (2.647)

Left foot operation

38/15 (2.533)

33/16 (2.063)

37/21 (1.762)

35/23 (1.522)

27/20 (1.350)

29/24 (1.208)

0.08 mm (0.0032 in)

0.08 mm (0.0032 in)

Guide bar

0.100 mm (0.0039 in)

5.80–5.88 mm (0.2283–0.2315 in)

Oil-coated paper element

Electrical

2D1/DENSO

4.3 A

324.0 kPa (47.0 psi) (3.24 kgf/cm²)

297500-0300/4

DENSO

2-6

SE 45EIDW-B10/1

MIKUNI

2D11 00

#100

4.9–5.1 k

Ω

0.63–0.73 V

Idling condition

Engine idling speed

Intake vacuum

Water temperature

Oil temperature

Throttle cable free play

ENGINE SPECIFICATIONS

1100–1300 r/min

30.0 kPa (8.9 inHg) (225 mmHg)

95.0–105.0

°

C (203.00–221.00

°

F)

80.0–90.0

°

C (176.00–194.00

°

F)

3.0–5.0 mm (0.12–0.20 in)

2-7

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

Size

Manufacturer/model

Manufacturer/model

Wear limit (front)

Rear tire

Size

Manufacturer/model

Manufacturer/model

Wear limit (rear)

Tire air pressure (measured on cold tires)

Loading condition

Front

Rear

Loading condition

Front

Rear

High-speed riding

Front

Rear

Front brake

Type

Operation

Front brake lever free play

Front 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

Diamond

25.00

°

109.0 mm (4.29 in)

Cast wheel

17M/C x MT3.50

Aluminum

130.0 mm (5.12 in)

1.0 mm (0.04 in)

0.5 mm (0.02 in)

Cast wheel

17M/C x MT6.00

Aluminum

130.0 mm (5.12 in)

1.0 mm (0.04 in)

0.5 mm (0.02 in)

120/70 ZR17M/C (58W)

MICHELIN/Pilot Road S

DUNLOP/D221FA

0.8 mm (0.03 in)

190/50 ZR17M/C (73W)

MICHELIN/Pilot Road D

DUNLOP/D221G

0.8 mm (0.03 in)

0–90 kg (0–198 lb)

250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar)

290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar)

90–196 kg (198–432 lb) (FZ1-N)

90–190 kg (198–419 lb) (FZ1-S)

250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar)

290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar)

250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar)

290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar)

2-8

Dual disc brake

Right hand operation

2.3–11.5 mm (0.09–0.45 in)

320.0

×

4.5 mm (12.60

×

0.18 in)

4.0 mm (0.16 in)

0.10 mm (0.0039 in)

4.5 mm (0.18 in)

0.5 mm (0.02 in)

4.5 mm (0.18 in)

0.5 mm (0.02 in)

Master cylinder inside diameter

Caliper cylinder inside diameter

Caliper cylinder inside diameter

Recommended fluid

Rear brake

Type

Operation

Brake pedal free play

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

Collar length

Installed length

Spring rate K1

Spring stroke K1

Inner tube outer diameter

Inner tube bending limit

Optional spring available

Recommended oil

Quantity

Level

Rear suspension

Type

Spring/shock absorber type

Rear shock absorber assembly travel

Spring free length

Installed length

Spring rate K1

Spring stroke K1

Optional spring available

Enclosed gas/air pressure (STD)

Drive chain

Type/manufacturer

Link quantity

Drive chain slack

15-link length limit

2-9

CHASSIS SPECIFICATIONS

16.00 mm (0.63 in)

30.20 mm (1.19 in)

27.00 mm (1.06 in)

DOT 4

Single disc brake

Right foot operation

4.3–9.3 mm (0.17–0.37 in)

245.0

×

5.0 mm (9.65

×

0.20 in)

4.5 mm (0.18 in)

0.15 mm (0.0059 in)

6.0 mm (0.24 in)

1.0 mm (0.04 in)

6.0 mm (0.24 in)

1.0 mm (0.04 in)

12.7 mm (0.50 in)

38.20 mm (1.50 in)

DOT 4

Angular bearing

33.0

°

33.0

°

Telescopic fork

Coil spring/oil damper

130.0 mm (5.12 in)

243.5 mm (9.59 in)

100.0 mm (3.94 in)

239.0 mm (9.41 in)

9.32 N/mm (53.22 lb/in) (0.95 kgf/mm)

0.0–130.0 mm (0.00–5.12 in)

43.0 mm (1.69 in)

0.2 mm (0.01 in)

No

Suspension oil 01 or equivalent

545.0 cm³ (18.43 US oz) (19.18 Imp.oz)

91.0 mm (3.58 in)

Swingarm (link suspension)

Coil spring/gas-oil damper

60.0 mm (2.36 in)

191.3 mm (7.53 in)

181.8 mm (7.16 in)

120.00 N/mm (685.20 lb/in) (12.24 kgf/mm)

0.0–60.0 mm (0.00–2.36 in)

No

1000 kPa (142.2 psi) (10.0 kgf/cm²)

50VA8/DAIDO

122

25.0–35.0 mm (0.98–1.38 in)

239.3 mm (9.42 in)

ELECTRICAL SPECIFICATIONS

EAS20310

ELECTRICAL SPECIFICATIONS

Voltage

System voltage

Ignition system

Ignition system

Ignition timing (B.T.D.C.)

Engine control unit

Model/manufacturer

Transistorized coil ignition

Crankshaft position sensor resistance

Ignition coil

Model/manufacturer

Minimum ignition spark gap

Primary coil resistance

Secondary coil resistance

AC magneto

Model/manufacturer

Standard output

Stator coil resistance

Voltage regulator

Rectifier/regulator

Regulator type

Model/manufacturer

Regulated voltage (DC)

Rectifier capacity

Withstand voltage

Battery

Model

Voltage, capacity

Specific gravity

Manufacturer

Ten hour rate amperage

Headlight

Bulb type

Bulb voltage, wattage

×

quantity

Headlight

Auxiliary light

Tail/brake light

Front turn signal light

Rear turn signal light

License plate light

Meter lighting

Indicator light

Neutral indicator light

Turn signal indicator light

Oil level warning light

High beam indicator light

12 V

Transistorized coil ignition (digital)

5.0

°

/1200 r/min

TBDF20/DENSO

336–504

Ω

at 20

°

C (68

°

F)

F6T558/MITSUBISHI

6.0 mm (0.24 in)

1.19–1.61

Ω

at 20

°

C (68

°

F)

8.5–11.5 k

Ω

at 20

°

C (68

°

F)

STATOR:F074T85073/MITSUBISHI

14.0 V40.0 A6500 r/min

0.14–0.18

Ω

at 20

°

C (68

°

F)

Semi conductor-short circuit

FH012AA/SHINDENGEN

14.2–14.8 V

50.0 A

40.0 V

YTZ14S

12 V, 11.2 Ah

1.310

GYM

1.12 A

Halogen bulb

2-10

LED

LED

LED

LED

12 V, 60 W/55.0 W

×

1 (FZ1-N)

12 V, 60 W/55.0 W

×

2 (FZ1-S)

12 V, 5.0 W

×

2

12 V, 5.0 W/21.0 W

×

1

12 V, 10.0 W

×

2

12 V, 10.0 W

×

2

12 V, 5.0 W

×

1

LED

Coolant temperature warning light

Engine trouble warning light

Immobilizer system indicator light

Electric starting system

System type

Starter motor

Model/manufacturer

Power output

Armature coil resistance

Brush overall length

Limit

Brush spring force

Commutator diameter

Limit

Mica undercut (depth)

Starter relay

Model/manufacturer

Amperage

Coil resistance

Horn

Horn type

Quantity

Model/manufacturer

Maximum amperage

Coil resistance

Performance

Turn signal/hazard relay

Relay type

Model/manufacturer

Built-in, self-canceling device

Turn signal blinking frequency

Wattage

Oil level gauge

Model/manufacturer

Servo motor

Model/manufacturer

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

ELECTRICAL SPECIFICATIONS

LED

LED

LED

Constant mesh

SM13/MITSUBA

0.80 kW

0.0250–0.0350

Ω

12.5 mm (0.49 in)

5.00 mm (0.20 in)

7.65–10.01 N (27.54–36.03 oz) (780–1021 gf)

28.0 mm (1.10 in)

27.0 mm (1.06 in)

0.70 mm (0.03 in)

2768109-A/JIDECO

180.0 A

4.18–4.62

Ω

at 20

°

C (68

°

F)

Plane

1 pcs

YF-12/NIKKO

3.0 A

1.15–1.25

Ω

at 20

°

C (68

°

F)

105–113 dB/2m

Full transistor

FE218BH/DENSO

No

75.0–95.0 cycles/min

10 W

×

2.0 +3.4 W

5VY/SOMIC ISHIKAWA

2D1/YAMAHA

50.0 A

15.0 A (FZ1-N)

25.0 A (FZ1-S)

10.0 A

10.0 A

15.0 A

10.0 A

×

2

15.0 A

10.0 A

25.0 A (FZ1-S)

15.0 A

10.0 A

2-11

EAS20320

TIGHTENING TORQUES

EAS20330

GENERAL TIGHTENING TORQUE SPECIFI-

CATIONS

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.

TIGHTENING TORQUES

A. Distance between flats

B. Outside thread diameter

A (nut) B (bolt)

10 mm 6 mm

12 mm 8 mm

14 mm 10 mm

17 mm 12 mm

19 mm 14 mm 85

22 mm 16 mm 130

6

15

30

55

General tightening torques

Nm m·kg ft·lb

0.6

1.5

3.0

5.5

8.5

13.0

4.3

11

22

40

61

94

2-12

TIGHTENING TORQUES

EAS20340

ENGINE TIGHTENING TORQUES

Item

Spark plug

Cylinder head nut

Cylinder head bolt

Camshaft caps bolt

Cylinder head cover bolt

Cylinder head stud bolt (exhaust pipe)

Air indication system cap bolt

Camshaft sprocket bolt

Cylinder head and throttle body clamp

Connecting rod cap bolt (1st)

Connecting rod cap bolt (final)

Generator rotor bolt

Timing chain tensioner bolt

Water pump outlet pipe bolt

Water pump inlet pipe bolt (water pump side)

Water pump inlet pipe bolt (front side)

Oil/water pump drive sprocket bolt

Water pump bolt

Thermostat cover nut

Thermostat inlet pipe bolt

Oil cooler bolt

Engine oil drain bolt

Oil pipe bolt

Oil strainer bolt

Oil delivery pipe bolt

Oil filter union bolt

Oil filter

Oil pan bolt

Oil pan bolt

Air filter case cover screw

Throttle body and throttle body joint clamp

Throttle body and funnel bolt

Throttle cable adjusting bolt

Thread size

M10

M10

Q’ty

4

10

M6

M6

M6

M8

2

28

6

8

M6

M7

M5

M8

M8

M10

M6

M6

M6

M6

M6

M6

M6

M6

M20

M14

M6

M6

M6

M20

M20

M6

M6

M5

M5

M5

M6

4

4

4

1

1

3

1

1

1

2

3

14

1

11

4

5

2

1

1

6

1

8

8

1

2

1

1

2-13

Tightening torque

13 Nm (1.3 m·kg, 9.4 ft·lb)

See NOTE

12 Nm (1.2 m·kg, 8.7 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

12 Nm (1.2 m·kg, 8.7 ft·lb)

15 Nm (1.5 m·kg, 11 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

24 Nm (2.4 m·kg, 17 ft·lb)

3 Nm (0.3 m·kg, 2.2 ft·lb)

20 Nm (2.0 m·kg, 14 ft·lb)

Specified angle 150

°

60 Nm (6.0 m·kg, 43 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

15 Nm (1.5 m·kg, 11 ft·lb)

12 Nm (1.2 m·kg, 8.7 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

63 Nm (6.3 m·kg, 46 ft·lb)

43 Nm (4.3 m·kg, 31 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

70 Nm (7.0 m·kg, 51 ft·lb)

17 Nm (1.7 m·kg, 12 ft·lb)

12 Nm (1.2 m·kg, 8.7 ft·lb)

12 Nm (1.2 m·kg, 8.7 ft·lb)

1.2 Nm (0.12 m·kg, 0.9 ft·lb)

3 Nm (0.3 m·kg, 2.2 ft·lb)

4.2 Nm (0.42 m·kg, 3.0 ft·lb)

4.5 Nm (0.45 m·kg, 3.3 ft·lb)

Remarks

Item

Cylinder head and exhaust pipe nut

Exhaust pipe and muffler bolt

EXUP pulley and shaft arm nut

EXUP valve pulley cover bolt

EXUP cable nut

Exhaust pipe and exhaust pipe bracket bolt

EXUP servo motor cover bolt

EXUP servo motor nut

Crankcase stud bolt

Crankcase bolt (main journal)

Crankcase bolt

Crankcase bolt

Crankcase bolt

Thread size

M8

Q’ty

8

M8

M6

M6

M6

M8

M5

M6

M10

M9

M6

M6

M8

1

1

2

2

2

8

1

2

1

10

10

2

Crankcase bolt

Generator rotor cover bolt

Generator rotor cover bolt

Drive sprocket cover bolt

Crankcase cover screw

Clutch cover bolt

Clutch cover bolt

Pickup rotor cover bolt

Breather cover bolt

Breather plate bolt

Plate bolt

Pickup rotor cover blind bolt

Generator rotor cover plug

Main gallery plug (oil return)

Main gallery plug

Oil return pipe bolt

Oil return plug

AC magneto lead bolt

Stator coil screw

Generator rotor cover screw

Thermostat assembly stay bolt

Starter clutch idler gear bolt

Clutch boss nut

5

1

3

3

2

1

1

6

4

3

2

3

7

1

4

3

3

3

1

1

1

2

2

M8

M6

M6

M6

M6

M6

M20

M6

M6

M6

M6

M6

M8

M6

M6

M6

M6

M8

M20

M16

M20

M6

M12

2-14

TIGHTENING TORQUES

Remarks Tightening torque

20 Nm (2.0 m·kg, 14 ft·lb)

20 Nm (2.0 m·kg, 14 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

14 Nm (1.4 m·kg, 10 ft·lb)

6 Nm (0.6 m·kg, 4.3 ft·lb)

20 Nm (2.0 m·kg, 14 ft·lb)

2 Nm (0.2 m·kg, 1.4 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

8 Nm (0.8 m·kg, 5.8 ft·lb)

See NOTE

10 Nm (1.0 m·kg, 7.2 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

24 Nm (2.4 m·kg, 17 ft·lb)

24 Nm (2.4 m·kg, 17 ft·lb)

12 Nm (1.2 m·kg, 8.7 ft·lb)

22 Nm (2.2 m·kg, 16 ft·lb)

12 Nm (1.2 m·kg, 8.7 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

12 Nm (1.2 m·kg, 8.7 ft·lb)

12 Nm (1.2 m·kg, 8.7 ft·lb)

12 Nm (1.2 m·kg, 8.7 ft·lb)

12 Nm (1.2 m·kg, 8.7 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

12 Nm (1.2 m·kg, 8.7 ft·lb)

15 Nm (1.5 m·kg, 11 ft·lb)

8 Nm (0.8 m·kg, 5.8 ft·lb)

8 Nm (0.8 m·kg, 5.8 ft·lb)

8 Nm (0.8 m·kg, 5.8 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

24 Nm (2.4 m·kg, 17 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

14 Nm (1.4 m·kg, 10 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

95 Nm (9.5 m·kg, 69 ft·lb) Stake

TIGHTENING TORQUES

Item

Clutch spring bolt

Drive sprocket nut

Bearing plate bolt

Shift fork stopper plate bolt

Stopper screw

Shift rod locknut (front)

Shift rod locknut (rear)

Shift rod joint bolt M6

Shift arm bolt

Neutral switch

Sub-throttle servo motor cover bolt

Coolant temperature sensor

Cylinder identification sensor bolt

M6

M10

M4

M12

M6

Atmospheric pressure sensor bolt M5

Crankshaft position sensor bolt M6

Oil level switch bolt

Starter motor bolt

M6

M6

Thread size

M6

Q’ty

6

M22

M6

M6

M8

M6

M6

1

1

1

1

3

2

1

1

1

3

2

1

1

1

2

2

Tightening torque

10 Nm (1.0 m·kg, 7.2 ft·lb)

85 Nm (8.5 m·kg, 61 ft·lb)

12 Nm (1.2 m·kg, 8.7 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

22 Nm (2.2 m·kg, 16 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

20 Nm (2.0 m·kg, 14 ft·lb)

2 Nm (0.2 m·kg, 1.4 ft·lb)

18 Nm (1.8 m·kg, 13 ft·lb)

8 Nm (0.8 m·kg, 5.8 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

Remarks

Use a lock washer

Left thread

NOTE:

• Cylinder head nut

1 First, tighten the bolts to approximately 19 Nm (1.9 m•kg, 14 ft•lb) with a torque wrench following the tightening order.

2 Retighten the bolts 67 Nm (6.7 m•kg, 48 ft•lb) with a torque wrench.

• Connecting rod cap bolt

1 Tighten the connecting rod bolts to 20 Nm (2.0 m•kg, 14 ft•lb) and then tighten them further to reach the specified angle 150°.

• Crankcase bolt (main journal)

1 First, tighten the bolts to approximately 20 Nm (2.0 m•kg, 14 ft•lb) with a torque wrench following the tightening order.

2 Loosen all the bolts one by one following the tightening order and then tighten them to 20 Nm (2.0 m•kg, 14 ft•lb) again.

3 Retighten the bolts further to reach the specified angle (60°)

2-15

2-16

TIGHTENING TORQUES

TIGHTENING TORQUES

EAS20350

CHASSIS TIGHTENING TORQUES

Item

Upper bracket pinch bolt

Steering stem nut

Upper handlebar holder bolt

Lower handlebar holder nut

Lower bracket pinch bolt

Lower ring nut

Cap bolt

Damper rod assembly bolt

Brake master cylinder bracket bolt M6

Brake master cylinder reservoir cap screw

M4

Front brake hose union bolt

Front brake hose holder bolt

Cowling stay bolt (FZ1-S)

Cowling bracket bolt (FZ1-S)

M10

M6

M8

M6

Front fender bolt

Clutch lever holder pinch bolt

M6

M6

Right front engine mounting bolt 1 M10

Right front engine mounting bolt 2 M10

Left front engine mounting bolt M10

Upper self-locking nut

Lower self-locking nut

Engine mounting adjust bolt

(upper)

Engine mounting adjust bolt

(lower)

Pivot shaft nut

Connecting arm nut (connecting arm and frame)

Relay arm nut (relay arm and swingarm)

Relay arm nut (relay arm and connecting arm)

Main frame and rear frame nut

M10

M10

M11

M11

M18

M10

M10

M10

M10

Clutch cable locknut

Throttle cable locknut

Rear shock absorber assembly upper nut

Rear shock absorber assembly lower nut

Drive chain guard bolt

Drive chain guide bolt

Rear fender screw

M8

M6

M10

M10

M6

M6

M6

Thread size

M8

M28

M8

M10

M8

M30

M46

M10

Q’ty

1

1

1

1

1

1

3

2

3

4

1

1

1

1

2

2

3

2

1

1

1

4

1

2

1

2

1

4

1

4

2

2

1

2

2

2-17

Tightening torque

26 Nm (2.6 m·kg, 19 ft·lb)

113 Nm (11.3 m·kg, 82 ft·lb)

24 Nm (2.4 m·kg, 17 ft·lb)

32 Nm (3.2 m·kg, 23 ft·lb)

23 Nm (2.3 m·kg, 17 ft·lb)

SEE NOTE

23 Nm (2.3 m·kg, 17 ft·lb)

23 Nm (2.3 m·kg, 17 ft·lb)

10 Nm (1.0 m·kg, 7.2 ft·lb)

2 Nm (0.2 m·kg, 1.4 ft·lb)

30 Nm (3.0 m·kg, 22 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

33 Nm (3.3 m·kg, 24 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

6 Nm (0.6 m·kg, 4.3 ft·lb)

11 Nm (1.1 m·kg, 8.0 ft·lb)

45 Nm (4.5 m·kg, 33 ft·lb)

50 Nm (5.0 m·kg, 36 ft·lb)

45 Nm (4.5 m·kg, 33 ft·lb)

51 Nm (5.1 m·kg, 37 ft·lb)

51 Nm (5.1 m·kg, 37 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

105 Nm (11 m·kg, 76 ft·lb)

44 Nm (4.4 m·kg, 32 ft·lb)

44 Nm (4.4 m·kg, 32 ft·lb)

44 Nm (4.4 m·kg, 32 ft·lb)

41 Nm (4.1 m·kg, 30 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

5 Nm (0.5 m·kg, 3.6 ft·lb)

44 Nm (4.4 m·kg, 32 ft·lb)

44 Nm (4.4 m·kg, 32 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

Remarks

TIGHTENING TORQUES

Item

Rear brake hose holder screw

Fuel tank bolt (front)

Fuel tank bolt (rear)

Fuel tank bracket screw

Fuel tank cap bolt

Fuel pump bolt

Seat lock assembly nut

Mud guard assembly bolt

License plate light screw

Rear reflector nut

Mud guard assembly bracket screw

Tail/brake light bracket bolt

Rear fender bracket bolt

Seat bracket bolt

Exhaust pipe assembly bracket bolt

Side cover screw

Lean angle sensor bolt

Coolant reserver tank bolt

Front wheel axle shaft

Front wheel axle pinch bolt

Front brake caliper bolt

Front brake disc screw

M8

M6

M6

M8

Brake caliper bleed screw

Rear wheel axle nut

Rear brake disc screw

Rear brake caliper bolt (front)

Rear brake caliper bolt (rear)

Rear wheel sprocket nut

Drive chain adjusting locknut

Rear brake hose union bolt

Sidestand nut

Sidestand bracket bolt

Sidestand switch bolt

M10

M5

Footrest bracket bolt M8

Rear brake fluid reserver tank bolt M5

Rear brake master cylinder bolt

Centerstand nut (FZ1-S)

Centerstand bracket nut (FZ1-S)

Centerstand bracket adapter bolt

(FZ1-S)

Footrest bolt

Throttle cable adjust nut

M8

M10

M10

M10

M10

M6

M12

M8

M10

M8

M10

M10

M6

M4

M6

M18

M8

M10

M6

M8

M24

M8

Thread size

M6

M6

M6

M6

M5

M5

M6

M8

M5

M5

M5

Q’ty

4

2

3

2

4

2

6

2

4

5

2

3

1

2

6

4

2

1

4

10

1

1

2

2

3

1

5

4

2

2

2

4

1

2

2

2

1

6

2

1

1

2-18

Tightening torque

7 Nm (0.7 m·kg, 5.1 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

6 Nm (0.6 m·kg, 4.3 ft·lb)

4 Nm (0.4 m·kg, 2.9 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

16 Nm (1.6 m·kg, 12 ft·lb)

4 Nm (0.4 m·kg, 2.9 ft·lb)

4 Nm (0.4 m·kg, 2.9 ft·lb)

2 Nm (0.2 m·kg, 1.4 ft·lb)

16 Nm (1.6 m·kg, 12 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

7 Nm (0.7 m·kg, 5.1 ft·lb)

20 Nm (2.0 m·kg, 14 ft·lb)

4 Nm (0.4 m·kg, 2.9 ft·lb)

2 Nm (0.2 m·kg, 1.4 ft·lb)

5 Nm (0.5 m·kg, 3.6 ft·lb)

72 Nm (7.2 m·kg, 52 ft·lb)

23 Nm (2.3 m·kg, 17 ft·lb)

40 Nm (4.0 m·kg, 29 ft·lb)

18 Nm (1.8 m·kg, 13 ft·lb)

5 Nm (0.5 m·kg, 3.6 ft·lb)

150 Nm (15.0 m·kg, 108 ft·lb)

30 Nm (3.0 m·kg, 22 ft·lb)

27 Nm (2.7 m·kg, 20 ft·lb)

22 Nm (2.2 m·kg, 16 ft·lb)

100 Nm (10.0 m·kg, 72 ft·lb)

16 Nm (1.6 m·kg, 12 ft·lb)

30 Nm (3.0 m·kg, 22 ft·lb)

48 Nm (4.8 m·kg, 35 ft·lb)

63 Nm (6.3 m·kg, 46 ft·lb)

4 Nm (0.4 m·kg, 2.9 ft·lb)

30 Nm (3.0 m·kg, 22 ft·lb)

4 Nm (0.4 m·kg, 2.9 ft·lb)

23 Nm (2.3 m·kg, 17 ft·lb)

56 Nm (5.6 m·kg, 41 ft·lb)

55 Nm (5.5 m·kg, 40 ft·lb)

73 Nm (7.3 m·kg, 53 ft·lb)

55 Nm (5.5 m·kg, 40 ft·lb)

4 Nm (0.4 m·kg, 2.9 ft·lb)

Remarks

TIGHTENING TORQUES

Item

Clutch cable adjust nut

Thread size

M8

Q’ty

1

Tightening torque

7 Nm (0.7 m·kg, 5.1 ft·lb)

Remarks

NOTE:

1 First, tighten the ring nut to approximately 52 Nm (5.2 m•kg, 38 ft•lb) with a torque wrench, then loosen the lower ring nut completely.

2 Retighten the lower ring nut 18 Nm (1.8 m•kg, 13 ft•lb).

2-19

LUBRICATION POINTS AND LUBRICANT TYPES

EAS20360

LUBRICATION POINTS AND LUBRICANT TYPES

EAS20370

ENGINE

Lubrication point

Oil seal lips

O-rings

Bearings

Crankshaft pins

Piston surfaces

Piston pins

Crankshaft journals

Camshaft lobes

Camshaft journals

Valve stems (intake and exhaust)

Valve stem ends (intake and exhaust)

Water pump impeller shaft

Oil pump rotors (inner and outer)

Oil pump housing

Oil strainer

Clutch (pull rod)

Oil/water pump drive sprocket and washer

Clutch (thrust plate)

Starter clutch idle gear inner surface

Starter clutch assembly

Primary driven gear

Transmission gears (wheel and pinion)

Main axle and drive axle

Shift drum

Shift forks and shift fork guide bars

Shift shaft

Shift shaft boss

Cylinder head cover mating surface

Lubricant

Crankcase mating surface

Clutch cover (crankcase mating surface)

Generator rotor cover (crankcase mating surface)

Yamaha bond No.

1215

Yamaha bond No.

1215

Yamaha bond No.

1215

Yamaha bond No.

1215

2-20

Pickup rotor cover

LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication point Lubricant

Yamaha bond No.

1215

2-21

LUBRICATION POINTS AND LUBRICANT TYPES

EAS20380

CHASSIS

Lubrication point

Steering bearings and bearing races (upper and lower)

Throttle grip inner surface

Brake lever pivoting point and metal-to-metal moving parts

Clutch lever pivoting point and metal-to-metal moving parts

Engine mount bolts (rear upper and lower)

Engine mount bolts (front left and right)

Relay arm, connecting rod and rear shock absorber collar

Pivot shaft

Swingarm pivot bearing

Swingarm head pipe end, oil seal and bush

Oil seal (relay arm, connecting arm and rear shock absorber)

Seat lock assembly moving parts

Sidestand pivoting point and metal-to-metal moving parts

Sidestand switch contact point

Sidestand hook and spring contact point

Shift shaft joint rod moving parts

Shift pedal pivoting parts

Rear footrest ball and metal-to-metal moving parts

Centerstand metal-to-metal moving parts (FZ1-S)

Front wheel oil seal (left and right)

Rear wheel oil seal

Rear wheel drive hub oil seal

Rear wheel drive hub mating surface

Lubricant

2-22

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20390

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20400

ENGINE OIL LUBRICATION CHART

2-23

LUBRICATION SYSTEM CHART AND DIAGRAMS

1. Oil strainer

2. Oil pump

3. Relief valve

4. Oil cooler

5. Oil filter

6. Main gallery

7. AC magneto drive gear shower

8. Shift fork (upper)

9. Main axle

10.Mission shower

11.Drive axle

12.AC magneto axle

13.Piston cooler

14.Chain tensioner

15.Intake camshaft

16.Exhaust camshaft

2-24

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20410

LUBRICATION DIAGRAMS

2-25

1. Intake camshaft

2. Exhaust camshaft

3. Oil filter cartridge

4. Oil level switch

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-26

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-27

1. Intake camshaft

2. Exhaust camshaft

3. Crankshaft

4. Oil cooler

5. Relief valve

6. Oil pipe

7. Oil strainer

8. Oil pump

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-28

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-29

1. Oil filter cartridge

2. Oil level switch

3. Oil pump

4. Oil strainer

5. Oil pipe

6. Oil cooler

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-30

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-31

1. Main axle

2. Oil delivery pipe

3. Drive axle

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-32

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-33

1. Cylinder head

2. Crankshaft

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-34

EAS20420

COOLING SYSTEM DIAGRAMS

COOLING SYSTEM DIAGRAMS

2-35

1. Water pump

2. Radiator

3. Radiator fan

COOLING SYSTEM DIAGRAMS

2-36

COOLING SYSTEM DIAGRAMS

2-37

1. Radiator cap

2. Radiator

3. Oil cooler

4. Thermostat

COOLING SYSTEM DIAGRAMS

2-38

EAS20430

CABLE ROUTING

CABLE ROUTING

2-39

1. Clutch cable

2. Left handlebar switch lead

3. Main switch lead

4. Immobilizer lead

5. Horn lead

6. Horn stay assembly

7. Throttle cable (pull side)

8. Throttle cable (return side)

9. Wire harness

10.Brake hose

11.Throttle cables

12.Right handlebar switch lead

A. Wire is connected to the meter.

B. Route the stay assembly above central cable guide.

C. After branching the lead from the left handlebar switch, route it under the stay assembly and upper guide wire (from the vehicle front side to the rear side).

D. Route the stay assembly below central cable guide.

E. Clamp the horn lead to the stay assembly.

Position the binding section in front of the vehicle body and cut the tip to be between

2 to 4mm (0.08 to 0.16in).

F. Clamp the wire harness at the place of the white tape and insert it to the stay assembly. Point the clamp opening to the outside of the vehicle.

G. Lay on the front brake light switch lead above the throttle cables.

H. Secure the brake hose to the front fork.

I. Secure the horn lead to the front fork. Cut the tip of the clamp head leaving 2 to 4mm

(0.08 to 0.16in) toward the outside of the vehicle.

J. The center position of the clamp shall be within this numeric range.

K. The outside of the vehicle.

L. The inside of the vehicle.

M. Pass the brake hose in the space by the right side of the vehicle from this wire and pass the throttle cables and right handlebar switch lead in the left side space. Next, route the right handlebar switch lead to the vehicle rear side where the throttle cables are routed.

CABLE ROUTING

2-40

2-41

CABLE ROUTING

1. Wire harness

2. Right handlebar switch lead

3. Throttle cable

4. Radiator inlet hose

5. Wire guide

6. Brake fluid reservoir hose

7. Fuel tank breather hose

8. EXUP cable wire bending attachment

9. EXUP cables

10.Rear brake light switch lead

11.Radiator fan motor lead (Right)

12.Coolant reservoir tank hose

13.Brake hose

14.Clutch cable

15.Radiator stay

16.Throttle cable (return side)

17.Throttle cable (pull side)

18.Frame

19.Rear brake light switch stay

20.Footrest bracket (Right)

21.Rear brake light switch

A. Wire is connected to the meter.

B. Clamp the brake hose to the stay assembly. Clamping position should be 5 mm

(0.20 in) or more away and less than 10 mm (0.39 in) from the top end of the brake hose protector. Cut the tip to be between 2 to 4 mm (0.08 to 0.16 in).

C. To the throttle bodies

D. Clamp the coolant reservoir hose and radiator inlet hose. Point the clamp opening to the outside of the vehicle and the tip of the clamp to the front upper side of the vehicle, and pay attention so that the tip does not protrude from the radiator cover.

E. Route the fuel tank breather hose by the wire guide. The white paint position of the hose shall be lower than the wire guide.

F. To the EXUP

G. Pass the fuel tank breather hose, and

EXUP cable through the wire guide of the rear brake light switch stay.

H. The clamp position shall be at the center of bending section of the brake fluid reservoir hose as shown in the illustration.

I. Bind the two EXUP cables with the clamp.

For the clamping position, a part of the clamp should be located within a range of

10 mm (0.39 in) from the end of wire bending attachment. Any direction of the clamp opening can be accepted.

J. To the wire harness

K. To the coolant reservoir tank

L. Route the radiator fan motor lead (right) so that there is no slack as much as possible in this section.

CABLE ROUTING

M. Pass the radiator fan motor lead (right) above the coolant reservoir hose and route it to the inside of the frame.

N. Pass the coolant reservoir hose to the vehicle inner side of the radiator inlet hose and route it to the lower outside of the vehicle of the thermostat assembly.

O. Route in the concavity section of the radiator stay.

P. Route the wire guide of the radiator stay as shown in the illustration. (Twisting not allowed)

Q. The outside of the vehicle.

R. The inside of the vehicle.

S. The front side of the vehicle.

T. Point the clamp head to the outside of the vehicle and fit it so that the band tip is positioned at the vehicle front side.

U. Pass the fuel tank breather hose through the guide wire of the sidestand bracket.

Make sure to place the white paint position of the hose lower than the guide wire.

2-42

2-43

CABLE ROUTING

1. Clutch cable

2. Water pump breather hose

3. Oil level switch lead

4. Sidestand switch lead

5. O

2

sensor lead

6. Coolant reservoir tank drain hose

7. Wire harness

8. Battery negative lead

9. Seat lock cable

10.AC magneto lead

11.Rectifier/regulator lead

12.Water pump inlet pipe

13.Radiator fan motor lead (left)

14.Radiator stay

15.Main switch lead

16.Immobilizer lead

17.Left handlebar switch lead

18.Horn

19.Clutch cable swaging metal

20.Throttle cable

21.Stay assembly

22.Upper bracket

23.Right handlebar switch lead

24.Brake hose

25.Horn lead

26.Throttle body

27.Stay 1

28.Drive chain case cover

29.Starter motor lead

30.Fuel tank breather hose

31.EXUP cables

32.Rear brake light switch lead

33.Rear brake fluid reservoir hose

34.Speed sensor lead

A. Route in the concavity section of the radiator stay.

B. To the coolant reservoir tank

C. Clamp the wire harness, AC magneto lead, rectifier/regulator lead, starter motor lead and battery negative lead. Point the clamp head to the inside of the vehicle and fit it so that the band tip is pointed downward.

D. Pass the O

2

sensor lead through the vehicle inner side of the hose assembly 1 junction pipe of the water pump inlet pipe and route it by the outer down side of the hose assembly 1 and to the upper direction as shown in the illustration.

E. To the exhaust

F. Route the O

2

sensor lead to the vehicle rear side where the water pump inlet pipe is routed.

G. Physical relationship between the coolant reservoir tank drain hose tip and sidestand switch lead can be in random order.

2-44

CABLE ROUTING

H. Route the hose assembly 1 by the vehicle front side where the water pump inlet pipe is routed. For the hose tip position, route the hose so that 10 mm (0.39 in) or more can be assured as shown in the illustration.

I. More than 10 mm (0.39 in)

J. Route the sidestand switch lead by the vehicle front side where the hose assembly

1 and water pump inlet pipe are routed.

K. Pass the oil level switch lead to the vehicle front side of the water pump breather hose and water pipe.

L. Route the AC magneto lead by the inside of the frame.

M. There should be no exposure of bare conductors due to the misalignment of tubes.

N. Route the AC magneto lead by the inside of vehicle away from the water hose.

O. Clamp the clutch cable, radiator fan motor lead (left) and water pump breather hose.

Point the clamp head to the upper side of the vehicle and fit it so that the band tip is positioned inside. For the band position, install the band using the engine position as a guide as shown in the illustration.

P. Insert the clamp to the frame and clamp the clutch cable. For the clamping position, place the clamp so that the caulking attachment on the clutch cable side is positioned at the vehicle front side where the clamp is located. Clamp opening should be positioned at the outside of the vehicle.

Q. The inserting direction of the onion-head of the horn lead shall be as shown in the illustration.

R. The front side of the vehicle.

S. The outside of the vehicle.

T. The upper side of the vehicle.

U. The inside of the vehicle.

V. Route the clutch cable under the convexity sections of the throttle bodies.

W. Route the radiator fan motor lead (left) between the convexity sections of the throttle bodies.

X. Route the wire harness between the convexity sections of the throttle bodies.

Y. Innermost section of the vehicle.

Z. Can be routed in any order.

AA.Route the water pump breather hose finally in the guide after passing other hoses so that it can be positioned on the outside of the vehicle.

AB.Route the coolant reservoir tank drain hose so that it is positioned at the innermost part in hoses and leads.

AC.The rear side of the vehicle.

AD.To the radiator

AE.Open to the air

2-45

CABLE ROUTING

AF.The coolant reservoir tank drain hose shall cross with the speed sensor lead under the rear arm bracket. The coolant reservoir tank drain hose shall be positioned above the vehicle.

CABLE ROUTING

2-46

2-47

CABLE ROUTING

1. Throttle cables

2. Right handlebar switch lead

3. Wire harness

4. Throttle cable (pull side)

5. Throttle cable (return side)

6. Radiator fan motor lead (Right)

7. Coolant reservoir tank hose

8. Radiator inlet hose

9. Air filter drain hose

10.Crankshaft position sensor lead

11.Direct ignition coil lead coupler

12.Immobilizer anti safety alarm coupler

13.Engine ground lead

14.Neutral switch lead

15.Rear brake light switch lead

16.EXUP cable

17.EXUP servo motor

18.Main fuse

19.Atmospheric pressure sensor

20.Battery positive lead

21.Radiator fan motor relay

22.Starting circuit cut-off relay

23.Fuse box

24.Lean angle sensor

25.Turn signal light lead (right)

26.License plate light lead

27.Turn signal relay

28.Turn signal light lead (left)

29.Seat lock cable

30.Tail/brake light lead

31.Tail/brake light lead coupler

32.Headlight relay

33.Turn signal light lead coupler (left)

34.Starter relay

35.Fuel tank breather hose

36.Battery negative lead

37.AC magneto lead

38.Starter motor lead

39.Coolant reservoir tank drain hose

40.Fuel hose bend R section

41.Idle adjust screw wire

42.Throttle body lead

43.Air cut-off valve hose

44.ECU (engine control unit)

45.Water pump breather hose

46.Radiator fan motor lead (left)

47.Clutch cable

48.Left handlebar switch lead

49.Main switch lead

50.Immobilizer lead

51.Frame

52.Cover

2-48

CABLE ROUTING

53.Direct ignition coil lead

54.Speed sensor lead

55.Lean angle sensor lead

56.Battery box

57.Turn signal light relay lead

58.Rear frame

59.Battery

60.Sidestand switch lead

61.Oil level switch lead

62.O

2

sensor lead

63.Velcro

64.Protector

65.Mad guard

66.Fender

67.Fuel hose

A. Check that it is secured with the guide of the radiator stay.

B. To the direct ignition coil lead

C. Make sure to install the air filter after checking that the leads are positioned outside of the vehicle from the throttle body side cover.

D. To the engine

E. Direct ignition coil lead protector edge

F. Bind the left handle bar switch leads, main switch leads, right handle bar switch leads, immobilizer leads, radiator fan motor leads

(right), wire harness and direct ignition leads (in random order). Make sure to set the clamping position to be ahead of the immobilizer anti-safety alarm coupler and rear brake switch leadÅfs branch position, and to be within a range of 0 to 30 mm (0 to 1.18 inches) away from the protector end of the direct ignition coil lead. Install the band pointing its tip end downward inside the vehicle.

G. Route the pickup coil lead below the fuel hose, throttle body hoses and air filter drain hose.

H. Route the wire harness below the clutch cable and route the coupler branched from the wire harness below the clutch cable and then connect it.

I. Insert the wire harness wrapping clamp to the hole of the frame.

J. To the rear brake light switch

K. Open to the air

L. Insert the main fuse to the battery band.

Soapy water can be spread.

M. Route the battery positive lead under the relays.

N. Route the fuse box lead under the radiator fan motor relay.

O. Route the battery positive lead above the fuse box lead.

P. Pass the license plate light lead and turn signal light lead under the turn signal relay.

2-49

CABLE ROUTING

Q. Pass the turn signal light lead (right) and license plate light lead under the rear fender bracket and route between the ribs of the battery box.

R. Pass the turn signal light lead (left) and tail/ brake light lead under the rear fender bracket and route between the ribs of the battery box.

S. Route the tail/brake light lead by the inner side of the rear fender bracket and the outside of the battery box ribs. When installing the tail cover assembly, pay attention so that it does not catch anything between rear frame and rear fender bracket surface.

T. After wiring the coupler, make sure to cover the connector with the squid-shaped protective cover on the wire harness side and then insert it to the space made by the external side of rear frame and tail cover assembly. At this time, the lead should be pushed in so that the lead does not hook on the seat loading accepter.

U. Route the tail/brake light lead in the space made by the top surface of the rear frame and the bottom face of the seat bracket.

When installing the seat bracket, pay attention so that the lead is not caught by the rear frame surface.

V. Route the battery positive lead from the inner side of the vehicle to the down side of the wire harness. It is not allowed to route the lead over the wire harness.

W. Route it so that the branch connection of the main fuse lead is placed in the upper side.

X. To the rectifier/regulator. Route the AC. magneto lead and rectifier/regulator lead inside the battery box.

Y. To the speed sensor

Z. Route the AC. magneto lead under the clutch cable.

AA.To the fuel pump

AB.Fit so that the engine ground lead is positioned below and the battery negative lead above. Fit the leads so that each projection of lead is positioned on the upper side of the vehicle.

AC.To the starter motor

AD.Route the leads under the throttle bodies.

AE.Route the intake air temperature sensor by the upper side of the air filter drain hose.

AF.To the air filter case

AG.Check that the radiator fan motor lead

(left) is secured with the guide of the radiator stay.

AH.Positioning tape (shaded area)

AI. Fit the protector by aligning the positioning tape end and protector end for the main switch lead, immobilizer lead and left handlebar switch lead. The misalignment tolerance of ends is ±5 mm (0.20 in).

CABLE ROUTING

AJ.Clamp each lead at the positioning taping section (white) and then insert it to the cover. (In random order)

AK.Clamp each lead at the positioning taping section (blue) and then insert it to the cover. For routing leads, the wire harness shall be downside but others can be in random order. Positioning tape is only used for the wire harness and right handlebar switch.

AL.The upper side of the vehicle.

AM.The inside of the vehicle.

AN.Secure the leads with a clamp. The cut position of the tip of the clamp shall be on the upper side of the vehicle. (Cut it leaving

2 to 4mm (0.08 to 0.16in) of the tip). Route the leads over the frame plate and insert them through the hole into the inside of the vehicle.

AO.Route the lean angle sensor lead at the uppermost side of the vehicle. Also, it must not be protruded from the battery box ribs toward the upper side.

AP.Routing can be in random order.

AQ.Push the wire harness securely in as far as it will go.

AR.Secure the leads with a clamp. The cut position of the tip of the clamp shall be on the upper side of the vehicle. (Cut it leaving

2 to 4mm (0.08 to 0.16in) of the tip). Route the leads over the frame plate and insert them through the hole into the inside of the vehicle. Route the wire harness at the position shown in the illustration and other leads can be in random order. Inserting the band can be in any direction.

AS.15 X 20 mm (0.59 X 0.79 in) (shaded area)

AT. Installation procedure 1. Secure the main switch lead and immobilizer lead with Velcro strap. 2. Secure the left handlebar switch lead with Velcro strap. The main switch lead and immobilizer lead shall not be twisted in the protector. The installation position is where the protector end and lead positioning tape end align.

AU.20 X 58 mm (0.79 X 2.28 in) (shaded area)

AV.Route it between the battery box ribs in the order indicated in the figure.

AW.Clamp the fuel hose and direct ignition coil lead. Point the opening section of the clamp to the front side of the vehicle and install it at the position as shown in the illustration.

2-50

2-51

CABLE ROUTING

FZ1-S

1. Clutch cable

2. Left handlebar switch lead

3. Immobilizer lead

4. Main switch lead

5. Protector

6. Throttle cables

7. Right handlebar switch lead

8. Throttle cable (pull side)

9. Throttle cable (return side)

10.Bracket

11.Wire harness

12.Turn signal light lead

13.Seat lock cable

14.Tail/brake light lead

15.Battery box

16.Mud guard

17.Fender

18.Frame

19.Cover

A. Positioning tape (shaded area)

B. Secure the wire harness to the bracket.

Position the clamp head on the upper side of the vehicle and point the tip to the front side of the vehicle.

C. Attach the clamp to the front upper cowling. Clamp the turn signal light lead (left) and headlight lead.

D. Pass the turn signal light lead (left) and tail/ brake light lead under the rear fender bracket.

E. Pass the turn signal light lead (left) the route between the ribs of the battery box and tail/brake light lead.

F. Clamp each lead at the positioning taping section and then insert it to the cover. (In random order) Positioning tape is only used for the right handlebar switch. Fit other leads so that they are not slack.

G. Clamp each lead at the positioning taping section and then insert it to the cover. (In random order) Route the rear side of the vehicle to the wire harness.

CABLE ROUTING

2-52

2-53

CABLE ROUTING

1. Fuel tank

2. Fuel tank drain hose

3. Fuel tank breather hose

4. Clip

5. Air filter bracket

6. 3 way connector

7. Hose

8. Fuel hose

9. Damper

10.Collar

11.Fuel tank bracket

12.O-ring

13.Fuel pump

A. Hook the cover pawl to the fuel tank bracket.

B. The knob of the clip can be positioned in any direction.

C. Assemble the two folding sections of the collar flange as shown in the illustration.

D. Fit the knob of the clip as shown in the illustration.

E. Fit the white paint section of the hose pointed downward.

F. Pass the hose through the fuel tank bracket clamp. There should be no bend of the hose between the fuel tank nipple and clamp.

G. Align the projection part with the pump seat nut.

H. Fit the orange double lock side to the pump side.

I. Fit the black double lock side to the engine side.

J. The fuel tank bracket shall not run on the tank flange as shown in the illustration.

K. Fit the O-ring with its lip pointed upward.

L. Tightening sequence

M. Fuel piping connector attachment directions. (fuel pump side) Always perform the connection/disconnection works by hand.

Do not use tools.

N. 1. Insert the connector until the click sound is heard and check that the connector does not come off. Make sure that no foreign matter is caught in the sealing section. (It is prohibited to wear the cotton work gloves or equivalent coverings.)

O. This part works as a dropout stopper.

P. 2.After Step [N] as above is finished, check that the connector is completely attached by sliding the double lock (orange part) on the connector as shown in the illustration and seeing if it touches firmly or not.

2-54

CABLE ROUTING

2-55

CABLE ROUTING

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE

………………………………………………………………. 3-1

INTRODUCTION ………………………………………………………………………… 3-1

ENGINE

…………………………………………………………………………………………… 3-4

ADJUSTING THE VALVE CLEARANCE ………………………………………… 3-4

SYNCHRONIZING THE THROTTLE BODIES ………………………………… 3-6

ADJUSTING THE EXHAUST GAS VOLUME………………………………….. 3-8

ADJUSTING THE ENGINE IDLING SPEED …………………………………… 3-9

ADJUSTING THE THROTTLE CABLE FREE PLAY ………………………… 3-9

CHECKING THE SPARK PLUGS………………………………………………… 3-10

MEASURING THE COMPRESSION PRESSURE …………………………. 3-10

CHECKING THE ENGINE OIL LEVEL…………………………………………. 3-11

CHANGING THE ENGINE OIL……………………………………………………. 3-12

MEASURING THE ENGINE OIL PRESSURE ………………………………. 3-13

ADJUSTING THE CLUTCH CABLE FREE PLAY ………………………….. 3-14

REPLACING THE AIR FILTER ELEMENT ……………………………………. 3-15

CHECKING THE THROTTLE BODY JOINTS ……………………………….. 3-16

CHECKING THE FUEL LINE ……………………………………………………… 3-16

CHECKING THE CRANKCASE BREATHER HOSE ………………………. 3-16

CHECKING THE EXHAUST SYSTEM …………………………………………. 3-17

ADJUSTING THE EXUP CABLES ………………………………………………. 3-17

CHECKING THE EXUP SERVO MOTOR …………………………………….. 3-18

CHECKING THE COOLANT LEVEL ……………………………………………. 3-18

CHECKING THE COOLING SYSTEM …………………………………………. 3-19

CHANGING THE COOLANT ………………………………………………………. 3-19

CHASSIS

………………………………………………………………………………………. 3-22

ADJUSTING THE FRONT DISC BRAKE ……………………………………… 3-22

ADJUSTING THE REAR DISC BRAKE ……………………………………….. 3-22

CHECKING THE BRAKE FLUID LEVEL ………………………………………. 3-23

CHECKING THE FRONT BRAKE PADS………………………………………. 3-23

CHECKING THE REAR BRAKE PADS ………………………………………… 3-23

CHECKING THE FRONT BRAKE HOSES……………………………………. 3-24

CHECKING THE REAR BRAKE HOSE ……………………………………….. 3-24

ADJUSTING THE REAR BRAKE LIGHT SWITCH ………………………… 3-24

BLEEDING THE HYDRAULIC BRAKE SYSTEM…………………………… 3-25

ADJUSTING THE SHIFT PEDAL ………………………………………………… 3-26

ADJUSTING THE DRIVE CHAIN SLACK …………………………………….. 3-26

LUBRICATING THE DRIVE CHAIN……………………………………………… 3-27

CHECKING AND ADJUSTING THE STEERING HEAD …………………. 3-27

CHECKING THE FRONT FORK …………………………………………………. 3-28

ADJUSTING THE FRONT FORK LEGS ………………………………………. 3-29

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY……………. 3-31

CHECKING THE TIRES …………………………………………………………….. 3-32

CHECKING THE WHEELS ………………………………………………………… 3-34

CHECKING AND LUBRICATING THE CABLES ……………………………. 3-34

LUBRICATING THE LEVERS……………………………………………………… 3-34

LUBRICATING THE PEDAL ……………………………………………………….. 3-34

LUBRICATING THE SIDESTAND………………………………………………… 3-34

3

LUBRICATING THE CENTERSTAND (FZ1-S) ………………………………. 3-34

LUBRICATING THE REAR SUSPENSION …………………………………… 3-34

ELECTRICAL SYSTEM

…………………………………………………………………… 3-35

CHECKING AND CHARGING THE BATTERY………………………………. 3-35

CHECKING THE FUSES……………………………………………………………. 3-35

REPLACING THE HEADLIGHT BULBS……………………………………….. 3-35

ADJUSTING THE HEADLIGHT BEAM ………………………………………… 3-36

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.

Periodic maintenance and lubrication chart

NOTE:

•

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.

• From 50000 km, repeat the maintenance intervals starting from 10000 km.

• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

NO.

ITEM CHECK OR MAINTENANCE JOB

1

2

3

*

*

*

Fuel line

Spark plugs

Valves

• Check fuel hoses for cracks or damage.

• Check condition.

• Clean and regap.

• Replace.

• Check valve clearance.

• Adjust.

4 *

Air filter element

• Replace.

5

6

7

8

9

10

11 * Wheel bearings

12

*

*

*

*

*

*

Clutch

Front brake

Rear brake

Brake hoses

Wheels

Tires

Swingarm

• Check operation.

• Adjust.

• Check operation, fluid level and vehicle for fluid leakage.

• Replace brake pads.

• Check operation, fluid level and vehicle for fluid leakage.

• Replace brake pads.

• Check for cracks or damage.

• Replace.

• Check runout and for damage.

• Check tread depth and for damage.

• Replace if necessary.

• Check air pressure.

• Correct if necessary.

• Check bearing for looseness or damage.

• Check operation and for excessive play.

ODOMETER READ-

ING (X 1000 km)

1 10 20 30 40

✓ ✓ ✓ ✓

Annual check

✓

✓

✓

✓

✓

✓

✓

✓

Every 40000 km

✓

✓

✓

✓

✓

✓

✓

✓

✓ ✓

Whenever worn to the limit

✓ ✓

✓

✓

✓

✓

✓

✓

✓

✓ ✓

Whenever worn to the limit

✓

✓

✓

✓

✓ ✓ ✓

Every 4 years

✓ ✓ ✓ ✓

✓

✓

✓

✓

✓

3-1

PERIODIC MAINTENANCE

NO.

ITEM CHECK OR MAINTENANCE JOB

ODOMETER READ-

ING (X 1000 km)

1 10 20 30 40

Annual check

13

14

15

16

*

*

Drive chain

Steering bearings

Chassis fasteners

Sidestand

• Check chain slack, alignment and condition.

• Adjust and lubricate chain with a special O-ring chain lubricant thoroughly.

• Check bearing play and steering for roughness.

• Lubricate with lithium-soap-based grease.

• Make sure that all nuts, bolts and screws are properly tightened.

• Check operation.

• Lubricate.

17 *

Sidestand switch

18 * Front fork

19

20

*

*

Shock absorber assembly

Rear suspension relay arm and connecting arm pivoting points

• Check operation.

• Check operation and for oil leakage.

• Check operation and shock absorber for oil leakage.

• Check operation.

21

22

23

24

*

*

Fuel injection

Engine oil

Cooling system

• Adjust engine idling speed and synchronization.

• Change.

• Check oil level and vehicle for oil leakage.

Engine oil filter cartridge

• Replace.

• Check coolant level and vehicle for coolant leakage.

• Change.

25

26

*

Front and rear brake switches

Moving parts and cables

• Check operation.

• Lubricate.

27 *

Throttle grip housing and cable

• Check operation and free play.

• Adjust the throttle cable free play if necessary.

• Lubricate the throttle grip housing and cable.

Every 1000 km and after washing the motorcycle or riding in the rain

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓ ✓ ✓

Every 20000 km

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

Every 3 years

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

3-2

PERIODIC MAINTENANCE

NO.

ITEM CHECK OR MAINTENANCE JOB

ODOMETER READ-

ING (X 1000 km)

1 10 20 30 40

Annual check

28 *

29 *

30 *

Air induction system

Muffler and exhaust pipe

Lights, signals and switches

• Check the air cut-off valve, reed valve, and hose for damage.

• Replace the entire air induction system if necessary.

• Check the screw clamp for looseness.

• Check operation.

• Adjust headlight beam.

✓ ✓ ✓ ✓

✓ ✓ ✓ ✓ ✓

✓ ✓ ✓ ✓ ✓

✓

✓

NOTE:

• Air filter

• This model’s 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

• Regularly check and, if necessary, correct the brake fluid level.

• 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

EAS20470

ENGINE

EAS20490

ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the valves.

NOTE:

• Valve clearance adjustment should be made on a cold engine, at room temperature.

• When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.

1. Remove:

• Rider and passenger seat

Refer to «GENERAL CHASSIS» on page 4-

1.

• Fuel tank

Refer to «FUEL TANK» on page 7-1.

• Air filter case

Refer to «GENERAL CHASSIS» on page 4-

1.

• Throttle body assembly

Refer to «THROTTLE BODIES» on page 7-

4.

• Air cut-off valve

Refer to «AIR INDUCTION SYSTEM» on page 7-13.

• Radiator

• Radiator fan motor

Refer to «RADIATOR» on page 6-1.

2. Remove:

• Ignition coils

• Spark plugs

• Cylinder head cover

• Cylinder head cover gasket

Refer to «CAMSHAFTS» on page 5-10.

3. Remove:

• Pickup rotor cover «1»

ENGINE

• Valve clearance

Out of specification

→

Adjust.

Valve clearance (cold)

Intake valve

0.11–0.20 mm (0.0043–0.0079 in)

Exhaust valve

0.21–0.25 mm (0.0083–0.0098 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise.

b. When piston #1 is at TDC on the compression stroke, align the TDC mark “a” on the pickup rotor with the crankcase mating surface “b”.

NOTE:

TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.

c. Measure the valve clearance with a thickness gauge “1”.

NOTE:

• If the valve clearance is incorrect, record the measured reading.

• Measure the valve clearance in the following sequence.

Valve clearance measuring sequence

Cylinder #1

→

#2

→

#4

→

#3

4. Measure:

3-4

ENGINE

6. Adjust:

• Valve clearance

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve lifter “1” and the valve pad “2” with a valve lapper “3”.

Valve lapper

90890-04101

NOTE:

• Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.

• Make a note of the position of each valve lifter “1” and valve pad “2” so that they can be installed in the correct place.

A. Front d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at

TDC, turn the crankshaft counterclockwise as specified in the following table.

Cylinder #2

Cylinder #4

Cylinder #3

180

°

360

°

540

°

A. Degrees that the crankshaft is turned counterclockwise

B. Cylinder

C. Combustion cycle

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Remove:

• Camshaft

NOTE:

• Refer to «CAMSHAFTS» on page 5-10.

• When removing the timing chain and camshafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase.

3-5

b. Calculate the difference between the specified valve clearance and the measured valve clearance.

Example:

Specified valve clearance = 0.11–0.20 mm

(0.004–0.008 in)

Measure valve clearance = 0.25 mm (0.010 in)

0.25 mm (0.010 in)–0.20 mm (0.008 in) =

0.05 mm (0.002 in) c. Check the thickness of the current valve pad.

NOTE:

The thickness “a” of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter.

Example:

ENGINE

If the valve pad is marked “158”, the pad thickness is 1.58 mm (0.062in) d. Calculate the sum of the values obtained in steps (b) and (c) to determine the required valve pad thickness and the valve pad number.

Example:

1.58 mm (0.062 in) + 0.05 mm (0.002 in) =

1.63 mm (0.064 in)

The valve pad number is 163.

e. Round off the valve pad number according to the following table, and then select the suitable valve pad.

Last digit

0,1,2

3,4,5,6

7,8,9

Rounded value

0

5

10

NOTE:

Refer to the following table for the available valve pads.

Valve pad range

Valve pad thickness

Available valve pads

Nos. 150–240

1.50–2.40 mm

(0.0591–0.0945 in)

25 thicknesses in

0.05 mm (0.002 in) increments

Example:

Valve pad number = 163

Rounded value = 165

New valve pad number = 165 f.

Install the new valve pad “1” and the valve lifter “2”.

NOTE:

• Lubricate the valve lifter with engine oil.

• Install the valve lifter and the valve pad in the correct place.

• The valve lifter must turn smoothly when rotated by hand.

3-6

g. Install the exhaust and intake camshafts, timing chain and camshaft caps.

Camshaft cap bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

NOTE:

• Refer to «CAMSHAFTS» on page 5-10.

• Lubricate the camshaft bearings, camshaft lobes and camshaft journals.

• First, install the exhaust camshaft.

• Align the camshafts marks with the camshaft cap marks.

• Turn the crankshaft clockwise several full turns to seat the parts.

h. Measure the valve clearance again.

i.

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

7. Install:

• All removed parts

NOTE:

For installation, reverse the removal procedure.

EAS20570

SYNCHRONIZING THE THROTTLE BODIES

NOTE:

Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked.

1. Stand the vehicle on a level surface.

NOTE:

Place the vehicle on a suitable stand.

2. Remove:

• Rider and passenger seat

Refer to «GENERAL CHASSIS» on page 4-

1.

• Fuel tank

Refer to «FUEL TANK» on page 7-1.

3. Remove:

• Synchronizing hoses “1”

4. Install:

• Vacuum gauge “1”

(onto the synchronizing hose)

• Digital tachometer

(near the spark plug)

Vacuum gauge

90890-03094

Carburetor synchronizer

YU-44456

ENGINE

• Throttle body synchronization

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. With throttle body #3 as standard, adjust throttle bodies #1, #2, and #4 using the air screw “1”.

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.

EC2D1080

CAUTION:

Do not use the throttle valve adjusting screws to adjust the throttle body synchronization.

Vacuum pressure at engine idling speed

30 kPa (225 mmHg, 8.9 inHg)

NOTE:

The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa

(10mmHg, 0.39 inHg).

5. Install:

• Fuel tank

Refer to «FUEL TANK» on page 7-1.

6. Start the engine and let it warm up for several minutes.

7. Check:

• Engine idling speed

Out of specification

→

Adjust.

Refer to «ADJUSTING THE ENGINE

IDLING SPEED» on page 3-9.

Engine idling speed

1.100–1.300 r/min

8. Adjust:

3-7

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

9. Measure:

• Engine idling speed

Out of specification

→

Adjust.

ENGINE

Make sure that the vacuum pressure is within specification.

10. Stop the engine and remove the measuring equipment.

11. Adjust:

• Throttle cable free play

Refer to «ADJUSTING THE THROTTLE

CABLE FREE PLAY» on page 3-9.

Throttle cable free play

(at the flange of the throttle grip)

3.0–5.0 mm (0.12–0.20 in)

12. Install:

• Synchronizing hoses

• Fuel tank

Refer to «FUEL TANK» on page 7-1.

• Rider and passenger seat

Refer to «GENERAL CHASSIS» on page 4-

1.

EAS20600

ADJUSTING THE EXHAUST GAS VOLUME

NOTE:

Be sure to set the CO density level to standard, and then adjust the exhaust gas volume.

1. Turn the main switch to “OFF” and set the engine stop switch to “ON”.

2. Simultaneously press and hold the

“SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.

NOTE:

“dI” appears on the clock LCD.

3. Press the “SELECT” button to select the

CO adjustment mode “Co” “1” or the diagnostic mode “dI”.

4. After selecting “Co”, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or more to execute the selection.

NOTE:

The selected cylinder number appears on the clock LCD.

• To decrease the selected cylinder number, press the “RESET” button.

• To increase the selected cylinder number, press the “SELECT” button.

5. After selecting the cylinder, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or more to execute the selection.

6. Change the CO adjustment volume by pressing the “SELECT” and “RESET” buttons.

NOTE:

The CO adjustment volume appears on the tripmeter LCD.

• To decrease the CO adjustment volume, press the “RESET” button.

• To increase the CO adjustment volume, press the “SELECT” button.

7. Release the switch to execute the selection.

3-8

8. Simultaneously press the “SELECT” and

“RESET” buttons to return to the cylinder selection (step 5).

9. Turn the main switch to “OFF” to cancel the mode.

EAS20610

ADJUSTING THE ENGINE IDLING SPEED

NOTE:

Prior to adjusting the engine idling speed, the throttle bodies’ synchronization should be adjusted properly, the air filter element should be clean, and the engine should have adequate compression.

1. Start the engine and let it warm up for several minutes.

2. Install:

• Digital tachometer

(onto the spark plug lead of cylinder #1)

3. Check:

• Engine idling speed

Out of specification

→

Adjust.

Engine idling speed

1,100–1,300 r/min

4. Adjust:

• Engine idling speed

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the idle adjusting screw “1” in direction

“a” or “b” until the specified engine idling speed is obtained.

Direction “a”

Engine idling speed is increased.

Direction “b”

Engine idling speed is decreased.

ENGINE

Throttle cable free play

(at the flange of the throttle grip)

3.0–5.0 mm (0.12–0.20 in)

EAS20630

ADJUSTING THE THROTTLE CABLE FREE

PLAY

NOTE:

Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly.

1. Check:

• Throttle cable free play “a”

Out of specification

→

Adjust.

Throttle cable free play

(at the flange of the throttle grip)

3.0–5.0 mm (0.12–0.20 in)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Adjust:

• Throttle cable free play

Refer to «ADJUSTING THE THROTTLE

CABLE FREE PLAY» on page 3-9.

3-9

2. Adjust:

• Throttle cable free play

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Handlebar side

a. Loosen the locknut “1”.

b. Turn the adjusting nut “2” in direction “a” or

“b” until the specified throttle cable free play is obtained.

Direction “a”

Throttle cable free play is increased.

Direction “b”

Throttle cable free play is decreased.

6. Measure:

• Spark plug gap “a”

(with a wire thickness gauge)

Out of specification

→

Regap.

Spark plug gap

0.6–0.7 mm

(0.0236–0.0276 in)

ENGINE

c. Tighten the locknut.

EW2D1001

WARNING

After adjusting the throttle cable free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS20680

CHECKING THE SPARK PLUGS

The following procedure applies to all of the spark plugs.

1. Remove:

• Radiator upper bolts

• Radiator lower bolt

Refer to «RADIATOR» on page 6-1.

2. Remove:

• Ignition coils

• Spark plugs

ECA13320

CAUTION:

Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders.

3. Check:

• Spark plug type

Incorrect

→

Change.

Spark plug type (manufacturer)

CR9EK (NGK)

4. Check:

• Electrode “1”

Damage/wear

→

Replace the spark plug.

• Insulator “2”

Abnormal color

→

Replace the spark plug.

Normal color is medium-to-light tan.

5. Clean:

• Spark plug

(with a spark plug cleaner or wire brush)

3-10

7. Install:

• Spark plugs

• Ignition coils

Spark plug

13 Nm (1.3 m·kg, 9.4 ft·lb)

NOTE:

Before installing the spark plug, clean the spark plug and gasket surface.

8. Install:

• Radiator upper bolts

• Radiator lower bolt

Refer to «RADIATOR» on page 6-1.

EAS20710

MEASURING THE COMPRESSION PRES-

SURE

The following procedure applies to all of the cylinders.

NOTE:

Insufficient compression pressure will result in a loss of performance.

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:

• Ignition coils

• Spark plugs

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.

4. Install:

• Compression gauge “1”

• Extension

Compression gauge

90890-03081

Engine compression tester

YU-33223

5. Measure:

• Compression pressure

Out of specification

→

Refer to steps (c) and (d).

Compression pressure (at sea level)

Minimum

1290 kPa (12.90 kg/cm

2

,12.90 bar, 183.5 psi)

Standard

1480 kPa (14.80 kg/cm

2

,14.80 bar, 210.5 psi)

Maximum

1660 kPa (16.60 kg/cm

2

, 16.60 bar, 236.1 psi)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “ON”.

b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.

EW2D1002

WARNING

To prevent sparking, ground all spark plug leads before cranking the engine.

ENGINE

NOTE:

The difference in compression pressure between cylinders should not exceed 100 kPa

(1 kg/cm², 1 bar, 14.22 psi).

c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits.

Carbon deposits

→

Eliminate.

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.

Compression pressure (with oil applied into the cylinder)

Higher than without oil

Reading Diagnosis

Piston ring(s) wear or damage

→

Repair.

Same as without oil Piston, valves, cylinder head gasket or piston possibly defective

→

Repair.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6. Install:

• Spark plug

Spark plug

13 Nm (1.3 m·kg, 9.4 ft·lb)

7. Install:

• Ignition coils

EAS20730

CHECKING THE ENGINE OIL LEVEL

1. Stand the vehicle on a level surface.

NOTE:

• Place the vehicle on a suitable stand.

• Make sure the vehicle is upright.

2. Start the engine, warm it up for several minutes, and then turn it off.

3. 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.

3-11

ENGINE

Recommended oil

Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures.

API standard

SE or higher grade

ACEA standard

G4 or G5

ECA13360

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 or use engine oils with a grade of CD “c” or higher and do not use oils labeled “ENERGY CON-

SERVING II” “d” or higher.

• Do not allow foreign materials to enter the crankcase.

NOTE:

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

4. Start the engine, warm it up for several minutes, and then turn it off.

5. Check the engine oil level again.

NOTE:

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

EAS20790

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 filler cap “1”

• Engine oil drain bolt “2”

(along with the gasket)

3-12

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

90890-01426

YU-38411

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.

ENGINE

8. Fill:

• Crankcase

(with the specified amount of the recommended engine oil)

Quantity

Total amount

3.8 L (3.34 lmp qt, 4.02 US qt)

Without oil filter cartridge replacement

2.9 L (2.55 lmp qt, 3.07 US qt)

With oil filter cartridge replacement

3.1 L (2.73 lmp qt, 3.28 US qt)

9. Install:

• Engine oil filler cap

10. Start the engine, warm it up for several minutes, and then turn it off.

11. Check:

• Engine

(for engine oil leaks)

12. Check:

• Engine oil level

Refer to «CHECKING THE ENGINE OIL

LEVEL» on page 3-11.

EAS20820

MEASURING THE ENGINE OIL PRESSURE

1. Check:

• Engine oil level

Below the minimum level mark “a”

→

Add the recommended engine oil to the proper level.

c. Tighten the new oil filter cartridge to specification with an oil filter wrench.

Oil filter cartridge

17 Nm (1.7 m·kg, 12 ft·lb)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6. Replace:

• Engine oil drain bolt gasket

7. Install:

• Engine oil drain bolt

(along with the new gasket)

Engine oil drain bolt

43 Nm (4.3 m·kg, 31 ft·lb)

3-13

2. Start the engine, warm it up for several minutes, and then turn it off.

ECA13410

CAUTION:

When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure

to measure the engine oil pressure after warming up the engine.

3. Remove:

• Oil gallery bolt “1”

EWA12980

WARNING

The engine, muffler and engine oil are extremely hot.

4. Install:

• Oil pressure gauge “1”

• Adapter “2”

Pressure gauge

90890-03153

YU-03153

Oil pressure adapter H

90890-03139

ENGINE

NOTE:

Regarding the oil pressure as its own data may fluctuate depending on the oil temperature and viscosity, the oil pressure may fluctuate when measuring. The following data should be used only as a reference when measuring the engine oil pressure.

Engine oil pressure Possible causes

Below specification • Faulty oil pump

• Clogged oil filter

• Leaking oil passage

• Broken or damaged oil seal

Above specification • Leaking oil passage

• Faulty oil filter

• Oil viscosity too high

6. Install:

• Oil gallery bolt “1”

Oil gallery bolt

8 Nm (0.8 m·kg, 5.8 ft·lb)

ECS2D1001

CAUTION:

Be careful to tighten too much.

5. Measure:

• Engine oil pressure

(at the following conditions)

Engine oil pressure

230 kPa

(2.3 kg/cm

2

, 2.3 bar, 32.71 psi)

Engine speed

Approx. 5,000 r/min

Engine oil temperature

100

°

C (212

°

F)

ET2D1004

ADJUSTING THE CLUTCH CABLE FREE

PLAY

1. Check

• Clutch cable free play “a”

Out of specification

→

Adjust.

Clutch cable free play (at the end of the clutch lever)

10–15 mm (0.39–0.59 in)

3-14

ENGINE

2. Adjust

• Clutch cable free play

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Handlebar side

a. Turn the adjusting dial “1” in direction “b” or

“c” until the specified clutch cable free play is obtained.

Direction “b”

Clutch cable free play is increased.

Direction “c”

Clutch cable free play is decreased.

NOTE:

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS20960

REPLACING THE AIR FILTER ELEMENT

1. Remove:

• Rider and passenger seat

Refer to «GENERAL CHASSIS» on page 4-

1.

• Fuel tank

Refer to «FUEL TANK» on page 7-1.

2. Remove:

• Air filter case cover “1”

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Engine side

a. Loosen the locknut “1” b. Turn the adjusting nut “2” in direction “a” or

“b” until the specified clutch cable free play is obtained.

Direction “a”

Clutch cable free play is increased.

Direction “b”

Clutch cable free play is decreased.

c. Tighten the locknuts.

Locknut

7 Nm (0.7 m·kg, 5.1 ft·lb)

3. Check:

• Air filter element “1”

Damage

→

Replace.

NOTE:

• Replace the air filter element every 40000 km (2400 mi) of operation.

• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

3-15

4. Install:

• Air filter case cover

ECA14400

CAUTION:

Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect throttle bodies synchronization, leading to poor engine performance and possible overheating.

NOTE:

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

5. Install:

• Fuel tank

Refer to «FUEL TANK» on page 7-1.

• Rider and passenger seat

Refer to «GENERAL CHASSIS» on page 4-

1.

EAS21010

CHECKING THE THROTTLE BODY JOINTS

The following procedure applies to all of the throttle body joints and intake manifolds.

1. Remove:

• Throttle bodies

Refer to «THROTTLE BODIES» on page 7-

4.

2. Check:

• Throttle body joints “1”

Cracks/damage

→

Replace.

ENGINE

1. Remove:

• Rider and passenger seat

Refer to «GENERAL CHASSIS» on page 4-

1.

• Fuel tank

Refer to «FUEL TANK» on page 7-1.

2. Check:

• Fuel hose “1”

• Vacuum hose “2”

• Breather hose “3”

Cracks/damage

→

Replace.

Loose connection

→

Connect properly.

NOTE:

Before removing the fuel hoses, place a few rags in the area under where it will be removed.

ECA14940

CAUTION:

Make sure the fuel tank breather hose is routed correctly.

3. Install:

• Throttle bodies

Refer to «THROTTLE BODIES» on page 7-

4.

EAS21030

CHECKING THE FUEL LINE

The following procedure applies to all of the fuel, vacuum and breather hoses.

3-16

3. Install:

• Fuel tank

Refer to «FUEL TANK» on page 7-1.

• Rider and passenger seat

Refer to «GENERAL CHASSIS» on page 4-

1.

ECS2D002

CAUTION:

To install the fuel tank, check that the breather hose is not folded or pinched by the fuel tank.

EAS21070

CHECKING THE CRANKCASE BREATHER

HOSE

1. Remove:

• Rider and passenger seat

Refer to «GENERAL CHASSIS» on page 4-

1.

• Fuel tank

Refer to «FUEL TANK» on page 7-1.

2. Check:

• Crankcase breather hose “1”

Cracks/damage

→

Replace.

Loose connection

→

Connect properly.

ECA13450

CAUTION:

Make sure the crankcase breather hose is routed correctly.

ENGINE

Exhaust pipe nut

20 Nm (2.0 m·kg, 14 ft·lb)

Exhaust pipe and exhaust pipe bracket bolt

20 Nm (2.0 m·kg, 14 ft·lb)

Exhaust pipe and muffler bolt

20 Nm (2.0 m·kg, 14 ft·lb)

Muffler and rear footrest bracket bolt

48 Nm (4.8 m·kg, 35 ft·lb)

NOTE:

When installing the EXUP cables, make sure they are parallel and not twisted.

• Upper cable: White metal section “8”

• Lower cable: Black metal section “9”

3. Install:

• Fuel tank

Refer to «FUEL TANK» on page 7-1.

• Rider and passenger seat

Refer to «GENERAL CHASSIS» on page 4-

1.

ECS2D003

CAUTION:

To install the fuel tank, check that the breather hose is not folded or pinched by the fuel tank.

EAS21080

CHECKING THE EXHAUST SYSTEM

The following procedure applies to all of the exhaust pipes and gaskets.

1. Check:

• Exhaust pipe “1”

• Muffler “2”

Cracks/damage

→

Replace.

• Gaskets “3”

Exhaust gas leaks

→

Replace.

2. Check:

Tightening torque

• Exhaust pipe nut “4”

• Exhaust pipe and exhaust pipe bracket bolt

“5”

• Exhaust pipe and muffler bolt “6”

• Muffler and rear footrest bracket bolt “7”

ET2D1005

ADJUSTING THE EXUP CABLES

1. Remove:

• EXUP valve pulley cover “1”

3-17

ENGINE

2. Check:

• EXUP system operation

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Activate the diagnostic mode and select the diagnostic code number “53”.

Refer to «FUEL INJECTION SYSTEM» on page 8-31.

b. Set the engine stop switch to “ ”.

c. Check that the EXUP valve operates properly.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Check:

• EXUP cable free play (at the EXUP valve pulley) “a” and “b”

Maximum EXUP cable free play

(at the EXUP valve pulley) a: Less than 3 mm (0.12 in) b: Less than 3 mm (0.12 in)

4. Adjust:

• EXUP cable free play

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the main switch to “ON” b. Check the EXUP pulley position.

c. Loosen the locknut “1”.

d. Loosen the locknut “3” e. Turn the adjusting nut “2” in or out.

f.

Tighten the locknut.

g. Turn the adjusting nut “4” in or out.

h. Tighten the locknut.

EXUP cable locknut

6 Nm (0.6 m·kg, 4.3 ft·lb)

3-18

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Install:

• EXUP valve pulley cover

EXUP valve pulley cover bolt

14 Nm (1.4 m·kg, 10 ft·lb)

EAS28360

CHECKING THE EXUP SERVO MOTOR

1. Check:

• EXUP servo motor operation

Out of specification

→

Replace.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check whether or not the EXUP valve is seized.

• Disconnect the EXUP cable and check that the EXUP valve is moved smoothly by hand.

• When the valve is not moved smoothly, repair or replace it.

Refer to «ADJUSTING THE EXUP

CABLES» on page 3-17.

b. When the EXUP valve is moved smoothly, replace the EXUP servo motor.

c. Perform the self-diagnosis mode and check the operation of EXUP valve by visual inspection (Code No: 53).

The operation should be carried out as 3second drive in the full open direction, 2second stop and 3-second drive in the full close direction.

d. Check that the EXUP servo motor pulley rotates several times.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

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:

ENGINE

• 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.

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. Start the engine, warm it up for several minutes, and then turn it off.

4. Check:

• Coolant level

NOTE:

Before checking the coolant level, wait a few minutes until it settles.

EAS21120

CHECKING THE COOLING SYSTEM

1. Check:

• Radiator “1”

• Radiator inlet hose “2”

• Radiator outlet hose “3”

• Oil cooler “4”

• Oil cooler inlet hose “5”

• Oil cooler outlet hose “6”

• Water jacket joint “7”

• Water jacket joint inlet hose “8”

• Water pump inlet pipe “9”

• Water pump outlet pipe “10”

Cracks/damage

→

Replace.

Refer to «RADIATOR» on page 6-1.

EAS21130

CHANGING THE COOLANT

1. Remove:

• Rider and passenger seat

Refer to «GENERAL CHASSIS» on page 4-

1.

2. Remove:

• Coolant reservoir tank

• Coolant reservoir hose

3. Disconnect:

• Coolant reservoir cap “1”

3-19

ENGINE

4. Drain:

• Coolant

(from the coolant reservoir)

5. Remove:

• Radiator cap “1”

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.

The following procedure applies to all of the coolant drain bolts and copper washers.

6. Remove:

• Coolant drain bolts “1”

(along with the copper washers)

7. Drain:

• Coolant

(from the water pump inlet pipe and outlet pipe)

8. Check:

• Copper washers “1”

9. Install:

• Coolant drain bolts “2”

Coolant drain bolt

10 Nm (1.0 m·Kg, 7.2 ft·lb)

3-20

10. Install:

• Coolant reservoir tank

11. Connect:

• Coolant reservoir hose

12. 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)

Quantity

Total amount

2.25 L

(1.98 lmp qt, 2.38 US qt)

Coolant reservoir capacity

0.25 L

(0.22 lmp qt, 0.26 US qt)

Handling notes for coolant

Coolant is potentially harmful and should be handled with special care.

EWA13040

WARNING

• 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.

13. Install:

• Radiator cap

14. Fill:

• Coolant reservoir tank

(with the recommended coolant to the maximum level mark “a”)

ENGINE

NOTE:

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

18. Install:

• Rider and passenger seat

Refer to «GENERAL CHASSIS» on page 4-

1.

15. Install:

• Coolant reservoir cap

16. Start the engine, warm it up for several minutes, and then stop it.

17. Check:

• Coolant level

Refer to «CHECKING THE COOLANT

LEVEL» on page 3-18.

3-21

EAS21140

CHASSIS

EAS21160

ADJUSTING THE FRONT DISC BRAKE

1. Adjust:

• Brake lever position

(distance “a” from the throttle grip to the brake lever)

NOTE:

• While pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in the desired position.

• Be sure to align the setting on the adjusting dial with the arrow mark “2” on the brake lever holder.

Direction “b”

Distance “a” is the largest.

Direction “c”

Distance “a” is the smallest.

EWA13060

WARNING

• After adjusting the brake lever position, make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial.

• A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will considerably reduce in loss of control and possibly an accident. Therefore, check and if necessary, bleed the brake system.

ECA13490

CAUTION:

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

CHASSIS

EAS21190

ADJUSTING THE REAR DISC BRAKE

1. Adjust:

• Brake pedal position

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”.

b. Turn the adjusting bolt “2” in direction “a” or

“b” until the specified brake pedal position is obtained.

Direction “a”

Brake pedal is raised.

Direction “b”

Brake pedal is lowered.

EWA13070

WARNING

After adjusting the brake pedal position, check that the end of the adjusting bolt “c” is visible through the hole “d”.

c. Tighten the locknut “1” to specification.

Locknut

18 Nm (1.8 m·kg, 13 ft·lb)

EWA13050

WARNING

A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will considerably reduce braking performance.

ECA13510

CAUTION:

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

3-22

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Adjust:

• Rear brake light switch

Refer to «ADJUSTING THE REAR BRAKE

LIGHT SWITCH» on page 3-24.

EAS21240

CHECKING THE BRAKE FLUID 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:

• Brake fluid level

Below the minimum level mark “a”

→

Add the recommended brake fluid to the proper level.

Recommended brake fluid

DOT4

CHASSIS the brake fluid and could cause vapor lock.

ECA13540

CAUTION:

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

NOTE:

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

EAS21250

CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the brake pads.

1. Operate the brake.

2. Check:

• Front brake pad

Wear indicators “a” almost touch the brake disc

→

Replace the brake pads as a set.

Refer to «FRONT BRAKE» on page 4-20.

A. Front brake

B. Rear brake

EWA13090

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

3-23

EAS21260

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 “b” almost touch the brake disc

→

Replace the brake pads as a set.

Refer to «REAR BRAKE» on page 4-32.

CHASSIS

EAS21280

CHECKING THE FRONT BRAKE HOSES

The following procedure applies to all of the brake hoses and brake hose clamps.

1. Check:

• Brake hose “1”

Cracks/damage/wear

→

Replace.

2. Check:

• Brake hose clamp “2”

Loose Connection

→

Tighten the clamp bolt.

2. Check:

• Brake hose clamp “2”

Loose

→

Tighten the clamp bolt.

3. Hold the vehicle upright and apply the front brake several times.

4. Check:

• Brake hose

Brake fluid leakage

→

Replace the damaged hose.

Refer to «FRONT BRAKE» on page 4-20.

EAS21290

CHECKING THE REAR BRAKE HOSE

1. Check:

• Brake hose “1”

Cracks/damage/wear

→

Replace.

3. Hold the vehicle upright and apply the rear brake several times.

4. Check:

• Brake hose

Brake fluid leakage

→

Replace the damaged hose.

Refer to «REAR BRAKE» on page 4-32.

EAS21330

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. Lifting the brake light switch, hold the main body “1” of the rear brake light switch so that it does not rotate and turn the adjusting

3-24

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.

CHASSIS

c. Connect a clear plastic hose “1” tightly to the bleed screw “2”.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS21350

BLEEDING THE HYDRAULIC BRAKE SYS-

TEM

EWA13100

WARNING

Bleed the hydraulic brake system whenever:

• The system is disassembled.

• A brake hose is loosened, disconnected or replaced.

• The brake fluid level is very low.

• Brake operation is faulty.

NOTE:

• Be careful not to spill any brake fluid or allow the brake 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.

1. Bleed:

• Hydraulic brake system

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.

b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir).

3-25

A. Front brake caliper

B. Rear brake caliper d. Place the other end of the hose into a container.

e. Slowly apply the brake several times.

f.

Fully pull the brake lever or fully press down the brake pedal and hold it in position.

g. Loosen the bleed screw.

NOTE:

Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend.

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

5 Nm (0.5 m·kg, 3.6 ft·lb)

k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.

Refer to «CHECKING THE BRAKE FLUID

LEVEL» on page 3-23.

EWA13110

WARNING

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

ET2D1006

ADJUSTING THE SHIFT PEDAL

1. Adjust:

• Shift pedal position

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen both locknuts “1”.

b. Turn the shift rod “2” in direction “a” or “b” to obtain the correct shift pedal position.

Direction “a”

Shift pedal is raised.

Direction “b”

Shift pedal is lowered.

CHASSIS

NOTE:

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

2. Spin the rear wheel several times and find the tightest position of drive chain.

3. Check:

• Drive chain slack “a”

Out of specification

→

Adjust.

Drive chain slack

25–35 mm (0.98–1.38 in)

c. Tighten both locknuts.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

ET2D1007

ADJUSTING THE DRIVE CHAIN SLACK

NOTE:

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

ECA13550

CAUTION:

A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits.

1. Stand the vehicle on a level surface.

EW2D1005

WARNING

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

3-26

4. Adjust:

• Drive chain slack

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the wheel axle nut “1” b. Loosen both locknuts “2” c. Turn both adjusting bolts “3” in direction “a” or “b” until the specified drive chain slack is obtained.

Direction “a”

Drive chain is tightened.

Direction “b”

Drive chain is loosened.

NOTE:

To maintain the proper wheel alignment, adjust both sides evenly.

d. Tighten both locknuts to specification.

Locknut

16 Nm (1.6 m·kg, 12 ft·lb)

e. Tighten the wheel axle nut to specification.

Wheel axle nut

150 Nm (15 m·kg, 108 ft·lb)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

ET2D1008

LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas.

This vehicle has a drive chain with small rubber O-rings between each side plate. Steam cleaning, high-pressure washing, certain solvents, and the use of a coarse brush can damage these O-rings. Therefore, use only kerosene to clean the drive chain. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for

O-ring chains. Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O-rings.

Recommended lubricant

Engine oil or chain lubricant suitable for O-ring chains

EAS21510

CHECKING AND ADJUSTING THE STEER-

ING 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.

Binding/looseness

→

Adjust the steering head.

3. Remove:

• Upper bracket

3-27

CHASSIS

Refer to «STEERING HEAD» on page 4-57.

4. Adjust:

• Steering head

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

b. Loosen the lower ring nut “4” and then tighten it to specification with a steering nut wrench “5”.

NOTE:

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

Steering nut wrench

90890-01403

Spanner wrench

YU-33975

Lower ring nut (initial tightening torque)

52 Nm (5.2 m·kg, 38 ft·lb)

c. Loosen the lower ring nut “4” completely, and then tighten it to specification.

EWA13140

WARNING

Do not overtighten the lower ring nut.

Lower ring nut (final tightening torque)

18 Nm (1.8 m·kg, 13 ft·lb)

CHASSIS

d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings.

Refer to «STEERING HEAD» on page 4-57.

e. Install the rubber washer “3”.

f.

Install the upper ring nut “2”.

g. Finger tighten the upper ring nut “2”, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned.

h. Install the lock washer “1”.

NOTE:

Make sure the lock washer tabs “a” sit correctly in the ring nut slots “b”.

d. Hold the spring gauge at a 90

°

angle from the handlebar, pull the spring gauge, and then record the measurement when the handlebar starts to run.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Install:

• Upper bracket

Refer to «STEERING HEAD» on page 4-57.

6. Measure:

• Steering head tension

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

NOTE:

Make sure all of the cables and wires are properly routed.

a. Point the front wheel straight ahead.

b. Install a plastic locking tie “1” loosely around the end of the handlebar as shown.

c. Hook a spring gauge “2” onto the plastic locking tie.

Steering head tension

200–500 g

e. Repeat the above procedure on the opposite handlebar.

f.

If the steering head tension is out of specification (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut.

g. Reinstall the upper bracket and measure the steering head tension again as described above.

h. Repeat the above procedure until the steering head tension is within specification.

i.

Grasp the bottom of the front fork legs and gently rock the front fork.

Binding/looseness

→

Adjust the steering head.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS21530

CHECKING THE FRONT FORK

1. Stand the vehicle on a level surface.

3-28

EWA13120

WARNING

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

2. Check:

• Inner tube “1”

Damage/scratches

→

Replace.

• Oil seal “2”

Oil leakage

→

Replace.

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 4-48.

CHASSIS

EWA13150

WARNING

• Always adjust both front fork legs evenly.

Uneven adjustment can result in poor handling and loss of stability.

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

Spring preload

ECA13570

CAUTION:

• Grooves are provided to indicate the adjustment position.

• Never go beyond the maximum or minimum adjustment positions.

1. Adjust:

• Spring preload

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting bolt “1” in direction “a” or

“b”.

Direction “a”

Spring preload is increased

(suspension is harder).

Direction “b”

Spring preload is decreased

(suspension is softer).

Spring preload adjusting positions

Minimum

8

Standard

6

Maximum

0

EAS21580

ADJUSTING THE FRONT FORK LEGS

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

NOTE:

Each front fork leg is equipped with a spring preload adjusting bolt, the right front fork leg is equipped with a reboumd damping force adjusting screw and left front fork leg with a compression damping force adjusting screw.

3-29

CHASSIS

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Rebound damping (Right side front fork)

EC2D1006

CAUTION:

• Never go beyond the maximum or minimum adjustment positions.

• When assembling the front forks, be careful not to assemble them to the opposite position because there are two kinds of forks (for the rebound side and for the compression side).

1. Adjust:

• Rebound damping

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”.

Direction “a” (turn in)

Rebound damping is increased

(suspension is harder).

Direction “b” (turn out)

Rebound damping is decreased

(suspension is softer).

Rebound damping adjusting positions

Minimum

26 clicks in direction: “b”*

Standard

15 clicks in direction: “b”*

Maximum

1 clicks in direction: “b”*

* With the adjusting screw fully turned-in direction “a”

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Compression damping (Left side front fork)

ECA13590

CAUTION:

• Never go beyond the maximum or minimum adjustment positions.

• When assembling the front forks, be careful not to assemble them to the opposite position because there are two kinds of forks (for the rebound side and for the compression side).

1. Adjust:

• Compression damping

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”.

Direction “a” (turn in)

Compression damping is increased

(suspension is harder).

Direction “b” (turn out)

Compression damping is decreased

(suspension is softer).

Compression damping adjusting positions

Minimum

26 clicks in direction: “b”*

Standard

5 clicks in direction: “b”*

Maximum

1 clicks in direction: “b”*

* With the adjusting screw fully turned-in direction “a”

3-30

CHASSIS

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EAS21620

ADJUSTING THE REAR SHOCK

ABSORBER ASSEMBLY

EWA13120

WARNING

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

Spring preload

ECA13590

CAUTION:

Never go beyond the maximum or minimum adjustment positions.

1. Adjust:

• Spring preload

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Adjust the spring preload with the special wrench and extension bar included in the owner’s tool kit.

b. Turn the adjusting ring “1” in direction “a” or

“b”.

c. Align the desired position on the adjusting ring with the stopper “2”

Direction “a”

Spring preload is increased

(suspension is harder).

Direction “b”

Spring preload is decreased

(suspension is softer).

Spring preload adjusting positions

Minimum

1

Standard

3

Maximum

7

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Rebound damping

ECA13590

CAUTION:

Never go beyond the maximum or minimum adjustment positions.

1. Adjust:

• Rebound damping

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”.

Direction “a”

Rebound damping is increased

(suspension is harder).

Direction “b”

Rebound damping is decreased

(suspension is softer).

Rebound damping adjusting position

Minimum

12 clicks in direction: “b”*

Standard

6 clicks in direction: “b”*

Maximum

1 clicks in direction: “b”*

* With the adjusting screw fully turned-in direction “a”

3-31

CHASSIS

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EAS21650

CHECKING THE TIRES

The following procedure applies to both of the tires.

1. Check:

• Tire pressure

Out of specification

→

Regulate.

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.

3-32

Tire air pressure (measured on cold tires):

Basic weight (with oil and a full fuel tank)

FZ1-N

214kg (472lb)

FZ1-S

220kg (485lb)

Loading condition*

0–90 kg (0–198 lb)

Front

250 kPa (2.5 kg/cm

2,

2.5 bar, 36 psi)

Rear

290 kPa (2.9 kg/cm

2,

2.9 bar, 42 psi)

Loading condition*

FZ1-N

90–196 kg (198–432 lb)

FZ1-S

90–190 kg (198–419 lb)

Front

250 kPa (2.5 kg/cm

2,

2.5 bar, 36 psi)

Rear

290 kPa (2.9 kg/cm

2,

2.9 bar, 42 psi)

High speed riding:

Front

250 kPa (2.5 kg/cm

2,

2.5 bar, 36 psi)

Rear

290 kPa (2.9 kg/cm

2,

2.9 bar, 42 psi)

Maximum load*

FZ1-N

196 kg (432 lb)

FZ1-S

190 kg (419 lb)

* Total weight of rider, passenger, cargo and accessories.

EWA13190

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.

1. Tire tread depth

2. Side wall

3. Wear indicator

Minimum tire tread depth

1.6 mm (0.06 in)

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.

CHASSIS

EWA14090

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

120/70 ZR17 M/C (58W)

Manufacturer/model

DUNLOP/D221FA

MICHELIN/PILOT ROAD S

Rear tire

Size

190/50 ZR17 M/C (73W)

Manufacturer/model

DUNLOP/D221G

MICHELIN/PILOT ROAD D

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

Tube tire only

Tube or tubeless tire

3-33

EAS21670

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.

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 point and metal-to-metal moving parts of the levers.

Recommended lubricant

Lithium — soap — based grease

CHASSIS

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

EAS21730

LUBRICATING THE CENTERSTAND (FZ1-S)

Lubricate the pivoting point and metal-to-metal moving parts of the centerstand.

Recommended lubricant

Lithium — soap — based grease

EAS21740

LUBRICATING THE REAR SUSPENSION

Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension.

Recommended lubricant

Molybdenum disulfide grease

3-34

ELECTRICAL SYSTEM

EAS21750

ELECTRICAL SYSTEM

EAS21760

CHECKING AND CHARGING THE BATTERY

Refer to «ELECTRICAL COMPONENTS» on page 8-89.

EAS21770

CHECKING THE FUSES

Refer to «ELECTRICAL COMPONENTS» on page 8-89.

EAS21780

REPLACING THE HEADLIGHT BULBS

1. Remove:

• Headlight side cover bolts “1” (FZ1-N)

A. FZ1-N

B. FZ1-S

4. Remove:

• Headlight bulb cover “1” (FZ1-S)

2. Disconnect:

• Headlight sub-wire harness coupler “2”

(FZ1-N)

5. Remove:

• Headlight bulb holder “1”

3. Disconnect:

• Headlight coupler “1”

3-35

A. FZ1-N

B. FZ1-S

6. Remove:

• Headlight bulb “1”

ELECTRICAL SYSTEM

EAS21800

ADJUSTING THE HEADLIGHT BEAM

1. Adjust:

• Headlight beam (vertically)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”.

Direction “a”

Headlight beam is raised.

Direction “b”

Headlight beam is lowered.

A. FZ1-N

B. FZ1-S

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

Secure the new headlight bulb with the headlight bulb holder.

ECA13690

CAUTION:

Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.

8. Install:

• Headlight bulb holder

9. Install:

• Headlight bulb cover

10. Connect:

• Headlight coupler

11. Connect:

• Headlight assembly coupler

12. Install:

• Headlight assembly bolts

3-36

A. FZ1-N

B. FZ1-S

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Adjust:

• Headlight beam (horizontally)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”.

Direction “a”

Headlight beam moves to the left.

Direction “b”

Headlight beam moves to the right.

A. FZ1-N

B. FZ1-S

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3-37

ELECTRICAL SYSTEM

CHASSIS

GENERAL CHASSIS

………………………………………………………………………… 4-1

REMOVING THE COVER…………………………………………………………….. 4-7

INSTALLING THE COVER …………………………………………………………… 4-7

FRONT WHEEL

……………………………………………………………………………….. 4-8

REMOVING THE FRONT WHEEL ………………………………………………. 4-10

CHECKING THE FRONT WHEEL……………………………………………….. 4-10

ADJUSTING THE FRONT WHEEL STATIC BALANCE ………………….. 4-11

INSTALLING THE FRONT WHEEL (DISC) …………………………………… 4-12

REAR WHEEL

……………………………………………………………………………….. 4-14

REMOVING THE REAR WHEEL (DISC) ……………………………………… 4-17

CHECKING THE REAR WHEEL…………………………………………………. 4-17

CHECKING THE REAR WHEEL DRIVE HUB ………………………………. 4-17

CHECKING AND REPLACING THE REAR WHEEL SPROCKET ……. 4-18

ADJUSTING THE REAR WHEEL STATIC BALANCE…………………….. 4-18

INSTALLING THE REAR WHEEL (DISC) …………………………………….. 4-18

FRONT BRAKE

……………………………………………………………………………… 4-20

INTRODUCTION ………………………………………………………………………. 4-25

CHECKING THE FRONT BRAKE DISCS …………………………………….. 4-25

REPLACING THE FRONT BRAKE PADS …………………………………….. 4-26

REMOVING THE FRONT BRAKE CALIPERS ………………………………. 4-27

DISASSEMBLING THE FRONT BRAKE CALIPERS ……………………… 4-27

CHECKING THE FRONT BRAKE CALIPERS ………………………………. 4-28

ASSEMBLING THE FRONT BRAKE CALIPERS …………………………… 4-28

INSTALLING THE FRONT BRAKE CALIPERS……………………………… 4-28

REMOVING THE FRONT BRAKE MASTER CYLINDER………………… 4-29

CHECKING THE FRONT BRAKE MASTER CYLINDER ………………… 4-30

ASSEMBLING THE FRONT BRAKE MASTER CYLINDER…………….. 4-30

INSTALLING THE FRONT BRAKE MASTER CYLINDER ………………. 4-30

REAR BRAKE

……………………………………………………………………………….. 4-32

INTRODUCTION ………………………………………………………………………. 4-37

CHECKING THE REAR BRAKE DISC…………………………………………. 4-37

REPLACING THE REAR BRAKE PADS ………………………………………. 4-37

REMOVING THE REAR BRAKE CALIPER…………………………………… 4-38

DISASSEMBLING THE REAR BRAKE CALIPER………………………….. 4-38

CHECKING THE REAR BRAKE CALIPER …………………………………… 4-39

ASSEMBLING THE REAR BRAKE CALIPER……………………………….. 4-39

INSTALLING THE REAR BRAKE CALIPER …………………………………. 4-40

REMOVING THE REAR BRAKE MASTER CYLINDER………………….. 4-41

CHECKING THE REAR BRAKE MASTER CYLINDER ………………….. 4-41

ASSEMBLING THE REAR BRAKE MASTER CYLINDER ………………. 4-41

INSTALLING THE REAR BRAKE MASTER CYLINDER…………………. 4-41

HANDLEBAR

…………………………………………………………………………………. 4-43

4

REMOVING THE HANDLEBAR ………………………………………………….. 4-45

CHECKING THE HANDLEBAR…………………………………………………… 4-45

INSTALLING THE HANDLEBAR …………………………………………………. 4-45

FRONT FORK

………………………………………………………………………………… 4-48

REMOVING THE FRONT FORK LEGS ……………………………………….. 4-50

DISASSEMBLING THE FRONT FORK LEGS ………………………………. 4-50

CHECKING THE FRONT FORK LEGS………………………………………… 4-51

ASSEMBLING THE FRONT FORK LEGS ……………………………………. 4-52

INSTALLING THE FRONT FORK LEGS ………………………………………. 4-56

STEERING HEAD

…………………………………………………………………………… 4-57

REMOVING THE LOWER BRACKET ………………………………………….. 4-59

CHECKING THE STEERING HEAD ……………………………………………. 4-59

INSTALLING THE STEERING HEAD…………………………………………… 4-60

REAR SHOCK ABSORBER ASSEMBLY

………………………………………….. 4-61

HANDLING THE REAR SHOCK ABSORBER ………………………………. 4-63

DISPOSING OF A REAR SHOCK ABSORBER…………………………….. 4-63

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY…………….. 4-63

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY …………….. 4-63

CHECKING THE CONNECTING ARM AND RELAY ARM ……………… 4-64

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY …………… 4-64

SWINGARM

…………………………………………………………………………………… 4-65

REMOVING THE SWINGARM ……………………………………………………. 4-67

CHECKING THE SWINGARM ……………………………………………………. 4-67

INSTALLING THE SWINGARM …………………………………………………… 4-68

CHAIN DRIVE

………………………………………………………………………………… 4-69

REMOVING THE DRIVE CHAIN …………………………………………………. 4-70

CHECKING THE DRIVE CHAIN …………………………………………………. 4-70

CHECKING THE DRIVE SPROCKET ………………………………………….. 4-71

CHECKING THE REAR WHEEL SPROCKET ………………………………. 4-71

CHECKING THE REAR WHEEL DRIVE HUB ………………………………. 4-71

INSTALLING THE DRIVE CHAIN ………………………………………………… 4-71

EAS21830

GENERAL CHASSIS

Removing the seat and battery

GENERAL CHASSIS

Order

1

2

3

6

7

4

5

8

Job/Parts to remove

Passenger seat

Rider seat

Battery band

Battery cover

Battery negative lead

Battery positive lead

Battery

Battery seat

1

1

1

1

1

Q’ty

1

1

1

Remarks

For installation, reverse the removal procedure.

4-1

Removing the headlight and meter assembly (FZ1-N)

GENERAL CHASSIS

Order

1

2

3

6

7

4

5

8

9

10

Job/Parts to remove

Headlight side cover bolt (left and right)

Headlight coupler

Headlight sub-wire harness coupler

Headlight assembly

Headlight bracket

Headlight side cover (left and right)

Meter cover

Meter coupler

Meter assembly

Headlight and meter stay

2

1

1

2

Q’ty

4

1

1

1

1

1

Disconnect.

Disconnect.

Remarks

For installation, reverse the removal procedure.

4-2

Removing the front cowling (FZ1-S)

GENERAL CHASSIS

Order

1

2

3

6

7

4

5

8

Job/Parts to remove

Inner panel

Headlight assembly coupler

Meter coupler

Front cowling assembly

Rear view mirror

Cowling stay

Meter assembly

Headlight unit

1

1

1

2

1

Q’ty

2

1

1

Disconnect.

Disconnect.

Remarks

For installation, reverse the removal procedure.

4-3

Removing the rear fender (FZ1-N)

GENERAL CHASSIS

Order Job/Parts to remove

Rider and passenger seat

6

7

4

5

8

1

2

3

Licence plate light lead coupler

Turn signal light lead coupler

Mud guard assembly

Rear fender

Tail/brake light lead coupler

Tail cover

Rear fender bracket

Tail/brake light

1

1

1

1

1

1

1

1

Q’ty Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

Disconnect.

Disconnect.

Disconnect.

For installation, reverse the removal procedure.

4-4

Removing the rear fender (FZ1-S)

GENERAL CHASSIS

Order Job/Parts to remove

Rider and passenger seat

7

8

5

6

3

4

1

2

9

10

Licence plate light lead coupler

Turn signal light lead coupler

Mud guard assembly

Rear fender

Tail/brake light lead coupler

Tail/brake light cover

Rear fender side cover (left and right)

Rear fender bracket

Tail/brake light

Tail cover

Q’ty

1

1

1

1

1

1

Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

Disconnect.

Disconnect.

2

1

1 Disconnect.

1

For installation, reverse the removal procedure.

4-5

Removing the air filter case

GENERAL CHASSIS

7

8

5

6

2

3

4

Order

1

Job/Parts to remove

Rider and passenger seat

Fuel tank

Intake air temperature sensor lead coupler

Intake air temperature sensor

Air filter case cover

Air filter

Funnel

Air filter case

Air induction system hose

Crankcase breather hose

Q’ty

1

Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

Refer to «FUEL TANK» on page 7-1.

Disconnect.

1

1

1

2

1

1

1

For installation, reverse the removal procedure.

4-6

EAS21840

REMOVING THE COVER

1. Remove:

• Tail cover

• Rear fender

NOTE:

To remove the quick fastener, push its center with a screwdriver, then pull the fastener out.

GENERAL CHASSIS

EAS21850

INSTALLING THE COVER

1. Install:

• Rear fender

• Tail cover

NOTE:

To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cover and push the pin “a” in with screwdriver. Make sure that the pin is flush with the fastener’s head.

4-7

EAS21870

FRONT WHEEL

Removing the front wheel and brake discs

FRONT WHEEL

Order

1

2

5

6

3

4

7

8

Job/Parts to remove

Brake hose holder (left and right)

Front brake caliper (left and right)

Front wheel axle pinch bolt

Front wheel axle

Collar (left and right)

Dust cover

Front wheel

Front brake disc (left and right)

Q’ty

2

2

2

2

1

1

1

2

Remarks

For installation, reverse the removal procedure.

4-8

Disassembling the front wheel

FRONT WHEEL

Order

1

2

3

Job/Parts to remove

Oil seal (left and right)

Wheel bearing (left and right)

Spacer

Q’ty

2

2

1

Remarks

For assembly, reverse the disassembly procedure.

4-9

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.

NOTE:

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

2. Remove:

• Left brake caliper

• Right brake caliper

Refer to «FRONT BRAKE» on page 4-20.

NOTE:

Do not apply the brake lever when removing the brake calipers.

3. Elevate:

• Front wheel

NOTE:

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

4. Loosen:

• Front wheel axle pinch bolt

5. Remove:

• Front wheel axle

• Front wheel

EAS21920

CHECKING THE FRONT WHEEL

1. Check:

• Wheel axle

Roll the wheel axle on a flat surface.

Bends

→

Replace.

EWA13460

WARNING

Do not attempt to straighten a bent wheel axle.

2. Check:

• Tire

• Front wheel

Damage/wear

→

Replace.

FRONT WHEEL

Refer to «CHECKING THE TIRES» on page

3-32 and «CHECKING THE WHEELS» on page 3-34.

3. Measure:

• Radial wheel runout “1”

• Lateral wheel runout “2”

Over the specified limits

→

Replace.

Radial wheel runout limit

1.0 mm (0.04 in)

Lateral wheel runout limit

0.5 mm (0.02 in)

4. Check:

• Wheel bearings

Front wheel turns roughly or is loose

→

Replace the wheel bearings.

• Oil seals

Damage/wear

→

Replace.

5. Replace:

• Wheel bearings

• Oil seals

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the front wheel hub.

b. Remove the oil seals “1” with a flat-head screwdriver.

NOTE:

To prevent damaging the wheel, place a rag “2” between the screwdriver and the wheel surface.

4-10

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

FRONT WHEEL

• Adjust the front wheel static balance with the brake disc installed.

1. Remove:

• Balancing weight(s)

2. Find:

• Front wheel’s heavy spot

NOTE:

Place the front wheel on a suitable balancing stand.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Spin the front wheel.

b. When the front wheel stops, put an “X

1

” mark at the bottom of the wheel.

d. Install the new wheel bearings and oil seals in the reverse order of disassembly.

ECA14130

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 “X

1

” mark is positioned as shown.

d. Release the front wheel.

e. When the wheel stops, put an “X

2

” mark at the bottom of the wheel.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS21970

ADJUSTING THE FRONT WHEEL STATIC

BALANCE

NOTE:

• After replacing the tire, wheel or both, the front wheel static balance should be adjusted.

4-11

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 wheel’s heavy spot “X”.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Adjust:

• Front wheel static balance

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

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

NOTE:

Start with the lightest weight.

b. Turn the front wheel 90

°

so that the heavy spot is positioned as shown.

FRONT WHEEL

EAS22000

INSTALLING THE FRONT WHEEL (DISC)

The following procedure applies to both of the brake discs.

1. Lubricate:

• Wheel axle

• Oil seal lips

Recommended lubricant

Lithium-soap-based grease

2. Lift the wheel up between the fork legs.

3. Insert the wheel axle.

NOTE:

Install the tire and wheel with the mark “1” pointing in the direction of wheel rotation.

c. If the heavy spot does not stay in that position, install a heavier weight.

d. Repeat steps (b) and (c) until the front wheel is balanced.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4. Check:

• Front wheel static balance

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

4. Lower the front wheel so that it is on the ground.

5. Tighten:

• Wheel axle

Wheel axle nut

72 Nm (7.2 m·kg, 52 ft·lb)

• Wheel axle pinch bolt

Wheel axle pinch bolt

23 Nm (2.3 m·kg, 17 ft·lb)

ECA14140

CAUTION:

Before tightening the front wheel axle, push down hard on the handlebar several times and check if the front fork rebounds smoothly.

6. Install:

• Brake caliper

Brake caliper bolt

40 Nm (4.0 m·kg, 29 ft·lb)

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4-12

EWA13490

WARNING

Make sure the brake cable is routed properly.

NOTE:

Make sure that there is enough space between the brake pads before installing the brake calipers onto the brake discs.

FRONT WHEEL

4-13

EAS22020

REAR WHEEL

Removing the rear wheel

REAR WHEEL

Order

1

2

3

6

7

4

5

8

9

10

Job/Parts to remove

Rear brake caliper

Locknut (left and right)

Adjusting bolt (left and right)

Wheel axle nut

Washer

Rear wheel axle

Adjusting block (left)

Adjusting block (right)

Rear wheel

Brake caliper bracket

1

1

1

1

Q’ty

1

2

2

1

1

1

Loosen.

Loosen.

Remarks

For installation, reverse the removal procedure.

4-14

Removing the brake disc and rear wheel sprocket

REAR WHEEL

Order

1

2

3

6

7

4

5

8

9

Job/Parts to remove

Rear brake disc

Rear wheel sprocket

Coller (left and right)

Dust cover

Oil seal

Bearing

Rear wheel drive hub

Rear wheel drive hub damper

Rear wheel

1

1

2

1

Q’ty

1

1

2

6

1

Remarks

For installation, reverse the removal procedure.

4-15

Disassembling the rear wheel

REAR WHEEL

Order

1

2

3

4

5

6

Coller

Bearing

Spacer

Oil seal

Circlip

Bearing

Job/Parts to remove Q’ty

1

1

1

1

1

1

Remarks

For assembly, reverse the disassembly procedure.

4-16

REAR WHEEL

EAS22040

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:

• Brake caliper “1”

NOTE:

Do not depress the brake pedal when removing the brake caliper.

5. Remove:

• Left collar “1”

• Rear wheel drive hub “2”

• Rear wheel drive hub damper

• Right collar

3. Loosen:

• Locknut “1”

• Adjusting bolt “2”

4. Remove:

• Wheel axle nut “1”

• Wheel axle “2”

• Rear wheel

NOTE:

Push the rear wheel forward and remove the drive chain from the rear wheel sprocket.

4-17

EAS22090

CHECKING THE REAR WHEEL

1. Check:

• Wheel axle

• Rear wheel

• Wheel bearings

• Oil seals

Refer to «FRONT WHEEL» on page 4-8.

2. Check:

• Tire

• Rear wheel

Damage/wear

→

Replace.

Refer to «CHECKING THE TIRES» on page

3-32 and «CHECKING THE WHEELS» on page 3-34.

3. Measure:

• Radial wheel runout

• Lateral wheel runout

Refer to «FRONT WHEEL» on page 4-8.

EAS22110

CHECKING THE REAR WHEEL DRIVE HUB

1. Check:

• Rear wheel drive hub “1”

Cracks/damage

→

Replace.

• Rear wheel drive hub dampers “2”

REAR WHEEL

Damage/wear

→

Replace.

EAS22120

CHECKING AND REPLACING THE REAR

WHEEL SPROCKET

1. Check:

• Rear wheel sprocket

More than 1/4 tooth “a” wear

→

Replace the rear wheel sprocket.

Bent teeth

→

Replace the rear wheel sprocket.

b. Correct

1. Drive chain roller

2. Rear wheel sprocket

2. Replace:

• Rear wheel sprocket

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the self-locking nuts and the rear wheel sprocket.

b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket.

c. Install the new rear wheel sprocket.

Rear wheel sprocket self-locking nut

100 Nm (10 m·kg, 72 ft·lb)

NOTE:

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

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 4-11.

EAS22160

INSTALLING THE REAR WHEEL (DISC)

1. Lubricate:

• Wheel axle

• Wheel bearings

• Oil seal lips

Recommended lubricant

Lithium-soap-based grease

2. Adjust:

• Drive chain slack

Refer to «ADJUSTING THE DRIVE CHAIN

SLACK» on page 3-26.

Drive chain slack

25–35 mm (0.98–1.38 in)

3. Tighten:

• Wheel axle nut

• Brake caliper bolts

Wheel axle nut

150 Nm (15 m·kg, 108 ft·lb)

Brake caliper bolt (front)

27 Nm (2.7 m·kg, 20 ft·lb)

Brake caliper bolt (rear)

22 Nm (2.2 m·kg, 16 ft·lb)

4-18

EWA13500

WARNING

Make sure the brake hose is routed properly.

REAR WHEEL

4-19

EAS22210

FRONT BRAKE

Removing the front brake pads

FRONT BRAKE

Order

1

2

3

6

7

4

5

Job/Parts to remove

Brake hose holder

Front brake caliper

Brake pad clip

Brake pad pin

Brake pad spring

Brake pad

Bleed screw

2

1

1

1

Q’ty

1

1

2

Remarks

For installation, reverse the removal procedure.

4-20

Removing the front brake master cylinder

FRONT BRAKE

Order Job/Parts to remove

Brake fluid

7

8

9

10

11

4

5

6

1

2

3

Right rearview mirror (FZ1-N)

Brake master cylinder reservoir cap

Brake master cylinder reservoir diaphragm holder

Brake master cylinder diaphragm

Brake lever

Front brake light switch lead coupler

Front brake light switch

Union bolt

Copper washer

Master cylinder bracket

Master cylinder assembly

4-21

2

1

1

1

1

1

1

1

Q’ty Remarks

Drain.

Refer to «BLEEDING THE HYDRAU-

LIC BRAKE SYSTEM» on page 3-

25.

1

1

1

Disconnect.

For assembly, reverse the disassembly procedure.

Disassembling the front brake master cylinder

FRONT BRAKE

Order

1

2

Job/Parts to remove

Brake master cylinder kit

Brake master cylinder body

Q’ty

1

1

Remarks

For assembly, reverse the disassembly procedure.

4-22

Removing the front brake calipers

FRONT BRAKE

Order Job/Parts to remove

Brake fluid

3

4

1

2

Union bolt

Copper washer

Brake hose

Brake caliper

1

1

1

2

Q’ty Remarks

Drain.

Refer to «BLEEDING THE HYDRAU-

LIC BRAKE SYSTEM» on page 3-

25.

For installation, reverse the removal procedure.

4-23

Disassembling the front brake calipers

FRONT BRAKE

Order

1

2

5

6

3

4

7

Job/Parts to remove

Brake pad clip

Brake pad pin

Brake pad spring

Brake pad

Brake caliper piston

Brake caliper piston seal

Bleed screw

Q’ty

2

1

4

8

1

2

1

Remarks

For assembly, reverse the disassembly procedure.

4-24

FRONT BRAKE

EAS22220

INTRODUCTION

EWA14100

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.

EAS22240

CHECKING THE FRONT BRAKE DISCS

The following procedure applies to both brake discs.

1. Remove:

• Front wheel

Refer to «FRONT WHEEL» on page 4-8.

2. Check:

• Brake disc

Damage/galling

→

Replace.

3. Measure:

• Brake disc deflection

Out of specification

→

Correct the brake disc deflection or replace the brake disc.

Brake disc deflection limit

0.1 mm (0.004 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 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.

Brake disc thickness limit

4.0 mm (0.16 in)

5. Adjust:

• Brake disc deflection

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the brake disc.

b. Rotate the brake disc by one bolt hole.

c. Install the brake disc.

4-25

NOTE:

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

Brake disc bolt

18 Nm (1.8 m·kg, 13 ft·lb)

LOCTITE®

FRONT BRAKE

Brake pad lining thickness

(inner)

4.5 mm (0.18 in)

Limit

0.5 mm (0.02 in)

Brake pad lining thickness

(outer)

4.5 mm (0.18 in)

Limit

0.5 mm (0.02 in)

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.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6. Install:

• Front wheel

Refer to «FRONT WHEEL» on page 4-8.

EAS22270

REPLACING THE FRONT BRAKE PADS

The following procedure applies to both brake calipers.

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.

2. Install:

• Brake pads

• Brake pad spring

NOTE:

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

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

4-26

b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger.

c. Tighten the bleed screw.

Bleed screw

5 Nm (0.5 m·kg, 3.6 ft·lb)

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

NOTE:

The arrow mark “a” on the brake pad spring must point in the direction of disc rotation.

FRONT BRAKE

NOTE:

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

1. Remove:

• Union bolt “1”

• Copper washers “2”

• Brake hose “3”

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Install:

• Brake pad pins

• Brake pad clips

• Brake caliper

Brake caliper bolt

40 Nm (4.0 m·kg, 29 ft·lb)

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 3-23.

NOTE:

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

EAS22360

DISASSEMBLING THE FRONT BRAKE

CALIPERS

The following procedure applies to both of the brake calipers.

1. Remove:

• Brake caliper pistons “1”

• Brake caliper piston seals “2”

5. Check:

• Brake lever operation

Soft or spongy feeling

→

Bleed the brake system.

Refer to «BLEEDING THE HYDRAULIC

BRAKE SYSTEM» on page 3-25.

EAS22300

REMOVING THE FRONT BRAKE CALIPERS

The following procedure applies to both of the brake calipers.

4-27

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Secure the brake caliper pistons with a piece of wood “a”.

b. Blow compressed air into the brake hose joint opening “b” to force out the left side pistons from the brake caliper.

EWA13570

WARNING

• Never try to pry out the brake caliper pistons.

• Do not loosen the bolts “3”.

FRONT BRAKE

c. Remove the brake caliper piston seals.

d. Repeat the previous steps to force out the right side pistons from the brake caliper.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS22390

CHECKING THE FRONT BRAKE CALIPERS

Recommended brake component replacement schedule

Brake pads

Piston seals

If necessary

Every two years

Brake hoses

Brake fluid

Every four years

Every two years and whenever the brake is disassembled

1. Check:

• Brake caliper pistons “1”

Rust/scratches/wear

→

Replace the brake caliper pistons.

• Brake caliper cylinders “2”

Scratches/wear

→

Replace the brake caliper assembly.

• Brake caliper body “3”

Cracks/damage

→

Replace the brake caliper assembly.

• Brake fluid delivery passages

(brake caliper body)

Obstruction

→

Blow out with compressed air.

EWA13600

WARNING

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

4-28

EAS22410

ASSEMBLING THE FRONT BRAKE CALI-

PERS

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 brake fluid

DOT4

EAS22440

INSTALLING THE FRONT BRAKE CALI-

PERS

The following procedure applies to both of the brake calipers.

1. Install:

• Brake caliper “1”

(temporarily)

• Copper washers

• Brake hose “2”

• Union bolt “3”

Brake hose union bolt

30 Nm (3.0 m·kg, 22 ft·lb)

EWA13530

WARNING

Proper brake hose routing is essential to insure safe vehicle operation. Refer to

«CABLE ROUTING» on page 2-39.

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.

FRONT BRAKE

ECA13540

CAUTION:

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

5. Bleed:

• Brake system

Refer to «BLEEDING THE HYDRAULIC

BRAKE SYSTEM» on page 3-25.

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 3-23.

2. Remove:

• Brake caliper

3. Install:

• Brake pads

• Brake pad spring

• Brake pad pin

• Brake pad clips

• Brake caliper

• Brake hose holder

Brake caliper bolt

40 Nm (4.0 m·kg, 29 ft·lb)

Brake hose holder bolt

7 Nm (0.7 m·kg, 5.1 ft·lb)

Refer to «REPLACING THE FRONT

BRAKE PADS» on page 4-26.

4. Fill:

• Brake master cylinder reservoir

(with the specified amount of the recommended brake fluid)

Recommended fluid

DOT4

EWA13090

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.

4-29

7. Check:

• Brake lever operation

Soft or spongy feeling

→

Bleed the brake system.

Refer to «BLEEDING THE HYDRAULIC

BRAKE SYSTEM» on page 3-25.

EAS22490

REMOVING THE FRONT BRAKE MASTER

CYLINDER

NOTE:

Before removing the front brake master cylinder, drain the brake fluid from the entire brake system.

1. Disconnect:

• Brake switch couplers “1”

(from the brake switch)

2. Remove:

• Union bolt “1”

• Copper washers “2”

• Brake hose “3”

NOTE:

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

FRONT BRAKE

EAS22520

ASSEMBLING THE FRONT BRAKE MAS-

TER CYLINDER

EWA13520

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

DOT4

EAS22530

INSTALLING THE FRONT BRAKE MASTER

CYLINDER

1. Install:

• Brake master cylinder “1”

• Brake master cylinder bracket “2”

Brake master cylinder bracket bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

NOTE:

• Install the brake master cylinder holder with the “UP” mark “a” facing up.

• Align the end of the brake master cylinder holder with the punch mark “b” on the handlebar.

• First, tighten the upper bolt, then the lower bolt.

• There should be more than 11 mm (0.43 in) for clearance between the right handlebar switch and the brake master cylinder bracket.

Also, the punch mark should be seen.

EAS22500

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.

4-30

2. Install:

• Copper washers

• Brake hose

• Union bolt

Brake hose union bolt

30 Nm (3.0 m·kg, 22 ft·lb)

EWA13530

WARNING

Proper brake hose routing is essential to insure safe vehicle operation. Refer to

«CABLE ROUTING» on page 2-39.

NOTE:

• While holding the brake hose, tighten the union bolt as shown.

• Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary.

EC2D1004

CAUTION:

Attach the brake hose so that its angle is

23

°

to 33

°

against the straight line in parallel with the ceiling plane of the master cylinder.

FRONT BRAKE

• 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

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 3-25.

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 3-23.

3. Fill:

• Brake master cylinder reservoir

(with the specified amount of the recommended brake fluid)

Recommended fluid

DOT4

EWA13540

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.

4-31

6. Check:

• Brake lever operation

Soft or spongy feeling

→

Bleed the brake system.

Refer to «BLEEDING THE HYDRAULIC

BRAKE SYSTEM» on page 3-25.

EAS22550

REAR BRAKE

Removing the rear brake pads

REAR BRAKE

Order

1

2

3

6

7

4

5

Job/Parts to remove

Screw plug

Brake pad pin

Rear brake caliper

Brake pad shim

Brake pad

Bleed screw

Brake pad spring

1

1

4

2

Q’ty

1

1

1

Remarks

For installation, reverse the removal procedure.

4-32

Removing the rear brake master cylinder

REAR BRAKE

6

7

4

5

1

2

3

8

9

10

11

Order Job/Parts to remove

Brake fluid

Brake fluid reservoir cap

Brake fluid reservoir diaphragm holder

Brake fluid reservoir diaphragm

Brake fluid reservoir tank

Brake fluid reservoir hose

Hose joint

Bushing

Union bolt

Copper washer

Brake hose

Brake master cylinder

1

1

1

1

1

1

1

1

1

1

2

Q’ty Remarks

Drain.

Refer to «BLEEDING THE HYDRAU-

LIC BRAKE SYSTEM» on page 3-

25.

For installation, reverse the removal procedure.

4-33

Disassembling the rear brake master cylinder

REAR BRAKE

Order

1

2

3

4

Job/Parts to remove

Brake master cylinder kit

Hose joint

Bushing

Brake master cylinder body

Q’ty

1

1

1

1

Remarks

For assembly, reverse the disassembly procedure.

4-34

Removing the rear brake caliper

REAR BRAKE

Order

1

2

3

4

Job/Parts to remove

Union bolt

Copper washer

Brake hose

Barke caliper

Q’ty

1

2

1

1

Remarks

For installation, reverse the removal procedure.

4-35

Disassembling the rear brake caliper

REAR BRAKE

Order

1

2

5

6

3

4

7

8

Job/Parts to remove

Screw plug

Brake pad pin

Brake pad

Brake pad shim

Brake pad spring

Brake caliper piston

Brake caliper piston seal

Bleed screw

Q’ty

1

1

1

1

2

4

2

1

Remarks

For assembly, reverse the disassembly procedure.

4-36

REAR BRAKE

EAS22560

INTRODUCTION

EWA14100

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

CHECKING THE REAR BRAKE DISC

1. Remove:

• Rear wheel

Refer to «REAR WHEEL» on page 4-14.

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 4-25.

Brake disc deflection limit

0.15 mm (0.0059 in)

4. Measure:

• Brake disc thickness

Measure the brake disc thickness at a few different locations.

Out of specification

→

Replace.

Refer to «CHECKING THE FRONT BRAKE

DISCS» on page 4-25.

4-37

Brake disc thickness limit

4.5 mm (0.18 in)

5. Adjust:

• Brake disc deflection

Refer to «CHECKING THE FRONT BRAKE

DISCS» on page 4-25.

Brake disc bolt

30 Nm (3.0 m·kg, 22 ft·lb)

LOCTITE®

6. Install:

• Rear wheel

Refer to «REAR WHEEL» on page 4-14.

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)

6.0 mm (0.24 in)

Limit

1.0 mm (0.04 in)

Brake pad lining thickness

(outer)

6.0 mm (0.24 in)

Limit

1.0 mm (0.04 in)

2. Install:

• Brake pad shims

(onto the brake pads)

• Brake pads

• Brake pad spring

NOTE:

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

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

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

REAR BRAKE

Refer to «CHECKING THE BRAKE FLUID

LEVEL» on page 3-23.

b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger.

c. Tighten the bleed screw.

Bleed screw

5 Nm (0.5 m·kg, 3.6 ft·lb)

d. Install a new brake pad shim “3” onto each new brake pad “4”.

e. Install new brake pads and a new brake pad spring “5”.

5. Check:

• Brake pedal operation

Soft or spongy feeling

→

Bleed the brake system.

Refer to «BLEEDING THE HYDRAULIC

BRAKE SYSTEM» on page 3-25.

EAS22590

REMOVING THE REAR BRAKE CALIPER

NOTE:

Before disassembling the brake caliper, drain the brake fluid from the entire brake system.

1. Remove:

• Union bolt “1”

• Copper washers “2”

• Brake hose “3”

NOTE:

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Install:

• Brake caliper

• Brake pad pin

• Screw plug

Brake caliper bolt (front)

27 Nm (2.7 m·kg, 20 ft·lb)

Brake caliper bolt (rear)

22 Nm (2.2 m·kg, 16 ft·lb)

4. Check:

• Brake fluid level

Below the minimum level mark “a”

→

Add the recommended brake fluid to the proper level.

EAS22600

DISASSEMBLING THE REAR BRAKE CALI-

PER

1. Remove:

• Brake caliper piston “1”

• Brake caliper piston seals “2”

4-38

REAR BRAKE

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

WARNING

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

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Secure the brake caliper pistons with a piece of wood “a”.

b. Blow compressed air into the brake hose joint opening “b” to force out the piston from the brake caliper.

EWA13550

WARNING

• 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.

2. Check:

• Brake caliper bracket “1”

Cracks/damage

→

Replace.

c. Remove the brake caliper piston seals.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS22640

CHECKING THE REAR BRAKE CALIPER

Recommended brake component replacement schedule

Brake pads If necessary

Piston seals

Brake hoses

Brake fluid

Every two years

Every four years

Every two years and whenever the brake is disassembled

1. Check:

• Brake caliper pistons “1”

Rust/scratches/wear

→

Replace the brake caliper pistons.

• Brake caliper cylinders “2”

4-39

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.

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

Recommended fluid

DOT4

EAS22670

INSTALLING THE REAR BRAKE CALIPER

1. Install:

• Brake caliper “1”

(temporarily)

• Copper washers “2”

• Brake hose “3”

• Union bolt “4”

Brake hose union bolt

30 Nm (3.0 m·kg, 22 ft·lb)

EWA13530

WARNING

Proper brake hose routing is essential to insure safe vehicle operation. Refer to

«CABLE ROUTING» on page 2-39.

EC2D1010

CAUTION:

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

2. Remove:

• Brake caliper

3. Install:

• Brake pad shims

• Brake pads

• Brake pad spring

• Brake pad pin

• Screw plug

REAR BRAKE

• Brake caliper

Refer to «REPLACING THE REAR BRAKE

PADS» on page 4-37.

Brake caliper bolt (front)

27 Nm (2.7 m·kg, 20 ft·lb)

Brake caliper bolt (rear)

22 Nm (2.2 m·kg, 16 ft·lb)

4. Fill:

• Brake fluid reservoir

(with the specified amount of the recommended brake fluid)

Recommended fluid

DOT4

EWA13090

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

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 3-25.

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 3-23.

4-40

7. Check:

• Brake pedal operation

Soft or spongy feeling

→

Bleed the brake system.

Refer to «BLEEDING THE HYDRAULIC

BRAKE SYSTEM» on page 3-25.

EAS22700

REMOVING THE REAR BRAKE MASTER

CYLINDER

1. Remove:

• Union bolt “1”

• Copper washers “2”

• Brake hose “3”

NOTE:

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

EAS22720

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.

4-41

REAR BRAKE

3. Check:

• Brake fluid reservoir

Cracks/damage

→

Replace.

• Brake fluid reservoir diaphragm

Cracks/damage

→

Replace.

4. Check:

• Brake hose

Cracks/damage/wear

→

Replace.

EAS22730

ASSEMBLING THE REAR BRAKE MASTER

CYLINDER

EWA13520

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

DOT4

ET2D1022

INSTALLING THE REAR BRAKE MASTER

CYLINDER

1. Install:

• Copper washers

• Brake hose “1”

• Union bolt “2”

Brake hose union bolt

30 Nm (3.0 m·kg, 22 ft·lb)

EW2D1004

WARNING

Proper brake hose routing is essential to insure safe vehicle operation.

Refer to «CABLE ROUTING» on page 2-39.

EC2D1005

CAUTION:

When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection “a” as shown.

REAR BRAKE

2. Fill:

• Brake fluid reservoir

(with the specified amount of the recommended brake fluid)

Recommended fluid

DOT4

EW2D1005

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.

EC2D1010

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 3-25.

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 3-23.

5. Check:

• Brake pedal operation

Soft or spongy feeling

→

Bleed the brake system.

Refer to «BLEEDING THE HYDRAULIC

BRAKE SYSTEM» on page 3-25.

6. Adjust:

• Brake pedal position

Refer to «ADJUSTING THE REAR DISC

BRAKE» on page 3-22.

7. Adjust:

• Rear brake light operation timing

Refer to «ADJUSTING THE REAR BRAKE

LIGHT SWITCH» on page 3-24.

4-42

EAS22840

HANDLEBAR

Removing the handlebar

HANDLEBAR

Order Job/Parts to remove

Front cowling (FZ1-S)

9

10

11

12

13

14

7

8

5

6

3

4

1

2

Rear view mirror (FZ1-N)

Front brake light switch connector

Front master cylinder bracket

Front brake master cylinder assembly

Right handlebar switch

Throttle cable housing

Throttle cable

Grip end

Throttle grip

Clutch cable

Handlebar grip

Left handlebar switch

Clutch lever holder

Upper handlebar holder

Q’ty Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

1

1

1

1

1

1

2

2

1

1

1

1

2

2 Disconnect.

4-43

Removing the handlebar

HANDLEBAR

Order

15

16

Job/Parts to remove

Handlebar

Lower handlebar holder

Q’ty

1

2

Remarks

For installation, reverse the removal procedure.

4-44

EAS22860

REMOVING THE HANDLEBAR

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:

• Handlebar grip “1”

NOTE:

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

HANDLEBAR

EAS22930

INSTALLING THE HANDLEBAR

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. Install:

• Lower handlebar holders “1”

NOTE:

Temporarily tighten the nuts “2”.

3. Remove:

• Throttle cable housing “1”

• Throttle grip “2”

NOTE:

While removing the throttle cable housing, pull back the rubber cover “3”.

3. Install:

• Handlebar “1”

• Upper handlebar holder “2”

Upper handlebar holder bolt

24 Nm (2.4 m·kg, 17 ft·lb)

ECA14250

CAUTION:

• First, tighten the bolts on the front side of the handlebar holder, and then on the rear side.

• 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:

• The upper handlebar holder should be installed with the punch mark “a” facing forward.

• Align the match marks “b” on the handlebar with the upper surface of the lower handlebar holders.

EAS22880

CHECKING THE HANDLEBAR

1. Check:

• Handlebar

Bends/cracks/damage

→

Replace.

EWA13690

WARNING

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

4-45

4. Tighten:

• Lower handlebar holder nuts

Lower handlebar holder nut

32 Nm (3.2 m·kg, 23 ft·lb)

5. Install:

• Clutch lever holder “1”

• Clutch cable

NOTE:

Align the slit in the clutch lever holder with the punch mark «a» in the handlebar.

HANDLEBAR

Grip end

26 Nm (2.6 m·kg, 19 ft·lb)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto the left end of the handlebar.

b. Side the handlebar grip over the left end of the handlebar.

c. Wipe off any excess rubber adhesive with a clean rag.

EW2D1007

WARNING

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

NOTE:

There should be 1–3 mm (0.04–0.12 in) of clearance “a” between the handlebar grip and the grip end.

6. Install:

• Left handlebar switch

NOTE:

Align the projections “a” on the left handlebar switch with the hole “b” in the handlebar.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

8. Install:

• Throttle grip “1”

• Throttle cable hoousing “2”

• Throttle cables

• Grip end “3”

NOTE:

Align the projections “a” on the throttle cable housing with the hole “b” in the handlebar.

7. Install:

• Handlebar grip “1”

• Grip end “2”

4-46

9. Install:

• Right handlebar switch

NOTE:

• Align the projections «a» on the handlebar switch with the holes «b» in the handlebar.

• Threre should be 1–3 mm (0.04–0.12 in) of clearance “c” between the handlebar grip and the grip end.

10. Install:

• Front brake master cylinder assembly

• Front brake master cylinder holder “1”

Front brake master cylinder bracket bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

ECS2D1010

CAUTION:

• Install the brake master cylinder bracket with the “UP” mark facing up.

• First, tighten the upper bolt, then the lower bolt.

NOTE:

Align the end of the brake master cylinder holder with the punch mark “a” on the handlebar.

11. Adjust:

• Throttle cable free play

4-47

HANDLEBAR

EAS22950

FRONT FORK

Removing the front fork legs

FRONT FORK

Order Job/Parts to remove

Front wheel

Front brake calipers

1

2

3

4

5

Front fender

Cap bolt

Upper bracket pinch bolt

Lower bracket pinch bolt

Front fork leg

1

1

1

2

1

Q’ty Remarks

Refer to «CHECKING THE TIRES» on page 3-32 and «CHECKING THE

WHEELS» on page 3-34.

Loosen.

Loosen.

Loosen.

For installation, reverse the removal procedure.

4-48

Disassembling the front fork legs

FRONT FORK

11

12

13

14

7

8

9

10

15

16

Order

1

2

5

6

3

4

Job/Parts to remove

Cap bolt

O-ring

Damper adjusting rod

Nut

Washer

Spacer

Fork spring

Dust seal

Oil seal clip

Oil seal

Washer

Damper rod assembly bolt

Copper washer

Damper rod assembly

Inner tube

Outer tube

4-49

1

1

1

1

1

1

1

1

1

1

Q’ty

1

1

1

1

1

1

Remarks

For assembly, reverse the disassembly procedure.

EAS22970

REMOVING THE FRONT FORK LEGS

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

NOTE:

Each front fork leg is eqipped with a spring preload adjusting bolt, the right fork leg is equipped with a rebound damping force adjusting screan and left front fprk is equipped with a compression damping force adjusting screw. Pay attention not to mistake the right and left.

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:

• Upper bracket pinch bolts “1”

• Cap bolt “2”

• Lower bracket pinch bolts “3”

EWA13640

WARNING

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

FRONT FORK

• Nut “3”

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Press down on the spacer with the fork spring compressor “4”.

b. Install the rod holder “5” between the nut

“3” and the spacer “2”.

Fork spring compressor

90890-01441

YM-01441

Rod holder

90890-01434

Damper rod holder double ended

YM-01434

NOTE:

Use the side of the rod holder that is marked

“B”.

c. Hold the spring preload adjusting bolt “6” and loosen the nut “3”.

d. Remove the cap bolt.

e. Remove the rod holder and fork spring compressor.

f.

Remove the spacer and nut.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Drain:

• Fork oil

NOTE:

Stroke the damper rod “1” several times while draining the fork oil.

3. Remove:

• Front fork leg

EAS22990

DISASSEMBLING THE FRONT FORK LEGS

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

1. Remove:

• Cap bolt “1”

(from the damper adjusting rod)

• Spacers “2”

4-50

FRONT FORK

A. Compression side

B. Rebound side

NOTE:

While holding the damper rod with the damper rod holder “1”, loosen the damper rod assembly bolt.

Damper rod holder

90890-01423

Damping rod holder

YM-01423

3. Remove:

• Oil seal clip “1”

(with a flat-head screwdriver)

ECA14180

CAUTION:

Do not scratch the inner tube.

4. Remove:

• Damper rod assembly bolt

• Damper rod assembly

EC2D1080

CAUTION:

For the damper rod assembly, the right side is used for the rebound operation and left side for the compression. Pay attention not to mistake the right and left.

NOTE:

The left side (for the compression) damper rod assembly has the four holes of oil path, unlike the right side.

EAS23010

CHECKING THE FRONT FORK LEGS

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

1. Check:

• Inner tube “1”

• Outer tube “2”

Bends/damage/scratches

→

Replace.

EWA13650

WARNING

Do not attempt to straighten a bent inner tube as this may dangerously weaken it.

4-51

2. Measure:

• Spring free length “a”

Out of specification

→

Replace.

Spring free length

243.5 mm (9.59 in)

Limit

238.6 mm (9.39 in)

3. Check:

• Damper rod “1”

Damage/wear

→

Replace.

Obstruction

→

Blow out all of the oil passages with compressed air.

• Damper adjusting rod

Bends/damage

→

Replace.

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.

FRONT FORK

• Damper rod assembly bolt

• Copper washer

EC2D1080

CAUTION:

For the damper rod assembly, the right side is used for the rebound operation and left side for the compression. Pay attention not to mistake the right and left.

NOTE:

The left side (for the compression) damper rod assembly has the four holes of oil path, unlike the right side.

ECA14210

CAUTION:

Allow the damper rod assembly to slide slowly down the inner tube “2” until it protrudes from the bottom of the inner tube.

Be careful not to damage the inner tube.

EAS23030

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:

• When assembling the front fork leg, be sure to replace the following parts:

— Oil seal

— Dust seal

• Before assembling the front fork leg, make sure all of the components are clean.

1. Install:

• Damper rod assembly “1”

• Inner tube “2”

4-52

2. Lubricate:

• Inner tube’s outer surface

Recommended oil

Suspension oil 01 or equivalent

3. Tighten:

• Damper rod assembly bolt “1”

Damper rod assembly bolt

23 Nm (2.3 m·kg, 17 ft·lb)

LOCTITE®

NOTE:

While holding the damper rod assembly with the damper rod holder “2”, tighten the damper rod assembly bolt.

Damper rod holder

90890-01423

Damping rod holder

YM-01423

FRONT FORK

4. Install:

• Dust seal “1”

• Oil seal clip “2”

• Oil seal “3”

• Washer “4”

ECA14220

CAUTION:

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

NOTE:

• Before installing the oil seal, lubricate its lips with lithium-soap-based grease.

• Lubricate the outer surface of the inner tube with fork oil.

• Before installing the oil seal, cover the top of the front fork leg with a plastic bag to protect the oil seal during installation.

6. Install:

• Oil seal clip “1”

NOTE:

Adjust the oil seal clip so that it fits into the outer tube’s groove.

7. Install:

• Dust seal “1”

(with the fork seal driver weight “2”)

Fork seal driver

90890-01442

Adjustable fork seal driver (36–

46 mm)

YM-01442

5. Install:

• Oil seal “1”

(with the fork seal driver “2”)

Fork seal driver

90890-01442

Adjustable fork seal driver (36–

46 mm)

YM-01442

4-53

8. Install:

• Rod puller “1”

• Rod puller attachment (M 10) “2”

(onto the damper rod “3”)

FRONT FORK

Rod puller

90890-01437

Rod puller attachment (M10)

90890-01436

9. Fill:

• Front fork leg

(with the specified amount of the recommended fork oil)

Quantity

545.0 cm

3

(18.43 US oz) (19.18 lmp.oz)

Recommended oil

Suspension oil 01 or equivalent

ECA14230

CAUTION:

• Be sure to use the recommended fork oil.

Other oils may have an adverse effect on front fork performance.

• When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork.

NOTE:

Be sure to bleed the front fork.

10. After filling the front fork leg, slowly stroke the damper rod “1” up and down (at least ten times) to distribute the fork oil.

NOTE:

Be sure to stroke the damper rod slowly because the fork oil may spurt out.

11. Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.

NOTE:

Be sure to bleed the front fork leg of any residual air.

12. Measure:

• Front fork leg oil level “a”

(from the top of the outer tube, with the outer tube fully compressed and without the fork spring)

Out of specification

→

Correct.

Front fork leg oil level

91 mm (3.58 in)

13. Install:

• Nut “1”

• Fork spring “2”

• Spacer “3”

• Damper adjusting rod “4”

• Cap bolt “5”

4-54

FRONT FORK

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the rod puller and adapter.

b. Install the nut.

c. Install the fork spring and spacer.

NOTE:

Install the spring with the smaller pitch “a” facing up “A”.

f.

Remove the rod puller and the rod puller attachment.

g. Install the nut “1” and position it as specified “b”.

Distance “b”

12 mm (0.47 in)

d. Press down in the spacer with the fork spring compressor “1” e. Pull up the rod puller and install the rod holder “2” between the damper adjusting rod locknut “3” and the spacer “4”.

NOTE:

Use the side of the rod holder that is marked

“B”.

Fork spring compressor

90890-01441

YM-01441

Rod holder

90890-01434

Damper rod holder double ended

YM-01434

h. Set the cap bolt distance “c” to specification.

Distance “c”

13 mm (0.51 in)

i.

Inatall the damper adjusting rod and cap bolt, and then finger tighten the cap bolt.

j.

Hold the cap bolt and tighten the damper adjusting rod locknut to specification.

Damper adjusting rod locknut

15 Nm (1.5 m·kg, 11 ft·lb)

k. Remove the rod holder and fork spring compressor.

4-55

FRONT FORK

EW2D1003

WARNING

• The fork spring is compressed.

• Always use a new cap bolt O-ring.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS23050

INSTALLING THE FRONT FORK LEGS

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

NOTE:

Each front fork leg is eqipped with a spring preload adjusting bolt, the right fork leg is equipped with a rebound damping force adjusting screw and left front fork is equipped with a compression damping force adjusting screw. Pay attension not to mistake the right and left.

1. Install:

• Front fork leg

Temporarily tighten the upper and lower bracket pinch bolts.

NOTE:

Make sure the inner fork tube is flush with the top of the handlebar holder.

2. Tighten:

• Lower bracket pinch bolt “1”

Lower bracket pinch bolt

23 Nm (2.3 m·kg, 17 ft·lb)

• Cap bolt “2”

Cap bolt

23 Nm (2.3 m·kg, 17 ft·lb)

• Upper bracket pinch bolt “3”

Upper bracket pinch bolt

26 Nm (2.6 m·kg, 19 ft·lb)

EWA13680

WARNING

Make sure the brake hoses are routed properly.

3. Adjust:

• Spring preload

• Rebound damping

• Compression damping

Refer to «ADJUSTING THE FRONT FORK

LEGS» on page 3-29.

4-56

EAS23090

STEERING HEAD

Removing the lower bracket

STEERING HEAD

Order

1

2

3

4

Job/Parts to remove

Front wheel

Front brake calipers

Front cowling (FZ1-S)

Headlight and meter assembly (FZ1-N)

Handlebar

Front fork legs

Main switch connector

Steering stem nut

Upper bracket

Front brake hose joint

1

1

2

1

Q’ty Remarks

Refer to «FRONT WHEEL» on page

4-8.

Refer to «FRONT BRAKE» on page

4-20.

Refer to «GENERAL CHASSIS» on page 4-1.

Refer to «GENERAL CHASSIS» on page 4-1.

Refer to «HANDLEBAR» on page 4-

43.

Refer to «FRONT FORK» on page 4-

48.

Disconnect.

4-57

Removing the lower bracket

STEERING HEAD

15

16

17

18

19

11

12

13

14

Order

5

6

7

8

9

10

Job/Parts to remove

Front brake hose joint bracket

Horn

Horn bracket

Lock washer

Upper ring nut

Rubber washer

Lower ring nut

Lower bracket

Lower bearing

Lower bearing dust seal

Lower bearing inner race

Bearing cover

Upper bearing inner race

Upper bearing

Bearing outer race

4-58

1

1

1

1

2

1

1

1

1

Q’ty

1

1

1

1

1

1

Remarks

For installation, reverse the removal procedure.

STEERING HEAD

Damage/pitting

→

Replace.

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 “1”

• Rubber washer

• Lower ring nut “2”

• Lower bracket

NOTE:

Hold the lower ring nut with the ring nut wrench

“3”, and then remove the upper ring nut with the steering nut wrench “4”.

Ring nut wrench

90890-01268

Spanner wrench

YU-01268

Steering nut wrench

90890-01403

Spanner wrench

YU-33975

EWA13730

WARNING

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

3. Replace:

• Bearings

• Bearing races

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 rubber seal and new bearing races.

ECA14270

CAUTION:

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

NOTE:

• Always replace the bearings and bearing races as a set.

• Whenever the steering head is disassembled, replace the rubber seal.

EAS23120

CHECKING THE STEERING HEAD

1. Wash:

• Bearings

• Bearing races

Recommended cleaning solvent

Kerosene

2. Check:

• Bearings “1”

• Bearing races “2”

4-59

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

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

2. Install:

• Lower ring nut “1”

• Rubber washer “2”

• Upper ring nut “3”

• Lock washer “4”

Refer to «INSTALLING THE STEERING

HEAD» on page 4-60.

STEERING HEAD

Steering stem nut

113 Nm (11.3 m·kg, 82 ft·lb)

3. Install:

• Front brake hose joint bracket

• Front brake hose joint

4. Install:

• Upper bracket

• Steering stem nut

NOTE:

Temporarily tighten the steering stem nut.

5. Install:

• Front fork legs

Refer to «FRONT FORK» on page 4-48.

NOTE:

Temporarily tighten the upper and lower bracket pinch bolts.

6. Tighten:

• Steering stem nut

4-60

REAR SHOCK ABSORBER ASSEMBLY

EAS23160

REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly

6

7

4

5

1

2

3

8

9

10

Order Job/Parts to remove

Rider and passenger seat

Side cover (left and right)

Brake fluid reservoir tank bolt

Self-locking nut/bolt

Self-locking nut/bolt

Self-locking nut/bolt

Self-locking nut/bolt/collar

Rear shock absorber assembly

Oil seal/bearing/collar

Collar/self-locking nut/bolt

Connecting arm

Oil seal/bearing/collar

Relay arm

4-61

1/1

1/1

1/1

1/1/1

1

6/3/3

1/1/1

2

2/1/1

1

Q’ty Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

Refer to «GENERAL CHASSIS» on page 4-1.

Refer to «REAR BRAKE» on page 4-

32.

REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly

Order Job/Parts to remove Q’ty Remarks

For installation, reverse the removal procedure.

4-62

REAR SHOCK ABSORBER ASSEMBLY

EAS23180

HANDLING THE REAR SHOCK ABSORBER

EWA13740

WARNING

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.

NOTE:

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

2. Remove:

• Rear shock absorber assembly lower bolt

“1”

• Relay arm-to-swingarm bolt “2”

• Connecting arm-to-relay arm bolt “3”

NOTE:

While removing the rear shock absorber assembly lower bolt, hold the swigarm so that it does not drop down.

EAS23190

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 2–3mm (0.079–

0.118 in) hole through the rear shock absorber at a point 15–20 mm (0.59–0.79 in) from its end as shown.

EWA13760

WARNING

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

3. Remove:

• Rear shock absorber assembly upper bolt

“1”

• Rear shock absorber assembly

NOTE:

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

EAS23210

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.

4-63

EAS23240

CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY

1. Check:

• Rear shock absorber rod

Bends/damage

→

Replace the rear shock absorber assembly.

• Rear shock absorber

REAR SHOCK ABSORBER ASSEMBLY

Gas leaks/oil leaks

→

Replace the rear shock absorber assembly.

• Spring

Damage/wear

→

Replace the rear shock absorber assembly.

• Bushings

Damage/wear

→

Replace.

• Dust seals

Damage/wear

→

Replace.

• Bolts

Bends/damage/wear

→

Replace.

3. Tighten:

• Rear shock absorber assembly upper nut

Rear shock absorber assembly upper nut

44 Nm (4.4 m·kg, 32 ft·lb)

• Rear shock absorber assembly lower nut

Rear shock absorber assembly lower nut

44 Nm (4.4 m·kg, 32 ft·lb)

• Relay-arm-to-swingarm nut

EAS23260

CHECKING THE CONNECTING ARM AND

RELAY ARM

1. Check:

• Connecting arms “1”

• Relay arm “2”

Damage/wear

→

Replace.

Relay-arm-to-swingarm nut

44 Nm (4.4 m·kg, 32 ft·lb)

2. Check:

• Bearings

• Oil seals

Damage/pitting

→

Replace.

3. Check:

• Coller

Damage/scratches

→

Replace.

EAS23300

INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY

1. Lubricate:

• Spacers

• Bearings

Recommended lubricant

Lithium-soap-based grease

2. Install:

• Rear shock absorber assembly

NOTE:

When installing the rear shock absorber assembly, lift up the swingarm.

4-64

EAS23330

SWINGARM

Removing the swingarm

SWINGARM

Order Job/Parts to remove

Rear wheel

Rear brake caliper

Rear shock absorber

6

7

4

5

1

2

3

Drive sprocket

Rear fender cover

Drive chain guard

Brake hose holder

Drive chain adjusting bolt/locknut

Pivot shaft nut/washer

Pivot shaft

Swingarm

4-65

2/2

1/1

1

1

1

1

1

Q’ty Remarks

Refer to «REAR WHEEL» on page 4-

14.

Refer to «REAR BRAKE» on page 4-

32.

Refer to «REAR SHOCK

ABSORBER ASSEMBLY» on page

4-61.

Refer to «ENGINE REMOVAL» on page 5-2.

Removing the swingarm

SWINGARM

Order

8

9

10

11

12

Job/Parts to remove

Drive chain

Dust cover

Drive chain guide

Spacer

Bearing

Q’ty

1

2

1

1

2

Remarks

For installation, reverse the removal procedure.

4-66

EAS23350

REMOVING THE SWINGARM

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:

• Relay arm-to-swingarm bolt “1”

• Connecting arm bolt “2”

• Rear shock absorber assembly lower bolt

“3”

NOTE:

When removing the rear shock absorber assembly lower bolt, hold the swingarm so that it does not drop down.

SWINGARM

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS23360

CHECKING THE SWINGARM

1. Check:

• Swingarm

Bends/cracks/damage

→

Replace.

2. Check:

• Pivot shaft

Roll the pivot shaft on a flat surface.

Bends

→

Replace.

EWA13770

WARNING

Do not attempt to straighten a bent pivot shaft.

3. Measure:

• Swingarm side play

• Swingarm vertical movement

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the tightening torque of the pivot shaft nut.

Pivot shaft nut

105 Nm (10.5 m·kg, 76 ft·lb)

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.

4-67

3. Wash:

• Pivot shaft

• Dust covers

• Spacer

• Washers

• Bearings

Recommended cleaning solvent

Kerosene

4. Check:

• Dust covers “1”

• Spacer “2”

• Bearings “3”

Damage/pitting

→

Replace.

SWINGARM

5. Check:

• Connecting arms “1”

• Relay arm “2”

Damage/wear

→

Replace.

6. Check:

• Bearings “3”

• Oil seals “4”

Damage/pitting

→

Replace.

7. Check:

• Collars “5”

Damage/scratches

→

Replace.

3. Install:

• Rear shock absorber assembly

• Rear wheel

Refer to «INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY» on page 4-64 and «INSTALLING THE REAR WHEEL

(DISC)» on page 4-18.

4. Adjust:

• Drive chain slack

Refer to «ADJUSTING THE DRIVE CHAIN

SLACK» on page 3-26.

Drive chain slack

25–35 mm (0.98–1.38 in)

EAS23380

INSTALLING THE SWINGARM

1. Lubricate:

• Bearings

• Spacers

• Dust covers

• Pivot shaft

Recommended lubricant

Lithium-soap-based grease

2. Install:

• Swingarm

• Pivot shaft “1”

• Pivot shaft nut “2”

4-68

EAS23400

CHAIN DRIVE

Removing the drive chain

CHAIN DRIVE

Order Job/Parts to remove

Drive sprocket

1

2

Drive chain guard

Drive chain

Q’ty Remarks

Refer to «ENGINE REMOVAL» on page 5-2.

1

1

For installation, reverse the removal procedure.

4-69

CHAIN DRIVE

EAS23410

REMOVING THE DRIVE CHAIN

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:

• Drive chain

(with the drive chain cutter)

NOTE:

Only cut the drive chain if it or the swingarm is to be replaced.

EAS23440

CHECKING THE DRIVE CHAIN

1. Measure:

• Measure the dimension between 15-links on the inner side “a” and outer side “b” of the roller and calculate the dimension between pin centers.

• Dimension “c” between pin centers = (Inner dimension “a” + Outer dimension “b”)/2

• 15-link section “c” of the drive chain

Out of specification

→

Replace the drive chain, front drive sprocket and rear drive sprocket as a set.

15-link drive chain section limit

(maximum)

239.3 mm (9.42 in)

NOTE:

• While measuring the 15-link section, push down on the drive chain to increase its tension.

• Perform this measurement at two or three different places.

2. Check:

• Drive chain

Stiffness

→

Clean and lubricate or replace.

3. Clean:

• Drive chain

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wipe the drive chain with a clean cloth.

b. Put the drive chain in kerosene and remove any remaining dirt.

c. Remove the drive chain from the kerosene and completely dry it.

ECA14290

CAUTION:

• This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s internals, and solvents will deteriorate the O-rings. A coarse brush can also damage the O-rings. Therefore, use only kerosene to clean the drive chain.

• Do not soak the drive chain in kerosene for more than ten minutes, otherwise the

O-rings can be damaged.

4-70

CHAIN DRIVE

• Drive sprocket

More than 1/4 tooth “a” wear

→

Replace the drive chain sprockets as a set.

Bent teeth

→

Replace the drive chain sprockets as a set.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4. Check:

• O-rings “1”

Damage

→

Replace the drive chain.

• Drive chain rollers “2”

Damage/wear

→

Replace the drive chain.

• Drive chain side plates “3”

Damage/wear

→

Replace the drive chain.

Cracks

→

Replace the drive chain and make sure the battery breather hose is properly routed away from the drive chain and below the swingarm.

b. Correct

1. Drive chain roller

2. Drive chain sprocket

EAS23470

CHECKING THE REAR WHEEL SPROCKET

Refer to «CHECKING AND REPLACING THE

REAR WHEEL SPROCKET» on page 4-18.

ET2D1031

CHECKING THE REAR WHEEL DRIVE HUB

Refer to «CHECKING THE REAR WHEEL

DRIVE HUB» on page 4-17.

EAS28800

INSTALLING THE DRIVE CHAIN

1. Lubricate:

• Drive chain

Recommended lubricant

Engine oil or chain lubricant suitable for O-ring chains

2. Install:

• Drive sprocket

• Lock washer

• Drive sprocket nut

Refer to «ENGINE REMOVAL» on page 5-

2.

Drive sprocket nut

85 Nm (8.5 m·kg, 61 ft·lb)

5. Lubricate:

• Drive chain

Recommended lubricant

Engine oil or chain lubricant suitable for O-ring chains

EAS23460

CHECKING THE DRIVE SPROCKET

1. Check:

4-71

ENGINE

ENGINE REMOVAL

………………………………………………………………………….. 5-2

INSTALLING THE ENGINE ………………………………………………………….. 5-8

CAMSHAFTS

…………………………………………………………………………………. 5-10

REMOVING THE CAMSHAFTS ………………………………………………….. 5-12

CHECKING THE CAMSHAFTS ………………………………………………….. 5-13

CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET……. 5-14

CHECKING THE TIMING CHAIN GUIDES …………………………………… 5-14

CHECKING THE TIMING CHAIN TENSIONER …………………………….. 5-14

INSTALLING THE CAMSHAFTS …………………………………………………. 5-16

CYLINDER HEAD

…………………………………………………………………………… 5-19

REMOVING THE CYLINDER HEAD ……………………………………………. 5-20

CHECKING THE CYLINDER HEAD ……………………………………………. 5-20

INSTALLING THE CYLINDER HEAD …………………………………………… 5-20

VALVES AND VALVE SPRINGS

………………………………………………………. 5-22

REMOVING THE VALVES ………………………………………………………….. 5-24

CHECKING THE VALVES AND VALVE GUIDES …………………………… 5-25

CHECKING THE VALVE SEATS …………………………………………………. 5-26

CHECKING THE VALVE SPRINGS……………………………………………… 5-28

CHECKING THE VALVE LIFTERS ………………………………………………. 5-29

INSTALLING THE VALVES…………………………………………………………. 5-29

GENERATOR

…………………………………………………………………………………. 5-31

REMOVING THE GENERATOR ………………………………………………….. 5-33

INSTALLING THE GENERATOR …………………………………………………. 5-33

STARTER CLUTCH

………………………………………………………………………… 5-35

REMOVING THE STARTER CLUTCH …………………………………………. 5-36

CHECKING THE DAMPER ………………………………………………………… 5-36

CHECKING THE STARTER CLUTCH………………………………………….. 5-36

INSTALLING THE STARTER CLUTCH ………………………………………… 5-37

CRANKSHAFT POSITION SENSOR

………………………………………………… 5-38

REMOVING THE CRANKSHAFT POSITION SENSOR …………………. 5-39

INSTALLING THE CRANKSHAFT POSITION SENSOR ………………… 5-39

ELECTRIC STARTER

……………………………………………………………………… 5-40

CHECKING THE STARTER MOTOR …………………………………………… 5-42

ASSEMBLING THE STARTER MOTOR ……………………………………….. 5-43

INSTALLING THE STARTER MOTOR………………………………………….. 5-43

CLUTCH

………………………………………………………………………………………… 5-44

REMOVING THE CLUTCH…………………………………………………………. 5-48

5

CHECKING THE FRICTION PLATES ………………………………………….. 5-49

CHECKING THE CLUTCH PLATES…………………………………………….. 5-49

CHECKING THE CLUTCH SPRINGS ………………………………………….. 5-50

CHECKING THE CLUTCH HOUSING …………………………………………. 5-50

CHECKING THE CLUTCH BOSS ……………………………………………….. 5-50

CHECKING THE PRESSURE PLATE ………………………………………….. 5-50

CHECKING THE PULL LEVER SHAFT AND PULL ROD……………….. 5-50

INSTALLING THE CLUTCH ……………………………………………………….. 5-51

SHIFT SHAFT

………………………………………………………………………………… 5-54

REMOVING THE SHIFT SHAFT …………………………………………………. 5-56

CHECKING THE SHIFT SHAFT …………………………………………………. 5-56

CHECKING THE STOPPER LEVER……………………………………………. 5-56

INSTALLING THE SHIFT SHAFT ………………………………………………… 5-56

OIL PUMP

……………………………………………………………………………………… 5-58

REMOVING THE OIL PAN …………………………………………………………. 5-62

CHECKING THE SPROCKET AND CHAIN ………………………………….. 5-62

CHECKING THE OIL PUMP ………………………………………………………. 5-62

CHECKING THE RELIEF VALVE ………………………………………………… 5-63

CHECKING THE OIL DELIVERY PIPES………………………………………. 5-63

CHECKING THE OIL STRAINER………………………………………………… 5-63

CHECKING THE OIL NOZZLES …………………………………………………. 5-63

ASSEMBLING THE OIL PUMP …………………………………………………… 5-63

INSTALLING THE OIL/WATER PUMP ASSEMBLY………………………… 5-64

INSTALLING THE OIL PAN ………………………………………………………… 5-65

CRANKCASE

………………………………………………………………………………… 5-66

DISASSEMBLING THE CRANKCASE …………………………………………. 5-68

CHECKING THE CRANKCASE ………………………………………………….. 5-68

CHECKING THE BEARING AND OIL SEALS ………………………………. 5-68

ASSEMBLING THE CRANKCASE………………………………………………. 5-68

CRANKSHAFT

………………………………………………………………………………. 5-70

REMOVING THE CONNECTING RODS AND PISTONS ……………….. 5-72

REMOVING THE CRANKSHAFT ASSEMBLY ………………………………. 5-72

CHECKING THE CYLINDER AND PISTON………………………………….. 5-73

CHECKING THE PISTON RINGS ……………………………………………….. 5-73

CHECKING THE PISTON PINS ………………………………………………….. 5-74

CHECKING THE BIG END BEARINGS ……………………………………….. 5-75

INSTALLING THE CONNECTING ROD AND PISTON …………………… 5-78

CHECKING THE CRANKSHAFT ………………………………………………… 5-81

CHECKING THE CRANKSHAFT DRIVE SPROCKET……………………. 5-81

CHECKING THE CRANKSHAFT JOURNAL BEARINGS ……………….. 5-81

INSTALLING THE CRANKSHAFT……………………………………………….. 5-83

TRANSMISSION

…………………………………………………………………………….. 5-85

REMOVING THE TRANSMISSION……………………………………………… 5-90

CHECKING THE SHIFT FORKS …………………………………………………. 5-90

CHECKING THE SHIFT DRUM ASSEMBLY…………………………………. 5-91

CHECKING THE TRANSMISSION ……………………………………………… 5-91

INSTALLING THE TRANSMISSION…………………………………………….. 5-92

EAS23710

ENGINE REMOVAL

Removing the drive sprocket

ENGINE REMOVAL

Order

1

2

5

6

3

4

7

8

Job/Parts to remove

Locknut

Shift rod

Shift arm

Drive sprocket cover

Drive sprocket nut

Lock washer

Drive sprocket

Plate

Q’ty

2

1

1

1

1

1

1

1

Remarks

For installation, reverse the removal procedure.

5-2

Removing the exhaust pipe

ENGINE REMOVAL

Order Job/Parts to remove

Rider and passenger seat

8

9

6

7

10

11

1

2

3

4

5

EXUP pulley cover

EXUP servo motor cover

EXUP cables

EXUP servo motor

O

2

sensor

Exhaust pipe assembly

Exhaust pipe gasket

Muffler

Muffler gasket

Muffler cover

Muffler end cover

Q’ty Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

1

1

1

4

1

1

1

1

2

1

1

For installation, reverse the removal procedure.

5-3

Disassembling the exhaust valve pipe

ENGINE REMOVAL

Order

1

2

3

4

Job/Parts to remove

Nut

Pulley

Spring

Spring seat

Q’ty

1

1

1

1

Remarks

For assembly, reverse the disassembly procedure.

5-4

Disconnecting the leads and hoses

ENGINE REMOVAL

Order

Fuel tank

Job/Parts to remove

Air filter case

Throttle body assembly

Engine oil

1

2

3

4

5

Oil cooler

Air cut-off valve

Starter motor

Battery negative lead

Battery positive lead

Clutch cable

Ground lead

Stator coil assembly coupler

5-5

1

1

1

2

1

Q’ty Remarks

Refer to «FUEL TANK» on page 7-1.

Refer to «GENERAL CHASSIS» on page 4-1.

Refer to «THROTTLE BODIES» on page 7-4.

Drain.

Refer to «CHANGING THE ENGINE

OIL» on page 3-12.

Refer to «OIL COOLER» on page 6-

4.

Refer to «AIR INDUCTION SYS-

TEM» on page 7-13.

Refer to «ELECTRIC STARTER» on page 5-40.

Disconnect.

Disconnecting the leads and hoses

ENGINE REMOVAL

Order

6

7

8

9

10

Job/Parts to remove Q’ty

Crankshaft position sensor lead coupler 1

Oil level switch connector 1

Neutral switch connector

Cylinder identification sensor coupler

Speed sensor coupler

1

1

1

Remarks

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

For assembly, reverse the removal procedure.

5-6

Removing the engine

ENGINE REMOVAL

Order

1

2

3

6

7

4

5

8

Job/Parts to remove

Right front engine mounting bolt 1

Left front engine mounting bolt

Upper self-locking nut

Upper engine mounting bolt

Lower self-locking nut

Lower engine mounting bolt

Engine mounting adjust bolt

Engine

1

2

1

1

1

Q’ty

1

1

1

Remarks

For assembly, reverse the removal procedure.

5-7

EAS23720

INSTALLING THE ENGINE

1. Install:

• Right front engine mounting bolt 2 “1”

Refer to «CYLINDER HEAD» on page 5-19.

ENGINE REMOVAL

2. Tighten:

• Right front engine mounting bolt 2

Right front engine mounting bolt 2

50 Nm (5.0 m·kg, 36 ft·lb)

3. Install:

• Engine mounting adjust bolts

(temporarily tighten)

4. Install:

• Engine

5. Install:

• Lower engine mounting bolt “1”

• Upper engine mounting bolt “2”

• Self-locking nuts

NOTE:

Do not fully tighten the bolts and nuts.

7. Tighten:

• Engine mounting adjust bolts

Engine mounting adjust bolt

7 Nm (0.7 m·kg, 5.1 ft·lb)

NOTE:

Use the pivot shaft wrench “1” and pivot shaft wrench adapter “2” to tighten the engine mounting adjust bolts.

Pivot shaft wrench

90890-01518

Frame spanner socket

YM-01518

Pivot shaft wrench adapter

90890-01476

6. Install:

• Left front engine mounting bolt “1”

(temporarily tighten)

• Right front engine mounting bolt 1 “2”

(temporarily tighten)

5-8

8. Tighten:

• Lower self-locking nut “1”

• Upper self-locking nut “2”

Upper self-locking nut

51 Nm (5.1 m·kg, 37 ft·lb)

Lower self-locking nut

51 Nm (5.1 m·kg, 37 ft·lb)

NOTE:

First tighten the lower self-locking nut, and then tighten the upper self-locking nut.

ENGINE REMOVAL

Left front engine mounting bolt

45 Nm (4.5 m·kg, 33 ft·lb)

Right front engine mounting bolt 1

45 Nm (4.5 m·kg, 33 ft·lb)

9. Tighten:

• Left front engine mounting bolt ”1”

• Right front engine mounting bolt 1 ”2”

5-9

EAS23760

CAMSHAFTS

Removing the cylinder head cover

CAMSHAFTS

6

7

4

5

1

2

3

Order

Fuel tank

Job/Parts to remove

Throttle body assembly

Radiator assembly

Air cut-off valve

Ignition coil

Spark plug

Cylinder head cover

Cylinder head cover gasket

Timing chain guide (top side)

Cylinder identification sensor

O-ring

1

1

1

1

4

4

1

Q’ty Remarks

Refer to «FUEL TANK» on page 7-1.

Refer to «THROTTLE BODIES» on page 7-4.

Refer to «RADIATOR» on page 6-1.

Refer to «AIR INDUCTION SYS-

TEM» on page 7-13.

For assembly, reverse the removal procedure.

5-10

Removing the camshafts

CAMSHAFTS

Order Job/Parts to remove

Pickup rotor cover

3

4

1

2

5

6

7

8

9

10

Camshaft sprocket bolt

Timing chain tensioner

Timing chain tensioner gasket

Intake camshaft cap

Dowel pin

Exhaust camshaft cap

Dowel pin

Intake camshaft

Exhaust camshaft

Camshaft sprocket

1

3

4

1

6

Q’ty Remarks

Refer to «CRANKSHAFT POSITION

SENSOR» on page 5-38.

Loosen.

Refer to «REMOVING THE CAM-

SHAFTS» on page 5-12.

3

6 Refer to «REMOVING THE CAM-

SHAFTS» on page 5-12.

1

1

2

For assembly, reverse the removal procedure.

5-11

CAMSHAFTS

EAS23810

REMOVING THE CAMSHAFTS

1. Remove:

• Pickup rotor cover

Refer to «CRANKSHAFT POSITION SEN-

SOR» on page 5-38.

2. Align:

• “T” mark “a” on the pickup rotor

(with the crankcase mating surface “b”)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise.

b. When piston #1 is at TDC on the compression stroke, align the “T” mark “a” on the pickup rotor with the crankcase mating surface “b”.

NOTE:

TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.

5. Remove:

• Camshaft caps “1”

• Dowel pins

ECA13720

CAUTION:

To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a crisscross pattern, working from the outside in.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Loosen:

• Camshaft sprocket bolts “1”

Camshaft wrench

90890-04143

6. Remove:

• Intake camshaft “1”

• Exhaust camshaft “2”

NOTE:

To prevent the timing chain from falling into the crankcase, fasten it with a wire “3”.

4. Remove:

• Timing chain tensioner “1”

• Gasket

5-12

CAMSHAFTS

EAS23850

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 dimension limit

Intake camshaft “a”

32.50–32.60 mm

(1.280–1.284 in)

Limit

32.40 mm (1.276 in)

Intake camshaft “b”

24.95–25.05 mm

(0.982–0.986 in)

Limit

24.85 mm (0.978 in)

Exhaust camshaft “a”

30.70–30.80 mm

(1.209–1.213 in)

Limit

30.60 mm (1.205 in)

Exhaust camshaft “b”

22.95–23.05 mm

(0.904–0.908 in)

Limit

22.85 mm (0.900 in)

3. Measure:

• Camshaft runout

Out of specification

→

Replace.

Camshaft runout limit

0.03 mm (0.0012 in)

4. Measure:

• Camshaft-journal-to-camshaft-cap clearance

Out of specification

→

Measure the camshaft journal diameter.

Camshaft-journal-to-camshaftcap-clearance

0.028–0.062 mm

(0.0011–0.0024 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the camshaft into the cylinder head

(without the dowel pins and camshaft caps).

b. Position strip of Plastigauge® “1” onto the camshaft journal as shown.

c. Install the dowel pins and camshaft caps.

NOTE:

• Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.

• Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge®.

5-13

Camshaft cap bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

d. Remove the camshaft caps and then measure the width of the Plastigauge® “2”.

CAMSHAFTS

2. Check:

• Camshaft sprocket

More than 1/4 tooth wear “a”

→

Replace the camshaft sprockets and the timing chain as a set.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Measure:

• Camshaft journal diameter “a”

Out of specification

→

Replace the camshaft.

Within specification

→

Replace the cylinder head and the camshaft caps as a set.

Camshaft journal diameter

22.459–22.472 mm

(0.8842–0.8847 in)

a. 1/4 tooth b. Correct

1. Timing chain roller

2. Camshaft sprocket

EAS23950

CHECKING THE TIMING CHAIN GUIDES

The following procedure applies to all of the camshaft sprockets and timing chain guides.

1. Check:

• Timing chain guide (exhaust side) “1”

• Timing chain guide (intake side) “2”

• Timing chain guide (top side) “3”

Damage/wear

→

Replace the defective part(s).

EAS23870

CHECKING THE TIMING CHAIN AND CAM-

SHAFT SPROCKET

1. Check:

• Timing chain “1”

Damage/stiffness

→

Replace the timing chain and camshaft and camshaft sprocket as a set.

5-14

EAS23960

CHECKING THE TIMING CHAIN TEN-

SIONER

1. Remove:

• Timing chain tensioner housing “1”

• Timing chain tensioner rod “2”

• Timing chain tensioner spring “3”

NOTE:

Squeeze the timing chain tensioner clip, and then remove the timing chain tensioner spring and timing chain tensioner rod.

CAMSHAFTS

b. Squeeze the timing chain tensioner clip “2” and push the timing chain tensioner rod “3”.

NOTE:

When the timing chain tensioner rod “3” is pushed while holding the grip of the timing chain tensioner clip “2”, make sure not to release the timing chain tensioner rod “3” before releasing the timing chain tensioner clip

“2”. (Otherwise, the timing chain tensioner rod

“3” may run off.)

2. Check:

• Timing chain tensioner housing

• Timing chain tensioner rod

• Timing chain tensioner spring

Damage/wear

→

Replace.

3. Install:

• Timing chain tensioner spring

• Timing chain tensioner rod “1”

NOTE:

Prior to installing the timing chain tensioner rod, drain the engine oil from the timing chain tensioner housing.

c. Hook the clip “4” to the timing chain tensioner rod “3”.

NOTE:

Hook the timing chain tensioner rod pin “5” to the center of the clip “4”. After the installation, check that the clip “4” can come off by its own weight by pushing the timing chain tensioner rod “3” at the position of installation.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the timing chain tensioner spring and timing chain tensioner rod “1”.

5-15

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

CAMSHAFTS

EAS24000

INSTALLING THE CAMSHAFTS

1. Align:

• “T” mark “a” on the pickup rotor

(with the crankcase mating surface “b”)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise.

b. When position #1 is at TDC, align the “T” mark “a” with the crankcase mating surface

“b”.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Install:

• Intake camshaft sprocket “1”

• Exhaust camshaft sprocket “2”

(with the camshaft sprockets temporarily tightened)

NOTE:

Install the camshaft sprockets as a illustration.

4. Install:

• Dowel pins

• Intake camshaft caps

• Exhaust camshaft caps

NOTE:

• Make sure each camshaft cap is installed in its original place. Refer to the identification marks as follows:

“I”: Intake side camshaft cap mark

“E”: Exhaust side camshaft cap mark

“L”: Left side camshaft cap mark

“R”: Right side camshaft cap mark

• Make sure the arrow mark “a” on each camshaft points towards the right side of the engine.

3. Install:

• Exhaust camshaft “1”

• Intake camshafts “2”

(with the camshaft sprockets temporarily tightened)

NOTE:

Make sure the punch mark “a” on each camshaft faces up.

5-16

5. Install:

• Camshaft cap bolts

Camshaft cap bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

NOTE:

Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.

EC2D1001

CAUTION:

• Lubricate the camshaft cap bolts with the engine oil.

• The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result.

• Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing.

6. Tighten:

• Camshaft sprocket bolts “1”

Camshaft sprocket bolt

24 Nm (2.4 m·kg, 17 ft·lb)

Camshaft wrench

90890-04143

EC2D1002

CAUTION:

Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine.

CAMSHAFTS

• Timing chain tensioner “1”

• Timing chain tensioner bolts “2”

Timing chain tensioner bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

EC2D1003

CAUTION:

The arrow mark “a” on the timing chain tensioner should face up.

EW2D1006

WARNING

Always use a new gasket.

7. Align:

• Camshaft punch mark “a”

Align the camshaft punch mark “a” and the camshaft cap arrow mark “b”.

Camshaft wrench

90890-04143

9. Turn:

• Crankshaft

(several turns clockwise)

10. Check:

• “T” mark “a”

Make sure the “T” mark on the pickup rotor is aligned with the crankcase mating surface “b”.

• Camshaft punch mark “c”

Make sure the punch mark “c” on the camshaft is aligned with the camshaft cap arrow mark “d”.

Out of alignment

→

Adjust.

Refer to the installation steps above.

8. Install:

• Gasket

5-17

11. Measure:

• Valve clearance

Out of specification

→

Adjust.

Refer to «ADJUSTING THE VALVE

CLEARANCE» on page 3-4.

12. Install:

• Pickup coil rotor cover

«CRANKSHAFT POSITION SENSOR» on page 5-38.

CAMSHAFTS

5-18

EAS24100

CYLINDER HEAD

Removing the cylinder head

CYLINDER HEAD

5

6

7

3

4

1

2

Order

Engine

Job/Parts to remove

Intake camshaft

Exhaust camshaft

Cylinder head

Cylinder head gasket

Dowel pin

Coolant pipe

O-ring

Thermo wax outlet hose

Right front engine mounting bolt 2

1

1

1

2

1

1

1

Q’ty Remarks

Refer to

«ENGINE REMOVAL» on page 5-2.

Refer to

«CAMSHAFTS» on page 5-10.

Refer to

«CAMSHAFTS» on page 5-10.

For assembly, reverse the removal procedure.

5-19

CYLINDER HEAD

EAS24120

REMOVING THE CYLINDER HEAD

1. Remove:

• Intake camshaft

• Exhaust camshaft

Refer to «REMOVING THE CAMSHAFTS» on page 5-12.

2. Remove:

• Cylinder head nuts

• Cylinder head bolts

NOTE:

• Loosen the nuts in the proper sequence as shown.

• Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place a straightedge “1” and a thickness gauge “2” across the cylinder head.

EAS24160

CHECKING THE CYLINDER HEAD

1. Eliminate:

• Combustion chamber carbon deposits

(with a rounded scraper)

NOTE:

Do not use a sharp instrument to avoid damaging or scratching:

• Spark plug bore threads

• Valve seats

2. Check:

• Cylinder head

Damage/scratches

→

Replace.

• Cylinder head water jacket

Mineral deposits/rust

→

Eliminate.

3. Measure:

• Cylinder head warpage

Out of specification

→

Resurface the cylinder head.

Maximum cylinder head warpage

0.10 mm (0.0039 in)

5-20

2. Install: b. Measure the warpage.

c. If the limit is exceeded, resurface the cylinder head as follows.

d. Place a 400–600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern.

NOTE:

To ensure an even surface, rotate the cylinder head several times.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS24240

INSTALLING THE CYLINDER HEAD

1. Check:

• Cylinder head bolts “1”

Cylinder head bolt

8 Nm (0.8 m·kg, 5.8 ft·lb)

NOTE:

Retighten the cylinder head bolts to specification, before installing the cylinder head.

• Gasket “1”

• Dowel pins

3. Install:

• Cylinder head

NOTE:

Pass the timing chain through the timing chain cavity.

4. Tighten:

• Cylinder head nuts “1” – “10”

Cylinder head nut (1st)

19 Nm (1.9 m·kg, 14 ft·lb)

Cylinder head nut (2nd)

67 Nm (6.7 m·kg, 48 ft·lb)

• Cylinder head bolts “11” “12”

Cylinder head bolt

12 Nm (1.2 m·kg, 8.7 ft·lb)

NOTE:

• First, tighten the nuts “1” – “10” to approximately 19 Nm (1.9 m·kg, 14 ft·lb) with a torque wrench, and then tighten the 67 Nm

(6.7 m·kg, 48 ft·lb).

• Lubricate the cylinder head nuts with engine oil.

• Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages.

CYLINDER HEAD

5. Install:

• Exhaust camshaft

• Intake camshaft

Refer to «INSTALLING THE CAMSHAFTS» on page 5-16.

5-21

EAS24270

VALVES AND VALVE SPRINGS

Removing the valves and valve springs

VALVES AND VALVE SPRINGS

Order Job/Parts to remove

Cylinder head

13

14

15

9

10

11

12

7

8

5

6

3

4

1

2

Intake valve lifter

Intake valve pad

Intake valve cotter

Intake valve upper spring seat

Intake valve spring

Intake valve stem seal

Intake valve lower spring seat

Intake valve

Intake valve guide

Exhaust valve lifter

Exhaust valve pad

Exhaust valve cotter

Exhaust valve upper spring seat

Exhaust valve spring

Exhaust valve stem seal

5-22

Q’ty Remarks

Refer to «CYLINDER HEAD» on page 5-19.

8

8

8

12

8

8

16

12

12

12

12

12

12

24

12

Removing the valves and valve springs

VALVES AND VALVE SPRINGS

Order

16

17

18

Job/Parts to remove

Exhaust valve lower spring seat

Exhaust valve

Exhaust valve guide

Q’ty

8

8

8

Remarks

For installation, reverse the removal procedure.

5-23

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, valve seats), make sure the valves properly seal.

1. Remove:

• Valve lifter “1”

• Valve pad “2”

NOTE:

Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place.

VALVES AND VALVE SPRINGS

NOTE:

Remove the valve cotters by compressing the valve spring with the valve spring compressor

“2” and the valve spring compressor attachment “3”.

Valve spring compressor

90890-04019

YM-04019

Valve spring compressor attachment

90890-04108

Valve spring compressor adapter 22 mm

YM-04108

Valve spring compressor attachment

90890-04114

Valve spring compressor adapter 19.5 mm

YM-04114

2. Check:

• Valve sealing

Leakage at the valve seat

→

Check the valve face, valve seat, and valve seat width.

Refer to «CHECKING THE VALVE SEATS» on page 5-26.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Pour a clean solvent “a” into the intake and exhaust ports.

b. Check that the valves properly seal.

NOTE:

There should be no leakage at the valve seat

“1”.

4. Remove:

• Upper spring seat “1”

• Valve spring “2”

• Valve stem seal “3”

• Lower spring seat “4”

• Valve “5”

NOTE:

Identify the position of each part very carefully so that it can be reinstalled in its original place.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Remove:

• Valve cotters “1”

5-24

EAS24290

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”

Valve-stem-to-valve-guide clearance

Intake

0.010 – 0.037 mm

(0.0004 – 0.0015)

Limit

0.08 mm (0.0032 in)

Exhaust

0.025 – 0.052 mm

(0.0010 – 0.0020 in)

Limit

0.10 mm (0.0039 in)

VALVES AND VALVE SPRINGS

NOTE:

To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100

°

C (212

°

F) in an oven.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with the valve guide remover “1”.

b. Install the new valve guide with the valve guide installer “2” and valve guide remover

“1”.

c. After installing the valve guide, bore the valve guide with the valve guide reamer “3” to obtain the proper valve-stem-to-valveguide clearance.

2. Replace:

• Valve guide

5-25

NOTE:

After replacing the valve guide, reface the valve seat.

VALVES AND VALVE SPRINGS

Intake

Valve guide remover (ø4)

90890-04111

YM-04111

Exhaust

Valve guide remover (ø4.5)

90890-04116

YM-04116

Intake

Valve guide installer (ø4)

90890-04112

YM-04112

Exhaust

Valve guide installer (ø4.5)

90890-04117

YM-04117

Intake

Valve guide reamer (ø4)

90890-04113

YM-04113

Exhaust

Valve guide reamer (ø4.5)

90890-04118

YM-04118

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Eliminate:

• Carbon deposits

(from the valve face and valve seat)

4. Check:

• Valve face

Pitting/wear

→

Grind the valve face.

• Valve stem end

Mushroom shape or diameter larger than the body of the valve stem

→

Replace the valve.

5. Measure:

• Valve margin thickness “a”

Out of specification

→

Replace the valve.

Valve margin thickness

0.5–0.9 mm (0.0197–0.0354 in)

Limit

0.5 mm (0.02 in)

6. Measure:

• Valve stem runout

Out of specification

→

Replace the valve.

NOTE:

• When installing a new valve, always replace the valve guide.

• If the valve is removed or replaced, always replace the oil seal.

Valve stem runout

0.01 mm (0.0004 in)

EAS24300

CHECKING THE VALVE SEATS

The following procedure applies to all of the valves and valve seats.

1. Eliminate:

• Carbon deposits

(from the valve face and valve seat)

2. Check:

• Valve seat

Pitting/wear

→

Replace the cylinder head.

3. Measure:

• Valve seat width “a”

Out of specification

→

Replace the cylinder head.

5-26

Valve seat width

Intake

0.90–1.10 mm

(0.0354–0.0433 in)

Exhaust

0.90–1.10 mm

(0.0354–0.0433 in)

Limit

1.6 mm (0.063 in)

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

CAUTION:

Do not let the lapping compound enter the gap between the valve stem and the valve guide.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face.

b. Apply molybdenum disulfide oil onto the valve stem.

c. Install the valve into the cylinder head.

d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound.

NOTE:

For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.

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.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4. Lap:

• Valve face

• Valve seat 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 Mechanic’s blueing dye (Dykem) “b” onto the valve face.

5-27

VALVES AND VALVE SPRINGS

h. Install the valve into the cylinder head.

i.

j.

Press the valve through the valve guide and onto the valve seat to make a clear impression.

Measure the valve seat width “c” again. If the valve seat width is out of specification, reface and lap the valve seat.

2. Measure:

• Compressed valve spring force “a”

Out of specification

→

Replace the valve spring.

Compressed valve spring force

(installed)

Intake valve spring

127.4–144.6 N

(12.99–14.74 kg, 28.64–32.51 lb) at 32.65 mm (1.285 in)

Exhaust valve spring

133.0–153.0 N

(13.56–15.60 kg, 29.90–34.39 lb) at 32.82 mm (1.292 in)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS24310

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.

Valve spring free length

Intake valve spring

40.5 mm (1.60 in)

Limit

38.5 mm (1.47 in)

Exhaust valve spring

40.5 mm (1.60 in)

Limit

38.5 mm (1.47 in)

b. Installed length

3. Measure:

• Valve spring tilt “a”

Out of specification

→

Replace the valve spring.

Spring tilt limit

Intake valve spring

1.8 mm (0.07 in)

Exhaust valve spring

1.8 mm (0.07 in)

5-28

VALVES AND VALVE SPRINGS

EAS24320

CHECKING THE VALVE LIFTERS

The following procedure applies to all of the valve lifters.

1. Check:

• Valve lifter

Damage/scratches

→

Replace the valve lifters and cylinder head.

3. Install:

• Valve “1”

• Lower spring seat “2”

• Valve stem seal “3”

• Valve spring “4”

• Upper spring seat “5”

(into the cylinder head)

NOTE:

• Make sure each valve is installed in its original place. Refer to the following embossed marks.

Right and left intake valve (-s): “5VY:”

Middle intake valve (-s): “5VY.”

Exhaust valve (-s): “5VY”.

• Install the valve springs with the larger pitch

“a” facing up.

EAS24330

INSTALLING THE VALVES

The following procedure applies to all of the valves and related components.

1. Deburr:

• Valve stem end

(with an oil stone) b. Smaller pitch

4. Install:

• Valve cotters “1”

NOTE:

Install the valve cotters by compressing the valve springs with the valve spring compressor

“2” and the valve spring compressor attachment “3”.

2. Lubricate:

• Valve stem “1”

• Valve stem seal “2”

(with the recommended lubricant)

Recommended lubricant

Molybdenum disulfide oil

5-29

Valve spring compressor

90890-04019

YM-04019

Intake

Valve spring compressor attachment

90890-04114

YM-04114

Exhaust

Valve spring compressor attachment

90890-04108

YM-04108

VALVES AND VALVE SPRINGS

• Each valve lifter and valve pad must be reinstalled in its original position.

5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a softface hammer.

ECA13800

CAUTION:

Hitting the valve tip with excessive force could damage the valve.

6. Install:

• Valve pad “1”

• Valve lifter “2”

NOTE:

• Lubricate the valve lifter and valve pad with molybdenum disulfide oil.

• The valve lifter must move smoothly when rotated with a finger.

5-30

EAS24480

GENERATOR

Removing the generator

GENERATOR

Order Job/Parts to remove

Rider and passenger seat

Fuel tank

Engine oil

6

7

4

5

1

2

3

8

9

10

Stator coil assembly lead coupler

Plug

Generator rotor cover

Gasket

Dowel pin

Generator rotor assembly

Stator coil assembly

Dowel pin

Bearing housing

Collar

5-31

1

1

1

2

1

1

1

2

1

1

Q’ty Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

Refer to «FUEL TANK» on page 7-1.

Drain.

Refer to «CHANGING THE ENGINE

OIL» on page 3-12.

Disconnect.

Removing the generator

GENERATOR

Order

11

12

13

14

15

16

Job/Parts to remove

Bearing

Stator coil assembly lead holder

Idler gear

Idler gear shaft

Washer

Bearing

Q’ty

1

1

1

1

1

1

Remarks

For assembly, reverse the removal procedure.

5-32

GENERATOR

EAS24490

REMOVING THE GENERATOR

1. Remove:

• Plug

• Generator rotor cover “1”

NOTE:

• While pushing generator rotor, remove the generator rotor cover.

• Loosen each bolt 1/4 of a turn a time, in stages and in a crisscross pattern.

• After all of the bolts are fully loosened, remove them.

EAS24500

INSTALLING THE GENERATOR

1. Install:

• Idle gear shaft

• Idle gear “1”

• Washer

• Idle gear shaft bolt “2”

Idle gear shaft bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

2. Remove:

• Generator rotor and starter clutch assembly “1”

2. Install

• Generator rotor and starter clutch assembly “1”

3. Remove:

• Idle gear shaft bolt “1”

• Idle shaft

• Idle gear “2”

5-33

3. Install:

• Generator rotor cover gasket

• Generator rotor cover “1”

Generator rotor cover bolt (M6)

12 Nm (1.2 m·kg, 8.7 ft·lb)

Generator rotor cover bolt (M8)

22 Nm (2.2 m·kg, 16 ft·lb)

GENERATOR

NOTE:

• First tighten the M8 bolts and then tighten the

M6 bolts.

• Tighten the generator rotor cover bolts in stages and in a crisscross pattern.

5-34

EAS24550

STARTER CLUTCH

Removing the starter clutch

STARTER CLUTCH

Order

1

2

3

6

7

4

5

8

9

Job/Parts to remove

Generator rotor

Damper

Driven gear

Washer

Starter clutch drive gear

Collar

Washer

Spacer

O-ring

1

1

1

1

Q’ty

1

3

1

1

1

Remarks

For assembly, reverse the removal procedure.

5-35

STARTER CLUTCH

EAS24560

REMOVING THE STARTER CLUTCH

1. Remove:

• Spacer “1”

• O-ring “2”

• Washer “3”

EAS24570

CHECKING THE STARTER CLUTCH

1. Check:

• Starter clutch rollers “1”

Damage/wear

→

Replace.

2. Remove:

• Starter clutch drive gear “1”

• Collar “2”

• Washer “3”

2. Check:

• Starter clutch idle gear “1”

• Starter clutch drive gear “2”

Burrs/chips/roughness/wear

→

Replace the defective part(s).

3. Remove:

• Driven gear “1”

• Dampers “2”

• Generator rotor “3”

ET2D1009

CHECKING THE DAMPER

1. Check:

• Dampers “1”

Damage/wear

→

Replace.

5-36

3. Check:

• Starter clutch gear’s contacting surfaces

Damage/pitting/wear

→

Replace the starter clutch gear.

4. Check:

• Starter clutch operation

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the starter clutch drive gear “1” onto the starter clutch “2” and hold the starter clutch.

b. When turning the starter clutch drive gear counterclockwise “A”, the starter clutch and the starter clutch drive gear should engage,

otherwise the starter clutch is faulty and must be replaced.

c. When turning the starter clutch drive gear clockwise “B”, it should turn freely, otherwise the starter clutch is faulty and must be replaced.

STARTER CLUTCH

3. Install:

• Washer “1”

• O-ring “2”

• Spacer “3”

NOTE:

Lubricate the engine oil to O-ring.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS24600

INSTALLING THE STARTER CLUTCH

1. Install:

• Generator rotor “1”

• Damper “2”

• Driven gear “3”

NOTE:

• The hole side of the damper is installed to the generator side.

• Lubricate the engine oil “4”.

2. Install

• Starter clutch drive gear “1”

• Collar “2”

• Washer “3”

Refer to «CHECKING THE STARTER

CLUTCH» on page 5-36.

5-37

CRANKSHAFT POSITION SENSOR

EAS24520

CRANKSHAFT POSITION SENSOR

Removing the crankshaft position sensor

3

4

1

2

5

6

Order Job/Parts to remove

Rider and passenger seat

Fuel tank

Engine oil

Crankshaft position sensor lead coupler 1

Crankshaft position sensor 1

O-ring

Pickup rotor cover

1

1

Gasket

Cover

1

1

Q’ty Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

Refer to «FUEL TANK» on page 7-1.

Drain.

Refer to «CHANGING THE ENGINE

OIL» on page 3-12.

Disconnect.

For assembly, reverse the removal procedure.

5-38

CRANKSHAFT POSITION SENSOR

EAS24530

REMOVING THE CRANKSHAFT POSITION

SENSOR

1. Disconnect:

• Crankshaft position sensor lead coupler

2. Remove:

• Crankshaft position sensor

• O-ring

• Pickup coil rotor cover “1”

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.

2. Connect

• Crankshaft position sensor lead coupler

EAS24540

INSTALLING THE CRANKSHAFT POSITION

SENSOR

1. Install:

• Gasket

• Pickup rotor cover “1”

Pickup rotor cover

12 Nm (1.2 m·kg, 8.7 ft·lb)

• O-ring

• Crankshaft posision sensor

Crankshaft position sensor bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

LOCTITE®

5-39

EAS24780

ELECTRIC STARTER

Removing the starter motor

ELECTRIC STARTER

Order Job/Parts to remove

Rider and passenger seat

1

2

Fuel tank

Throttle body assembly

Starter motor lead

Starter motor

Q’ty Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

Refer to «FUEL TANK» on page 7-1.

Refer to «THROTTLE BODIES» on page 7-4.

1

1

For assembly, reverse the removal procedure.

5-40

Disassembling the starter motor

ELECTRIC STARTER

Order

1

2

3

6

7

4

5

8

9

10

Job/Parts to remove

O-ring

Front cover

Lock washer

Washer

Starter motor yoke

Armature assembly

O-ring

Starter motor lead

Brush holder

Rear cover

1

2

1

1

Q’ty

1

1

1

2

1

1

Remarks

For assembly, reverse the disassembly procedure.

5-41

EAS24790

CHECKING THE STARTER MOTOR

1. Check:

• Commutator

Dirt

→

Clean with 600 grit sandpaper.

2. Measure:

• Commutator diameter “a”

Out of specification

→

Replace the starter motor.

Commutator wear limit

27.0 mm (1.06 in)

ELECTRIC STARTER

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

Armature coil

Commutator resistance “1”

0.0250–0.0350

Ω

at 20

°

C (68

°

F)

Insulation resistance “2”

Above 1 M

Ω

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

0.7 mm (0.03 in)

NOTE:

The mica of the commutator must be undercut to ensure proper operation of the commutator.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Measure:

• Brush length “a”

Out of specification

→

Replace the brushes as a set.

Brush length wear limit

5.0 mm (0.20 in)

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

7.65–10.0 N

(780–1021 gf, 27.54–36.03 oz)

5-42

ELECTRIC STARTER

NOTE:

Align the match marks “a” on the starter motor yoke with the match marks “b” on the front and starter motor rear covers.

7. Check:

• Gear teeth

Damage/wear

→

Replace the gear.

EAS24800

ASSEMBLING THE STARTER MOTOR

1. Install:

• Brush seat “1”

NOTE:

Align the tab “a” on the brush seat with the tab

“b” in the starter motor rear cover.

EAS24810

INSTALLING THE STARTER MOTOR

1. Install:

• Starter motor “1”

• Starter motor bolts “2”

Starter motor bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

2. Connect:

• Starter motor lead “3”

2. Install:

• Armature “1”

3. Install:

• Starter motor yoke “1”

• O-rings “2”

• Starter motor rear cover “3”

• Starter motor assembling bolts

Starter motor assembling bolt

5 Nm (0.5 m·kg, 3.6 ft·lb)

5-43

EAS25060

CLUTCH

Removing the clutch cover

CLUTCH

Order Job/Parts to remove

Engine oil

1

2

3

4

5

Clutch cable

Clutch cover

Clutch cover gasket

Dowel pin

Oil filler cap

1

1

1

2

1

Q’ty Remarks

Drain.

Refer to «CHANGING THE ENGINE

OIL» on page 3-12.

For installation, reverse the removal procedure.

5-44

Removing the pull lever shaft

CLUTCH

Order

1

2

5

6

3

4

Circlip

Pull lever

Job/Parts to remove

Pull lever spring

Pull lever shaft

Oil seal

Bearing

Q’ty

2

1

1

2

1

1

Remarks

For installation, reverse the removal procedure.

5-45

Removing the clutch

CLUTCH

11

12

13

14

7

8

9

10

Order

1

2

5

6

3

4

15

16

17

18

Job/Parts to remove

Compression spring

Pressure plate

Pull rod

Bearing

Friction plate 1

Clutch plate 1

Friction plate 2

Wire circlip

Clutch plate 2

Friction plate 3

Clutch damper spring

Clutch damper spring seat

Clutch boss nut

Washer

Clutch boss assembly

Thrust plate

Clutch housing

Bearing

5-46

1

1

1

1

1

1

7

1

1

1

1

1

Q’ty

6

1

1

7

1

1

Remarks

Removing the clutch

CLUTCH

Order Job/Parts to remove Q’ty Remarks

For assembly, reverse the removal procedure.

5-47

CLUTCH

EAS25080

REMOVING THE CLUTCH

1. Remove:

• Clutch cover “1”

• Gasket

NOTE:

Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.

After all of the bolts are fully loosened, remove them.

4. Remove:

• Clutch plate 1 “1”

• Friction plate 2

5. Straighten the clutch boss nut rib “1”.

2. Remove:

• Compression spring bolts “1”

• Compression springs

• Pressure plate “2”

• Pull rod “3”

6. Loosen:

• Clutch boss nut “1”

NOTE:

While holding the clutch boss “2” with the universal clutch holder “3”, loosen the clutch boss nut.

Universal clutch holder

90890-04086

YM-91042

3. Remove:

• Friction plate 1 “1”

5-48

7. Remove:

• Clutch boss nut

• Washer

• Clutch boss assembly

• Thrust plate

8. Remove:

• Wire circlip “1”

NOTE:

There is a built-in damper between the clutch boss and the clutch plate. It is not necessary to remove the wire circlip “1” and disassemble the built-in damper unless there is serious clutch chattering.

CLUTCH

1. Check:

• Friction plate

Damage/wear

→

Replace the friction plates as a set.

2. Measure:

• Friction plate thickness

Out of specification

→

Replace the friction plates as a set.

NOTE:

Measure the friction plate at four places.

Friction plate thickness

2.9 — 3.1 mm (0.114 — 0.122 in)

Limit

2.8 mm (0.110 in)

9. Remove:

• Clutch plate 2 “1”

• Friction plate 3 “2”

10. Remove:

• Clutch damper spring “1”

• Clutch damper spring seat “2”

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.

Clutch plate warpage limit

0.1 mm (0.0039 in)

ET2D1010

CHECKING THE FRICTION PLATES

The following procedure applies to all of the friction plates.

5-49

CLUTCH

EAS25140

CHECKING THE CLUTCH SPRINGS

The following procedure applies to all of the clutch springs.

1. Check:

• Clutch spring

Damage

→

Replace the clutch springs as a set.

2. Measure:

• Clutch spring free length “a”

Out of specification

→

Replace the clutch springs as a set.

Clutch spring free length

52.5 mm (2.07 in)

Limit

49.9 mm (1.96 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.

EAS25170

CHECKING THE PRESSURE PLATE

1. Check:

• Pressure plate “1”

Cracks/damage

→

Replace.

• Bearing “2”

Damage/wear

→

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.

5-50

EAS25220

CHECKING THE PULL LEVER SHAFT AND

PULL ROD

1. Check:

CLUTCH

• Pull lever shaft pinion gear teeth “1”

• Pull rod teeth “2”

Damage/wear

→

Replace the pull rod and pull lever shaft pinion gear as a set.

3. Install:

• Wire circlip “1”

2. Check:

• Pull rod bearing

Damage/wear

→

Replace.

EAS25240

INSTALLING THE CLUTCH

1. Install:

• Clutch damper spring seat “1”

• Clutch damper spring “2”

4. Install:

• Clutch housing “1”

NOTE:

Align the projection of clutch housing “a” and hollow of the oil pump drive gear “b”.

2. Install:

• Friction plate 3 “1”

• Clutch plate 2 “2”

NOTE:

Lubricate the engine oil.

5-51

5. Install:

• Thrust plate

• Clutch boss assembly “1”

• Washer

• Clutch boss nut “2”

Clutch boss nut

95 Nm (9.5 m·kg, 69 ft·lb)

NOTE:

• Install the washer on the main axle with the

“OUT” mark facing away from the vehicle.

CLUTCH

• Lock the threads on the clutch boss nut by staking them with a drift punch at the point aligned with the groove in the axle.

• While holding the clutch boss assembly “1” with the clutch holding tool “3”, tighten the clutch boss nut.

Universal clutch holder

90890-04086

YM-91042

8. Install:

• Friction plate 1 “1”

NOTE:

Install the last friction plate shifting half phase.

6. Lubricate

• Friction plates

• Clutch plates

(with the recommended lubricant)

Recommended lubricant

Engine oil

7. Install:

• Friction plate 2

• Clutch plate 1 “1”

9. Install:

• Bearing

• Pull rod “1”

• Pressure plate “2”

• Clutch springs

• Clutch spring bolts “3”

Clutch spring bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

NOTE:

Tighten the clutch spring bolts in stages and in a crisscross pattern.

5-52

CLUTCH

10. Install:

• Pull lever

NOTE:

Install the pull lever with the “O“ mark facing toward lower side.

12. Tighten

• Clutch cover bolts “1”

Clutch cover bolt

12 Nm (1.2 m·kg, 8.7 ft·lb)

• Clutch cover bolt “2”

Clutch cover bolt

12 Nm (1.2 m·kg, 8.7 ft·lb)

LOCTITE®

NOTE:

Tighten the clutch cover bolts in a stages and in a crisscross pattern.

11. Install:

• Clutch cover

• Clutch cover gasket

NOTE:

• Install the pull rod so that the teeth a face towards the rear of the vehicle. Then, install the clutch cover.

• Apply oil onto the bearing.

• Apply molybdenum disulfide grease onto the pull rod.

• When installing the clutch cover, push the pull lever and check that the punch mark “a” on the pull lever aligns with the mark “b” on the clutch cover. Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged.

• Tighten the clutch cover bolts in stages and in a crisscross pattern.

13. Adjust:

• Clutch cable free play

Refer to «ADJUSTING THE CLUTCH

CABLE FREE PLAY» on page 3-14.

5-53

EAS25410

SHIFT SHAFT

Removing the shift shaft and stopper lever

SHIFT SHAFT

Order Job/Parts to remove

Clutch assembly

Shift arm and shift rod

7

8

5

6

3

4

1

2

9

10

11

12

13

Circlip

Washer

Shift shaft

Collar

Shift shaft spring

Washer

Stopper screw

Stopper lever

Washer

Oil seal

Bearing

Bearing

Stopper lever spring

5-54

1

1

1

1

1

1

1

1

1

1

1

1

1

Q’ty Remarks

Refer to «CLUTCH» on page 5-44.

Refer to «ENGINE REMOVAL» on page 5-2.

Removing the shift shaft and stopper lever

SHIFT SHAFT

Order Job/Parts to remove Q’ty Remarks

For installation, reverse the removal procedure.

5-55

SHIFT SHAFT

ET2D1011

REMOVING THE SHIFT SHAFT

1. Remove:

• Clutch assembly

Refetr to «CLUTCH» on page 5-44

2. Remove:

• Shift arm

• Shift rod

Refetr to «ENGINE REMOVAL» on page 5-

2

3. Remove:

• Circlip “1”

• Washer “2”

(left side of the engine)

EAS25420

CHECKING THE SHIFT SHAFT

1. Check:

• Shift shaft “1”

Bends/damage/wear

→

Replace.

• Shift shaft spring “2”

• Collar “3”

Damage/wear

→

Replace.

4. Remove

• Shift shaft “1”

• Shift shaft spring “2”

• Collar

• Washer

EAS25430

CHECKING THE STOPPER LEVER

1. Check:

• Stopper lever “1”

Bends/damage

→

Replace.

Roller turns roughly

→

Replace the stopper lever.

5. Remove:

• Stopper lever spring “1”

• Stopper screw “2”

• Stopper lever “3”

• Washer

5-56

EAS25450

INSTALLING THE SHIFT SHAFT

1. Install:

• Washer

• Stopper lever “1”

• Stopper screw “2”

Stopper screw

22 Nm (2.2 m·kg, 16 ft·lb)

LOCTITE®

• Stopper lever spring “3”

2. Install:

• Washer

• Collar

• Shift shaft spring “1”

• Shift shaft “2”

NOTE:

• Mesh the stopper lever with the shift drum segment assembly.

• Lubricate the oil seal lips with lithium soap base grease.

• Install the end of the shift shaft spring onto the shift shaft spring stopper.

SHIFT SHAFT

• Shift rod

• Shift arm

Refer to «ENGINE REMOVAL» on page 5-

2.

5. Install:

• Clutch assembly

Refer to «CLUTCH» on page 5-44.

3. Install:

• Washer “1”

• Circlip “2”

4. Install:

5-57

EAS24920

OIL PUMP

Removing the oil pan and oil pump

OIL PUMP

Order Job/Parts to remove

Engine oil

1

EXUP cables

O

2

sensor

Muffler

Exhaust pipe assembly

Clutch assembly

Water pump inlet pipe

Water pump outlet pipe

Oil level switch lead coupler

5-58

Q’ty

1

Remarks

Drain.

Refer to «CHANGING THE ENGINE

OIL» on page 3-12.

Refer to «ENGINE REMOVAL» on page 5-2.

Refer to «ENGINE REMOVAL» on page 5-2.

Refer to «ENGINE REMOVAL» on page 5-2.

Refer to «ENGINE REMOVAL» on page 5-2.

Refer to «CLUTCH» on page 5-44.

Refer to «OIL COOLER» on page 6-

4.

Refer to «OIL COOLER» on page 6-

4.

Disconnect.

Removing the oil pan and oil pump

OIL PUMP

7

8

9

10

11

12

Order

2

5

6

3

4

13

14

15

16

17

Job/Parts to remove

Oil level switch

Oil level switch lead holder

Oil pan

Oil pan gasket

Dowel pin

Drain pipe

Oil strainer

Oil pipe

Oil delivery pipe

Relief valve assembly

Oil/water pump assembly drive chain guide

Collar

Oil/water pump assembly drive sprocket

Washer

Oil/water pump assembly drive chain

Dowel pin

1

1

1

1

1

1

1

1

1

1

1

Q’ty

1

1

2

1

1

5-59

Remarks

Removing the oil pan and oil pump

OIL PUMP

Order

18

Job/Parts to remove

Oil/water pump assembly

Q’ty

1

Remarks

For assembly, reverse the removal procedure.

5-60

Disassembling the oil pump

OIL PUMP

Order

1

2

3

6

7

4

5

8

Job/Parts to remove

Oil/water pump driven sprocket

Collar

Oil pump housing

Bearing

Pin

Oil pump outer roter

Oil pump inner roter

Pin

1

1

1

2

1

Q’ty

1

1

1

Remarks

For assembly, reverse the disassembly procedure.

5-61

EAS24930

REMOVING THE OIL PAN

1. Remove:

• Oil level switch “1”

• Oil pan “2”

• Oil pan gasket

• Dowel pins

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.

OIL PUMP

EAS24960

CHECKING THE OIL PUMP

1. Check:

• Oil pump driven gear “1”

• Oil pump rotor housing “2”

• Oil pump cover

Cracks/damage/wear

→

Replace the defective part(s).

ET2D1012

CHECKING THE SPROCKET AND CHAIN

1. Check:

• Oil/water pump assembly drive sprocket “1”

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”

Inner-rotor-to-outer-roter-tipclearance

0.01–0.10 mm

(0.0004–0.0039 in)

Limit

0.18 mm (0.0071 in)

Outer-rotor-to-oil-pump-housingclearance

0.09–0.15 mm

(0.0035–0.0059 in)

Limit

0.22 mm (0.0087 in)

2. Check:

• Oil/water pump assembly drive chain “1”

Damag/stiffness

→

Replace the oil/water pump assembly drive chain and oil/water pump assembly drive sprocket as a set.

1. Oil pump inner rotor

2. Oil pump outer rotor

3. Oil pump housing

3. Check:

• Oil pump operation

Rough movement

→

Repeat steps (1) and

(2) or replace the defective part(s).

5-62

OIL PUMP

EAS24970

CHECKING THE RELIEF VALVE

1. Check:

• Relief valve body “1”

• Relief valve “2”

• Spring “3”

• O-ring “4”

Damage/wear

→

Replace the defective part(s).

ET2D1013

CHECKING THE OIL NOZZLES

The following procedure applies to all of the oil nozzles.

1. Check:

• Oil nozzle “1”

Damage/wear

→

Replace the oil nozzles.

• O-ring “2”

Damage/wear

→

Replace.

• Oil nozzle passage

Obstruction

→

Blow out with compressed air.

EAS24980

CHECKING THE OIL DELIVERY PIPES

1. Check:

• Oil delivery pipe “1”

• Oil pipe “2”

Damage

→

Replace.

Obstruction

→

Wash and blow out with compressed air.

EAS24990

CHECKING THE OIL STRAINER

1. Check:

• Oil strainer “1”

Damage

→

Replace.

Contaminants

→

Clean with solvent.

EAS25010

ASSEMBLING THE OIL PUMP

1. Lubricate:

• Inner rotor

• Outer rotor

• Oil pump shaft

(with the recommended lubricant)

Recommended lubricant

Engine oil

2. Install:

• Pin “1”

• Inner rotor “2”

• Outer rotor “3”

• Oil pump housing “4”

5-63

OIL PUMP

NOTE:

When installing the inner rotor, align the pin “1” in the oil pump shaft with the groove in the inner rotor “2”.

3. Install:

• Oil/water pump driven sprocket “1”

Oil/water pump driven sprocket bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

LOCTITE®

NOTE:

5VY mark of the oil/water pump driven gear is installed at oil pump side.

2. Install:

• Washer

• Oil/water pump assembly drive chain “1”

• Oil/water pump assembly drive sprocket “2”

• Collar

NOTE:

Install the oil/water pump assembly drive chain

“1” onto the oil/water pump assembly drive sprocket “2”.

EC2D1008

CAUTION:

After installing the oil/water pump assembly drive chain and drive sprocket, make sure the oil/water pump turns smoothly.

4. Check:

• Oil pump operation

Refer to «CHECKING THE OIL PUMP» on page 5-62.

EAS25030

INSTALLING THE OIL/WATER PUMP

ASSEMBLY

1. Install:

• Oil ring

• Oil/water pump assembly “1”

• Dowel pin

• Bolts “2”

Oil/water pump assembly bolt

12 Nm (1.2 m·kg, 8.7 ft·lb)

LOCTITE®

5-64

3. Install:

• Oil/water pump assembly drive chain guide

“1”

Oil/water pump assembly drive chain guide bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

LOCTITE®

NOTE:

“UP” mark of the oil/water pump assembly drive chain guide is upward.

OIL PUMP

4. Install:

• Oil delivery pipe “1”

Oil delivery pipe bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

LOCTITE®

5. Install:

• Relief valve “1”

• O-ring

• Oil strainer “2”

Oil strainer bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

LOCTITE®

• O-ring

• Oil pipe “3”

• O-ring

• Drain pipe “4”

• O-ring

EAS25050

INSTALLING THE OIL PAN

1. Install:

• Dowel pins

• Gasket

• Oil pan “1”

Oil pan bolt

12 Nm (1.2 m·kg, 8.7 ft·lb)

• Oil level switch “2”

Oil level switch bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

• Engine oil drain bolt “3”

Engine oil drain bolt

43 Nm (4.3 m·kg, 31 ft·lb)

EWA12820

WARNING

Always use new copper washers.

NOTE:

• Tighten the oil pan bolts in stages and in a crisscross pattern.

• Lubricate the oil level switch O-ring with engine oil.

5-65

EAS25540

CRANKCASE

Separating the crankcase

CRANKCASE

Order Job/Parts to remove

Air filter case

Throttle body assembly

Engine

Cylinder head

Generator

Starter clutch

Shift shaft

Crankshaft position sensor

Clutch

5-66

Q’ty Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

Refer to «THROTTLE BODIES» on page 7-4.

Refer to «ENGINE REMOVAL» on page 5-2.

Refer to «CYLINDER HEAD» on page 5-19.

Refer to «GENERATOR» on page 5-

31.

Refer to «STARTER CLUTCH» on page 5-35.

Refer to «SHIFT SHAFT» on page 5-

54.

Refer to «CRANKSHAFT POSITION

SENSOR» on page 5-38.

Refer to «CLUTCH» on page 5-44.

Separating the crankcase

CRANKCASE

Order Job/Parts to remove

Oil pump

Starter motor

6

7

4

5

8

9

1

2

3

Timing chain

Timing chain guide (intake side)

Pin

Timing chain guide (exhaust side)

Left side cover

O-ring

Lower crankcase

Dowel pin

Damper

1

1

1

1

3

1

1

1

2

Q’ty Remarks

Refer to «OIL PUMP» on page 5-58.

Refer to «ELECTRIC STARTER» on page 5-40.

For assembly, reverse the removal procedure.

5-67

EAS25550

DISASSEMBLING THE CRANKCASE

1. Place the engine upside down.

2. 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.

• Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration).

• The numbers embossed on the crankcase indicate the crankcase tightening sequence.

M9 x 105 mm (4.1 in) bolts: “1” – “10”

M8 x 60 mm (2.4 in) bolt: “11” LOCTITE®

M8 x 60 mm (2.4 in) bolts: “12”, “16”

M6 x 70 mm (2.8 in) bolts: “19”, “21”, “23”

M6 x 65 mm (2.5 in) bolts: “17”, “18”

M6 x 60 mm (2.4 in) bolt and washer: “22”

M6 x 60 mm (2.4 in) bolts: “24”, “25”

M6 x 50 mm (2.0 in) bolts: “20”, “26”

M8 x 50 mm (2.0 in) bolts: “13” – “15”

3. Remove:

• Lower crankcase

ECA13900

CAUTION:

Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly.

4. Remove:

• Dowel pins

5. Remove:

• Crankshaft journal lower bearing

(from the lower crankcase)

5-68

CRANKCASE

NOTE:

Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place.

EAS25580

CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a mild solvent.

2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces.

3. Check:

• Crankcase

Cracks/damage

→

Replace.

• Oil delivery passages

Obstruction

→

Blow out with compressed air.

ET2D1014

CHECKING THE BEARING AND OIL SEALS

1. Check:

• Bearings

Clean and lubricate the bearings, then rotate the inner race with your finger.

Rough movement

→

Replace.

2. Check:

• Oil seals

Damage/wear

→

Replace.

EAS25650

ASSEMBLING THE CRANKCASE

1. Lubricate:

• Crankshaft journal bearings

(with the recommended lubricant)

Recommended lubricant

Engine oil

2. Apply:

• Sealant

Yamaha bond No. 1215

(Three Bond No.1215®)

90890-85505

NOTE:

Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2–3 mm

(0.08–0.12 in) of the crankshaft journal bearings.

3. Install:

• Dowel pin

4. Set the shift drum assembly and transmission gears in the neutral position.

5. Install:

• Lower crankcase “1”

(onto the upper crankcase “2”)

ECA13980

CAUTION:

Before tightening the crankcase bolts, make sure the transmission gears shift correctly when the shift drum assembly is turned by hand.

CRANKCASE

Crankcase bolt

Bolt “1”–“10”

1st: 20 Nm (2.0 m·kg, 14 ft·lb)

2nd*: 20 Nm (2.0 m·kg, 14 ft·lb)

3rd: +60

°

Bolt “11”–“16”

24 Nm (2.4 m·kg, 17 ft·lb)

Bolt “17”–“26”

12 Nm (1.2 m·kg, 8.7 ft·lb)

*Following the tightening order, loosen the bolt one by one and then retighten it to the specific torque.

6. Install:

• Crankcase bolts

NOTE:

• Lubricate the bolt threads with engine oil.

• Install a washer on bolts “1” – “10” and “22”.

• Seal bolt “18”

• Tighten the bolts in the tightening sequence cast on the crankcase.

M9 x 105 mm (4.1 in) bolts: “1” – “10”

M8 x 60 mm (2.4 in) bolt: “11” LOCTITE®

M8 x 60 mm (2.4 in) bolts: “12”, “16”

M6 x 70 mm (2.8 in) bolts: “19”, “21”, “23”

M6 x 65 mm (2.5 in) bolts: “17”, “18”

M6 x 60 mm (2.4 in) bolt and washer: “22”

M6 x 60 mm (2.4 in) bolts: “24”, “25”

M6 x 50 mm (2.0 in) bolts: “20”, “26”

M8 x 50 mm (2.0 in) bolts: “13” – “15”

5-69

EAS25950

CRANKSHAFT

Removing the connecting rods and pistons

CRANKSHAFT

Order Job/Parts to remove

Lower crankcase

6

7

4

5

1

2

3

8

9

10

11

12

Connecting rod cap

Big end lower bearing

Big end upper bearing

Piston pin clip

Piston pin

Piston

Connecting rod

Top ring

2nd ring

Oil ring

Cylinder

Cylinder gasket

5-70

Q’ty Remarks

Refer to «CRANKCASE» on page 5-

66.

4

4

8

4

4

4

4

4

1

4

4

1

For installation, reverse the removal procedure.

Removing the crankshaft

CRANKSHAFT

Order Job/Parts to remove

Crankcase

5

6

7

3

4

1

2

Connecting rod and connecting rod caps

Crankshaft

Crankshaft journal lower bearing

Crankshaft journal upper bearing

Washer

Crankshaft drive gear

Pin

Pickup rotor

1

1

1

5

1

1

5

Q’ty Remarks

Separate.

Refer to «CRANKCASE» on page 5-

66.

Refer to «REMOVING THE CON-

NECTING RODS AND PISTONS» on page 5-72.

For assembly, reverse the disassembly procedure.

5-71

EAS26030

REMOVING THE CONNECTING RODS AND

PISTONS

The following procedure applies to all of the connecting rods and pistons.

1. Remove:

• Connecting rod cap “1”

• Big end bearings

NOTE:

• Idetify the position of each big end bearing so that it can be reinstalled in its original place.

• After removing the connecting rods and connecting rod caps, care should be taken not to damage the mating surfaces of the connecting rods and connecting rod caps.

CRANKSHAFT

Piston pin puller set

90890-01304

Piston pin puller

YU-01304

2. Remove:

• Cylinder

• Cylinder gasket

• Cylinder stud bolts

3. Remove:

• Piston pin clips “1”

• Piston pin “2”

• Piston “3”

EC2D1006

CAUTION:

Do not use a hammer to drive the piston pin out.

NOTE:

• For reference during installation, put identification marks on the piston crown.

• Before removing the piston pin, deburr the piston pin clip groove and the piston pin bore area. If both areas are debarred and the piston pin is still difficult to remove, remove it with the piston pin puller set “4”.

4. Remove:

• Top ring

• 2nd ring

• Oil ring

NOTE:

When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.

EAS25980

REMOVING THE CRANKSHAFT ASSEMBLY

1. Remove:

• Crankshaft assembly

• Crankshaft journal upper bearings

(from the upper crankcase)

Refer to «CRANKSHAFT» on page 5-70.

5-72

NOTE:

Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place.

ET2D1032

CHECKING THE CYLINDER AND PISTON

1. Check:

• Piston wall

• Cylinder wall

Vertical scratches

→

Replace the cylinder, and the piston and piston rings as a set.

2. Measure:

• Piston-to-cylinder clearance

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge.

NOTE:

Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements.

Cylinder bore “C”

Wear limit

Taper limit “T”

Out of round “R”

77.00 – 77.01 mm

(3.0315 – 3.0319 in)

77.06 mm (3.03 in)

0.005 mm (0.0002 in)

0.005 mm (0.0002 in)

“C” = maximum of D

1

– D

6

“T” = maximum of D

1

or D

2

– maximum of D

5

or D

6

“R” = maximum of D

1

D

3

or D

5

– minimum of D

2

D

4

or D

6

CRANKSHAFT

4 mm (0.16 in) “a” from the bottom edge of the piston

Piston size “P”

76.975 — 76.990 mm

(3.0305 — 3.0311 in)

d. If out of specification, replace the piston and piston rings as a set.

e. Calculate the piston-to-cylinder clearance with the following formula.

Piston-to-cylinder clearance =

Cylinder bore “C” –

Piston skirt diameter “P”

Piston-to-cylinder clearance

0.010–0.035 mm

(0.0004–0.0014 in)

Limit: 0.120 mm (0.0047 in)

f.

If out of specification, replace the cylinder, and the piston and piston rings as a set.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

ET2D1015

CHECKING THE PISTON RINGS

1. Measure:

• Piston ring side clearance

Out of specification

→

Replace the piston and piston rings as a set.

NOTE:

Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

b. If out of specification, replace the cylinder, and the pistons and piston rings as a set.

c. Measure piston skirt diameter “P” with the micrometer.

5-73

Piston ring side clearance

Top ring

0.030–0.065 mm

(0.0012–0.0026 in)

Limit

0.115 mm (0.0045 in)

2nd ring

0.020–0.055 mm

(0.0008–0.0022 in)

Limit

0.115 mm (0.0045 in)

2. Install:

• Piston ring

(into the cylinder)

NOTE:

Level the piston ring into the cylinder with the piston crown.

5 mm (0.20 in) “a”

CRANKSHAFT

Piston ring end gap

Top ring

0.15–0.25 mm

(0.0059–0.0098 in)

Limit

0.50 mm (0.0197 in)

2nd ring

0.30–0.45 mm

(0.0118–0.0177 in)

Limit

0.80 mm (0.0315 in)

Oil ring

0.10–0.40 mm

(0.0039–0.0157 in)

ET2D1016

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.

Piston pin bore outside diameter

16.991–17.000 mm

(0.6689–0.6693 in)

Limit

16.971 mm (0.6682 in)

3. Measure:

• Piston ring end gap

Out of specification

→

Replace the piston ring.

NOTE:

The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.

3. Measure:

• Piston pin bore inside diameter “b”

Out of specification

→

Replace the piston.

5-74

Piston pin bore inside diameter

17.002–17.013 mm

(0.6694–0.6698 in)

Limit

17.043 mm (0.6710 in)

CRANKSHAFT end bearings must be installed in their original positions.

a. Clean the big end bearings, crankshaft pins, and the inside of the connecting rods halves.

b. Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap.

NOTE:

Align the projections “a” on the big end bearings with the notches “b” in the connecting rod and connecting rod cap.

4. Calculate:

• Piston-pin-to-position clearance

Out of specification

→

Replace the position pin and piston as a set.

Piston-pin-to-pistonclearance =

Piston pin bore size —

Piston pin outside diameter

Piston-pin-to-piston clearance

0.002–0.022 mm

(0.0001–0.009 in)

Limit

0.072 mm (0.0028 in)

ET2D1017

CHECKING THE BIG END BEARINGS

1. Measure:

• Crankshaft-pin-to-big-end-bearing crearance

Out of specification

→

Replace the big end bearings.

Crankshaft-pin-to-big-end-bearing clearance

0.034–0.058 mm

(0.0013–0.0023 in)

Limit

0.09 mm (0.0035 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

The following procedure applies to all of the connecting rods.

ECA14900

CAUTION:

Do not interchange the big end bearings and connecting rods. To obtain the correct creankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big

5-75

c. Put a piece of Pleastigauge® “1” on the crankshaft pin.

d. Assemble the connecting rod halves.

NOTE:

• Do not move the connecting rod or crankshaft until the clearance measurement has been completed.

• Lubricate the bolt threads with molybdenum disulfide grease.

• Make sure that the “Y” mark “c” on the connecting rod faces towards the left side of the crankshaft.

• Make sure that the characters “d” on both the connecting rod and connecting rod cap are aligned.

CRANKSHAFT

e. Tighten the connecting rod bolts.

NOTE:

Install by carrying out the following procedures in order to assemble in the most suitable condition.

Connecting rod bolt

29.4 Nm (3.0 m·kg, 21 ft·lb)

NOTE:

• First, tighten the bolts to 15 Nm (1.5 m·kg, 11 ft·lb).

• Retighten the bolts to 29.4 Nm (3.0 m·kg, 21 ft·lb).

f.

Replace the connecting rod bolts with new ones.

g. Clean the connecting rod bolts.

h. After installing big end bearing, assemble the connecting rod and connecting rod cap once using a single unit of the connecting rod.

i.

Tighten the connecting rod bolt while checking that the sections shown “a” and

“b” are flush with each other by touching the surface.

• Side machined face “a”

• Thrusting faces (4 places at front and rear)

“b”

NOTE:

To install the big end bearing, care should be taken not to install it at an angle and the position should not be out of alignment.

j.

Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condition.

k. Tighten the connecting rod bolts.

Connecting rod bolt

20 Nm (2.0 m·kg, 14 ft·lb)

+150

°

EC2D1014

CAUTION:

Tighten the connecting rod bolts using the plastic-region tightening angle method.

l.

Clean the connecting rod bolts.

m. Tighten the connecting rod bolts.

n. Put a mark “1” on the corner of the connecting rod bolt “2” and the connecting rod

“3”.

o. Tighten the bolt further to reach the specified angle (150

°

).

5-76

p. After the installation, check that the section shown “a” is flush with each other by touching the surface.

• Side machined face “a”

EWA13120

WARNING

• When the bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it.

Replace the bolt with a new one and perform the procedure again.

• If they are not flush with each other, remove the connecting rod bolt and big end bearing and restart from step “e”. In this case, make sure to replace the connecting rod bolt.

EC2D1015

CAUTION:

• Do not use a torque wrench to tighten the nut to the specified angle.

• Tighten the bolt until it is at the specified angles.

CRANKSHAFT

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Select:

• Big end bearings (P1 – P4)

NOTE:

• The numbers “A” stamped into the crankshaft wed and the numbers “1” on the connecting rods are used to determine the replacement big end bearings sizes.

• “P1” — ”P4” refer to the bearings shown in the crankshaft illustration.

For example, if the connecting rod “P

1

” and the crankshaft web “P

1

” numbers are “5” and “2” respectively, then the bearing size for “P

1

” is:

“P

1

” (connecting rod) – “P

1

”

(crankshaft) =

5 – 2 = 3 (brown)

BIG END BEARING COLOR CODE

1 Blue

2

3

4

Black

Brown

Green q. Remove the connecting rod and big end bearings.

Refer to «REMOVING THE CONNECTING

RODS AND PISTONS» on page 5-72.

r.

Measure the compressed Plastigauge® width on the crankshaft pin.

If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings.

5-77

EAS26190

INSTALLING THE CONNECTING ROD AND

PISTON

The following procedure applies to all of the connecting rods and pistons.

1. Install:

• Top ring “1”

• 2nd ring “2”

• Upper oil ring rail “3”

• Oil ring expander “4”

• Lower oil ring rail “5”

NOTE:

Be sure to install the piston rings so that the manufacturer’s marks or numbers “a” face up.

CRANKSHAFT

(with the recommended lubricant)

Recommended lubricant

Engine oil

4. Offset:

• Piston ring end gaps

2. Install:

• Piston “1”

(onto the respective connecting rod “2”)

• Piston pin “3”

• Piston pin clip “4”

NOTE:

• Apply engine oil onto the piston pin.

• Make sure that the “Y” mark “a” on the connecting rod faces left when the arrow mark

“b” on the piston is pointing up as shown.

• Reinstall each piston into its original cylinder

(numbering order starting from the left: #1 to

#4).

a. Top ring b. Lower oil ring rail c. Upper oil ring rail d. 2nd ring e. Oil ring expander

5. Lubricate:

• Crankshaft pins

• Big end bearings

• Connecting rod big end inner surface

(with the recommended lubricant)

Recommended lubricant

Engine oil

6. Check:

• Cylinder stud bolts “1”

Cylinder stud bolt

8 Nm (0.8 m·kg, 5.8 ft·lb)

3. Lubricate:

• Piston

• Piston rings

• Cylinder

5-78

7. Install:

• Cylinder gasket “2”

8. Install:

• Big end bearings

(onto the connecting rods and connecting rod caps)

NOTE:

• Align the projections “a” on the big end bearings with the notches “b” in the connecting rods and connecting rod caps.

• Be sure to reinstall each big end bearing in its original place.

• Make sure that the characters “c” a on both the connecting rod and connecting rod cap are aligned.

CRANKSHAFT

NOTE:

• Install by carrying out the following procedures in order to assemble in the most suitable condition.

• First tighten the bolts to 15 Nm (1.5 m·kg, 11 ft·lb)

• Retighten the bolts to 29.4 Nm (3.0 m·kg, 21 ft·lb)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Replace the connecting rod bolts with new ones.

b. Clean the connecting rod bolts.

c. After installing the big end bearing, assemble the connecting rod and connecting rod cap once using a single unit of the connecting rod.

d. Tighten the connecting rod bolt while checking that the sections shown “a” and

“b” are flush with each other by touching the surface.

NOTE:

To install the big end bearing, care should be taken not to install it at an angle and the position should not be out of alignment.

9. Tighten:

• Connecting rod bolts

Connecting rod bolt

29.4 Nm (3.0 m·kg, 21 ft·lb)

5-79

a. Side machined face b. Thrusting faces (4 places at front and rear) e. Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condition.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

10. Install:

• Piston assemblies “1”

(into the cylinder)

NOTE:

While compressing the piston rings with one hand, install the connecting rod assembly into the cylinder with the other hand.

CRANKSHAFT

ECA14980

CAUTION:

Tighten the connecting rod bolts using the plastic-region tightening angle method.

a. Clean the connecting rod bolts.

b. Tighten the connecting rod bolts.

c. Put a mark “1” on the connecting rod bolt

“2” and the connecting rod cap “3”.

11. Install:

• Cylinder assembly “1”

• Connecting rod caps “2”

NOTE:

• Make sure that the “Y” marks “a” on the connecting rods face towards the left side of the crankshaft.

• Make sure that the characters on both the connecting rod and connecting rod cap are aligned.

d. Tighten the bolt further to reach the specified angle (150

°

).

e. After the installation, check that the section shown “a” is flush with each other by touching the surface.

12. Tighten:

• Connecting rod bolts

Connecting rod bolt

20 Nm (2.0 m·kg, 14 ft·lb)+150

°

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Side machined face

EWA13990

WARNING

• When the bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and perform the procedure again.

5-80

CRANKSHAFT

• If they are not flush with each other, remove the connecting rod bolt and big end bearing and restart from step “9”. In this case, make sure to replace the connecting rod bolt.

ECA14680

CAUTION:

• Do not use a torque wrench to tighten the bolt to the specified angle.

• Tighten the bolt until it is at the specified angles.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

ET2D1018

CHECKING THE CRANKSHAFT

1. Measure:

• Crankshaft runout

Out of specification

→

Replace the crankshaft.

Crankshaft runout

Less than 0.03 mm (0.0012 in)

2. Check:

• Crankshaft journal surfaces

• Crankshaft pin surfaces

• Bearing surfaces

Scratches/wear

→

Replace the crankshaft.

ET2D1019

CHECKING THE CRANKSHAFT DRIVE

SPROCKET

1. Check:

• Crankshaft drive sprocket “1”

Cracks/damage/wear

→

Replace the defective part(s).

ET2D1020

CHECKING THE CRANKSHAFT JOURNAL

BEARINGS

1. Measure:

• Crankshaft-journal-to-crankshaft-journalbearing clearance

Out of specification

→

Replace the crankshaft journal bearings.

Crankshaft-journal-to-crankshaft-journal-bearing clearance

0.014–0.037 mm

(0.0006–0.0015 in)

Limit

0.10 mm (0.0039 in)

EC2D1008

CAUTION:

Do not interchange the crankshaft journal bearings. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing clearance and prevent engine damage, the crankshaft journal bearings must be installed in their original positions.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the crankshaft journal bearings, cranshaft journals, and bearing portions of the crankcase.

b. Place the upper crankcase upside down on a bench.

c. Install the crankshaft journal upper bearings “1” and the crankshaft into the upper crankcase.

NOTE:

Align the projections “a” on the crankshaft journal upper bearings with the notches “b” in the upper crankcase.

5-81

d. Put a piece of Plastigauge® “2” on each crankshaft journal.

NOTE:

Do not put the Plastigauge® over the oil hole in the crankshaft journal.

CRANKSHAFT

Crankcase bolt

Bolt “1”–“10”

1st: 20 Nm (2.0 m·kg, 14 ft·lb)

2nd: 20 Nm (2.0 m·kg, 14 ft·lb)

3rd: +60

°

Bolt “11”–“16”

24 Nm (2.4m·kg, 17 ft·lb)

Bolt “17”–“26”

12 Nm (1.2m·kg, 8.7 ft·lb)

M9 x 105 mm (4.1 in) bolts: “1”–“10”

M8 x 60 mm (2.4 in) bolt: “11” LOCTITE®

M8 x 60 mm (2.4 in) bolts: “12”, “16”

M6 x 70 mm (2.8 in) bolts: “19”, “21”, “23”

M6 x 65 mm (2.5 in) bolts: “17”, “18”

M6 x 60 mm (2.4 in) bolt and washer: “22”

M6 x 60 mm (2.4 in) bolts: “24”, “25”

M6 x 50 mm (2.0 in) bolts: “20”, “26”

M8 x 50 mm (2.0 in) bolts: “13”–“15”

* Following the tightening order, loosen the bolt one by one and then retighten it to the specific torque.

NOTE:

Lubricate the crankcase bolt threads with engine oil.

Refer to «CRANKCASE» on page 5-66.

e. Install the crankshaft journal lower bearings “1” into the lower crankcase and assemble the crankcase halves.

NOTE:

• Align the projections “a” of the crankshaft journal lower bearings with the notches “b” in the lower crankcase.

• Do not move the crankshaft until the clearance measurement has been completed.

f.

Tighten the bolts to specification in the tightening sequence cast on the crankcase.

g. Remove the lower crankcase and the crankshaft journal lower bearings.

h. Measure the compressed Plastigauge® width “c” on each crankshaft journal.

If the crankshaft-journal-to-crankshaft-journal-bearing clearance is out of specification, select replacement crankshaft journal bearings.

5-82

CRANKSHAFT

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Select:

• Crankshaft journal bearings (J1–J5)

NOTE:

• The numbers “A” stamped into the crankshaft web and the numbers “1” stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes.

• “J1–J5” refer to the bearings shown in the crankshaft illustration.

• If “J1–J5” are the same, use the same size for all of the bearings.

• If the size is the same for all “J

1

to J

5

” one digit for that size is indicated. (Crankcase side only)

For example, if the crankcase “J

1

” and crankshaft web “J

1

” numbers are “6” and

“2” respectively, then the bearing size for

“J

1

” is:

“J

1

” (crankcase) – “J

1

”

(crankshaft web) – 1 =

6 – 2 – 1 = 3 (brown)

CRANKSHAFT JOURNAL BEARING

COLOR CODE

0 White

3

4

1

2

Blue

Black

Brown

Green

ET2D1021

INSTALLING THE CRANKSHAFT

1. Install:

• Crankshaft journal upper bearings “1”

(into the upper crankcase)

2. Lubricate:

• Crankshaft journal upper bearings

(with the recommended lubricant)

Recommended lubricant

Engine oil

5-83

NOTE:

• Align the projections “a” on the crankshaft journal upper bearings with the notches “b” in the upper crankcase.

• Be sure to install each crankshaft journal upper bearing in its original place.

3. Install:

• Crankshaft

4. Install:

• Crankcase (lower)

Refer to «CRANKCASE» on page 5-66.

5. Install:

• Pin

• Pickup rotor “1”

• Drive sprocket “2”

Drive sprocket bolt

60 Nm (6.0 m·kg, 43 ft·lb)

CRANKSHAFT

5-84

EAS26240

TRANSMISSION

Removing the transmission, shift drum assembly, and shift forks

TRANSMISSION

Order Job/Parts to remove

Crankcase lower

7

8

5

6

3

4

1

2

9

10

11

12

13

Drive axle assembly

Circlip

Oil seal

Bearing

Washer

Shift fork guide bar retainer

Spring

Shift fork guide bar

Shift fork “L”

Shift fork “R”

Shift drum assembly

Shift fork “C”

Main axle retainer

5-85

2

2

1

2

1

1

1

1

1

1

1

1

1

Q’ty Remarks

Separate.

Refer to «CRANKCASE» on page 5-

66.

Removing the transmission, shift drum assembly, and shift forks

TRANSMISSION

Order

14

15

16

17

Job/Parts to remove

Main axle assembly

Oil pipe

O-ring

Oil baffle plate

Q’ty

1

1

2

1

Remarks

For installation, reverse the removal procedure.

5-86

Disassembling the main axle assenbly

TRANSMISSION

12

13

14

15

8

9

10

11

Order

1

2

3

6

7

4

5

Job/Parts to remove

2nd pinion gear

Toothed lock washer

Toothed lock washer retainer

6th pinion gear

Collar

Washer

Circlip

3rd pinion gear

Circlip

Washer

5th pinion gear

Collar

Main axle

Bearing housing

Bearing

1

1

1

1

1

1

1

1

1

1

1

1

Q’ty

1

1

1

Remarks

For assembly, reverse the disassembly procedure.

5-87

Disassembling the drive axle assenbly

TRANSMISSION

12

13

14

15

8

9

10

11

16

17

18

19

20

Order

1

2

3

6

7

4

5

Job/Parts to remove

Washer

1st wheel gear

Collar

5th wheel gear

Circlip

Washer

3rd wheel gear

Collar

Toothed lock washer

Toothed lock washer retainer

4th wheel gear

Collar

Washer

Circlip

6th wheel gear

Circlip

Washer

Collar

2nd wheel gear

Collar

5-88

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Q’ty

1

1

1

Remarks

Disassembling the drive axle assenbly

TRANSMISSION

Order

21

22

23

Job/Parts to remove

Oil seal

Bearing

Drive axle

Q’ty

1

1

1

Remarks

For assembly, reverse the disassembly procedure.

5-89

TRANSMISSION

EAS26250

REMOVING THE TRANSMISSION

1. Remove:

• Drive axle asseembly “1”

• Shift drum retainers “2”

• Shift fork guide bars

• Shift fork “L” and “R”

• Shift drum assembly

• Shift fork “C”

2. Remove:

• Bearing housing “1”

• Main axle assembly “2”

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert two bolts “3” of the proper size, as shown in the illustration, into the main axle assembly bearing housing.

EAS26260

CHECKING THE SHIFT FORKS

The following procedure applies to all of the shift forks.

1. Check:

• Shift fork cam follower “1”

• Shift fork pawl “2”

Bends/damage/scoring/wear

→

Replace the shift fork.

b. Tighten the bolts until they contact the crankcase surface.

c. Continue tightening the bolts until the main axle assembly comes free from the upper crankcase.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Remove:

• Oil pipe “1”

• Bearing “2”

2. Check:

• Shift fork guide bar

Roll the shift fork guide bar on a flat surface.

Bends

→

Replace.

EWA12840

WARNING

Do not attempt to straighten a bent shift fork guide bar.

5-90

TRANSMISSION

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)

EAS26270

CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:

• Shift drum grooves “1”

Damage/scratches/wear

→

Replace the shift drum assembly.

• Shift drum segment “2”

Damage/wear

→

Replace the shift drum assembly.

• Shift drum bearing “3”

Damage/pitting

→

Replace the shift drum assembly.

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).

EAS26280

CHECKING THE TRANSMISSION

1. Measure:

• Main axle runout

(with a centering device and dial gauge “1”)

5-91

TRANSMISSION

ET2D1022

INSTALLING THE TRANSMISSION

1. Install:

• Bearing “1”

NOTE:

Make the seal side of bearing face to the outside and install it close to the right end face of the crankcase.

• Oil pipe “2”

2. Install:

• Main axle assembly “1”

• Bearing housing “2”

Bearing housing bolt

12 Nm (1.2 m·kg, 8.7 ft·lb)

LOCTITE®

• Shift fork “C”

• Shift drum assembly

• Shift fork guide bar

• Shift fork guide bar retainer

Shift fork guide bar retainer bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

LOCTITE®

NOTE:

• The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”,

“C”, “L”.

• Carefully position the shift forks so that they are installed correctly into the transmission gears.

• Install shift fork “C” into the groove in the 3rd and 4th pinion gear on the main axle.

3. Install:

• Shift fork “L” “1” and “R” “2”

• Drive axle assembly “3”

• Shift fork guide bar

• Shift fork guide bar retainer “4”

Shift fork guide bar retainer bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

LOCTITE®

NOTE:

• Install shift fork “L” into the groove in the 6th wheel gear and shift fork “R” into the groove in the 5th wheel gear on the drive axle.

• Make sure that the drive axle bearing circlip

“a” is inserted into the grooves in the upper crankcase.

5-92

4. Check:

• Transmission

Rough movement

→

Repair.

NOTE:

Oil each gear, shaft, and bearing thoroughly.

5-93

TRANSMISSION

COOLING SYSTEM

RADIATOR

………………………………………………………………………………………. 6-1

CHECKING THE RADIATOR………………………………………………………… 6-3

INSTALLING THE RADIATOR ………………………………………………………. 6-3

OIL COOLER

…………………………………………………………………………………… 6-4

CHECKING THE OIL COOLER…………………………………………………….. 6-5

INSTALLING THE OIL COOLER …………………………………………………… 6-5

THERMOSTAT

…………………………………………………………………………………. 6-6

CHECKING THE THERMOSTAT…………………………………………………… 6-8

ASSEMBLING THE THERMOSTAT ASSEMBLY …………………………….. 6-8

INSTALLING THE THERMOSTAT ASSEMBLY ……………………………….. 6-8

WATER PUMP

……………………………………………………………………………….. 6-10

DISASSEMBLING THE WATER PUMP ……………………………………….. 6-11

CHECKING THE WATER PUMP …………………………………………………. 6-11

ASSEMBLING THE WATER PUMP …………………………………………….. 6-11

6

EAS26380

RADIATOR

Removing the radiator

RADIATOR

Order Job/Parts to remove

Rider and passenger seat

Fuel tank

Air filter case

Coolant

7

8

5

6

9

3

4

1

2

Radiator side covers

Coolant reservoir hose

Radiator front cover

Radiator

Radiator fan motor

Radiator inlet hose

Oil cooler outlet hose

Water pump breather hose

Radiator outlet hose

6-1

1

1

2

1

1

1

1

2

1

Q’ty Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

Refer to «FUEL TANK» on page 7-1.

Refer to «GENERAL CHASSIS» on page 4-1.

Drain.

Refer to «CHANGING THE COOL-

ANT» on page 3-19.

Removing the radiator

RADIATOR

Order

10

11

Job/Parts to remove

Water pump inlet pipe

O-ring

Q’ty

1

1

Remarks

For installation, reverse the removal procedure.

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.

2. Check:

• Radiator hoses

• Radiator pipes

Cracks/damage

→

Replace.

3. Measure:

• Radiator cap opening pressure

Below the specified pressure

→

Replace the radiator cap.

Radiator cap opening pressure

93.3 — 122.7 kPa

(0.93 — 1.23 kg/cm

2

, 0.9 — 1.2 bar, 13.5 — 17.8 psi)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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

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 «RADIATOR» on page 6-1.

EAS26400

INSTALLING THE RADIATOR

1. Fill:

• Cooling system

(with the specified amount of the recommended coolant)

Refer to «CHANGING THE COOLANT» on page 3-19.

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

EAS26410

OIL COOLER

Removing the oil cooler

OIL COOLER

Order Job/Parts to remove

Engine oil

7

8

5

6

3

4

1

2

9

10

11

12

Oil cooler inlet hose

Oil cooler bolt

Washer

Oil cooler

O-ring

Water pump outlet pipe

O-ring

Water jacket joint inlet hose

O-ring

Water jacket joint

Stay

O-ring

6-4

1

1

1

1

1

1

1

1

1

1

1

1

Q’ty Remarks

Drain.

Refer to «CHANGING THE ENGINE

OIL» on page 3-12.

For assembly, reverse the removal procedure.

EAS26420

CHECKING THE OIL COOLER

1. Check:

• Oil cooler

Cracks/damage

→

Replace.

2. Check:

• Oil cooler inlet hose

• Oil cooler outlet hose

Cracks/damage/wear

→

Replace.

EAS26430

INSTALLING THE OIL COOLER

1. Clean:

• Mating surfaces of the oil cooler and the crankcase

(with a cloth dampened with lacquer thinner)

2. Install:

• O-ring

• Oil cooler “1”

• Washer “2”

• Oil cooler bolt “3”

Oil cooler bolt

63 Nm (6.3 m·kg, 46 ft·lb)

NOTE:

• Before installing the oil cooler, lubricate the oil cooler bolt and O-ring with a thin coat of engine oil.

• Make sure the O-ring is positioned properly.

• Align the projection “a” on the oil cooler with the slot “b” in the crankcase.

OIL COOLER

3. Fill:

• Cooling system

(with the specified amount of the recommended coolant)

Refer to «CHANGING THE COOLANT» on page 3-19.

• Crankcase

(with the specified amount of the recommended engine oil)

Refer to «CHANGING THE ENGINE OIL» on page 3-12.

4. Check:

• Cooling system

Leaks

→

Repair or replace any faulty part.

5. Measure:

• Radiator cap opening pressure

Below the specified pressure

→

Replace the radiator cap.

Refer to «CHECKING THE RADIATOR» on page 6-3.

6-5

EAS26440

THERMOSTAT

Removing the thermostat assembly

THERMOSTAT

Order Job/Parts to remove

Rider and passenger seat

Fuel tank

Air filter case

Coolant

3

4

1

2

Thermostat assembly outlet hose

Thermostat assembly

Thermostat assembly inlet hose

Band

1

2

1

1

Q’ty Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

Refer to «FUEL TANK» on page 7-1.

Refer to «GENERAL CHASSIS» on page 4-1.

Drain.

Refer to «CHANGING THE COOL-

ANT» on page 3-19.

For installation, reverse the removal procedure.

6-6

Disassembling the thermostat assembly

THERMOSTAT

Order

1

2

3

4

Job/Parts to remove

Thermostat housing cover

Thermostat

Thermostat housing

O-ring

Q’ty

1

1

1

1

Remarks

For assembly, reverse the disassembly procedure.

6-7

EAS26450

CHECKING THE THERMOSTAT

1. Check:

• Thermostat

Does not open at 71 – 85

°

C (160 – 185

°

F)

→

Replace.

THERMOSTAT

• Thermostat housing “2”

Cracks/damage

→

Replace.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “3” in a container

“4” filled with water.

b. Slowly heat the water “2”.

c. Place a thermometer “1” in the water.

d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.

EAS26460

ASSEMBLING THE THERMOSTAT ASSEM-

BLY

1. Install:

• Thermostat housing “1”

• Thermostat “2”

• O-ring “3”

• Thermostat housing cover “4”

Thermostat housing cover nut

10 Nm (1.0 m·kg, 7.2 ft·lb)

NOTE:

Install the thermostat with its breather hole “a” facing up.

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.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Check:

• Thermostat housing cover “1”

6-8

EAS26480

INSTALLING THE THERMOSTAT ASSEM-

BLY

1. Fill:

• Cooling system

(with the specified amount of the recommended coolant)

Refer to «CHANGING THE COOLANT» on page 3-19.

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.

THERMOSTAT

6-9

EAS26500

WATER PUMP

Removing the impeller shaft

WATER PUMP

6

7

4

5

8

1

2

3

Order Job/Parts to remove

Oil/water pump assembly

Oil pump roter

Water pump cover

O-ring

Pin

Impeller shaft (along with the impeller)

Water pump seal

Oil seal

Bearing

O-ring

Q’ty Remarks

Refer to «OIL PUMP» on page 5-58.

Refer to «OIL PUMP» on page 5-58.

1

1

1

1

1

1

1

2

For installation, reverse the removal procedure.

6-10

WATER PUMP

EAS26520

DISASSEMBLING THE WATER PUMP

1. Remove:

• Water pump seal “1”

• Water pump housing “2”

NOTE:

Tap out the water pump seal from the inside of the water pump housing.

2. Remove:

• Oil seal “1”

• Bearing “2”

• Water pump housing “3”

NOTE:

Tap out the bearing and oil seal from the outside of the water pump housing.

EAS26540

CHECKING THE WATER PUMP

1. Check:

• Water pump housing cover “1”

• Water pump housing “2”

• Impeller “3”

• Rubber damper “4”

• Rubber damper holder “5”

• Water pump seals

• Oil seal

Cracks/damage/wear

→

Replace.

3. Remove:

• Rubber damper holder “1”

• Rubber damper “2”

(from the impeller, with a thin, flat-head screwdriver)

NOTE:

Do not scratch the impeller shaft.

2. Check:

• Bearing

Rough movement

→

Replace.

3. Check:

• Water pump outlet pipe

Cracks/damage/wear

→

Replace.

EAS26560

ASSEMBLING THE WATER PUMP

1. Install:

• Oil seal “1”

(into the water pump housing “2”)

NOTE:

• Before installing the oil seal, apply tap water or coolant onto its out surface.

• Install the oil seal with a socket that matches its outside diameter.

6-11

WATER PUMP

NOTE:

Before installing the rubber damper, apply tap water or coolant onto its outer surface.

2. Install:

• Water pump seal “1”

ECA14080

CAUTION:

Never lubricate the water pump seal surface with oil or grease.

NOTE:

• 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”.

Mechanical seal installer “4”

90890-04078

Water pump seal installer

YM-33221-A

Middle driven shaft bearing driver “5”

90890-04058

Bearing driver 40 mm

YM-04058

Yamaha bond No. 1215 (Three

Bond No.1215®)

90890-85505

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.

Impeller shaft tilt limit

0.15 mm (0.006 in)

1. Straightedge

2. Impeller

A. Push down.

3. Install:

• Rubber damper holder “1”

• Rubber damper “2”

6-12

6-13

WATER PUMP

FUEL SYSTEM

FUEL TANK

…………………………………………………………………………………….. 7-1

REMOVING THE FUEL TANK ………………………………………………………. 7-2

REMOVING THE FUEL PUMP……………………………………………………… 7-2

CHECKING THE FUEL PUMP BODY ……………………………………………. 7-2

CHECKING THE FUEL PUMP OPERATION ………………………………….. 7-2

INSTALLING THE FUEL PUMP ……………………………………………………. 7-2

INSTALLING THE FUEL TANK……………………………………………………… 7-3

THROTTLE BODIES

…………………………………………………………………………. 7-4

CHECKING THE INJECTORS ……………………………………………………… 7-8

CHECKING THE THROTTLE BODIES ………………………………………….. 7-8

CHECKING THE FUEL PRESSURE……………………………………………… 7-8

ADJUSTING THE THROTTLE POSITION SENSOR ……………………….. 7-8

ADJUSTING THE SUB-THROTTLE POSITION SENSOR ……………….. 7-9

CHECKING THE SUB-THROTTLE SERVO MOTOR ……………………… 7-10

CHECKING THE THERMO WAX ………………………………………………… 7-11

ADJUSTING THE THERMO WAX……………………………………………….. 7-11

AIR INDUCTION SYSTEM

………………………………………………………………. 7-13

CHECKING THE AIR INDUCTION SYSTEM ………………………………… 7-14

INSTALLING THE AIR INDUCTION SYSTEM ………………………………. 7-15

7

EAS26620

FUEL TANK

Removing the fuel tank

FUEL TANK

Order Job/Parts to remove

Rider and passenger seat

6

7

4

5

8

1

2

3

Fuel hose

Fuel sender coupler

Fuel pump coupler

Fuel tank drain hose

Fuel tank breather hose

Fuel tank

Fuel tank cover

Fuel pump

1

1

1

1

1

1

1

1

Q’ty Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

For installation, reverse the removal procedure.

7-1

EAS26630

REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the fuel tank cap with a pump.

2. Remove:

• Fuel hose connector cover

• Fuel hose

• Fuel sender coupler

• Fuel pump coupler

• Fuel tank breather hose

• Fuel tank drain hose

EC2D1009

CAUTION:

• Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools.

• Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remaining in it.

NOTE:

• To remove the fuel hose from the fuel injection pipe, slide the cover “a” on the end of the hose in the direction of the arrow shown and then remove the hose.

• Before removing the hoses, place a few rags in the area under where it will be removed.

3. Remove:

• Fuel tank

NOTE:

Do not set the fuel tank down so that the installation surface of the fuel pump is directly under the tank. Be sure to lean the fuel tank in an upright position.

EAS26640

REMOVING THE FUEL PUMP

1. Remove:

• Fuel pump

FUEL TANK

ECA14720

CAUTION:

• Do not drop the fuel pump or give it a strong shock.

• Do not touch the base section of the fuel sender.

EAS26670

CHECKING THE FUEL PUMP BODY

1. Check:

• Fuel pump body

Obstruction

→

Clean.

Cracks/damage

→

Replace fuel pump assembly.

2. Check:

• Diaphragms and gaskets

Turn/fatigue/cracks

→

Replace fuel pump assembly.

3. Check:

• Valves

Cracks/damage

→

Replace fuel pump assembly.

EAS26690

CHECKING THE FUEL PUMP OPERATION

1. Check:

• Fuel pump operation

Refer to «CHECKING THE FUEL PRES-

SURE» on page 7-8.

EAS26710

INSTALLING THE FUEL PUMP

1. Install:

• Fuel pump

Fuel pump bolt

4 Nm (0.4 m·kg, 2.9 ft·lb)

NOTE:

• Do not damage the installation surface of the 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.

• Tighten the fuel pump bolts in stages in a crisscross pattern and to the specified torque.

7-2

ET2D1023

INSTALLING THE FUEL TANK

1. Install:

• Fuel hose

• Fuel hose connector cover

ECA14740

CAUTION:

When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct position, otherwise the fuel hose will not be properly installed.

NOTE:

Install the fuel hose connector securely onto the fuel tank until a distinct “click” is heard, and then make sure that it does not come loose.

To install the fuel hose from the fuel injection hose, slide the cover “a” on the end of the hose in the direction of arrow shown.

2. Install:

• Fuel sender coupler

• Fuel pump coupler

• Fuel tank breather hose

• Fuel tank drain hose

NOTE:

There is white paint mark on the fuel tank breather hose.

Refer to «CABLE ROUTING» on page 2-39.

7-3

FUEL TANK

EAS26970

THROTTLE BODIES

Removing the throttle bodies

THROTTLE BODIES

7

8

5

6

3

4

1

2

9

10

Order Job/Parts to remove

Rider and passenger seat

Fuel tank

Air filter case

Sub-wire harness coupler

Coolant temperature sensor coupler

Thermo wax inret hose

Thermo wax outlet hose

Idle adjust screw wire

Throttle body joint clamp

Throttle bodies

Throttle cables

Throttle body joint

Fuel hose

1

2

1

4

4

1

1

1

2

1

Q’ty Remarks

Refer to «GENERAL CHASSIS» on page 4-1.

Refer to «FUEL TANK» on page 7-1.

Refer to «GENERAL CHASSIS» on page 4-1.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Loosen.

Disconnect.

Disconnect.

7-4

Removing the throttle bodies

THROTTLE BODIES

Order Job/Parts to remove Q’ty Remarks

For installation, reverse the removal procedure.

7-5

Removing the injectors

THROTTLE BODIES

11

12

13

14

7

8

9

10

Order

1

2

5

6

3

4

15

16

17

18

Job/Parts to remove

Throttle position sensor coupler

Sub-throttle position sensor coupler

Sub-throttle motor assembly coupler

Intake air pressure sensor coupler

Cylinder #1-injector coupler

Cylinder #2-injector coupler

Cylinder #3-injector coupler

Cylinder #4-injector coupler

Sub-wire harness

Negative pressure hose

Intake air pressure sensor

Fuel distributor

Injector

Spring

Thermo wax assembly

Idle adjust screw wire

Link cover

Cotter pin

7-6

4

1

1

1

1

1

1

1

1

2

1

1

Q’ty

1

1

1

1

1

1

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Loosen.

Remarks

Removing the injectors

THROTTLE BODIES

Order

19

20

21

22

23

Job/Parts to remove

Washer

Link

Sub-throttle servo motor assembly

Throttle position sensor

Throttle body assembly

Q’ty

2

1

1

1

1

Remarks

For installation, reverse the removal procedure.

7-7

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 petroleum- based solvent.

Do not use any caustic carburetor cleaning solution.

b. Blow out all of the passages with compressed air.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

ET2D1033

CHECKING THE FUEL PRESSURE

1. Check:

• Fuel pressure

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the rider and passenger seat.

Refer to «GENERAL CHASSIS» on page 4-

1.

b. Disconnect the fuel hose (fuel tank to primary injector fuel rail) “1” from the primary injector fuel rail.

EW2C01008

WARNING

Cover fuel hose connections with a cloth when disconnecting them. Residual pressure in the fuel lines could cause fuel to spurt out when removing the hoses.

c. Connect the pressure gauge “2” and adapter “3” to the fuel hose (fuel tank to primary injector fuel rail).

Vacuum/pressure pump gauge set

90890-06756

Pressure gauge

90890-03153

YU-03153

Fuel pressure adapter

90890-03176

YM-03176

d. Start the engine.

e. Measure the fuel pressure.

Fuel pressure

324 kPa (46.1 psi) (3.24 kg/ cm²)

Faulty

→

Replace the fuel pump.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS27020

ADJUSTING THE THROTTLE POSITION

SENSOR

NOTE:

Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted.

7-8

1. Check:

• Throttle position sensor

Refer to «CHECKING THE THROTTLE

POSITION SENSOR» on page 8-109.

2. Adjust:

• Throttle position sensor angle

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the throttle position sensor coupler to the wire harness.

b. Connect the digital circuit tester to the throttle position sensor.

• Positive tester probe yellow terminal “1”

• Negative tester probe black/blue terminal “2”

Digital circuit tester

90890-03174

c. Measure the throttle position sensor voltage.

d. Adjust the throttle position sensor angle so the measured voltage is within the specified range.

Throttle position sensor voltage

0.63–0.73 V

THROTTLE BODIES

ET2D1024

ADJUSTING THE SUB-THROTTLE POSI-

TION SENSOR

1. Check:

• Sub-throttle position sensor

Refer to «CHECKING THE SUB-THROT-

TLE POSITION SENSOR» on page 8-110.

2. Adjust:

• Sub-throttle position sensor full open angle

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the nut “1” of the worm shaft of the sub-throttle counterclockwise until it contacts with the full open stopper.

b. When the dimension of “a” sections of the throttle bodies #3 and #4 is measured with a micrometer caliper, adjust with the adjuster “2” of the output shaft section of the sub-throttle servo motor so that the dimension is in a range from 24.2 to 24.6 mm (0.95 to 0.97 in.)

Sub-throttle dimension “a”

24.2–24.6 mm (0.95–0.97 in)

c. After adjusting the dimension of “a” sections of the throttle bodies #3 and #4, measure the dimension of “a” sections of #1 and #2.

d. If the dimension of “a” sections of the throttle bodies #1 and #2 is different from the dimension of “a” sections of the throttle bodies #3 and #4, adjust it to the same dimension as the measurement value adjusted for the throttle bodies #3 and #4, using the tuning screw “3” located between the throttle bodies #2 and #3.

e. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

7-9

THROTTLE BODIES

4. Adjust:

• Sub-throttle position sensor voltage

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the sub-throttle position sensor coupler to the wire harness.

b. Connect the digital circuit tester to the subthrottle position sensor.

• Positive tester probe

Green/Yellow terminal “1”

• Negative tester probe

Black/Blue terminal “2”

Digital circuit tester

90890-03174

A. Front side

B. Rear side

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Adjust:

• Primary opening

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. After performing the full open angle of the sub-throttle position sensor, turn the nut of the worm shaft clockwise, measure the dimension of “b” section with a micrometer caliper or other device and adjust so that the dimension is in a range from 8.1 to 8.5 mm (0.32 to 0.33 in).

Sub-throttle dimension “b”

8.1–8.5 mm (0.32–0.33 in)

A. Front side

B. Rear side

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

7-10

c. Move the sub-throttle position sensor to adjust to be in the specified range.

Sub-throttle position sensor voltage

0.97–1.07 V

d. After adjusting the sub-throttle position sensor voltage, tighten the sub-throttle position sensor screws.

NOTE:

• After setting up the sub-throttle position sensor, check that the sub-throttle position sensor output voltage is 0.4 V or more with the nut of worm shaft turned to the full close side until it stops.

• When the sub-throttle position sensor output voltage is 0.4 V or more, check that the subthrottle position sensor output voltage is 4.6

V or less with the nut of worm shaft turned to the full open side until it stops.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Connect

• Sub-throttle motor assembly coupler

EAS2D1011

CHECKING THE SUB-THROTTLE SERVO

MOTOR

1. Check:

• Sub-throttle servo motor operation

Out of specification

→

Replace.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check whether or not the sub-throttle valve is seized.

1 Turn the nut of worm shaft of the sub-throttle servo motor by hand to check that the sub-throttle valve is moved smoothly by hand.

2 If it is not moved smoothly, disconnect the link between the sub-throttle servo motor and sub-throttle valve, and then check whether or not the sub-throttle valve is moved smoothly by hand.

Refer to «THROTTLE BODIES» on page 7-

4.

3 When the sub-throttle valve is not moved smoothly, repair or replace it since the cause is the seizure of sub-throttle valve body itself.

When it moved smoothly at Step (1) and

(2), replace the sub-throttle servo motor.

b. Perform the self-diagnosis mode and check the operation of sub-throttle valve by visual inspection (Code No: 56).

The operation should be carried out as 5second drive in the full open direction, 2second stop and 5-second drive in the full close direction.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAT2D1004

CHECKING THE THERMO WAX

1. Check:

• Thermo wax “1”

Damage

→

Replace the thermo wax assembly.

THROTTLE BODIES

a. Before adjusting the distance, push the rod

“b” in order to be fitted in several times by hand.

b. Measure the outside air temperature, and adjust the distance “a” by turning the adjusting screw “2”. Refer to the thermo wax tolerance table based on the measured outside air temperature for correct adjustment.

ET2D1025

ADJUSTING THE THERMO WAX

1. Adjust:

• Thermo wax the end face distance “a”

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

NOTE:

• Setup tolerance of the longitudinal axis should be ± 0.2 mm ( ± 0.008 in).

• After adjusting the thermo wax, check that the first idling is released at the coolant temperature around 60

°

C (140

°

F) by idling.

• If the first idling is not released around 60

°

C

(140

°

F), make sure to set it again. (When the coolant temperature is low, adjust the distance between the end faces longer or adjust

7-11

it shorter when the coolant temperature is high.)

• In case of turning the adjusting bolt two-third turn, the temperature varies about 10

°

C

(50

°

F).

THROTTLE BODIES

7-12

EAS27040

AIR INDUCTION SYSTEM

Removing the air cut-off valve assembly and hoses

AIR INDUCTION SYSTEM

Order

1

2

5

6

3

4

7

8

Job/Parts to remove

Air cut-off valve coupler

Air cut-off valve hose 1

Air cut-off valve hose 2

Air cut-off valve hose 3

Air cut-off valve

Reed valve cap

Reed valve assembly

Plate

Q’ty

1

1

1

2

1

1

2

4

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Remarks

For assembly, reverse the removal procedure.

7-13

EAS27060

CHECKING THE AIR INDUCTION SYSTEM

Air injection

The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approximately 600 to 700

°

C.

Air cut-off valve

The air cut-off valve is controlled by the signals from the ECU in accordance with the combustion conditions. Ordinarily, the air cut-off valve opens to allow the air to flow during idle and closes to cut-off the flow when the vehicle is being driven. However, if the coolant temperature is below the specified value, the air cut-off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value.

AIR INDUCTION SYSTEM

A. From the air cleaner

B. To the cylinder head

1. Check:

• Hoses

Loose connections

→

Connect properly.

Cracks/damage

→

Replace.

• Pipes

Cracks/damage

→

Replace.

2. Check:

• Reed valve “1”

• Reed valve stopper

• Reed valve seat

Cracks/damage

→

Replace the reed valve.

7-14

3. Measure:

• Reed valve bending limit “a”

Out of specification

→

Replace the reed valve.

Reed valve bending limit

0.4 mm (0.016 in)

AIR INDUCTION SYSTEM

• Plate

• Reed valve assembly

• Reed valve cap

2. Install:

• Air cut-off valve

• Air cut-off valve hose 1

• Air cut-off valve hose 2

• Air cut-off valve hose 3

• Air cut-off valve coupler

4. Check:

• Air cut-off valve

Cracks/damage

→

Replace.

5. Check

• Air induction system solenoid

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the air induction system solenoid coupler from the wire harness.

b. Connect the pocket tester (

Ω ×

1) to the air induction system solenoid terminals as shown.

• Positive tester probe

Brown terminal “1”

• Negative tester probe

Brown/Red terminal “2” c. Measure the air induction system solenoid resistance.

Air induction system solenoid resistance

18–22

Ω

at 20

°

C (68

°

F)

d. Out of specification

→

Replace.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS27070

INSTALLING THE AIR INDUCTION SYSTEM

1. Install:

7-15

ELECTRICAL SYSTEM

IGNITION SYSTEM

…………………………………………………………………………… 8-1

CIRCUIT DIAGRAM…………………………………………………………………….. 8-1

TROUBLESHOOTING …………………………………………………………………. 8-3

ELECTRIC STARTING SYSTEM

………………………………………………………… 8-5

CIRCUIT DIAGRAM…………………………………………………………………….. 8-5

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION……………………. 8-7

TROUBLESHOOTING …………………………………………………………………. 8-9

CHARGING SYSTEM

……………………………………………………………………… 8-11

CIRCUIT DIAGRAM…………………………………………………………………… 8-11

TROUBLESHOOTING ……………………………………………………………….. 8-13

LIGHTING SYSTEM

……………………………………………………………………….. 8-15

CIRCUIT DIAGRAM (FZ1-N) ………………………………………………………. 8-15

CIRCUIT DIAGRAM (FZ1-S) ………………………………………………………. 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

TROUBLESHOOTING ……………………………………………………………….. 8-33

ECU SELF-DIAGNOSTIC FUNCTION …………………………………………. 8-37

SELF-DIAGNOSTIC FUNCTION TABLE………………………………………. 8-38

TROUBLESHOOTING METHOD ………………………………………………… 8-41

DIAGNOSTIC MODE…………………………………………………………………. 8-42

TROUBLESHOOTING DETAILS …………………………………………………. 8-50

FUEL PUMP SYSTEM

…………………………………………………………………….. 8-75

CIRCUIT DIAGRAM…………………………………………………………………… 8-75

TROUBLESHOOTING ……………………………………………………………….. 8-77

IMMOBILIZER SYSTEM

………………………………………………………………….. 8-79

CIRCUIT DIAGRAM…………………………………………………………………… 8-79

GENERAL INFORMATION …………………………………………………………. 8-81

KEY CODES REGISTRATION METHOD……………………………………… 8-81

TROUBLESHOOTING ……………………………………………………………….. 8-85

SELF-DIAGNOSIS ERROR CODE INDICATION …………………………… 8-85

8

ELECTRICAL COMPONENTS

…………………………………………………………. 8-89

CHECKING THE SWITCHES……………………………………………………… 8-93

CHECKING THE BULBS AND BULB SOCKETS…………………………… 8-96

CHECKING THE FUSES……………………………………………………………. 8-97

CHECKING AND CHARGING THE BATTERY………………………………. 8-97

CHECKING THE RELAYS………………………………………………………… 8-100

CHECKING THE TURN SIGNAL/HAZARD RELAY ……………………… 8-102

CHECKING THE RELAY UNIT (DIODE) …………………………………….. 8-102

CHECKING THE IGNITION COILS ……………………………………………. 8-103

CHECKING THE CRANKSHAFT POSITION SENSOR ………………… 8-104

CHECKING THE LEAN ANGLE SENSOR………………………………….. 8-105

CHECKING THE STARTOR MOTOR OPERATION ……………………… 8-105

CHECKING THE STARTOR COIL……………………………………………… 8-106

CHECKING THE RECTIFIER/REGULATOR……………………………….. 8-106

CHECKING THE HORN …………………………………………………………… 8-106

CHECKING THE FUEL SENDER ……………………………………………… 8-107

CHECKING THE SPEED SENSOR …………………………………………… 8-107

CHECKING THE RADIATOR FAN MOTOR…………………………………. 8-108

CHECKING THE COOLANT TEMPERATURE SENSOR ……………… 8-108

CHECKING THE THROTTLE POSITION SENSOR …………………….. 8-109

CHECKING THE SUB-THROTTLE POSITION SENSOR ……………… 8-110

CHECKING THE AIR INDUCTION SYSTEM SOLENOID …………….. 8-110

CHECKING THE ATMOSPHERIC PRESSURE SENSOR…………….. 8-111

CHECKING THE CYLINDER IDENTIFICATION SENSOR ……………. 8-111

CHECKING THE INTAKE AIR PRESSURE SENSOR ………………….. 8-112

CHECKING THE INTAKE AIR TEMPERATURE SENSOR ……………. 8-112

EAS27090

IGNITION SYSTEM

EAS27110

CIRCUIT DIAGRAM

IGNITION SYSTEM

8-1

1. Main switch

6. Fuse (main)

7. Battery

11.Relay unit

12.Starting circuit cut-off relay

14.Neutral switch

15.Sidestand switch

17.Crankshaft position sensor

21.Lean angle sensor

23.ECU

24.Ignition coil #1

25.Ignition coil #2

26.Ignition coil #3

27.Ignition coil #4

28.Spark plug

56.Engine stop switch

60.Clutch switch

78.Fuse (ignition)

IGNITION SYSTEM

8-2

IGNITION SYSTEM

EAS27150

TROUBLESHOOTING

The ignition system fails to operate (no spark or intermittent spark).

NOTE:

• Before troubleshooting, remove the following part(s):

1 Rider and passenger seat

2 Fuel tank

NG

→

1 Check the fuses.

(Main and ignition)

Refer to «CHECKING THE FUSES» on page 8-97.

OK

↓

2 Check the battery.

Refer to «CHECKING AND

CHARGING THE BATTERY» on page 8-97.

OK

↓

3 Check the spark plugs.

Refer to «CHECKING THE SPARK

PLUGS» on page 3-10.

OK

↓

4 Check the ignition spark gap.

Refer to «CHECKING THE IGNI-

TION COILS» on page 8-103.

NG

↓

5 Check the ignition coils.

Refer to «CHECKING THE IGNI-

TION COILS» on page 8-103.

NG

↓

6 Check the crankshaft position sensor.

Refer to «CHECKING THE

CRANKSHAFT POSITION SEN-

SOR» on page 8-104.

OK

↓

7 Check the main switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

NG

NG

OK

NG

NG

NG

→

→

→

→

→

→

Replace the fuse(s).

• Clean the battery terminals.

• Recharge or replace the battery.

Re-gap or replace the spark plugs.

Ignition system is OK.

Replace the ignition coils.

Replace the crankshaft position sensor

Replace the immobilizer kit.

8-3

8 Check the engine stop switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

9 Check the neutral switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

10 Check the sidestand switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

11 Check the clutch switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

12 Check the starting circuit cut-off relay.

Refer to «CHECKING THE

RELAYS» on page 8-100.

OK

↓

13 Check the lean angle sensor.

Refer to «CHECKING THE LEAN

ANGLE SENSOR» on page 8-105.

OK

↓

14 Check the entire ignition system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-1.

OK

↓

Replace the ECU

IGNITION SYSTEM

NG

→

Replace the right handlebar switch.

NG

NG

NG

→

→

→

NG

→

NG

NG

→

→

Replace the neutral switch.

Replace the sidestand switch.

Replace the clutch switch.

Replace the relay unit.

Replace the lean angle sensor.

Properly connect or repair the ignition system’s wiring

8-4

EAS27160

ELECTRIC STARTING SYSTEM

EAS27170

CIRCUIT DIAGRAM

ELECTRIC STARTING SYSTEM

8-5

1. Main switch

6. Fuse (main)

7. Battery

9. Starter relay

10.Starter motor

11.Relay unit

12.Starting circuit cut-off relay

14.Neutral switch

15.Sidestand switch

56.Engine stop switch

57.Start switch

60.Clutch switch

78.Fuse (ignition)

ELECTRIC STARTING SYSTEM

8-6

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 starter switch.

8-7

a. WHEN THE TRANSMISSION IS IN NEU-

TRAL 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. Starting circuit cut-off relay

7. Diode

8. Clutch switch

9. Sidestand switch

10.Neutral switch

11.Start switch

12.Starter relay

13.Starter motor

ELECTRIC STARTING SYSTEM

8-8

ELECTRIC STARTING SYSTEM

EAS27190

TROUBLESHOOTING

The starter motor fails to turn.

NOTE:

• Before troubleshooting, remove the following part(s):

1 Rider and passenger seat

2 Fuel tank

3 Air filter case

NG

→

1 Check the fuses.

(Main and ignition)

Refer to «CHECKING THE FUSES» on page 8-97.

OK

↓

2 Check the battery.

Refer to «CHECKING AND

CHARGING THE BATTERY» on page 8-97.

OK

↓

3 Check the starter motor operation.

Refer to «CHECKING THE STAR-

TOR MOTOR OPERATION» on page 8-105.

OK

↓

4 Check the starter motor.

Refer to «CHECKING THE

STARTER MOTOR» on page 5-42.

OK

↓

5 Check the relay unit (starting circuit cut-off relay).

Refer to «CHECKING THE

RELAYS» on page 8-100.

OK

↓

6 Check the relay unit (diode).

Refer to «CHECKING THE

RELAYS» on page 8-100.

OK

↓

7 Check the starter relay.

Refer to «CHECKING THE

RELAYS» on page 8-100.

OK

↓

NG

→

NG

→

NG

→

NG

→

NG

→

NG

→

Replace the fuse(s).

• Clean the battery terminals.

• Recharge or replace the battery.

Replace the starter motor.

Repair or replace the starter motor.

Replace the relay unit.

Replace the relay unit.

Replace the starter relay.

8-9

8 Check the main switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

9 Check the engine stop switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

10 Check the neutral switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

11 Check the sidestand switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

12 Check the clutch switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

13 Check the start switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

14 Check the entire starting system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-5.

OK

↓

The starting system circuit is OK.

ELECTRIC STARTING SYSTEM

NG

→

Replace the immobilizer kit.

NG

→

Replace the right handlebar switch.

NG

NG

NG

NG

NG

→

→

→

→

→

Replace the neutral switch.

Replace the sidestand switch.

Replace the clutch switch.

Replace the right handlebar switch.

Properly connect or repair the starting system’s wiring

8-10

EAS27200

CHARGING SYSTEM

EAS27210

CIRCUIT DIAGRAM

CHARGING SYSTEM

8-11

2. Rectifier/regulator

3. A.C.magneto

6. Fuse (main)

7. Battery

CHARGING SYSTEM

8-12

CHARGING SYSTEM

EAS27230

TROUBLESHOOTING

The battery is not being charged.

NOTE:

• Before troubleshooting, remove the following part(s):

1 Rider and passenger seat

NG

→

1 Check the fuse.

(Main)

Refer to «CHECKING THE FUSES» on page 8-97.

OK

↓

2 Check the battery.

Refer to «CHECKING AND

CHARGING THE BATTERY» on page 8-97.

OK

↓

3 Check the stator coil.

Refer to «CHECKING THE STATOR

COIL» on page 8-106.

OK

↓

4 Check the rectifier/regulator.

Refer to «CHECKING THE RECTI-

FIER/REGULATOR» on page 8-

106.

OK

↓

5 Check the entire charging system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-11.

OK

↓

This circuit is OK.

NG

NG

NG

NG

→

→

→

→

Replace the fuse.

• Clean the battery terminals.

• Recharge or replace the battery.

• Replace the startor assembly.

Replace the rectifier/regulator.

Properly connect or repair the charging system’s wiring.

8-13

8-14

CHARGING SYSTEM

EAS27240

LIGHTING SYSTEM

EAS27250

CIRCUIT DIAGRAM (FZ1-N)

LIGHTING SYSTEM

8-15

1. Main switch

6. Fuse (main)

7. Battery

23.ECU

49.High beam indicator light

52.Meter light

61.Pass switch

62.Dimmer switch

72.Auxiliary light

73.Headlight

74.License plate light

75.Tail/brake light

76.Headlight relay (on/off)

77.Fuse (tail light))

81.Fuse (headlight)

LIGHTING SYSTEM

8-16

ET2D1026

CIRCUIT DIAGRAM (FZ1-S)

LIGHTING SYSTEM

8-17

1. Main switch

6. Fuse (main)

7. Battery

23.ECU

49.High beam indicator light

52.Meter light

61.Pass switch

62.Dimmer switch

72.Auxiliary light

73.Headlight

74.License plate light

75.Tail/brake light

76.Headlight relay (on/off)

77.Headlight relay (dimmer)

78.Fuse (tail light)

82.Fuse (headlight)

LIGHTING SYSTEM

8-18

LIGHTING SYSTEM

EAS27260

TROUBLESHOOTING

Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light.

NOTE:

• Before troubleshooting, remove the following part(s):

1 Rider and passenger seat

2 Fuel tank

3 Air filter case

NG

→

1 Check the each bulbs and bulb sockets condition.

Refer to «CHECKING THE BULBS

AND BULB SOCKETS» on page 8-

96.

OK

↓

2 Check the fuses.

(Main, headlight and tail/beake light)

Refer to «CHECKING THE FUSES» on page 8-97.

OK

↓

3 Check the battery.

Refer to «CHECKING AND

CHARGING THE BATTERY» on page 8-97.

OK

↓

4 Check the main switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

5 Check the dimmer switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

6 Check the pass switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

7 Check the rear brake light switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

NG

→

NG

→

NG

→

NG

→

NG

→

NG

→

Replace the bulb(s) and bulb socket(s).

Replace the fuse(s).

• Clean the battery terminals.

• Recharge or replace the battery.

Replace the immobilizer kit.

The dimmer switch is faulty. Replace the left handlebar switch.

The pass switch is faulty. Replace the left handlebar switch.

The rear brake light switch is faulty.

Replace the rear brake light switch.

8-19

LIGHTING SYSTEM

8 Check the headlight relay (on/off).

Refer to «CHECKING THE

RELAYS» on page 8-100.

OK

↓

9 Check the headlight relay (dimmer)

(FZ1-S).

Refer to «CHECKING THE

RELAYS» on page 8-100.

OK

↓

10 Check the entire lighting system’s wiring.

Refer to «CIRCUIT DIAGRAM

(FZ1-N)» on page 8-15.

OK

↓

This circuit is OK.

NG

→

NG

→

NG

→

Replace the headlight relay.

Replace the headlight relay.

Properly connect or repair the lighting system’s wiring.

8-20

EAS27270

SIGNALING SYSTEM

EAS27280

CIRCUIT DIAGRAM

SIGNALING SYSTEM

8-21

1. Main switch

6. Fuse (main)

7. Battery

11.Relay unit

14.Neutral switch

16.Fuel pump

19.Speed sensor

23.ECU

42.Fuel level warning light

43.Oil level warning light

44.Neutral indicator light

45.Tacho meter

46.Multi function meter

48.Coolant temperature indicator light

50.Turn signal indicator light (left)

51.Turn signal indicator light (right)

53.Oil level switch

55.Front brake light switch

58.Rear brake light switch

63.Hazard switch

64.Turn signal switch

65.Horn switch

66.Horn

67.Turn signal/hazard relay

68.Front turn signal light (left)

69.Front turn signal light (right)

70.Rear turn signal light (left)

71.Rear turn signal light (right)

75.Tail/brake light

77.Fuse (tail/brake light)

78.Fuse (ignition)

80.Fuse (signal)

SIGNALING SYSTEM

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.

NOTE:

• Before troubleshooting, remove the following part(s):

1 Rider and passenger seat

2 Fuel tank

3 Air filter case

NG

→

1 Check the fuses.

(Main, ignition, signal and tail/brake light)

Refer to «CHECKING THE FUSES» on page 8-97.

OK

↓

2 Check the battery.

Refer to «CHECKING AND

CHARGING THE BATTERY» on page 8-97.

OK

↓

3 Check the main switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

4 Check the entire signaling system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-21.

OK

↓

This circuit is OK.

Check the signaling system

The horn fails to sound.

1 Check the horn switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

2 Check the horn.

Refer to «CHECKING THE HORN» on page 8-106.

OK

↓

NG

→

NG

→

NG

→

NG

→

NG

→

Replace the fuse(s).

• Clean the battery terminals.

• Recharge or replace the battery.

Replace the immobilizer kit.

Properly connect or repair the signaling system’s wiring.

Replace the left handlebar switch.

Replace the horn.

8-23

SIGNALING SYSTEM

3 Check the entire signaling system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-21.

OK

↓

This circuit is OK.

The tail/brake light fails to come on.

1 Check the tail/brake light bulb and socket.

Refer to «CHECKING THE BULBS

AND BULB SOCKETS» on page 8-

96.

OK

↓

2 Check the front brake light switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

3 Check the rear brake light switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

4 Check the entire signaling system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-21.

OK

↓

NG

NG

NG

NG

NG

→

→

→

→

→

Properly connect or repair the signaling system wiring.

Replace the tail/brake light bulb, socket or both.

Replace the front brake light switch.

Replace the rear brake light switch.

Properly connect or repair the signaling system’s wiring.

This circuit is OK.

The turn signal light, turn signal indicator light or both fail to blink.

1 Check the turn signal bulb.

Refer to «CHECKING THE BULBS

AND BULB SOCKETS» on page 8-

96.

OK

↓

NG

→

Replace the turn signal bulb.

NG

→

2 Check the turn signal switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

Replace the left handlebar switch.

8-24

SIGNALING SYSTEM

3 Check the hazard switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

4 Check the turn signal/hazard relay.

Refer to «CHECKING THE

RELAYS» on page 8-100.

OK

↓

5 Check the entire signaling system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-21.

OK

↓

This circuit is OK.

The neutral indicator light fails to come on.

1 Check the neutral switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

2 Check the entire signaling system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-21.

OK

↓

This circuit is OK.

The oil level warning light fails to come on.

1 Check the oil level switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

2 Check the entire signaling system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-21.

OK

↓

This circuit is OK.

The fuel level warning light fails to come on.

NG

→

NG

→

NG

→

NG

→

NG

→

NG

→

NG

→

Replace the left handlebar switch.

Replace the turn signal/hazard relay.

Properly connect or repair the signaling system’s wiring.

Replace the neutral switch.

Properly connect or repair the signaling system’s wiring.

Replace the oil level switch.

Properly connect or repair the signaling system’s wiring.

8-25

SIGNALING SYSTEM

1 Check the fuel sender.

Refer to «CHECKING THE FUEL

SENDER» on page 8-107.

OK

↓

2 Check the entire signaling system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-21.

OK

↓

This circuit is OK.

The speedometer fails to operate.

1 Check the speed sensor.

Refer to «CHECKING THE SPEED

SENSOR» on page 8-107.

OK

↓

2 Check the entire signaling system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-21.

OK

↓

Replace the meter assembly.

NG

→

NG

→

NG

→

NG

→

Replace the fuel pump assembly.

Properly connect or repair the signaling system’s wiring.

Replace the speed sensor.

Properly connect or repair the signaling system’s wiring.

8-26

EAS27300

COOLING SYSTEM

EAS27310

CIRCUIT DIAGRAM

COOLING SYSTEM

8-27

1. Main switch

6. Fuse (main)

7. Battery

23.ECU

38.Coolant temperature sensor

78.Fuse (ignition)

82.Radiator fan motor relay

83.Fuse (radiator fan motor left)

84.Fuse (radiator fan motor right)

85.Radiator fan motor (left)

86.Radiator fan motor (right)

COOLING SYSTEM

8-28

COOLING SYSTEM

EAS27320

TROUBLESHOOTING

NOTE:

• Before troubleshooting, remove the following part(s):

1 Rider and passenger seat

2 Fuel tank

3 Air filter case

NG

→

1 Check the fuses.

(Main, ignition and radiator fan motor)

Refer to «CHECKING THE FUSES» on page 8-97.

OK

↓

2 Check the battery.

Refer to «CHECKING AND

CHARGING THE BATTERY» on page 8-97.

OK

↓

3 Check the main switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

4 Check the radiator fan motor (left and right).

Refer to «CHECKING THE RADIA-

TOR FAN MOTOR» on page 8-108.

OK

↓

5 Check the radiator fan motor relay.

Refer to «CHECKING THE

RELAYS» on page 8-100.

OK

↓

6 Check the coolant temperature.

Refer to «CHECKING THE COOL-

ANT TEMPERATURE SENSOR» on page 8-108.

OK

↓

7 Check the entire cooling system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-27.

OK

↓

This circuit is OK.

NG

NG

NG

NG

NG

NG

→

→

→

→

→

→

8-29

Replace the fuse(s).

• Clean the battery terminals.

• Recharge or replace the battery.

Replace the immobilizer kit.

The radiator fan motor is faulty and must be replaced.

Replace the radiator fan motor relay.

Replace the coolant temperature sensor.

Properly connect or repair the cooling system’s wiring.

8-30

COOLING SYSTEM

EAS27330

FUEL INJECTION SYSTEM

EAS27340

CIRCUIT DIAGRAM

FUEL INJECTION SYSTEM

8-31

1. Main switch

4. Fuse (backup)

6. Fuse (main)

7. Battery

8. Fuse (fuel injection)

11.Relay unit

12.Starting circuit cut-off relay

13.Fuel pump relay

14.Neutral switch

15.Sidestand switch

16.Fuel pump

17.Crankshaft position sensor

18.Cylinder identification sensor

19.Speed sensor

20.Atmospheric pressure sensor

21.Lean angle sensor

22.O

2

sensor

23.ECU

24.Ignition coil #1

25.Ignition coil #2

26.Ignition coil #3

27.Ignition coil #4

28.Spark plug

29.Injector #1

30.Injector #2

31.Injector #3

32.Injector #4

34.Sub-throttle position sensor

35.EXUP servo motor

36.Intake air pressure sensor

37.Throttle position sensor

38.Coolant temperature sensor

39.Air temperature sensor

46.Multi function meter

56.Engine stop switch

78.Fuse (ignition)

FUEL INJECTION SYSTEM

8-32

FUEL INJECTION SYSTEM

EAS27370

TROUBLESHOOTING

The ignition system fails to operate (no spark or intermittent spark).

NOTE:

• Before troubleshooting, remove the following part(s):

1 Rider and passenger seat

2 Fuel tank

3 Air filter case

NG

→

1 Check the fuses.

(Main, backup, fuel injection and ignition)

Refer to «CHECKING THE FUSES» on page 8-97.

OK

↓

2 Check the battery.

Refer to «CHECKING AND

CHARGING THE BATTERY» on page 8-97.

OK

↓

3 Check the spark plugs.

Refer to «CHECKING THE SPARK

PLUGS» on page 3-10.

OK

↓

4 Check the ignition coils.

Refer to «CHECKING THE IGNI-

TION COILS» on page 8-103.

OK

↓

5 Check the crankshaft position sensor.

Refer to «CHECKING THE

CRANKSHAFT POSITION SEN-

SOR» on page 8-104.

OK

↓

6 Check the relay unit (fuel pump relay).

Refer to «CHECKING THE

RELAYS» on page 8-100.

OK

↓

7 Check the fuel pump.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

NG

→

NG

→

NG

→

NG

→

NG

→

NG

→

Replace the fuse(s).

• Clean the battery terminals.

• Recharge or replace the battery.

Re-gap or replace the spark plugs.

Replace the ignition coils.

Replace the crankshaft position sensor.

Replace the relay unit.

Replace the fuel pump.

8-33

FUEL INJECTION SYSTEM

8 Check the main switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

9 Check the engine stop switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

10 Check the neutral switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

11 Check the sidestand switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

12 Check the clutch switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

13 Check the relay unit (starting circuit cut-off relay).

Refer to «CHECKING THE

RELAYS» on page 8-100.

OK

↓

14 Check the lean angle sensor.

Refer to «CHECKING THE LEAN

ANGLE SENSOR» on page 8-105.

OK

↓

15 Check the cylinder identificatin sensor.

Refer to «CHECKING THE CYLIN-

DER IDENTIFICATION SENSOR» on page 8-111.

OK

↓

16 Check the speed sensor.

Refer to «CHECKING THE SPEED

SENSOR» on page 8-107.

OK

↓

NG

→

NG

→

NG

→

NG

→

NG

→

NG

→

NG

→

NG

→

NG

→

Replace the immobilizer kit.

Replace the right handlebar switch.

Replace the neutral switch.

Replace the sidestand switch.

Replace the clutch switch.

Replace the relay unit.

Replace the lean angle sensor.

Reeplace the cylinder identification sensor.

Replace the spped sensor.

8-34

FUEL INJECTION SYSTEM

17 Checking the aomospheric pressure sensor.

Refer to «CHECKING THE ATMO-

SPHERIC PRESSURE SENSOR» on page 8-111.

OK

↓

18 Check the injector.

Refer to «CHECKING THE INJEC-

TORS» on page 7-8.

OK

↓

19 Check the throttle position sensor.

Refer to «CHECKING THE THROT-

TLE POSITION SENSOR» on page

8-109.

OK

↓

20 Check the sub-throttle position sensor.

Refer to «CHECKING THE SUB-

THROTTLE POSITION SENSOR» on page 8-110.

OK

↓

21 Check the intake air pressure sensor.

Refer to «CHECKING THE INTAKE

AIR PRESSURE SENSOR» on page 8-112.

OK

↓

22 Check the coolant temperature sensor.

Refer to «CHECKING THE COOL-

ANT TEMPERATURE SENSOR» on page 8-108.

OK

↓

23 Check the inatke air temperature sensor.

Refer to «CHECKING THE INTAKE

AIR TEMPERATURE SENSOR» on page 8-112.

OK

↓

NG

→

NG

→

NG

→

NG

→

NG

→

NG

→

NG

→

Replace the atomospheric pressure sensor.

Replace the injector.

Replace the throttle position sensor.

Replace the sub-throttle position sensor.

Replace the intake air pressure sensor

Replace the coolant temperature sensor.

Replace the intake air temperature sensor.

8-35

24 Check the entire ignition system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-1.

OK

↓

Replace the ECU.

FUEL INJECTION SYSTEM

NG

→

Properly connect or repair the ignition system’s wiring

8-36

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 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 FI system operation

Warning light indication

Flashing*

Remains on

ECU operation FI operation

Warning provided when unable to start engine

Operation stopped

Malfunction detected Operated with substitute characteristics in accordance with the description of the malfunction

Vehicle operation

Cannot be operated

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:

11: Cylinder identification sensor 30: Lean angle sensor

(latch up detected)

12: Crankshaft position sensor 41:

19: Sidestand switch

(open circuit in the wire to the ECU)

50:

Lean angle sensor

(open or short-circuit)

ECU internal malfunction

(faulty ECU memory)

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.

8-37

FUEL INJECTION SYSTEM

a. Main switch “OFF” b. Main switch “ON” c. Engine trouble warning light off d. Engine trouble warning light on for 1.4 seconds

ET2D1027

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.

11

12

13

14

15

16

17

18

19

20

Item Symptom

Able/ unable to start

Able/ unable to drive

Cylinder identification sensor

Crankshaft position sensor

Intake air pressure sensor

(open or short circuit)

Intake air pressure sensor hose line

(piping system)

Throttle position sensor

(open or short circuit)

Throttle position sensor

(stuck)

EXUP servo motor potention circuit

(open or short circuit)

EXUP servo motor

(stuck)

Sidestand switch

(open circuit in the wire to the ECU)

Intake air pressure sensor or atmospheric pressure sensor

No normal signals are received from the cylinder identification sensor when the engine is started or while the vehicle is being driven.

No normal signals are received from the crankshaft position sensor.

Intake air pressure sensor: open or short circuit detected.

Intake air pressure sensor: faulty intake air pressure sensor system.

Throttle position sensor: open or short circuit detected.

Throttle position sensor is stuck.

EXUP servo motor potension circuit: open or short circuit detected.

EXUP servo motor is stuck.

Open circuit in the input line of ECU No.24 terminal is detected when start switch is pressed from the sidestand switch to the

ECU.

When the main switch is turned to “ON”, the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ greatly.

Unable

Unable Unable

Able

Able

Able

Able

Able

Able

Unable Unable

Able

Able

Able

Able

Able

Able

Able

Able

Able

8-38

FUEL INJECTION SYSTEM

Fault code No.

21

22

23

24

30

33

34

35

36

Item Symptom

Able/ unable to start

Able/ unable to drive

Coolant temperature sensor

(open or short circuit)

Intake air temperature sensor

(open or short circuit)

Atmospheric pressure sensor

(open or short circuit)

O

2

sensor

Lean angle sensor

(latch up detected)

Cylinder-#1 ignition coil

(open circuit)

Coolant temperature sensor: open or short circuit detected.

Intake air temperature sensor: open or short circuit detected.

Atmospheric pressure sensor: open or short circuit detected.

No normal signal is received from the O

2 sensor.

No normal signal is received from the lean angle sensor.

Primary lead of the cylinder-#1 ignition coil: open circuit detected.

Cylinder-#2 ignition coil

(open circuit)

Cylinder-#3 ignition coil

(open circuit)

Cylinder-#4 ignition coil

(open circuit)

Primary lead of the cylinder-#2 ignition coil: open circuit detected.

Primary lead of the cylinder-#3 ignition coil: open circuit detected.

Primary lead of the cylinder-#4 ignition coil: open circuit detected.

Able

Able

Able

Able

Unable

Able

Able

Able

Able

Unable

Able

(depending on the number of faulty cylinders)

Able

(depending on the number of faulty cylinders)

Able

(depending on the number of faulty cylinders)

Able

(depending on the number of faulty cylinders)

Able

(depending on the number of faulty cylinders)

Able

(depending on the number of faulty cylinders)

Able

(depending on the number of faulty cylinders)

Able

(depending on the number of faulty cylinders)

8-39

FUEL INJECTION SYSTEM

Fault code No.

39

41

42

43

44

46

47

Injector

Item

(open circuit)

Injector:

Symptom

open circuit detected.

Able/ unable to start

Able

(depending on the number of faulty cylinders)

Able/ unable to drive

Able

(depending on the number of faulty cylinders)

Lean angle sensor

(open or short-circuit)

Speed sensor

Neutral switch

Fuel system voltage

(monitoring voltage)

Error in writing the amount of CO adjustment on EEPROM

Vehicle system power supply

(monitoring voltage)

Sub-throttle servo motor potention (open or short circuit)

Lean angle sensor: open or short circuit detected.

No normal signals are received from the speed sensor.

Neutral switch: open or short circuit detected.

Power supply to the injectors and the fuel pump is not normal.

An error is detected while reading or writing on EEPROM (CO adjustment value).

Power supply to the fuel injection system is not normal.

sub-throttle servo motor potention:open or short circuit detected.

Unable Unable

Able

Able

Able

Able

Able

Able

Able

Able

Able

Able

48

50

–

Sub-throttle servo motor (lock)

ECU internal malfunction

(memory check error)

A lock of the sub-throttle servo motor is detected.

ECU memory is faulty. (When this malfunction is detected in the ECU, the fault code number might not appear on the meter.)

Start unable warning Relay is not turned ON even if the crank signal is input while the start switch is turned ON.

When the start switch is turned ON while an error is detected with the fault code of

No.11, 12, 19, 30, 41 or 50.

Communication error with the meter

Fault code No.

Item Symptom

Able

Unable Unable

Unable Unable

Able/ unable to start

Able

Able/ unable to drive

Er-1

ECU internal malfunction

(output signal error)

No signals are received from the ECU.

Unable Unable

8-40

FUEL INJECTION SYSTEM

Fault code No.

Item Symptom

Able/ unable to start

Able/ unable to drive

Er-2

Er-3

Er-4

ECU internal malfunction

(output signal error)

ECU internal malfunction

(output signal error)

ECU internal malfunction

(input signal error)

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.

EAS27400

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 malfunction.

Refer to “Diagnostic code table”.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Checking and repair the probable cause of malfunction.

Fault code No.

Check and repair.

Refer to «TROUBLE-

SHOOTING

DETAILS» on page 8-

50.

Monitor the operation of the sensors and actuators in the diagnostic mode. Refer to

“Sensor operation table” and “Actuator operation table”.

Fault code No.

Check and repair.

Refer to Self-Diagnostic Function table.

3. Perform ECU reinstatement action.

Refer to “Reinstatement method” of table in

“TROUBLESHOOTING DETAILS”.

4. Turn the main switch to “OFF” and back to

“ON”, then check that no fault code number is displayed.

NOTE:

If fault codes are displayed, repeat steps (1) to

(4) until no fault code number is displayed.

5. Erase the malfunction history in the diagnostic mode. Refer to “Sensor operation table (Diagnostic code No.62)”.

NOTE:

Turning the main switch to “OFF” will not erase the malfunction history.

Unable

Unable

Unable

Unable

Unable

Unable

The engine operation is not normal but the engine trouble warning light does not come on.

1. Check the operation of following sensors and actuators in the Diagnostic mode.

Refer to “Sensor operation table” and

“Actuator operation table”.

01: Throttle position sensor (throttle angle)

02: Atmospheric pressure sensor

05: Intake air pressure sensor

06: Coolant temperature sensor

07: Vehicle speed pulse

09: Fuel system voltage (battery bolt)

21: Neutral switch

30: Ignition coil #1

31: Ignition coil #2

32: Ignition coil #3

33: Ignition coil #4

36: Injector #1

37: Injector #2

38: Injector #3

39: Injector #4

48: AI system solenoid

53: EXUP servo motor

56: Sub-throttle servo motor

8-41

FUEL INJECTION SYSTEM

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 inner parts of the engine.

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 “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.

NOTE:

• All displays on the meter disappear except the odometer/tripmeter/fuel reserve tripmeter display.

• “dI” appears on the odometer/tripmeter/fuel reserve tripmeter LCD.

4. Press the “SELECT” button to select the diagnostic mode “dI”.

5. After selecting “dI”, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or more to activate the diagnostic mode. The diagnostic code number “d01” appears on the clock

LCD.

6. Set the engine stop switch to “ ”.

7. Select the diagnostic code number corresponding to the fault code number by pressing the

“SELECT” and “RESET” buttons.

NOTE:

• The diagnostic code number appears on the LCD meter (d01–70).

• To decrease the selected diagnostic code number, press the “RESET” button. Press the “RESET” button for 1 second or longer to automatically decrease the diagnostic code numbers.

• To increase the selected diagnostic code number, press the “SELECT” button. Press the

“SELECT” button for 1 second or longer to automatically increase the diagnostic code numbers.

8. Verify the operation of the sensor or actuator.

• Sensor operation

8-42

FUEL INJECTION SYSTEM

The data representing the operating conditions of the sensor appears on the odometer/tripmeter/fuel reserve tripmeter LCD.

• Actuator operation

Set the engine stop switch to “ ” to operate the actuator.

NOTE:

If the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ ” again.

9. Turn the main switch to “OFF” to cancel the diagnostic mode.

Fault code table

Fault code

No.

11

12

13

14

15

16

17

18

19

Symptom Probable cause of malfunction

• No normal signals are received from the cylinder identification sensor when the engine is started or while the vehicle is being driven.

No normal signals are received from the crankshaft position sensor.

Intake air pressure sensor: open or short circuit detected.

Intake air pressure sensor: faulty intake air pressure sensor system.

Throttle position sensor: open or short circuit detected.

• Open or short circuit in sub wire harness.

• Open or short circuit in wire harness.

• Defective cylinder identification sensor.

• Improperly installed sensor.

• Malfunction in ECU.

• Open or short circuit in wire harness.

• Defective crankshaft position sensor.

• Malfunction in pickup rotor.

• Improperly installed sensor.

• Malfunction in ECU.

• Open or short circuit in wire harness.

• Open or short circuit in sub wire harness.

• Defective intake air pressure sensor.

• Malfunction in ECU.

• Intake air pressure sensor hose is detached, clogged, kinked, or pinched.

• Malfunction in ECU.

• Open or short circuit in wire harness.

• Open or short circuit in sub wire harness.

• Defective throttle position sensor.

• Improperly installed throttle position sensor.

• Malfunction in ECU.

Throttle position sensor: stuck

• Stuck throttle position sensor.

• Malfunction in ECU.

EXUP servo motor potention circuit: open or short circuit detected.

• Open or short circuit in sub wire harness.

• Detective EXUP servo motor (potention circuit).

EXUP servo motor is stuck. • Open or short circuit in sub wire harness.

• Stuck EXUP servo motor (mechanism).

• Stuck EXUP servo motor (motor).

Open circuit is detected in the input line of ECU No.24 terminal is detected when the start switch is pressed.

• Open circuit in wire harness (ECU Coupler).

• Malfunction in ECU.

Diagnostic code No.

—

—

03

03

01

01

53

53

20

8-43

FUEL INJECTION SYSTEM

Fault code

No.

20

21

22

23

24

30

33

34

35

Symptom Probable cause of malfunction

When the main switch is turned to “ON”, the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ greatly.

Coolant temperature sensor: open or short circuit detected.

Intake air temperature sensor: open or short circuit detected.

Atmospheric pressure sensor: open or short circuit detected.

No normal signal is received from the O

2

sensor.

No normal signal is received from the lean angle sensor.

Open circuit detected in the primary lead of the cylinder-

#1 ignition coil.

Open circuit detected in the primary lead of the cylinder-

#2 ignition coil.

Open circuit detected in the primary lead of the cylinder-

#3 ignition coil.

• Atmospheric pressure sensor hose is clogged.

• Intake air pressure sensor hose is clogged, kinked, or pinched.

• Malfunction of the atmospheric pressure sensor in the intermediate electrical potential.

• Malfunction of the intake air pressure sensor in the intermediate electrical potential.

• Malfunction in ECU.

• Open or short circuit in wire harness.

• Defective coolant temperature sensor.

• Improperly installed coolant temperature sensor.

• Malfunction in ECU.

• Open or short circuit in wire harness.

• Defective intake air temperature sensor.

• Improperly installed intake air temperature sensor.

• Malfunction in ECU.

• Open or short circuit in sub wire harness.

• Defective atmospheric pressure sensor.

• Improperly installed atmospheric pressure sensor.

• Malfunction in ECU.

• Open or short circuit in wire harness.

• Defective O

2

sensor.

• Improperly installed O

2

sensor.

• Malfunction in ECU.

• Vehicle has overturned.

• Defective lean angle sensor.

• Improperly installed lean angle sensor.

• Malfunction in ECU.

• Open circuit in wire harness.

• Malfunction in ignition coil.

• Malfunction in a component of ignition cutoff circuit system.

• Malfunction in ECU.

• Open circuit in wire harness.

• Malfunction in ignition coil.

• Malfunction in a component of ignition cutoff circuit system.

• Malfunction in ECU.

• Open or short circuit in wire harness.

• Malfunction in ignition coil.

• Malfunction in a component of ignition cutoff circuit system.

• Malfunction in ECU.

Diagnostic code No.

02

03

06

05

02

—

08

30

31

32

8-44

FUEL INJECTION SYSTEM

Fault code

No.

36

39

41

42

43

44

46

47

48

50

Er-1

Symptom Probable cause of malfunction

Open circuit detected in the primary lead of the cylinder-

#4 ignition coil.

Open circuit detected in a injector.

Lean angle sensor: open or short circuit detected.

• Open or short circuit in wire harness.

• Malfunction in ignition coil.

• Malfunction in a component of ignition cutoff circuit system.

• Malfunction in ECU.

• Open or short circuit sub-wire- harness.

• Open or short circuit in wire harness.

• Improperly installed injector.

• Defective injector.

• Open or short circuit in wire harness.

• Defective lean angle sensor.

• Malfunction in ECU.

No normal signals are recieved from the speed sensor.

Neutral switch: open or short circuit detected.

• Open or short circuit in wire harness.

• Malfunction in speed sensor.

• Malfunction in ECU.

• Open or short circuit in wire haraness.

• Malfunction in neutral switch.

• Malfunction in ECU.

• Open circuit in wire harness.

• Malfunction in ECU.

Power supply to the injectors and the fuel pump is not normal.

An error is detected while reading or writing on

EEPROM (CO adjustment value).

Power supply to the fuel injection system relay is not normal.

• Malfunction in ECU. (The CO adjustment value is not properly written on or read from the internal memory).

Sub-throttle servo motor potention circuit: open or short circuit detected.

Sub-throttle servo motor is stuck.

• Malfunction in the charging system.

Refer to «CHARGING SYSTEM» on page 8-

11.

• Open or short circuit in wire harness.

• Detective Sub-throttle servo motor (potention circuit).

Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number might not appear on the meter.)

No signals are received from the ECU.

• Open or short circuit in wire harness.

• Stuck Sub-throttle servo motor (mechanism).

• Stuck Sub-throttle servo motor (motor).

• Malfunction in ECU. (The program and data are not properly written on or read from the internal memory.)

• Open or short circuit in wire harness.

• Malfunction in meter.

• Defective wire connection of the ECU coupler.

• Malfunction in ECU.

Diagnostic code No.

33

36

37

38

39

08

07

21

09

60

—

56

56

—

—

8-45

FUEL INJECTION SYSTEM

Fault code

No.

Er-2

Er-3

Er-4

Symptom Probable cause of malfunction

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.

• 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.

Diagnostic code No.

—

—

—

Sensor operation table

Diagnostic code

No.

Item

01

02

03

05

06

07

08

Meter display Checking method

Throttle position sensor signal

• Fully closed position 15–18

• Fully opened position

Atmospheric pressure

Intake air pressure

Intake air temperature

Coolant temperature

Vehicle speed pulse

Lean angle sensor

• Upright

• Overturned

95–100

Displays the atmospheric pressure.

Displays the cylinder-#1 intake air pressure.

Displays the intake air temperature.

Displays the coolant temperature.

0–999

0.4–1.4

3.7–4.4

Check with throttle valve fully closed.

Check with throttle valve fully opened.

Compare the actually measured atmospheric pressure with the meter display value.

Set the engine stop switch to “ ” then operate the throttle while pushing the start switch “ ”. (If the display value changes, the performance is OK.)

Compare the actually measured air temperature with the meter display value.

Compare the actually measured coolant temperature with the meter diaplay value.

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.

8-46

FUEL INJECTION SYSTEM

Diagnostic code

No.

09

20

21

60

61

Item

Fuel system voltage

(battery voltage)

Malfunction history code

• No history

• History exists

Meter display

Approximately 12.0

Sidestand switch

• Stand retracted

• Stand extended

Neutral switch

• Neutral

• In gear

EEPROM fault cylinder No

• No fault

• Fault detected

ON

OFF

ON

OFF

00

01–04 (fault cylinder No.)

• (If more than one cylinder is defective, the display changes every two seconds to show all the detected cylinder numbers. When all cylinder numbers are shown, the display repeats.)

00

Fault codes 11–50

• (If more than one code number is detected, the display changes every two seconds to show all the detected code numbers.

When all code numbers are shown, the display repeats.)

Checking method

Set the engine stop switch to “ ” and then compare with the actually measured battery voltage. (If the battery voltage is lower, recharge the battery.)

Set ON/OFF the sidestand switch (with the transmission in gear).

Set ON/OFF the neutral switch (shift the transmission).

—

—

Malfunction history code erasure

• No history

• History exists

62

00

Fault codes 01-28

• (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.)

—

To erase the history, set the engine stop switch to “ “ .

8-47

FUEL INJECTION SYSTEM

Diagnostic code

No.

63

70

Item Meter display Checking method

Malfunction code reinstate

• No mulfunction code 00

• Malfunction code exists Fault code 24

• (If more than one code number is detected, the display changes every two seconds to show all the detected code numbers.

When all code numbers are shown, the display repeats.)

Control number 0–255

—

To reinstate, set the engine stop switch to “ “ .

—

Actuator operation table

Diagnostic code

No.

Item

Cylinder-#1 ignition coil

Actuation Checking method

30

31

32

33

36

37

Cylinder-#2 ignition coil

Cylinder-#3 ignition coil

Cylinder-#4 ignition coil

Injector #1

Injector #2

Actuates the cylinder-#1 ignition coil five times at one second intervals.

Illuminates the engine trouble warning light.

Actuates the cylinder-#2 ignition coil five times at one-second intervals.

Illuminates the engine trouble warning light.

Actuates the cylinder-#3 ignition coil five times at one-second intervals.

Illuminates the engine trouble warning light.

Actuates the cylinder-#4 ignition coil five times at one-second intervals.

Illuminates the engine trouble warning light.

Actuates the injector #1 five times at one-second intervals.

Illuminates the engine trouble warning light.

Actuates the injector #2 five times at one-second intervals.

Illuminates the engine trouble warning light.

Check the spark five times.

• Connect an ignition checker.

Check the spark five times.

• Connect an ignition checker.

Check the spark five times.

• Connect an ignition checker.

Check the spark five times.

• Connect an ignition checker.

Check the operating sound of the injector #1 five times.

Check the operating sound of the injector #2 five times.

8-48

FUEL INJECTION SYSTEM

Diagnostic code

No.

38

39

48

50

51

52

53

Item Actuation Checking method

Injector #3

Injector #4

Air induction system solenoid

Actuates the injector #3 five times at one-second intervals.

Illuminates the engine trouble warning light.

Actuates the injector #4 five times at one-second intervals.

Illuminates the engine trouble warning light.

Actuates the Air induction system solenoid five times at one-second intervals.

Illuminates the engine trouble warning light.

Fuel injection system relay Actuates the fuel injection system relay five times at one-second intervals.

Illuminates the engine trouble warning light.

(The engine trouble warning light is OFF when the relay is

ON, and the engine trouble warning light is ON when the relay is OFF).

Radiator fan motor relay Actuates the radiator fan motor relay five times at onesecond intervals. (ON 2 seconds, OFF 3 seconds)

Illuminates the engine trouble warning light.

Headlight relay

Exup servo motor

Actuates the headlight relay for five times every five-second. (ON 2 seconds, OFF 3 seconds)

Illuminates the engine trouble warning light.

Actuate the servo motor turns to close side and to open side.

Illuminates the engine trouble warning light only while the motor is runnning.

Check the operating sound of the injector #3 five times.

Check the operating sound of the injector #4 five times.

Check the operating sound of the Air induction system solenoid five times.

Check the operating sound of the fuel injection system relay five times.

Check the operating sound of the Radiator fan motor relay five times.

Check the operating sound of the headlight relay five times.

Check the operating sound of the EXUP servo motor.

8-49

FUEL INJECTION SYSTEM

Diagnostic code

No.

Item

Sub-throttle servo motor

Actuation Checking method

56

Actuate the servo motor turns to close side and to open side.

Illuminates the engine trouble warning light only while the motor is runnning.

Check the operating sound of the Sub-throttle servo motor.

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 8-42.

Fault code No.

11 Symptom

No normal signals are received from the cylinder identification sensor when the engine is started or while the vehicle is being driven.

Diagnostic code No.

Orde r

—

Item/components and probable cause

1

2

Installed condition of cylinder identification sensor.

Connections

• Cylinder identification sensor coupler

• Main wire harness ECU coupler

• Sub-wire harness coupler

—

Check or maintenance job

Reinstatement method

Check for looseness or pinching.

Starting the

• Check the coupler for any pins that may be pulled out.

• Check the locking condition of engine and operate it at idle.

the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

3

4

Open or short circuit in wire harness.

• Repair or replace if there is an open or short circuit.

• Between the cylinder identification sensor coupler and ECU coupler

(Blue–Blue)

(White/Black–White/Black)

(Black/Blue–Black/Blue)

Defective cylinder identification sensor.

• Replace if defective.

Refer to «CHECKING THE

CYLINDER IDENTIFICATION

SENSOR» on page 8-111.

8-50

FUEL INJECTION SYSTEM

Fault code No.

12 Symptom

No normal signals are received from the crankshaft position sensor.

— Diagnostic code No.

Orde r

1 Installed condition of crankshaft position sensor

—

Item/components and probable cause

Check or maintenance job

Check for looseness or pinching.

Reinstatement method

Cranking the engine.

2

3

4

Connections

• Crankshaft position sensor coupler

• Main wire harness ECU coupler

• Check the couplers for any pins that may have pulled out.

• Check the locking condition of the couplers.

• 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 the crankshaft position sensor coupler and ECU coupler.

(Gray–Gray)

(Black/Blue–Black/Blue)

Defective crankshaft position sensor.

• Replace if defective.

Refer to «CHECKING THE

CRANKSHAFT POSITION

SENSOR» on page 8-104.

8-51

FUEL INJECTION SYSTEM

Fault code No.

13 Symptom Intake air pressure sensor:open or short circuit detected.

Diagnostic code No.

Orde r

1

03

Item/components and probable cause

Connections

• Intake air pressure sensor coupler

• Main wire harness ECU coupler

• Sub-wire harness coupler

Intake air pressure sensor

Check or maintenance job

• Check the couplers for any pins that may have pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

Reinstatement method

Turn the main switch to ON.

2

3

Open or short circuit in wire harness and/or sub wire harness.

• Repair or replace if there is an open or short circuit.

• Between intake air pressure sensor coupler and ECU coupler

(Black/Blue–Black/Blue)

(Pink/White–Pink/White)

(Blue–Blue)

Defective intake air pressure sensor • Execute the diagnostic mode.

(Code No.03)

• Replace if defective.

Refer to «CHECKING THE

INTAKE AIR PRESSURE SEN-

SOR» on page 8-112.

Fault code No.

14 Symptom

Intake air pressure sensor: faulty intake air pressure sensor system.

Intake air pressure sensor Diagnostic code No.

Orde r

03

Item/components and probable cause

Check or maintenance job

Reinstatement method

1

2

3

Intake air pressure sensor hose • Check the intake air pressure sensor hose condition.

• Repair or replace the sensor hose.

Connections

• Intake air pressure sensor coupler

• Main wire harness ECU coupler

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

Defective intake air pressure sensor • Execute the diagnostic mode.

(Code No.03)

• Replace if defective.

Refer to «CHECKING THE

INTAKE AIR PRESSURE SEN-

SOR» on page 8-112.

Starting the engine and operate it at idle.

8-52

FUEL INJECTION SYSTEM

Fault code No.

15 Symptom Throttle position sensor:open or short circuit detected.

Diagnostic code No.

Order

1

2

Item/components and probable cause

Installed condition of throttle position sensor.

Connections

01

• Throttle position sensor coupler

• Main wire harness ECU coupler

• Sub-wire harness coupler

Throttle position sensor

Check or maintenance job

• Check for looseness or pinching.

• Check that is installed in the specified position.

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

Reinstatement method

Turning the main switch to

“ON”.

3

4

5

Open or short circuit in wire harness.

• Repair or replace if there is an open or short circuit.

• Between throttle position sensor coupler and ECU coupler

(Black/Blue–Black/Blue)

(Yellow–Yellow)

(Blue–Blue)

Throttle position sensor lead wire open circuit output voltage check.

• Check for open circuit and replace the throttle position sensor.

(Black/Blue–Yellow)

Output voltage Open circuit item

Ground wire open circuit

5 V

Defective throttle position sensor.

Output wire open circuit

Power supply wire open circuit

0 V

0 V

• Execute the diagnostic mode.

(Code No.01)

• Replace if defective.

Refer to «CHECKING THE

THROTTLE POSITION SEN-

SOR» on page 8-109.

8-53

FUEL INJECTION SYSTEM

Fault code No.

16 Symptom

Diagnostic code No.

Order

01

Item/components and probable cause

Installed condition of throttle position sensor.

1

2

Defective throttle position sensor.

Stuck throttle position sensor detected.

Throttle position sensor

Check or maintenance job

• Check the installed area for looseness or pinching.

• Check that is installed in the specified position.

Refer to «THROTTLE BODIES» on page 7-4 section.

• Execute the diagnostic mode.

(Code No.01)

• Replace if defective.

Refer to «THROTTLE BODIES» on page 7-4 section.

Reinstatement method

Reinstated by starting the engine, operating it at idle, and then racing it.

Fault code No.

17 Symptom EXUP servo motor circuit:open or short circuit detected.

Diagnostic code No.

Order

1

53

Item/components and probable cause

Connections

• EXUP servo motor coupler

• Main wire harness ECU coupler

EXUP servo motor

Check or maintenance job

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

Reinstatement method

Turning the main switch to

“ON”.

2

3

Open or short circuit in wire harness.

• Repair or replace if there is an open or short circuit.

• Between EXUP servo motor coupler and ECU coupler

(Blue–Blue)

(White/Red–White/Red)

(Black/Blue–Black/Blue)

Defective EXUP servo motor (potention circuit).

• Execute the diagnostic mode.

(Code No.53)

• Replace if defective.

Refer to «CHECKING THE

EXUP SERVO MOTOR» on page 3-18.

8-54

FUEL INJECTION SYSTEM

Fault code No.

2

3

4

18 Symptom

Diagnostic code No.

Order

53

Item/components and probable cause

Connections

• EXUP servo motor coupler

• Main wire harness ECU coupler

1

EXUP servo motor is stuck.

EXUP servo motor

Check or maintenance job

• Check the couplers 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.

Reinstatement method

Turning the main switch to

“ON”.

Open or short circuit in wire harness.

• Repair or replace if there is an open or short circuit.

• Between EXUP servo motor coupler and ECU coupler.

(Black/Green–Black/Green)

(Black/Red–Black/Red)

Defective EXUP servo motor • Execute the diagnostic mode.

(Code No.53)

• Replace if defective.

Refer to «CHECKING THE

EXUP SERVO MOTOR» on page 3-18.

Defective EXUP valve, pulley, and cables

Replace if defective.

Fault code No.

19 Symptom

Open circuit is detected in the input line of ECU No.24 terminal is difected when the start switch is pressed.

Sidestand switch Diagnostic code No.

Order

20

Item/components and probable cause

Check or maintenance job

Reinstatement method

1

2

3

Connections

• Main wire harness ECU coupler

Open or short circuit in wire harness or sub lead.

Defective sidestand switch

• 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 sidestand switch coupler and ECU coupler

(Black–Black)

• Replace if defective.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

If the transmission is in gear, retracting the sidestand.

If the transmission is in neutral, reconnecting the wiring.

8-55

FUEL INJECTION SYSTEM

Fault code No.

Diagnostic code No.

Orde r

02

03

Item/components and probable cause

1

20 Symptom

When the main switch is turned to “ON”, the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ greatly.

Defective intake air pressure sensor or atmospheric pressure sensor.

Atmospheric pressure sensor

Intake air pressure sensor

Check or maintenance job

• Execute the diagnostic mode.

(Code Nos. 02, 03)

• Replace if defective.

Refer to «CHECKING THE

INTAKE AIR PRESSURE SEN-

SOR» on page 8-112 or

«CHECKING THE ATMO-

SPHERIC PRESSURE SEN-

SOR» on page 8-111.

Reinstatement method

Turning the main switch to

“ON”.

Fault code No.

21 Symptom

Coolant temperature sensor:open or short circuit detected.

Diagnostic code No.

Order

06

Item/components and probable cause

1

Connections

• Coolant temperature sensor coupler

• Main wire harness ECU coupler

• Sub-wire harness coupler

Coolant temperature sensor

Check or maintenance job

• Check the coupler for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

Reinstatement method

Turning the main switch to

“ON”.

2

3

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.

(Green/White–Green/White)

(Black/Blue–Black/Blue)

Defective coolant temperature sensor. • Execute the diagnostic mode.

(Code No.06)

• Replace if defective.

Refer to «CHECKING THE

COOLANT TEMPERATURE

SENSOR» on page 8-108.

8-56

FUEL INJECTION SYSTEM

Fault code No.

22 Symptom

Intake air temperature sensor:open or short circuit detected.

Intake air temperature sensor Diagnostic code No.

Order

05

Item/components and probable cause

Check or maintenance job

Reinstatement method

1

2

3

Connections

• Intake air temperature sensor coupler

• Main wire harness ECU coupler

• Sub-wire harness coupler

Open or short circuit in wire harness.

• Repair or replace if there is an open or short circuit.

• Between intake air temperature sensor coupler and ECU coupler.

(Brown/White–Brown/White)

(Black/Blue–Black/Blue)

Defective intake air temperature sensor.

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

• Execute the diagnostic mode.

(Code No.05)

• Replace if defective.

Refer to «CHECKING THE

INTAKE AIR TEMPERATURE

SENSOR» on page 8-112.

Turning the main switch to

“ON”.

8-57

FUEL INJECTION SYSTEM

Fault code No.

23 Symptom

Atmospheric pressure sensor:open or short circuit detected.

Atmospheric pressure sensor Diagnostic code No.

Order

02

Item/components and probable cause

Check or maintenance job

Reinstatement method

1

2

3

Connections

• Atmospheric pressure sensor coupler

• Main wire harness ECU coupler

Open or short circuit in wire harness and/or sub wire harness 2.

Defective atmospheric pressure sensor.

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

• Repair or replace if there is an open or short circuit.

• Between atmospheric pressure sensor coupler and ECU coupler.

(Black/Blue–Black/Blue)

(Pink–Pink)

(Blue–Blue)

• Execute the diagnostic mode.

(Code No.02)

• Replace if defective.

Refer to «CHECKING THE

ATMOSPHERIC PRESSURE

SENSOR» on page 8-111.

Turning the main switch to

“ON”.

8-58

FUEL INJECTION SYSTEM

Fault code No.

24 Symptom

No normal signal is received from the O

2

sensor.

Diagnostic code No.

Order

—

Item/components and probable cause

—

Check or maintenance job

Reinstatement method

1

2

3

Installed state of O

Connections

• O

2

2

sensor coupler

sensor.

• Main wire harness ECU coupler

Open or short circuit in wire harness.

Check for looseness or pinching.

Start and warm

• Check the couplers for any pins up the engine until the coolthat may be pulled out.

• Check the locking condition of the couplers

• If there is a malfunction, repair it and connect the coupler ant temperature rises over

60

°

C.

when acceleratsecurely.

• Repair or replace if there is an open or short circuit.

• Between O

2

sensor coupler and

ECU coupler.

(Gray/Green–Gray/Green) ing the throttle, the waring light is turned off, or it is reset by the

No.63).

(Black/Blue–Black/Blue) diagnostic mode (Code

(Pink/Black–Pink/Black)

(Red/White–Red/White)

4

Check fuel pressure.

• Refer to «THROTTLE BODIES» on page 7-4.

5

Defective O

2

sensor.

• Replace if defective.

Fault code No.

30 Symptom No normal signal is received from the lean angle sensor.

Diagnostic code No.

08 Lean angle sensor

Order

2

3

Item/components and probable cause

1 The vehicle has overturned.

Installed state of the lean angle sensor

Connections

• Lean angle sensor coupler

• Main wire harness ECU coupler

Check or maintenance job

Raise the vehicle upright.

Check the installed direction and condition of the sensor.

• 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.

Reinstatement method

Turning the main switch to

”ON” (however, the engine cannot be restarted unless the main switch is first turned to

“OFF”).

4

Defective lean angle sensor • Execute the diagnostic mode.

(Code No.08)

• Replace if defective.

Refer to «CHECKING THE

LEAN ANGLE SENSOR» on page 8-105.

8-59

FUEL INJECTION SYSTEM

Fault code No.

33 Symptom

Open circuit detected in the primary lead of the cylinder-

#1 ignition coil.

Cylinder-#1 ignition coil Diagnostic code No.

Order

30

Item/components and probable cause

Check or maintenance job

Reinstatement method

1

2

3

Connections

• Cylinder-#1 ignition coil coupler

• Main wire harness ECU coupler

• Sub-wire harness 1 coupler

Open or short circuit in wire harness and/or sub-wire harness 1.

Defective cylinder-#1 ignition coil

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

• Repair or replace if there is an open or short circuit.

• Between cylinder-#1 ignition coil coupler and ECU coupler.

(Red/Black–Red/Black)

(Orange–Orange)

• Execute the diagnostic mode.

(Code No.30)

• Test the primary and secondary coils for continuity.

• Replace if defective.

Refer to «CHECKING THE

IGNITION COILS» on page 8-

103.

Starting the engine and operating it at idle.

8-60

FUEL INJECTION SYSTEM

Fault code No.

34 Symptom

Open circuit detected in the primary lead of the cylinder-

#2 ignition coil

Cylinder-#2 ignition coil Diagnostic code No.

Order

31

Item/components and probable cause

Check or maintenance job

Reinstatement method

1

2

3

Connections

• Cylinder-#2 ignition coil coupler

• Main wire harness ECU coupler

• Sub-wire harness 1 coupler

Open or short circuit in wire harness and/or sub-wire harness 1.

Defective cylinder-#2 ignition coil.

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

• Repair or replace if there is an open or short circuit.

• Between cylinder-#2 ignition coil coupler and ECU coupler.

(Red/Black–Red/Black)

(Gray/Red–Gray/Red)

• Execute the diagnostic mode.

(Code No.31)

• Test the primary and secondary coils for continuity.

• Replace if defective.

Refer to «CHECKING THE

IGNITION COILS» on page 8-

103.

Starting the engine and operating it at idle.

8-61

FUEL INJECTION SYSTEM

Fault code No.

35 Symptom

Open circuit detected in the primary lead of the cylinder-

#3 ignition coil

Cylinder-#3 ignition coil Diagnostic code No.

Order

32

Item/components and probable cause

Check or maintenance job

Reinstatement method

1

2

3

Connections

• Cylinder-#3 ignition coil coupler

• Main wire harness ECU coupler

• Sub-wire harness 1 coupler

Open or short circuit in wire harness and/or sub-wire harness 1.

Defective cylinder-#3 ignition coil.

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

• Repair or replace if there is an open or short circuit.

• Between cylinder-#3 ignition coil coupler and ECU coupler.

(Red/Black–Red/Black)

(Orange/Green–Orange/Green)

• Execute the diagnostic mode.

(Code No.32)

• Test the primary and secondary coils for continuity.

• Replace if defective.

Refer to «CHECKING THE

IGNITION COILS» on page 8-

103.

Starting the engine and operating it at idle.

8-62

FUEL INJECTION SYSTEM

Fault code No.

36 Symptom

Open circuit detected in the primary lead of the cylinder-

#4 ignition coil

Cylinder-#4 ignition coil Diagnostic code No.

Order

33

Item/components and probable cause

Check or maintenance job

Reinstatement method

1

2

3

Connections

• Cylinder-#4 ignition coil coupler

• Main wire harness ECU coupler

• Sub-wire harness 1 coupler

Open or short circuit in wire harness and/or sub-wire harness 1.

Defective cylinder-#4 ignition coil.

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

• Repair or replace if there is an open or short circuit.

• Between cylinder-#4 ignition coil coupler and ECU coupler.

(Red/Black–Red/Black)

(Gray/Green–Gray/Green)

• Execute the diagnostic mode.

(Code No.33)

• Test the primary and secondary coils for continuity.

• Replace if defective.

Refer to «CHECKING THE

IGNITION COILS» on page 8-

103.

Starting the engine and operating it at idle.

8-63

FUEL INJECTION SYSTEM

Fault code No.

39 Symptom

Diagnostic code No.

Order

1

2

3

Item/components and probable

Connections

36

37

38

39 cause

• Injector coupler

• Main wire harness ECU coupler

• Sub-wire harness coupler

Open or short circuit in wire harness and/or sub-wire harness.

Defective primary injector.

Open circuit detected in a injector.

Injector #1

Injector #2

Injector #3

Injector #4

Check or maintenance job

Reinstatement method

Start the engine and operating it at idle.

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the copler securely.

• Repair or replace if there is an open or short circuit.

• Between primary injector coupler and ECU coupler.

(Red/Blue-Red/Blue)

#1: (Red/Black–Red/Black)

#2: (Green/Black–Green/Black)

#3: (Blue/Black–Blue/Black)

#4: (Orange/Black–Orange/

Black)

• Execute the diagnostic mode.

(Code Nos.36, 37, 38, 39)

• Replace if defective.

Refer to «CHECKING THE

INJECTORS» on page 7-8.

8-64

FUEL INJECTION SYSTEM

Fault code No.

41 Symptom Lean angle sensor:open or short circuit detected.

Diagnostic code No.

Order

08

Item/components and probable cause

1

Connections

• Lean angle sensor coupler

• Main wire harness ECU coupler

Lean angle sensor

Check or maintenance job

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

Reinstatement method

Turning the main switch to

“ON”.

2

3

Open or short circuit in lead.

Defective lean angle sensor.

• Repair or replace if there is an open or short circuit.

• Between lean angle sensor coupler and ECU coupler.

(Blue–Blue)

(Yellow/Green–Yellow/Green)

(Black/Blue–Black/Blue)

• Execute the diagnostic mode.

(Code No.08)

• Replace if defective.

Refer to «CHECKING THE

LEAN ANGLE SENSOR» on page 8-105.

8-65

FUEL INJECTION SYSTEM

Fault code No.

A-1

A-2

A-3

A-4

Connections

42 Symptom

• Speed sensor coupler

Open or short circuit in lead.

Defective speed sensor

A. No normal signals are received from the speed sensor.

B. Open circuit is detected in the neutral switch.

Diagnostic code No.

Order

A 07

B 21

Item/components and probable cause

Installed state of speed sensor.

• Main wire harness ECU coupler

Speed sensor

Neutral switch

Check or maintenance job

• Check for looseness or pinching.

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• 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.

(Blue–Blue)

(White/Yellow–White/Yellow)

(Black/Blue–Black/Blue)

• Execute the diagnostic mode.

(Code No.07)

• Replace if defective.

Refer to «CHECKING THE

SPEED SENSOR» on page 8-

107.

Reinstatement method

Starting the engine, and activating the speed sensor by operating the vehicle at 20 to

30 km/h.

8-66

FUEL INJECTION SYSTEM

Fault code No.

B-5

Faulty shift drum (neutral detection area).

42 Symptom

Diagnostic code No.

Order

B-1

A 07

B 21

Item/components and probable cause

Installed state of neutral switch.

B-2

B-3

B-4

Connections

• Neutral switch coupler

Defective neutral switch.

A. No normal signals are received from the speed sensor.

B. Open circuit is detected in the neutral switch.

• Main wire harness ECU coupler

Open circuit in neutral switch lead.

Speed sensor

Neutral switch

Check or maintenance job

• Check for looseness or pinching.

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

• Repair or replace if there is an open or short circuit.

• Between neutral switch coupler and relay unit coupler

(Sky blue–Sky blue)

• Between relay unit coupler and

ECU coupler.

(Blue/Yellow–Blue/Yellow)

• Execute the diagnostic mode.

(Code No.21)

• Replace if defective.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

• Replace if defective.

Refer to «TRANSMISSION» on page 5-85.

Reinstatement method

Starting the engine, and activating the speed sensor by operating the vehicle at 20 to

30 km/h.

8-67

FUEL INJECTION SYSTEM

Fault code No.

43 Symptom

Power supply to the injectors and fuel pump is not normal.

Fuel system voltage (battery voltage) Diagnostic code No.

Order

09

Item/components and probable cause

Check or maintenance job

Reinstatement method

1

2

3

Connections

• Relay unit coupler (fuel pump relay)

• Main wire harness ECU coupler

Open or short circuit in wire harness.

• Repair or replace if there is an open or short circuit.

• Between relay unit coupler and

ECU coupler.

(Blue/Yellow–Blue/Yellow)

(Red/Blue–Red/Blue)

• Between relay unit coupler and battery terminal.

(Red–Red)

• Between relay unit coupler and engine stop switch coupler.

(Red/Black–Red/Black)

Malfunction or open circuit in fuel pump relay

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect it securely.

• Execute the diagnostic mode.

(Code No. 09)

• Replace if defective.

• If there is no malfunction with the fuel pump relay, replace the

ECU.

Starting the engine and operating it at idle.

8-68

FUEL INJECTION SYSTEM

Fault code No.

44 Symptom

An error is detected while reading or writing on EEPROM

(CO adjustment value).

EEPROM fault cylinder No.

Diagnostic code No.

Orde r

60

Item/components and probable cause

Check or maintenance job

Reinstatement method

1

Malfunction in ECU • Set the faulty cylinder’s exhaust gas volume.

1 Execute the diagnostic mode

(Code No. 60) to check the faulty cylinder number. (If multiple cylinders are defective, the numbers of the faulty cylinders are displayed alternately at 2-second intervals.)

2 Execute the CO adjustment mode and set the exhaust gas volume of the faulty cylinder to

“0”.

If “0” is displayed, set the numerical value other than

“0”. When the malfunction is recovered, reset “0”.

Refer to «ADJUSTING THE

EXHAUST GAS VOLUME» on page 3-8.

• Replace ECU if it does not recover from the malfunction.

Turning the main switch to

“ON”.

(Readjust the exhaust gas volume after it is reinstated.)

8-69

FUEL INJECTION SYSTEM

Fault code No.

46 Symptom

Power supply to the fuel injection system relay is not normal.

— Diagnostic code No.

Order

—

Item/components and probable cause

Check or maintenance job

Reinstatement method

1

2

3

4

Connections.

• Main wire harness ECU coupler

Faulty battery

Malfunction in rectifier/regulator

• 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.

• Replace or change the battery

Refer to «CHECKING AND

CHARGING THE BATTERY» on page 8-97.

• Replace if defective.

Refer to «CHARGING SYS-

TEM» on page 8-11.

Open or short circuit in wire harness.

• Repair or replace if there is an open or short circuit.

• Between battery and main switch

(Red–Red)

• Between main switch and ignition fuse

(Brown/Blue–Brown/Blue)

• Between ignition fuse and ECU

(Red/White–Red/White)

Starting the engine and operating it at idle.

8-70

FUEL INJECTION SYSTEM

Fault code No.

Diagnostic monitoring code No.

Order

56

Item/components and probable cause

1

47 Symptom

Sub-throttle position sensor:open or short circuit detected.

Installed state of sub-throttle position sensor.

ing.

Sub-throttle servo motor

Check or maintenance job

• Check for looseness or pinch-

• Check that the sensor is installed in the specified position.

Reinstatement method

Turning the main switch to

“ON”.

2

3

4

Connections

• Sub-throttle position sensor coupler

• Main wire harness ECU coupler

• Sub-wire harness coupler

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• 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 sub-throttle position sensor coupler and ECU coupler.

(Black/Blue–Black/Blue)

(Green/Yellow–Green/Yellow)

(Blue–Blue)

Defective sub-throttle position sensor. • Execute the diagnostic mode.

(Code No. 56)

• Replace if defective.

Refer to «CHECKING THE

SUB-THROTTLE POSITION

SENSOR» on page 8-110.

8-71

FUEL INJECTION SYSTEM

Fault code No.

2

3

48 Symptom

Diagnostic code No.

Order

56

Item/components and probable cause

Connections

• Sub-throttle servo motor coupler

• Main wire harness ECU coupler

1

Sub-throttle servo motor:stuck.

Sub-throttle servo motor

Check or maintenance job

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

Reinstatement method

Turning the main switch to

“ON”.

Open or short circuit in wire harness.

• Repair or replace if there is an open or short circuit.

• Between sub-throttle servo motor coupler and ECU coupler

(Yellow/Red–Yellow/Red)

(Yellow/White–Yellow/White)

Defective sub-throttle servo motor • Execute the diagnostic mode.

(Code No. 56)

• Replace if defective.

Refer to «CHECKING THE

SUB-THROTTLE SERVO

MOTOR» on page 7-10.

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.)

— Diagnostic code No.

Order

—

Item/components and probable cause

Malfunction in ECU.

Check or maintenance job

Replace the ECU.

Reinstatement method

Turning the main switch to

“ON”

1

NOTE:

Do not perform this procedure with the main switch turned to

“ON”.

8-72

FUEL INJECTION SYSTEM

Fault code No.

Er-1 Symptom

Diagnostic code No.

Order

—

Item/components and probable cause

1

Connections

• Main wire harness ECU coupler

• Main wire harness meter assembly coupler

• Sub-wire harness coupler

No signals are received from the ECU.

—

Check or maintenance job

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

Reinstatement method

Turning the main switch to

“ON”.

2

Open or short circuit in wire harness.

• Repair or replace if there is an open or short circuit.

• Between meter assembly coupler and ECU coupler.

(Yellow/Blue–Yellow/Blue)

3 Malfunction in meter assembly.

Replace the meter assembly.

4 Malfunction in ECU.

Replace the ECU.

Fault code No.

Er-2 Symptom

No signals are received from the ECU within the specified duration.

— Diagnostic code No.

Order

—

Item/components and probable cause

1

Connections

• Main wire harness ECU coupler

• Main wire harness meter assembly coupler

• Sub-wire harness coupler

Check or maintenance job

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

Reinstatement method

Turning the main switch to

“ON”.

2

Open or short circuit in wire harness.

• Repair or replace if there is an open or short circuit.

• Between meter assembly coupler and ECU coupler.

(Yellow/Blue–Yellow/Blue)

3 Malfunction in meter assembly.

Replace the meter assembly.

4 Malfunction in ECU.

Replace the ECU.

8-73

FUEL INJECTION SYSTEM

Fault code No.

Er-3 Symptom

Diagnostic code No.

Order

1

—

Data from the ECU cannot be received correctly.

—

Item/components and probable cause

Connections

• Main wire harness ECU coupler

• Main wire harness meter assembly coupler

• Sub-wire harness coupler

Check or maintenance job

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

Reinstatement method

Turning the main switch to

“ON”.

2

Open or short circuit in wire harness.

• Repair or replace if there is an open or short circuit.

• Between meter assembly coupler and ECU coupler.

(Yellow/Blue–Yellow/Blue)

3 Malfunction in meter assembly.

Replace the meter assembly.

4 Malfunction in ECU.

Replace the ECU.

Fault code No.

Er-4 Symptom Non-registered data has been received from the meter.

Diagnostic code No.

— —

Order

1

Item/components and probable cause

Connections

• Main wire harness ECU coupler

• Main wire harness meter assembly coupler

• Sub-wire harness coupler

Check or maintenance job

• Check the couplers for any pins that may be pulled out.

• Check the locking condition of the couplers.

• If there is a malfunction, repair it and connect the coupler securely.

2

Open or short circuit in wire harness.

• Repair or replace if there is an open or short circuit.

• Between meter assembly coupler and ECU coupler.

(Yellow/Blue–Yellow/Blue)

3 Malfunction in meter assembly.

Replace the meter assembly.

4 Malfunction in ECU.

Replace the ECU.

Reinstatement method

Turning the main switch to

“ON”.

8-74

EAS27550

FUEL PUMP SYSTEM

EAS27560

CIRCUIT DIAGRAM

FUEL PUMP SYSTEM

8-75

1. Main switch

6. Fuse (main)

7. Battery

8. Fuse (fuel injection)

13.Fuel pump relay

16.Fuel pump

23.ECU

46.Multi function meter

56.Engine stop switch

78.Fuse (ignition)

FUEL PUMP SYSTEM

8-76

FUEL PUMP SYSTEM

EAS27570

TROUBLESHOOTING

If the fuel pump fails to operate.

NOTE:

• Before troubleshooting, remove the following part(s):

1 Rider and passenger seat

2 Fuel tank

3 Air filter case

NG

→

1 Check the fuses.

(Main, ignition and fuel injection system)

Refer to «CHECKING THE FUSES» on page 8-97.

OK

↓

2 Check the battery.

Refer to «CHECKING AND

CHARGING THE BATTERY» on page 8-97.

OK

↓

3 Check the main switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

4 Check the engine stop switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

5 Check the relay unit (fuel pump relay).

Refer to «CHECKING THE

RELAYS» on page 8-100.

OK

↓

6 Check the fuel pump.

Refer to «CHECKING THE FUEL

PRESSURE» on page 7-8.

OK

↓

7 Check the entire fuel pump system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-75.

OK

↓

Replace the ECU.

NG

NG

NG

NG

NG

NG

→

→

→

→

→

→

8-77

Replace the fuse(s).

• Clean the battery terminals.

• Recharge or replace the battery.

Replace the immobilizer kit.

Replace the right handlebar switch.

Replace the relay unit.

Replace the fuel pump.

Properly connect or repair the fuel pump system’s wiring.

8-78

FUEL PUMP SYSTEM

EAS27640

IMMOBILIZER SYSTEM

EAS27650

CIRCUIT DIAGRAM

IMMOBILIZER SYSTEM

8-79

1. Main switch

4. Fuse (backup)

5. Immobilizer unit

6. Fuse (main)

7. Battery

23.ECU

41.Immobilizer indicator

46.Multi function meter

78.Fuse (ignition)

IMMOBILIZER SYSTEM

8-80

IMMOBILIZER SYSTEM

EAS27670

GENERAL INFORMATION

This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following.

• A code re-registering key (with a red bow)

• Two standard keys (with a black bow) that can be re-registered with new codes

• A transponder (which is installed in each key bow)

• An immobilizer unit

• The ECU

• An immobilizer system indicator light

The key with the red bow is used to register codes in each standard key. Do not use the key with the red bow for driving. It should only be used for re-registering new codes in the standard keys. The immobilizer system cannot be operated with a new key until the key registered with a code. If you lose the code re-registering key, the ECU and main switch (included with an immobilizer unit) needs to be replaced.

Therefore, always use a standard key for driving. (See caution below.)

NOTE:

Each standard key is registered during production, therefore re-registering at purchase is not necessary.

ECA14970

CAUTION:

• DO NOT LOSE THE CODE RE-REGISTERING KEY! If the code re-registering key is lost, registering new codes in the standard keys is impossible. The standard keys can still be used to start the vehicle, however if code re-registering is required (i.e., if a new standard key is made or all keys are lost) the entire immobilizer system must be replaced. Therefore, it is highly recommended to use either standard key after any code re-registering and keep the code re-registering key in a safe place.

• Do not submerse either of the keys in water.

• Do not expose the keys to excessively high temperatures.

• Do not place either of the keys close to magnets (this includes, but not limited to, products such as speakers, etc.).

• Do not place heavy items on either key.

• Do not grind either key or alter their shape.

• Do not disassemble the plastic part of either key.

• Keep other immobilizer keys away for this unit’s code re-registering key and main switch.

EAS27691

PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS

In the course of use, you may encounter the following cases where replacement of parts and registration of code re-registering/standard keys are required.

NOTE:

Each standard key is registered during production, therefore re-registering at purchase is not necessary.

Standard key is lost

Main switch/immobilizer unit

Main switch

Parts to be replaced

Immobilizer unit

Standard key

ECU

✓

Accessory lock* and key

Key registration requirement

New standard key

8-81

IMMOBILIZER SYSTEM

All keys have been lost (including code re-registering key)

ECU is defective

Immobilizer unit is defective

Main switch is defective

Accessory lock* is defective

Main switch/immobilizer unit

Main switch

Parts to be replaced

Immobilizer unit

Standard key

ECU

Accessory lock* and key

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

Key registration requirement

Code re-registering key and standard keys

Code re-registering key and standard keys

Code re-registering key and standard keys

Code re-registering key and standard keys

No required

* Accessory locks mean the seat lock, fuel tank cap or the helmet holder.

Code re-registering key registration:

When the immobilizer unit or ECU is replaced, the code re-registering key must be registered to the unit.

To register a code re-registering key:

1. Turn the main switch to “ON” with the code re-registering key.

NOTE:

Check that the immobilizer system indicator light comes on for one second, then goes off. When the immobilizer system indicator light goes off, the code re-registering key has been registered.

2. Check that the engine can be started.

3. Register the standard key, following the instructions in the section below.

Standby mode:

To enable the immobilizer system, turn the ignition key to “OFF”. 30 seconds later, the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours. After that time, the indicator light will stop flashing, but the immobilizer system is still enabled.

8-82

IMMOBILIZER SYSTEM

Standby mode

a. Main switch “ON” b. Main switch “OFF” c. LED on d. LED off e. Standby mode on f. Standby mode off

Standard key registration:

Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.

NOTE:

Do not start the engine with a standard key that has not been registered. If the main switch is turned

“ON” with a standared key that has not been registered, the immobilizer system indicator light flashes to indicate fault code “52”. (Refer to «SELF-DIAGNOSIS FAULT CODE INDICATION» on page 8-85).

1. Check that the immobilizer system indicator light signals the standby mode.

2. Using the code re-registering key, turn the main switch “ON”, then “OFF”, and then remove the key within 5 seconds.

3. Insert the first standard key to be registered into the main switch, then turn the key to “ON” within

5 seconds to activate the key registration mode.

NOTE:

The existing standard key code is erased from the memory when the key registration mode is activated. When the key registration mode is activated, the immobilizer system indicator light flashes rapidly.

4. While the indicator light is flashing, turn the main switch to “OFF”, remove the key, and within 5 seconds, insert the second standard key to be registered into the main switch.

NOTE:

If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered, the registration mode is deactivated. If this occurs, the second standard key cannot be registered, and steps 2 to 4 need to be repeated to register both standard keys.

5. Turn the main switch to “ON”.

NOTE:

When the indicator light goes off, the registration is complete.

6. Check that the engine can be started with the two registered standard keys.

8-83

IMMOBILIZER SYSTEM

Standard key registration

a. Main switch “ON” b. Main switch “OFF” c. LED on d. LED off e. Less than 5.0 s f. Code re-registering key g. First standard key h. Second standard key i. Registration mode

A. Registration of the second standard key is complete.

B. Immobilizer system indicator light stops flashing when the registration of the second standard key is complete.

Voiding the standard key code:

If a standard key has been lost, it is possible to disable its use by re-registering the remaining standard key. Standard key registration erases the stored standard key code from the memory, thus disabling the lost standard key. To re-register, refer to “Standard key registration”.

Standard key code voiding method

a. Main switch “ON” b. Main switch “OFF” c. LED on d. LED off e. Less than 5.0 s f. Code re-registering key g. Remaining standard key h. Registration mode

A. If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered, the second standard key cannnot be registered.

8-84

IMMOBILIZER SYSTEM

EAS27700

TROUBLESHOOTING

When the main switch is turn “ON”, the indicator light does not come on or flashing.

NG

→

1 Check the fuses.

(Main, ignition and backup)

Refer to «CHECKING THE FUSES» on page 8-97.

OK

↓

Replace the fuse(s).

NG

→

2 Check the battery.

Refer to «CHECKING AND

CHARGING THE BATTERY» on page 8-97.

OK

↓

• Clean the battery terminals.

• Recharge or replace the battery.

NG

→

3 Check the main switch.

Refer to «CHECKING THE

SWITCHES» on page 8-93.

OK

↓

Replace the immobilizer kit.

NG

→

4 Check the entire immobilizer system’s wiring.

Refer to «CIRCUIT DIAGRAM» on page 8-79.

OK

↓

Properly connect or repair the immobilizer system’s wiring.

• Check the condition of the each immobilizer system’s circuits.

• Refer to «SELF-DIAGNOSIS FAULT

CODE INDICATION» on page 8-85.

EAS27720

SELF-DIAGNOSIS FAULT CODE INDICATION

When the system failure occurred, the error code number is indicated in the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code.

Error code

Detection Symptoms Trouble Measures

51

IMMOBILIZER

UNIT

Cannot transmit code between the key and immobilizer unit.

1 Objects that may keep off radio waves exist around the keys and antennas.

2 Immobilizer unit failure.

3 Key failure.

1 Keep clear of magnets, metals and other keys form the surroundings of keys and antennas.

2 Replace the immobilizer unit.

3 Replace the key.

8-85

IMMOBILIZER SYSTEM

Error code

Detection Symptoms Trouble Measures

52

53

54

55

56

IMMOBILIZER

UNIT

IMMOBILIZER

UNIT

IMMOBILIZER

UNIT

IMMOBILIZER

UNIT

ECU

Codes do not match between the key and immobilizer unit.

Cannot transmit code between the

ECU and immobilizer unit.

Codes do not match between ECU and immobilizer unit.

Key code registration error.

Undefinition code is received.

1 Disturbed by other transponder.

Failed to verify continually for ten times.

2 Unregistered sub key was used.

Noise interference or disconnected lead/cable.

1 Obstruction due to radio wave noise.

2 Error by disconnection of the communication harness.

3 Immobilizer unit failure.

4 ECU failure.

Noise interference or disconnected lead/cable.

1 Obstruction due to radio wave noise.

2 Error by disconnection of the communication harness.

3 Immobilizer unit failure.

4 ECU failure.

(When the used parts form other vehicles are used, the code re-registering key ID is not registered to the ECU.)

1 Place the immobilizer unit away more than 50 mm from the transponder of other vehicle.

2 Register the standard key.

1 Check the wire harness and connector.

2 Replace the immobilizer unit.

3 Replace the ECU.

1 Register the code re-registering key

ID.

2 Check the wire harness and connector.

3 Replace the immobilizer unit.

4 Replace the ECU.

Same standard key was attempted to continuously two times register.

Noise interference or disconnected lead/cable.

1 Obstruction due to radio wave noise.

2 Error by disconnection of the communication harness.

3 Immobilizer unit failure

4 ECU failure

Prepare the new standard key and register it.

1 Check the wire harness and connector.

2 Replace the immobilizer unit.

3 Replace the ECU.

Immobilizer system indicator light error code indication

Digit of 10 : Cycles of 1 sec. ON and 1.5 sec. OFF.

Digit of 1 : Cycles of 0.5 sec. ON and 0.5 sec. OFF.

8-86

a. Light on b. Light off

IMMOBILIZER SYSTEM

8-87

8-88

IMMOBILIZER SYSTEM

EAS27970

ELECTRICAL COMPONENTS

ELECTRICAL COMPONENTS

8-89

1. Main switch (immobilizer unit)

2. Front brake light switch

3. Starter relay

4. Battery

5. Fuse box

6. Rear brake light switch

7. Neutral switch

8. Sidestand switch

9. Oil level switch

10.Radiator fan motor

11.Horn

12.Ignition coil

ELECTRICAL COMPONENTS

8-90

8-91

ELECTRICAL COMPONENTS

1. Coolant temperature sensor

2. Intake air temperature sensor

3. Intake air pressure sensor

4. Fuel pump

5. ECU

6. Lean angle sensor

7. Starting circuit cut-off relay

8. Headlight relay (on/off)

9. Radiator fan motor relay

10.Turn signal relay

11.Recifier/regulator

12.Throttle position sensor

13.Sub-throttle position sensor

ELECTRICAL COMPONENTS

8-92

EAS27980

CHECKING THE SWITCHES

ELECTRICAL COMPONENTS

8-93

1. Main switch

2. Horn switch

3. Dimmer switch

4. Pass switch

5. Turn signal switch

6. Hazard switch

7. Clutch switch

8. Sidestand switch

9. Engine stop switch

10.Front brake light switch

11.Start switch

12.Oil level switch

13.Neutral switch

14.Rear brake light switch

15.Fuse box

16.O

2

sensor

ELECTRICAL COMPONENTS

8-94

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 “1”. 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 “

Ω ×

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 indication by “ ” There is continuity between red, brown/blue, and brown/red when the switch is set to

“ON” and between red and brown/red when the switch is set to “ ”.

8-95

EAS27990

CHECKING THE BULBS AND BULB SOCK-

ETS

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 socket by turning them counterclockwise.

• Bulbs “c” is used for turn signal and tail/brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise.

ELECTRICAL COMPONENTS hands away from the bulb until it has cooled down.

ECA14380

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 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 “

Ω ×

1” range.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the positive tester probe to terminal “1” and the negative tester probe to terminal “2”, and check the continuity.

b. Connect the positive tester probe to terminal “1” and the negative tester probe to terminal “3”, and check the continuity.

c. If either of the readings indicate no continuity, replace the bulb.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Checking the condition of the bulbs

The following procedure applies to all of the bulbs.

1. Remove:

• Bulb

EWA13320

WARNING

Since the headlight bulb gets extremely hot, keep flammable products and your

8-96

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:

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 indicate no continuity, replace the bulb socket.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS28000

CHECKING THE FUSES

The following procedure applies to all of the fuses.

ECA13680

CAUTION:

To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse.

1. Remove:

• Rider and passenger seat

2. Check:

• Fuse

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity.

NOTE:

Set the pocket tester selector to “

Ω ×

1”.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

b. If the pocket tester indicates “

∞

”, replace the fuse.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

8-97

ELECTRICAL COMPONENTS

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 Q’ty

Main

Headlight (FZ1-N)

Headlight (FZ1-S)

Signaling system

Tail/brake light

Ignition

Buckup

Radiator fan motor

Reserve

Reserve (FZ1-N)

Reserve (FZ1-S)

Amperage rating

50 A

15 A

25 A

10 A

10 A

15 A

10 A

10 A

10 A

15 A

25 A

1

1

1

1

1

1

1

1

1

2

1

EWA13310

WARNING

Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4. Install:

• Rider and passenger seat

EAS28030

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.

• Charge batteries in a well-ventilated area.

ELECTRICAL COMPONENTS

• 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.

ECA13660

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 as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably.

Therefore, take special care when charging the battery.

NOTE:

Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.

1. Remove:

• Rider and passenger seat

2. Disconnect:

• Battery leads

(from the battery terminals)

ECA13640

CAUTION:

First, disconnect the negative battery lead

“1”, and then positive battery lead “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

8-98

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 = 20–30%

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5. Charge:

• Battery

(refer to the appropriate charging method illustration)

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.

• 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.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

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 machine is stopped.

b. Connect a charged and AMP meter to the battery and start charging.

NOTE:

Set the charging voltage at 16–17 V.If the setting is lower, charging will be insufficient. If too high, the battery will be over-charged.

8-99

ELECTRICAL COMPONENTS

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, set the charging voltage adjust dial at 20–24 V and monitor the amperage for 3–5 minutes to check the battery.

• Reach the standard charging current

Battery is good.

• Does not reach the standard charging current

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.

Refer to “Battery condition checking steps”.

f.

If charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging current.

g. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes.

12.8 V or more — Charging is complete.

12.7 V or less — Recharging is required.

Under 12.0 V — Replace the battery.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Charging method using a constant voltage charger

a. Measure the open-circuit voltage prior to charging.

NOTE:

Voltage should be measured 30 minutes after the machine is stopped.

b. Connect a charger and AMP meter to the battery and start charging.

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 battery’s charging voltage is 15 V.

NOTE:

Set the charging time at 20 hours (maximum).

e. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes.

12.8 V or more — Charging is complete.

12.7 V or less — Recharging is required.

Under 12.0 V — Replace the battery.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6. Install:

• Battery

7. Connect:

• Battery leads

(to the battery terminals)

ECA13630

CAUTION:

First, connect the positive battery lead “1”, and then the negative battery lead “2”.

ELECTRICAL COMPONENTS

EAS28040

CHECKING THE RELAYS

Check each switch 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 (

Ω ×

1) and battery (12 V) to the relay terminal as shown.

Check the relay operation.

Out of specification

→

Replace.

1. Positive battery terminal

2. Negative battery terminal

3. Positive tester probe

4. Negative tester probe

Relay operation

Continuity/No continuity

(between “3” to “4”)

Relay unit (starting circuit cut-off relay)

FZ1-N

8. Check:

• Battery terminals

Dirt

→

Clean with a wire brush.

Loose connection

→

Connect properly.

9. Lubricate:

• Battery terminals

Recommended lubricant

Dielectric grease

10. Install:

• Rider and passenger seat

FZ1-S

8-100

1. Positive battery terminal

2. Negative battery terminal

3. Positive tester probe

4. Negative tester probe

Result

Continuity/No continuity

(between “3” to “4”)

Relay unit (fuel pump relay)

FZ1-N

ELECTRICAL COMPONENTS

4. Negative tester probe

Result

Continuity/No continuity

(between “3” to “4”)

Headlight relay (on/off)

(FZ1-S)

FZ1-S

1. Positive battery terminal

2. Negative battery terminal

3. Positive tester probe

4. Negative tester probe

Result

Continuity/No continuity

(between “3” to “4”)

Headlight relay (dimmer)

(FZ1-S)

1. Positive battery terminal

2. Negative battery terminal

3. Positive tester probe

4. Negative tester probe

Result

Continuity/No continuity

(between “3” to “4”)

Headlight relay (on/off)

(FZ1-N)

1. Positive battery terminal

2. Negative battery terminal

3. Positive tester probe

8-101

1. Positive battery terminal

2. Negative battery terminal

3. Positive tester probe

4. Negative tester probe

Result

Continuity/No continuity

(between “3” to “4”)

(between “3” to “5”)

Radiator fan motor relay

ELECTRICAL COMPONENTS

1. Positive battery terminal

2. Negative battery terminal

3. Positive tester probe

4. Negative tester probe

Result

Continuity/No continuity

(between “3” to “4”)

ET2D1030

CHECKING THE TURN SIGNAL/HAZARD

RELAY

1. Check:

• Turn signal/hazard relay input voltage

Out of specification

→

The wiring circuit from the main switch to the turn signal/hazard relay coupler is faulty and must be repaired.

Turn signal/hazard relay input voltage

DC 12 V

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the turn signal/hazard relay terminal as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Positive tester probe

→

Blue/Red “1”

• Negative tester probe

→

Ground b. Turn the main switch to “ON”.

c. Measure the turn signal/hazard relay input voltage.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Check:

• Turn signal/hazard relay output voltage

Out of specification

→

Replace.

Turn signal/hazard relay output voltage

DC 12 V

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the turn signal/hazard relay terminal as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Positive tester probe

→

Brown/White “1”

• Negative tester probe

→

Ground b. Turn the main switch to “ON”.

c. Measure the turn signal/hazard relay output voltage.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

ET2D1021

CHECKING THE RELAY UNIT (DIODE)

1. Check:

• Relay unit (diode)

Out of specification

→

Replace.

8-102

ELECTRICAL COMPONENTS

FZ1-N

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

→

Sky blue “1”

Negative tester probe

→

Yellow/Black “2” (FZ1-N) Black/

Yellow “2” (FZ1-S)

No continuity

Positive tester probe

→

Yellow/Black “2” (FZ1-N) Black/

Yellow “2” (FZ1-S)

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/

Black “5”

Negative tester probe

→

Blue/

Yellow “3”

No continuity

Positive tester probe

→

Blue/

Yellow “3”

Negative tester probe

→

Blue/

Black “5”

FZ1-S

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the wire harness.

b. Connect the pocket tester (

Ω×

1) to the relay unit terminal as shown.

c. Check the relay unit (diode) for continuity.

d. Check the relay unit (diode) for no continuity.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

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

1.19–1.61

Ω

at 20

°

C (68

°

F)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the ignition coil leads from the wire harness.

b. Connect the pocket tester (

Ω ×

1) to the ignition coil as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

8-103

ELECTRICAL COMPONENTS

• Positive tester probe

Ignition coil terminal

• Negative tester probe

Ignition coil terminal

3. Check:

• Ignition spark gap “a”

Out of specification

→

Replace.

Minimum ignition spark gap

6.0 mm (0.24 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the spark plug.

b. Connect the ignition checker/dynamic spark tester “2” as shown.

Ignition checker

90890-06754

Opama pet-4000 spark checker

YM-34487

c. Measure the primary coil resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Check:

• Secondary coil resistance

Out of specification

→

Replace.

Secondary coil resistance

8.5–11.5 k

Ω

at 20

°

C (68

°

F)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the ignition coil leads from the wire harness.

b. Connect the pocket tester (

Ω ×

1k) to the ignition coil as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Negative tester probe

Ignition coil terminal “1”

• Positive tester probe

Spark plug terminal “2” c. Measure the secondary coil resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

8-104

1. Spark plug cap c. Set the main switch to “ON”.

d. Measure the ignition spark gap “a”.

e. Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

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.

Crankshaft position sensor resistance

336–504

Ω

at 20

°

C (68

°

F)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

ELECTRICAL COMPONENTS

a. Connect the pocket tester (

Ω ×

100) to the crankshaft position sensor coupler as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Positive tester probe

Gray “1”

• Negative tester probe

Black “2” b. Measure the crankshaft position sensor resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS28130

CHECKING THE LEAN ANGLE SENSOR

1. Remove:

• Lean angle sensor

2. Check:

• Lean angle sensor out put voltage

Out of specification

→

Replace.

Lean angle sensor output voltage

Less than 65

°

: 0.4–1.4 V

More than 65

°

: 3.7–4.4 V

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the lean angle sensor coupler to the 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” c. When turn the lean angle sensor to 65

°

.

d. Measure the lean angle sensor output voltage.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

ET2D1034

CHECKING THE STARTOR MOTOR OPERA-

TION

1. Check:

• Starter motor operation

Does not operate

→

Perform the electric starting system troubleshooting, starting with step5.

Refer to «TROUBLESHOOTING» on page

8-9.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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, 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.

8-105

b. Check the starter motor operation.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Check:

• Startor coil resistance

Out of specification

→

Replace the startor coil.

EAS28150

CHECKING THE STATOR COIL

1. Disconnect:

• Stator coil coupler

(from the wire harness)

2. Check:

• Stator coil resistance

Out of specification

→

Replace the startor coil.

Stator coil resistance

0.14–0.18

Ω

at 20

°

C (68

°

F)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (

Ω ×

1) to the startor 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”

ELECTRICAL COMPONENTS

• Charging voltage

Out of specification

→

Replace the rectifier/ regulator.

Charging voltage

14 V at 5000 r/min

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachometer to the ignition coil of cylinder #1.

b. Connect the pocket tester (AC 20 V) to the rectifier/regulator coupler as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Positive tester probe

Red “1”

• Negative tester probe

Black “2” b. Measure the stator coil resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS28170

CHECKING THE RECTIFIER/REGULATOR

1. Check:

8-106

c. Start the engine and let it run at approximately 5000 r/min.

d. Measure the charging voltage.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS28180

CHECKING THE HORN

1. Check:

• Horn resistance

Out of specification

→

Replace.

Horn resistance

1.15–1.25

Ω

at 20

°

C (68

°

F)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the horn leads from the horn terminals.

b. Connect the pocket tester (

Ω ×

1) to the horn terminals.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Positive tester probe

Horn terminal “1”

• Negative tester probe

Horn terminal “2”

ELECTRICAL COMPONENTS

(from the fuel tank)

4. Check:

• Fuel sender resistance

Fuel sender resistance

Full position of the float

19–21

Ω

at 20

°

C (68

°

F)

Empty position of the float

139–141

Ω

at 20

°

C (68

°

F)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (

Ω ×

10) to the fuel sender terminal as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Positive tester probe

Green/white “1”

• Negative tester probe

Black “2” 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.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS28230

CHECKING THE FUEL SENDER

1. Remove:

• Fuel tank

2. Disconnect:

• Fuel pump coupler

• Fuel sender coupler

(from the wire harness)

3. Remove:

• Fuel pump

8-107

b. Measure the fuel sender resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

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” b. Set the main switch to “ON”.

c. Elevate the rear wheel and slowly rotate it.

d. Measure the voltage (DC 5 V) of White/Yellow and 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.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the radiator fan motor coupler from the wire harness.

b. Connect the battery (DC 12 V) as shown.

• Positive tester probe

Blue “1”

• Negative tester probe

Black “2”

ELECTRICAL COMPONENTS

EWA14130

WARNING

• Handle the coolant temperature sensor with special care.

• Never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor is dropped, replace it.

2. Check:

• Coolant temperature sensor resistance

Out of specification

→

Replace.

Coolant temperature sensor resistance

0

°

C (32

°

F) : 5.21–6.37 k

Ω

80

°

C (176

°

F) : 0.29–0.35 k

Ω

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (

Ω ×

1k) to the coolant temperature sensor “1” as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Positive tester probe

Coolant temperature sensor terminal

• Negative tester probe

Coolant temperature sensor terminal b. Immerse the coolant temperature sensor in a container filled with coolant “2”.

NOTE:

Make sure the coolant temperature sensor terminals do not get wet.

c. Place a thermometer “3” in the coolant.

c. Measure the radiator fan motor movement.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS28260

CHECKING THE COOLANT TEMPERATURE

SENSOR

1. Remove:

• Coolant temperature sensor

8-108

ELECTRICAL COMPONENTS

• Tester positive lead

→

Blue “1”

• Tester negative lead

→

Black/Blue “2” b. Check the throttle position sensor maximum resistance.

Out of specification

→

Replace the throttle position sensor.

Maximum throttle position sensor resistance

4–6 k

Ω

at 20

°

C (68

°

F)

c. Connect the pocket tester (

Ω ×

1k) to the throttle position sensor as shown.

• Tester positive lead

→

Yellow “3”

• Tester negative lead

→

Black/Blue “2” d. Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table.

e. Check the coolant temperature sensor for continuity at the temperatures indicated in the table.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS28300

CHECKING THE THROTTLE POSITION

SENSOR

1. Remove:

• Throttle position sensor

(from the throttle body)

2. Check:

• Throttle position sensor

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (

Ω ×

1k) to the throttle position sensor as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

d. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range.

The resistance does not change or it changes abruptly

→

Replace the throttle position sensor.

Throttle position sensor resistance

0–6 k

Ω

at 20

°

C (68

°

F)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Install:

• Throttle position sensor

8-109

ELECTRICAL COMPONENTS

NOTE:

When installing the throttle position sensor, adjust its angle properly. Refer to «ADJUST-

ING THE THROTTLE POSITION SENSOR» on page 7-8.

EAS2D1010

CHECKING THE SUB-THROTTLE POSITION

SENSOR

1. Remove:

• Sub-throttle position sensor

(from the throttle body)

2. Check:

• Sub-throttle position sensor

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the sub-throttle motor coupler.

b. Disconnect the sub-throttle position sensor coupler.

c. Remove the sub-throttle position sensor from the sub-throttle servo motor.

d. Connect the pocket tester (

Ω ×

1k) to the sub-throttle position sensor as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Tester positive lead

→

Blue “1”

• Tester negative lead

→

Black/Blue “2” e. Check the throttle position sensor maximum resistance.

Out of specification

→

Replace the throttle position sensor.

Maximum sub-throttle position sensor resistance

4–6 k

Ω

at 20

°

C (68

°

F)

f.

Connect the pocket tester (

Ω ×

1k) to the throttle position sensor as shown.

• Tester positive lead

→

Green/Yellow “3”

• Tester negative lead

→

Black/Blue “2” g. While slowly opening the sub-throttle worm nut, check that the sub-throttle position sensor resistance is within the specified range.

The resistance does not change or it changes abruptly

→

Replace the sub-throttle position sensor.

NOTE:

Check mainly that the resistance changes gradually when turning the sub-throttle worm nut, since the readings (from closed to wideopen sub-throttle) may differ slightly from those specified.

Throttle position sensor resistance

0–6 k

Ω

at 20

°

C (68

°

F)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Install:

• Sub-throttle position sensor

NOTE:

When installing the throttle position sensor, adjust its angle properly. Refer to «CHECKING

THE SUB-THROTTLE POSITION SENSOR» on page 8-110.

EA2D1012

CHECKING THE AIR INDUCTION SYSTEM

SOLENOID

1. Check:

• Air induction system solenoid resistance

Out of specification

→

Replace.

8-110

Air induction system solenoid resistance

18–22

Ω

at 20

°

C (68

°

F)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the Air induction system solenoid coupler from the wire harness.

b. Connect the pocket tester (

Ω ×

1) to the Air induction system solenoid terminal as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Positive tester probe

Brown “1”

• Negative tester probe

Brown/Red “2” c. Measure the Air induction system solenoid resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS28380

CHECKING THE ATMOSPHERIC PRES-

SURE SENSOR

1. Check:

• Atmospheric pressure sensor output voltage

Out of specification

→

Replace.

Atmospheric pressure sensor output voltage

3.75–4.25 V

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the atmospheric pressure sensor coupler (wire harness side) as shown.

ELECTRICAL COMPONENTS

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Positive tester probe

Pink “1”

• Negative tester probe

Black/Blue “2” b. Set the main switch to “ON”.

c. Measure the atmospheric pressure sensor output voltage.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS28390

CHECKING THE CYLINDER IDENTIFICA-

TION SENSOR

1. Check:

• Cylinder identification sensor output voltage

Out of specification

→

Replace.

Cylinder identification sensor output voltage

When sensor is on

4.8 V or more

When sensor is off

0.8 V or less

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the cylinder identification sensor coupler (wire harness side) as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Positive tester probe

White/Black “1”

• Negative tester probe

Black/Blue “2”

8-111

b. Set the main switch to “ON”.

c. Rotate the crankshaft.

d. Measure the voltage (DC 20 V) of White/

Black and Black/Blue. With each full rotation of the crankshaft, the voltage reading should cycle from 0.8 V to 4.8 V to 0.8 V to

4.8 V.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS28410

CHECKING THE INTAKE AIR PRESSURE

SENSOR

1. Check:

• Intake air pressure sensor output voltage

Out of specification

→

Replace.

Intake air pressure sensor output voltage

3.75–4.25 V

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the intake air pressure sensor coupler (wire harness side) as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Positive tester probe

Pink/White “1”

• Negative tester probe

Black/Blue “2”

ELECTRICAL COMPONENTS

EAS28420

CHECKING THE INTAKE AIR TEMPERA-

TURE SENSOR

1. Remove:

• Intake air temperature sensor

(from the air filter case.)

EWA14110

WARNING

• Handle the intake air temperature sensor with special care.

• Never subject the intake air temperature sensor to strong shocks. If the intake air temperature sensor is dropped, replace it.

2. Check:

• Intake air temperature sensor resistance

Out of specification

→

Replace.

Intake air temperature sensor resistance

2.21–2.69 k

Ω

at 20

°

C (68

°

F)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (

Ω ×

100) to the intake air temperature sensor terminal as shown.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

• Positive tester probe

Brown/White “1”

• Negative tester probe

Black/Blue “2” b. Set the main switch to “ON”.

c. Measure the intake air pressure sensor output voltage.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

8-112

b. Measure the intake air temperature sensor resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Install:

• Intake air temperature sensor

Intake air temperature sensor bolt

1.2 Nm (0.12 m·kg, 0.87 ft·lb)

8-113

ELECTRICAL COMPONENTS

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 ………………………………………………………………………….. 9-2

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

9

EAS28450

TROUBLESHOOTING

EAS28460

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 strainer

• Clogged fuel tank drain hose

• Clogged rollover valve hose

• Deteriorated or contaminated fuel

2. Fuel pump

• Faulty fuel pump

• Faulty fuel pump relay

3. Throttle body (-ies)

• Deteriorated or contaminated fuel

9-1

TROUBLESHOOTING

• 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

4. Ignition coil(s)

• Cracked or broken ignition coil body

• Broken or shorted primary or secondary coils

5. Ignition system

• Faulty ECU

• Faulty crankshaft position sensor

6. Switches and wiring

• Faulty main switch

• Faulty engine stop switch

• Broken or shorted wiring

• Faulty neutral switch

• Faulty start switch

• Faulty sidestand switch

• Faulty clutch switch

• Improperly grounded circuit

• Loose connections

7. Starting system

• Faulty starter motor

• Faulty starter relay

• Faulty starting circuit cut-off relay

• Faulty starter clutch

EAS28490

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

Fuel system

1. Throttle body (-ies)

• Damaged or loose throttle body joint

• Improperly synchronized throttle bodies

• Improperly adjusted engine idling speed

(idle adjusting screw)

• Improper throttle cable free play

• Flooded throttle body

• Faulty air induction system

Electrical system

1. Battery

• Discharged battery

• Faulty battery

2. Spark plug(s)

• Incorrect spark plug gap

• Incorrect spark plug heat range

• Fouled spark plug

• Worn or damaged electrode

• Worn or damaged insulator

3. Ignition coil(s)

• Broken or shorted primary or secondary coils

• Cracked or broken ignition coil

4. Ignition system

• Faulty ECU

• Faulty crankshaft position sensor

EAS28510

POOR MEDIUM-AND-HIGH-SPEED PER-

FORMANCE

Refer to «STARTING FAILURES» on page 9-1.

Engine

1. Air filter

• Clogged air filter element

Fuel system

1. Fuel pump

• Faulty fuel pump

EAS28530

FAULTY GEAR SHIFTING

Shifting is difficult

Refer to Clutch drags.

EAS28540

SHIFT PEDAL DOES NOT MOVE

Shift shaft

• Improperly adjusted shift rod

• Bent shift shaft

Shift drum and shift forks

• Foreign object in a shift drum groove

• Seized shift fork

• Bent shift fork guide bar

Transmission

• Seized transmission gear

• Foreign object between transmission gears

9-2

TROUBLESHOOTING

• 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 push rod

• Broken clutch boss

• Burnt primary driven gear bushing

• Match marks not aligned

2. Engine oil

• Incorrect oil level

• Incorrect oil viscosity (high)

• Deteriorated oil

EAS28600

OVERHEATING

Engine

1. Clogged coolant passages

• Cylinder head(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

• Thermostat

• Thermostat stays closed

• Oil cooler

• Clogged or damaged oil cooler

• Hose(s) and pipe(s)

• Damaged hose

• Improperly connected hose

• Damaged pipe

• Improperly connected pipe

Fuel system

1. Throttle body (-ies)

• Damaged or loose throttle body joint

2. Air filter

• Clogged air filter element

Chassis

1. Brake(s)

• Dragging brake

Electrical system

1. Spark plug(s)

• Incorrect spark plug gap

• Incorrect spark plug heat range

2. Ignition system

• Faulty ECU

EAS28610

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

9-3

TROUBLESHOOTING

• Faulty brake caliper seal

• Loose union bolt

• Damaged brake hose

• Oil or grease on the brake disc

• Oil or grease on the brake pad

• Incorrect brake fluid level

EAS28660

FAULTY FRONT FORK LEGS

Leaking oil

• Bent, damaged or rusty inner tube

• Cracked or damaged outer tube

• Improperly installed oil seal

• Damaged oil seal lip

• Incorrect oil level (high)

• Loose damper rod assembly 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)

• 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(-ies)

• 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 LIGHTING OR SIGNALING SYS-

TEM

Headlight does not come on

• Wrong headlight bulb

• Too many electrical accessories

• Hard charging

• Incorrect connection

• Improperly grounded circuit

• Poor contacts (main or light switch)

• Burnt-out headlight bulb

Headlight bulb burnt out

• Wrong headlight bulb

• Faulty battery

• Faulty rectifier/regulator

• Improperly grounded circuit

• Faulty main switch

• Faulty light 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

• 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

TROUBLESHOOTING

• Improperly grounded circuit

• Faulty battery

• Blown, damaged or incorrect fuse

Turn signal blinks 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 blinks 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

9-4

EAS28740

WIRING DIAGRAM

FZ1-N (V) 2006

1. Main switch

2. Rectifier/regulator

3. A.C.magneto

4. Fuse (backup)

5. Immobilizer unit

6. Fuse (main)

7. Battery

8. Fuse (fuel injection)

9. Starter relay

10. Starter motor

11. Relay unit

12. Starting circuit cut-off relay

13. Fuel pump relay

14. Neutral switch

15. Sidestand switch

16. Fuel pump

17. Crankshaft position sensor

18. Cylinder identification sensor

19. Speed sensor

20. Atmospheric pressure sensor

21. Lean angle sensor

22. O2 sensor

23. E.C.U.

24. Ignition coil #1

25. Ignition coil #2

26. Ignition coil #3

27. Ignition coil #4

28. Spark plug

29. Injector #1

30. Injector #2

31. Injector #3

32. Injector #4

33. Air induction system solenoid

34. Sub-throttle position sensor

35. EXUP servo motor

36. Intake air pressure sensor

37. Throttle position sensor

38. Coolant temperature sensor

39. Air temperature sensor

40. Meter assembly

41. Immobilizer indicator light

42. Fuel level warning light

43. Oil level warning light

44. Neutral indicator light

45. Tacho meter

46. Multi function meter

47. Engine trouble warning light

48. Coolant temperature indicator light

49. Hi beam indicator light

50. Turn signal indicator light (left)

51. Turn signal indicator light

(right)

52. Meter light

53. Oil level switch

54. Right handlebar switch

55. Front brake light switch

56. Engine stop switch

57. Start switch

58. Rear brake light switch

59. Left handlebar switch

60. Clutch switch

61. Pass switch

62. Dimmer switch

63. Hazard switch

64. Turn signal switch

65. Horn switch

66. Horn

67. Turn signal relay

68. Front turn signal light (left)

69. Front turn signal light (right)

70. Rear turn signal light (left)

71. Rear turn signal light (right)

72. Auxiliary light

73. Headlight

74. License plate light

75. Tail/brake light

76. Headlight relay (on/off)

77. Fuse (tail light)

78. Fuse (ingition)

79. Anti safety alarm (option)

80. Fuse (signal)

81. Fuse (headlight)

82. Radiator fan motor relay

83. Fuse (radiator fan motor left)

84. Fuse (radiator fan motor right)

85. Radiator fan motor (left)

86. Radiator fan motor (right)

87. Ground

EAS28750

COLOR CODE

Lg

O

P

R

Sb

W

Y

B/G

B

Br

Ch

Dg

G

Gy

L

B/L

B/R

B/W

B/Y

Br/G

Br/L

Br/R

Black

Brown

Chocolate

Dark green

Green

Gray

Blue

Light green

Orange

Pink

Red

Sky blue

White

Yellow

Black/Green

Black/Blue

Black/Red

Black/White

Black/Yellow

Brown/Green

Brown/Blue

Brown/Red

Brown/White

Brown/Yellow

Green/Black

Green/Red

Green/White

Green/Yellow

Gray/Green

Gray/Red

Blue/Black

Blue/Red

Blue/White

Blue/Yellow

Orange/Black

Orange/Green

Orange/Yellow

Pink/Black

Pink/White

Red/Black

Red/Green

Red/Blue

Red/White

Red/Yellow

Sky blue/White

White/Black

White/Red

White/Yellow

Yellow/Black

Yellow/Green

Yellow/Blue

Yellow/Red

Yellow/White

W/R

W/Y

Y/B

Y/G

Y/L

Y/R

Y/W

P/W

R/B

R/G

R/L

R/W

R/Y

Sb/W

W/B

L/B

L/R

L/W

L/Y

O/B

O/G

O/Y

P/B

Br/W

Br/Y

G/B

G/R

G/W

G/Y

Gy/G

Gy/R

FZ1-S (V) 2006

1. Main switch

2. Rectifier/regulator

3. A.C.magneto

4. Fuse (backup)

5. Immobilizer unit

6. Fuse (main)

7. Battery

8. Fuse (fuel injection)

9. Starter relay

10. Starter motor

11. Relay unit

12. Starting circuit cut-off relay

13. Fuel pump relay

14. Neutral switch

15. Sidestand switch

16. Fuel pump

17. Crankshaft position sensor

18. Cylinder identification sensor

19. Speed sensor

20. Atmospheric pressure sensor

21. Lean angle sensor

22. O2 sensor

23. E.C.U.

24. Ignition coil #1

25. Ignition coil #2

26. Ignition coil #3

27. Ignition coil #4

28. Spark plug

29. Injector #1

30. Injector #2

31. Injector #3

32. Injector #4

33. Air induction system solenoid

34. Sub-throttle position sensor

35. EXUP servo motor

36. Intake air pressure sensor

37. Throttle position sensor

38. Coolant temperature sensor

39. Air temperature sensor

40. Meter assembly

41. Immobilizer indicator light

42. Fuel level warning light

43. Oil level warning light

44. Neutral indicator light

45. Tacho meter

46. Multi function meter

47. Engine trouble warning light

48. Coolant temperature indicator light

49. Hi beam indicator light

50. Turn signal indicator light (left)

51. Turn signal indicator light

(right)

52. Meter light

53. Oil level switch

54. Right handlebar switch

55. Front brake light switch

56. Engine stop switch

57. Start switch

58. Rear brake light switch

59. Left handlebar switch

60. Clutch switch

61. Pass switch

62. Dimmer switch

63. Hazard switch

64. Turn signal switch

65. Horn switch

66. Horn

67. Turn signal relay

68. Front turn signal light (left)

69. Front turn signal light (right)

70. Rear turn signal light (left)

71. Rear turn signal light (right)

72. Auxiliary light

73. Headlight

74. License plate light

75. Tail/brake light

76. Headlight relay (on/off)

77. Headlight relay (dimmer)

78. Fuse (tail light)

79. Fuse (ingition)

80. Anti safety alarm (option)

81. Fuse (signal)

82. Fuse (headlight)

83. Radiator fan motor relay

84. Fuse (radiator fan motor left)

85. Fuse (radiator fan motor right)

86. Radiator fan motor (left)

87. Radiator fan motor (right)

88. Ground

EAS28750

COLOR CODE

Y

B/G

B/L

B/R

B/W

B/Y

Br/G

Br/L

Br/R

Br/W

Br/Y

P

R

Sb

W

Gy

L

Lg

O

B

Br

Ch

Dg

G

Black

Brown

Chocolate

Dark green

Green

Gray

Blue

Light green

Orange

Pink

Red

Sky blue

White

Yellow

Black/Green

Black/Blue

Black/Red

Black/White

Black/Yellow

Brown/Green

Brown/Blue

Brown/Red

Brown/White

Brown/Yellow

Green/Black

Green/Red

Green/White

Green/Yellow

Gray/Green

Gray/Red

Blue/Black

Blue/Red

Blue/White

Blue/Yellow

Orange/Black

Orange/Green

Orange/Yellow

Pink/Black

Pink/White

Red/Black

Red/Green

Red/Blue

Red/White

Red/Yellow

Sky blue/White

White/Black

White/Red

White/Yellow

Yellow/Black

Yellow/Green

Yellow/Blue

Yellow/Red

Yellow/White

R/G

R/L

R/W

R/Y

Sb/W

W/B

W/R

W/Y

Y/B

Y/G

Y/L

Y/R

Y/W

L/W

L/Y

O/B

O/G

O/Y

P/B

P/W

R/B

G/B

G/R

G/W

G/Y

Gy/G

Gy/R

L/B

L/R

YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN

FZ1-N (V) 2006

WIRING DIAGRAM

FZ1-N (V) 2006

SCHEMA DE CABLAGE

FZ1-N (V) 2006

SCHALTPLAN

FZ1-N (V) 2006

SCHEMA ELETTRICO

DIAGRAMA DE CONEXIONES

DE FZ1-N (V) 2006

FZ1-S (V) 2006

WIRING DIAGRAM

FZ1-S (V) 2006

SCHEMA DE CABLAGE

FZ1-S (V) 2006

SCHALTPLAN

FZ1-S (V) 2006

SCHEMA ELETTRICO

DIAGRAMA DE CONEXIONES

DE FZ1-S (V) 2006

FZ1-N (V) 2006

WIRING DIAGRAM

1

ON

OFF

P

81

80

82

77

78

79

75

76

2

3

4

FZ1-N (V) 2006

SCHEMA DE CABLAGE

5

6

85

7

10

8

9

74

FZ1-N (V) 2006

SCHALTPLAN

C

11

B

WIRE HARNESS

HEADLIGHT

SUB-WIRE HARNESS

WIRE HARNESS SUB-WIRE HARNESS 2

FZ1-N (V) 2006

SCHEMA ELETTRICO

A

WIRE HARNESS SUB-WIRE HARNESS 1

12

13

14

56

52

53

54

OFF

RUN

55

FREE

PUSH

57

58

OFF

ON

59 60

HI

LO

OFF

ON

61

62

L

N

R

OFF

ON

63

65

64

51

Ch

Dg

38

40

41

42

43

39

44

47

48

45

46

49

50

50

16

18

19

17

15

37

36

35

20

34

83 84

73

72

70 70

71

66 67

Dg

B

B

Dg

68 69

21

DIAGRAMA DE CONEXIONES

DE FZ1-N (V) 2006

29

30

31

26

27

22

26

23

26

24

26

25

28

33

32

FZ1-S (V) 2006

WIRING DIAGRAM

1

ON

OFF

P

82

81

83

79

80

78

76

77

FZ1-S (V) 2006

SCHEMA DE CABLAGE

5

D

FZ1-S (V) 2006

SCHALTPLAN

C B

FZ1-S (V) 2006

SCHEMA ELETTRICO

WIRE HARNESS

HEADLIGHT

SUB-WIRE HARNESS 2

WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS 1 WIRE HARNESS SUB-WIRE HARNESS 2

A

WIRE HARNESS SUB-WIRE HARNESS 1

4

6

2

3

86

7

10

8

9

11

12

13 14

16

18

17

19

15

52

53

54

OFF

RUN

55

FREE

PUSH

74

75

56

B B

57

58

59

OFF

ON

60

HI

LO

61

ON

OFF

62

R

N

L

63

OFF

ON

65

64

51

38

40

41

42

43

39

44

50

50

48

49

45

46

47

37

36

35

34

20

84 85

66 67 68 69

70 71 71 70

73

72

21

DIAGRAMA DE CONEXIONES

DE FZ1-S (V) 2006

29

30

31

26

27

22

26

23

26

24

26

25

28

33

32

FZ1-N (V) 2006

WIRING DIAGRAM

FZ1-N (V) 2006

SCHEMA DE CABLAGE

FZ1-N (V) 2006

SCHALTPLAN

FZ1-N (V) 2006

SCHEMA ELETTRICO

DIAGRAMA DE CONEXIONES

DE FZ1-N (V) 2006

FZ1-S (V) 2006

WIRING DIAGRAM

FZ1-S (V) 2006

SCHEMA DE CABLAGE

FZ1-S (V) 2006

SCHALTPLAN

C B

FZ1-S (V) 2006

SCHEMA ELETTRICO

A D

WIRE HARNESS

HEADLIGHT

SUB-WIRE HARNESS 2

WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS 1 WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 1

DIAGRAMA DE CONEXIONES

DE FZ1-S (V) 2006

ON

OFF

P

B B

OFF

RUN

FREE

PUSH

OFF

ON

HI

LO

ON

OFF

R

N

L

OFF

ON